greenlion is a...international symposium on green chemistry – isgc 2015 may 3-7, la rochelle...

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NEW MATERIALS

Development of new active and inactive battery materials viable for

water processing

INNOVATIVE ELECTRODE PROCESSES

Innovative processes leading to reduce electrode production cost and

avoid environmental pollution

NEW ASSEMBLY PROCEDURE

Development of new assembly procedures capable of substantially

reducing time and cost of cell fabrication

ECO-DESIGN BONDING TECHNIQUES

Lighter battery modules with air cooling and easier disassembly

through eco-designed bonding techniques

AUTOMATED MODULE ASSEMBLY

Development of an automated module and battery pack assembly line

for increased production output and reduced cost

WASTE REDUCTION

The use of the water solubility of the binders, allow an extensive

recovery of the active and inactive battery materials with a waste and

pollution reduction.

GREENLION is a Large Scale

Collaborative Project within the

FP7 leading to the manufacturing of

greener and cheaper Li-Ion batteries for

electric vehicle applications via the use of water soluble, fluorine-

free, high thermally stable

binders, which would eliminate the use of VOCs and reduce the

cell assembly cost

7 June 2015

GC.NMP.2011-1

Project financially supported by 7th Framework Program of the European Commission under Grant Agreement no. 285268

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OBJECTIVES

Introduction

The GREENLION project aims at addressing issues

of the industrial development of eco-designed processes at the electrode, cell and battery module level.

The GREENLION project is covering topics from lab to industries issues. At the end, the goal of the

project is to develop innovative greener Li-Ion batteries at an industrial scale with recognition of the environmental consideration

Therefore this newsletter edition is focusing on upscaling issues at different levels:

Active material Manufacturing………………p.3

Integration of electronic system……………p.5

Assembly Lay out manufacturing ………..…p.7

With a regard of environmental aspects through the creation of an “eco” – label……………………...p.9

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GREENLION is a Large Scale Collaborative Project within the FP7 leading to the manufacturing of greener and cheaper Li-Ion batteries for electric vehicle applications via the use of water soluble, fluorine-free, high thermally stable binders, which would eliminate the use of VOCs and reduce the cell assembly cost

S E R V I C E S

D I S P O N I B L E S

Technical Review

Regarding the electrode/separator stacking/winding step, the traditional approach is Stacking. This process however presents a low manufacturing throughput, index feeding and improvements are needed to make product more cost effective. The Stack Winding process is an innovative solution that incorporates continuous process of Winding with volumetric efficiency and energy density of Stacking and will be developed in GREENLION for the aqueous-based electrodes

Cel l Assembly

Module Design

Graphite 01 developed by Imerys Graphite & Carbon was selected in the project

as candidate for the anodes of generation 3 cell. This product was initially

developed in the R&D stage on laboratory equipment. During this phase several

possible materials were produced however only a few candidates could meet all

the required material parameters among these special attention was given to

the specific and irreversible capacities.”.

This R&D stage was followed by two piloting phases performed on pre-industrial

scale equipment.

The first phase consisted in the qualification of the equipment and the target

was to reproduce and optimize the material developed in the previous R&D

stage. Via this optimization work the set of key material parameters was

reached.

The second piloting phase was characterized by the optimization of the

production capacity on the same equipment in order to maximize production

capacity and correlate process parameters to material parameters. Piloting

phases are then followed by a production phase on industrial equipment; the

feasibility of the industrialization of the product was demonstrated.

(…)

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Production capacity evolution during up-scaling process is reported in Figure 1

Figure Production capacity during the various phases of the up-scaling

process for Graphite 01

Dario Cericola, Imerys

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The GREENLION battery module includes twelve battery cells in serial

connection and electronic components.

The function of electronic is monitoring of cell and module behavior. Central

component of electronic is the printed circuit board (PCB) of Cell Management

Controller (CMC).

Printed board of GREENLION CMC

Every battery module has its own CMC. The CMC monitors following data of

module:

five temperatures at defined positions to avoid high thermal load

Individual cell voltage

and communicate with external Battery Management Controller (BMC). The

CAN-Bus rate is 500 kbit/s. Additional there is a status LED for rough

information in failure case.

For validation of simulation results and the thermal behavior of module the first

prototype has one thermal couple per cell. The signals of the thermal couples

are analyzed by external monitoring system of the test bench.

(…)

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For easy assembly and disassembly the PCB has plug connections for sensor

wires and CAN-Bus

Assembled PCB, prototype of GREENLION battery module

Implemented functions:

Single cell voltage monitoring.

The main focus of CMC is the monitoring of single cell voltage. The cell voltage

is important in order to identify the correct operation of all cells and the module.

The total voltage of one module is calculated by the single cell voltages.

Cell balancing.

Based on single cell voltage monitoring, the CMC enables passive cell balancing.

Balancing algorithm is implemented into CMC, e.g. threshold voltage of

balancing. The status of balancing of cells is monitored and can be controlled by

CAN-Bus. The effective discharge current of balancing is defined by pulse width

modulation (PDM). The PDM rate is adjustable by CAN-Bus, too.

