Advanced Manufacturing Processes for Low Cost … GREENLION.pdf · Fondation Universitaire, Rue d'Egmont 11, 1000 Bruxelles 11/12 July 2012 Advanced Manufacturing Processes for Low

Joint EC / European Green Cars Initiative

Clustering Event 2012Fondation Universitaire, Rue d'Egmont 11, 1000 Bruxelles

11/12 July 2012

Advanced Manufacturing Processesfor Low Cost Greener Li-ion Batteries

GC.NMP.2011-1Project financially supported by 7th Framework Program of the European Commission under Grant Agreement no. 285268

GREENLIONAdvanced Manufacturing Processes for

Low Cost GREENer Li-ION BatteriesCall: FP7-2011-GC-ELECTROCHEMICAL-STORAGE

Topic: Advanced eco-design and manufacturing processes for batteries

and electrical components

Grant Agreement #285268

Total budget: 8.6 M€

EC contribution: 5.6 M€

Starting date: 1/11/11

Duration: 4 years

Electrode Cell Modulewith integrated

BMS

Batterypack

Actions at 3 key levels of the battery value chain:

i) more environmentally friendly production of

the battery componentsii) substantial shortening of the battery assembly

procedure

iii) easier and more effective disassembly and end-of-life

recycling

From green materials to greener batteries

GREENLION CONCEPT

i.Electrode Processing

- Aqueous Processing of Natural Binders(independent of active materials chemistry – starting selection: C/LFP)

Non-fluorinated polymers RECYC

COST

Laser cutting COST

Aqueous slurries WASTE/ ECO

Non-thermoplastic polymers COST

GREENLION

Improvements

Cell Assembly

- Slot-die coating process adjustment on pilot line

ii. Cell Assembly

Stack-Winding process COST

Eco-friendly bonding process

ECO

Adjusted formation step time

COST

Pre-drying for lower dry room

requirements COST

More efficient and long-life cell

sealing ECO

Laser cutting instead of die

notching COST

GREENLION

Improvements

iii. Module Design & Assembly

Module

Testing

Packaging &

Management

System

Module

Assembly

Automation of module assembly process

COST

Easy disassembling for maintenance

and recycling at their end of life ECO

Lighter battery module design through

air cooled solutions ECO/ COST

Pouch cells

Battery Pack

- Lighter module design through air cooled solutions:Electrical and thermal simulation of GREENLION cells to develop a module including BMS (SOC, SOH algorithms, equalization) and Thermal Management System.

- Eco-designed bonding techniques to improve sealing and disassembly:Degreasing and activation/primering of surfaces for structural bonding. Adhesives/glues with additives to activate easier disassembly for maintenance/reuse/recycling.

- 3D design of automatic battery module/pack assembly line:Pilot line in 3D (validation of a prototype for Key-Processes) as a turn-key production line for Li-ion module manufacturing (Cycle time: 3 sec/cell production capacity 880MWh/year)

GREENLION

Improvements

...through an step by step approach:

Electrode Cell Module

GEN1 GEN2 GEN3

Electrodes (0.5 m2, s.s.)Laboratory coater

Electrodes (m2, d.s)Industrial pilot plant coater

Cells (ca. 5 Ah) Cells (ca. 20 Ah)

Modules

GREENLION Consortium

16 partners from 7 member states:

• 10 Industries

(8 Large, 2 SME)

• 3 Research Institutes

• 3 Universities

MODULECELL

Materials Electrodes Manufacturing Design / Assembly

Specs. /Validation

GREENLION Partnership and RolesIN

DR

ES

Recycling / LCA

NOTE: atribution of roles to partners not exhaustive; here limited to only one mention per partner for clarity

http://twitter.com/account/profile_image/TECREUNIDASnews?hreflang=

WorkPackage structure

WP2 Advancedelectrode

development & testing

WP3Cell design,


WP4Battery module

eco-design, assembly &

testing

WP7Demonstration of battery module &

validation

WP1 Management

WP5 Manufacturing of electrodes, cells & modules in pilot-line

WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)

WP8 Dissemination, Exploitation & Training

MAIN ACHIEVEMENTS

SO FAR

WP2Advancedelectrode

development& testing



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




2.1 Battery materials for aqueous coating

UL, POLIMI, SOLVAY, TIMCAL, WWU

2.2 Formulations and processes for aqueous coatings

WWU, ENEA, UL, SOLVAY, TIMCAL

2.3 Characterization and testing of electrodes

ENEA, WWU, POLIMI, VW

Selection of components

for GEN1 cells (≈ 5Ah):

Graphite / NMC

CMC binder

0.5 m2 negative and

positive electrodes for

GEN1 cell:

