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Determination of Process-Structure-Performance Correlations and Development of Alternative Production Processes by the German Cell-Production Research Cluster “ProZellArno Kwade and Henrike Bockholt Institute for Particle Technology and Battery LabFactory, TU Braunschweig

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Page 1: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Determination of Process-Structure-Performance Correlations

and Development of Alternative Production Processes

by the German Cell-Production Research Cluster “ProZell”

Arno Kwade and Henrike Bockholt

Institute for Particle Technology and Battery LabFactory, TU Braunschweig

Page 2: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Battery Cell Production, Demand and Utilization

2013 2014 2015 20160

20

40

60

80

100

120 entire capacity (max)

entire capacity (min)

entire utilization (max) [%]

entire utilization (min) [%]

[GW

h]

0

20

40

60

80

100

120

[%]

According to: Fraunhofer Institute for Systems and Innovation Research ISI

Global Cell Production Capacities (2013 to 2016)

Existing cell factories are

fully utilized

+

Strong increasing

demand of battery cells,

prediction of up to

400 GWh/a in 2025

Continuous increase of

manufacturing capacity is

required to satisfy the

demand and avoid

bottlenecks

Demand

Page 3: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Ele

ctr

od

e

pro

du

cti

on

Cell

pro

du

cti

on

Cell

Co

nd

itio

nin

g

Materialpre-treatment

and mixing

coating and

dryingcalendering

cutting and

drying

package

formingcontacting

housing and

sealing

electrolyte

fillingformation and

aging

electrochemical

quality checkCells

Process Chain of Cell Manufacturing

Page 4: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Calculation Model for Cell Production

Influencing Factors

cell

parameters

production

parameters

economical

parameters

Calculation Model

calculation with

combined input

Results

factory design

cost planning

J.-H. Schünemann, Volkswagen VARTA Microbattery,

A. Kwade, TU Braunschweig, Vortrag Kraftwerk Batterie 2014

Page 5: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cost of a Battery Cell

J.-H. Schünemann – Modell zur Bew ertung der Herstellkosten von

Lithiumionenbatteriezellen, Dissertation, iPAT Schriftenreihe, Sierke-Verlag

Manufacturing

Cost

188,96 €/kWh

Material Cost

dominated by

exogenic factors

Production Cost

accessible

cost potential

Other*

4,43 €/kWh

2,3 %

Material

135,98 €/kWh

72,0 %

Direct Labor

22,09 €/kWh

11,7 %

Depreciation

15,56 €/kWh

8,2 %

Capital

5,20 €/kWh

2,8 %

Energy

5,70 €/kWh

3,0 %

* maintenance, insurance, imputed area rent

Page 6: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Electrode and Cell Production@ Battery LabFactory Braunschweig

Facts and Figures

▪ Battery research since 2008

▪ 7 institutes of TU BS and

PTB

▪ 900 m² pilot processing area

(+ 500 m2 laboratories)

▪ 160 m² dry room

▪ approx. 50 researchers and

technicians

Page 7: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Research Strategy of BMBF and BMWiBattery Research Germany

Economically Attractive Lithium-Ion Battery Cells

with Excellent Performance

Material Science

Electrochemistry

Process Engineering

Production Engineering

Batterie 2020

ProZellApplication-related

Technologies

6. Energie-forschungsprogramm

Page 8: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Competence Cluster for Battery Cell Production (ProZell)Members

11 research projects

1 accompanying project

22 research institutes

12 locations

(5 Institutes)

(4 Institutes)

(4 Institutes)

sponsored by

Page 9: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Competence Cluster for Battery Cell Production (ProZell)Aims

Superior Aim:

Long-term, holistic and profound scientific basis for

erection and sustainable further development of an

international competitive battery cell production in

Germany and Europe

Process

x

Inter-

mediate x

Process

y

Battery

Cell

Intermediate

PropertiesCost Cost

Process-Cost-Function of Battery Cell

Process-Quality-Property-Function of Battery Cell

Holistic

Understanding

Of Battery

Cell Production

sponsored by

Page 10: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Research Aims of ProZell Projectswith specific focus on one particular process step

Coating Dry Coating Drying

Assembling FormationDispersing Drying Calendering

Electrolyte Filling

KonSuhl – continuous slurry processing

MultiDis – multiscale simulation of slurry processing

LoCoTroP – low-cost dry coating

ProKal – modelling the calendering process

Roll-it – R2R intensive drying

Cell-Fi – process optimization

for efficient electrolyte filling

OptiZellForm – energetic

optimization of formation

Page 11: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Research Aims of ProZell Projectswith a more holistic view on the manufacturing