DELIVERED

WP3Cell design,




WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




3.1 Cell specs & design

CEGASA, KEMET, WWU, ENEA, RESCOLL

3.2 Cell assembly process optimization

KEMET, CEGASA, RESCOLL, CIDETEC, WWU

3.3 - Cell testing procedure

AIT, CIDETEC, ENEA, WWU, VW, SEAT

3.4 - Testing and evaluation of Cells

ENEA, AIT, CIDETEC, WWU

3.5 – Cell simulation & modelling

AIT, CIDETEC

Design of the final

GREENLION cell (≈ 20Ah)

UNDERWAY Manufacture of GEN1 cells

from fluorine-free binders,

small area electrodes

ABOUT TO START

MAIN ACHIEVEMENTS

SO FAR

WP4Battery module


testing



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




4.1- Battery module design

CIDETEC, CEGASA, AIT, RESCOLL, SEAT, VW

4.2 - Assembly processes development

CEGASA , CIDETEC, AIT, MASS

4.3 - Testing procedure

AIT, ENEA, CIDETEC, SEAT

4.4 - Battery module testing

AIT, ENEA

Design of the GREENLION battery modules

UNDER DISCUSSION

COUPLED WITH CELL DESIGN & ECODESIGN

MAIN ACHIEVEMENTS

SO FAR



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management





5.1: Electrode manufacturing process on pilot line

PCF, CEGASA, SOLVAY, TIMCAL, WWU5.2: Cell manufacturing process on pilot line

KEMET, CEGASA

5.3: Design battery module assembling processes/equipments

MASS, CEGASA

Electrode manufacturing :

transference from lab-coater

to industrial pilot line :

ALREADY STARTED

MAIN ACHIEVEMENTS

SO FAR



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




WP6 Eco-design (LCA & Reuse/Recycling Strategies)

6.1: Regulatory assessment concerning REACH- CLP (GHS).

RESCOLL, TR, TIMCAL

Task 6.2: Eco-designTask 6.3: LCA

RESCOLL, TR, CEGASA, SEAT Task 6.4: Recycling/Reuse

TR, RESCOLL, CEGASA, WWU, TIMCAL

Benchmarking on recycling

processes done

LCA& ecodesign ;

gathering of inputs from partners

• reference cell

• Greenlion cell

MAIN ACHIEVEMENTS

SO FAR

http://twitter.com/account/profile_image/TECREUNIDASnews?hreflang=



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




WP7Demonstration

of battery module

& validation

Task 7.1: Specs. of demonstrator and validation test plan

SEAT, CEGASA, VW

Task 7.2: Battery-pack production process validation

CEGASA , KEMET, MASS

Task 7.3: Testing and Validation of battery module

SEAT, VW

SCHEDULED FOR 4TH YEAR

WP7 parners already

contributing in other related

WPs, esp. in 4.1 Battery

module design

MAIN ACHIEVEMENTS

SO FAR



WP3Cell design,


WP4Battery module


testing


validation

WP1 Management




WP8 Dissemination, Exploitation& Training

8.1: Training activities

RESCOLL, All partners 8.2: Dissemination

RESCOLL, All partners

8.3: Exploitation of results

CEGASA, All partners

www.greenlionproject.eu

MAIN ACHIEVEMENTS

SO FAR

Exploitation Potential

•The key objective of GREENLION is to improve lithium ion battery cells & modules at

•cell and module components processing, assembly and manufacturing

•lowering production costs

•energy and environmentally friendly processes

...specifically aiming at electric vehicle applications.

•Ten out of sixteen partners (62%) in GREENLION are industries including:

• materials suppliers (SOLVAY, TIMCAL),

•machinery developers (POLYTYPE , KEMET, MONDRAGON ASSEMBLY),

•battery manufacturer (CEGASA),

•(recycling) process developer (TECNICAS REUNIDAS)

•automotive end-users (SEAT, VW).

...covering the whole battery manufacturing value chain

•Also, GREENLION will provide advances to a number of scientific and engineering challenges

for battery cell and module manufacturing.

•The successful resolution of these challenges will lead to breakthroughs in Li Ion batteries to

be directly exploitable by industry and scientific contributions to benefit the tech. community

Topics for cooperation within the cluster

• in contact with ELIBAMA similar project running in parallel:

• Participation in ELCAR project workshop on LCA:

ANYWAY:

• Several clusters of projects with related scope i.e. see program!!

• Cross-participation of individual partners in complementary projects i.e. GREENLION partners in:

HELIOS, AMELIE, CORE, SOMABAT, DELIVER, E3CAR, EDASH, ELVA, MOTORBRAIN, SMART-LIC.....

• Technical topics– materials, processing

– recycling, LCA

– BMS, module development

• Cross-cutting issues– benchmarking

– standards

• Dissemination & Training

Thank you !!

[email protected]

Documents

Advanced Manufacturing Processes for Low Cost … GREENLION.pdf · Fondation Universitaire, Rue d'Egmont 11, 1000 Bruxelles 11/12 July 2012 Advanced Manufacturing Processes for Low