QS-Zell – QA methods in the

production of large-format LIB-cells

Sim2Pro – multi-level simulation

of process-product-interactionsHighEnergy – high-capacity structured electrodes

HiLo – processes and electrode

structures for high-load cathodes

Coating Dry Coating Drying Electrolyte Filling

Assembling FormationDispersing Drying Calendering

Page 12: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster Objectives Slurry Processing

Continuous processing of

battery slurries by extrusion

▪ Enhancing the efficiency in

production

▪ Reducing the mixing and

dispersing time (dwell time

~ 3 - 6 min)

▪ Possibility to decrease

dryer length

Prediction of carbon black destructuring in

planetary mixers of different geometry

▪ Simulation on different scales (particle scale

and machine scale)

▪ Structure characterization

▪ Decease of Carbon Black usage

Page 13: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster Objectives Electrode Production

Development of thick and multilayered electrodes

▪ Reducing the amount of inactive cell materials

(current collector e.g.) to enhance energy density

▪ Enhancing binders, particle size distributions, use

of material blends

▪ Decreasing material- and production costs

▪ Electrode structure optimization by simulation tools

to ensure maximum transport performance

T. Danner et al. J Power Sources, 334, 191–201 (2016)

Source: ZSW, Ulm

Dry and water based coating of

battery electrodes

▪ Massive cost reduction, especially

energy and solvent usage

▪ Mixing and structuring of materials

▪ Electrostatically enhanced spray

coating, also multilayer deposition

Source: IPA, Stuttgart

Page 14: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster Objectives Electrode Finishing

Defined porosity- und structure-

adjustment by defined calandering

▪ Enhancing energy- and power-density

and life time expectation by prediction of

favourable calandering parameters

▪ Increasing the operability of calendaring

machines by dynamic machine model

Roll to roll condinuous IR dryer

▪ Fast heat and solvent transport

▪ Short drying times and controlled

remaining solvent content

▪ Prevention of water reuptakeSource: ZSW, Ulm

Page 15: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster projects „HighEnergy“Design and production of high-load electrodes

Integrated slitting and stacking of

thick electrodes

▪ Decreasing failures and

enhancing quality

▪ Increasing production rate

▪ Decreasing costs and production

failures

Page 16: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster Objectives Cell Finishing

Accelerating, homogenization and

inline process control of electrolyte

filling

▪ Decrease of filling time and costs

▪ Simulation of wetting processes

during cell filling

▪ Effect of separator and cell design

Accelarating formation and decreasing aging

time

▪ Systematic approach to optimize formation

routines

▪ Investigation of chemical and electrochemical

parameters

▪ Effect of production parameters on formation

Page 17: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Cluster project „Sim2Pro“Simulation of cell production chain

Frame for process simulation

and performance prediction

▪ Coupling process models to

calculate production rates,

energy and labour demand etc.

▪ Effect of processes on cell

performance

Quality assurance in lithium ion

battery cell production

▪ Investigating of crucial process

steps for cell quality

▪ Development and investigation

of new measurement methods

and overall quality assurance

concepts

Page 18: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Connection of the individual projects of the clusterSystematic cooperation

Page 19: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

acatech – DEUTSCHE AKADEMIE DER TECHNIKWISSENSCHA FTEN, 2016

ProZell

provides

knowledge for

today´s and

future cell

factories

Competence Cluster for Battery Cell Production (ProZell)Networking with Industry

sponsored byElectrode Production

Assembly Activation

Further Processing

Module:Dispersing

Module:Coating &

Drying

Module:Calendering

Module:Coil Handling

Module:Cutting

Module:Contacting

Module:Stacking

Module:Packaging

Module:Drying

Module:Electrolyte

Filling

Module:Formation

Module:Aging

Process Step X

Standardized

Interface

Research Platformfor

Industrial Production

Giga Factory

Pilot plant

Page 20: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Conclusions

▪ ProZell will provide detailed knowledge

about cell production processes and their

costs

▪ Detailed process knowledge will help to

strengthen the existing German medium-

sized cell manufacturers and to establish a

mass cell production in Europe both in

intermediate- and long-term

▪ Many other fields for use of battery cells

are known beside electro mobility

EAS Germany GmbH 2016

w ww.litarion.com/litarion_litacell_cells.html

liacon-batteries.de/

Stationary

storage

from Liacon

Batteries

Battery cell from

Electrovaya-Litarion

Battery cells

from EAS in

fieldCoinPower from

Varta Microbatteries

Page 21: Determination of Process-Structure-Performance …cii-resource.com/cet/AABE-03-17/Presentations/BMGT/Kwade...Determination of Process-Structure-Performance Correlations and Development

Acknowledgements