Flexible design

The CMC-design allows a flexible design of module with different numbers of

cells per module from four up to twelve cells per module. The CMC allows a

scalable design of battery pack with up to 16 battery modules.

Michael Rudolph, AIT

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CAN-Bus connectors

Sensor wires and connector

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own in F

“Mondragon Assembly has finished the development of 3 production lay-outs,

corresponding to different cycle time requirements (throughput).

Designation Consumption (kW) Cadence (Pack /h) Grade of automation

Asssembly Line

transfer 240 100 High

Lay out in Island 152 50 High

U-lay out 35.2 20 Low

Battery manufacturing for automotive applications will require a very repetitive

and traceable production process, where manual stations will be limited to very

few manipulation and handling operations.

In this context, key processes have been identified during GREENLION project

o Tab bending without short-circuiting

o Cell interconnection (Laser welding)

o Quality control of electrical interconnection

(…)

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Medium size production system configuration

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Electrical interconnection of individual cells,

respecting automotive industry quality and

safety requirements has been specifically

focused by Mondragon Assembly and CEGASA

As a result, a robotized laser welding station have been built, where seven real

Lithium-ion batteries for cars have been produced.

Laser Welding head

Together with this station, automatic tab bending has been developed

(avoiding electrical shock risk for operators) and also a quality control stations

and process has been optimized able to detect soldering mistakes on the

battery module.

Aitor Apraiz, Mondragon Assembly

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Tab bending equipment developed and validated with real module

Laser welding machine developed during the project

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To comply with last EU directives, recycling process of li-ion batteries shall

achieve 50% by average weight of the whole Li-Ion battery in term of

constituting element as well as materials.

As cells of batteries contain diverse precious metals which have a high added

value ; a labelling system is required to inform recycling center on the type of

chemistry used both to know the most suitable recycling process adapted to the

metal used and eventually a way to retrieve those precious metals.

With the help of CIDETEC and TECNICAS REUNIDAS, RESCOLL designed

recycling logos according to main chemistries used in batteries. It was inspired

from the logos designed in the Call2Recycle US program. Call2recycle

(http://www.call2recycle.org/who-is-call2recycle/) is an american program on

the recycling of Battery

Different parameters must be considered:

- Visibility (in color and without), « recycling meaning » recognizable

(simple, direct, without double meaning),

- Details about chemistry used in the battery,

- Industrial contact for disassembly/recycling protocol.

(…)

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http://www.call2recycle.org/who-is-call2recycle/

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RESCOLL created the following design with colors associated to the 5 main

chemistries used in the batteries :

Lithium ion Nickel cadmium Nickel metal hybride Nickel zinc Lead

NMC, LMO, LFP,

LTO, Polymer, … nd nd nd nd

Recycling logo for Greenlion battery

Mickaël LeGoff, Claire Michaud, RESCOLL

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« Recycling meaning »

recognizable with

Möbius strip and

identification

Greenlion module

from CAO with

green color for « Li-ion visibility”

Contact to locate a

drop-off site (website

of Greenlion project)

Chemistry

identification

(NiMnCo)

Large green circle for

« Li-ion visibility »

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EVENTS

28-29th of October 2014, Ulm

A final event will take place in San Sebastian last week of Octobre 2015.

The aim of this final will be to present outcomes of the projects but also about

EV & Li-batteries from the chemical point of view and the engineering point of

view. GREENLION partners which have gained more expertise in Li-Ion

batteries together with actors working on the field of green batteries will be

present. It will be an great opportunity to gather both the scientific

community and the industrials on this challenging topics

Please feel free to contact us to have more information

about this event and to save the date !!

More information :

[email protected]

UPCOMING GREENLION EVENTS

Final Event :

GC.NMP.2011-1


mailto:[email protected]


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International symposium on Green Chemistry – ISGC 2015

May 3-7, La Rochelle (France)

For this third edition, ISGC aimed at widening the scope of the symposium to other fields of green

chemistry. In particular, ISGC-2015 will cover nine general topics related to 1. biomass conversion,

2. clean hydrogen production, 3. alternative solvents, 4. waste, 5. polymers and materials, 6. atom-

economy synthesis, 7. eco-technology, 8. predictive methods and 9. environmental and ethical

assessments. Each topic will be introduced by a plenary lecture delivered by an eminent scientist of

the field.

During this event, POLIMI research team presented one contribution with work developed within

GREENLION:

“Blending Ionic Liquids: anomalous diffusion of TFSI and FSI anions in the pure ILs and their blends”

(ORAL COMMUNICATION) by A Mele

EEVC

December 2, Brussels (Belgium)

EEVC therefore clearly strengthens its position as premier global European platform to foster

exchange of views between the researchers, the industry, the authorities, the end-users and

the NGO’s in the field of eMobility. This event is notably composed of the The European Project Day.

This special day aims at providing the audience with a complete overview of the different programs

supported by the European Authorities (FP7, Horizon 2020, IEE, EUROSTARS, INTEREG, ...) & related

funded projects dealing with eMobility.

This will be a unique opportunity to identify possible actions, overlaps, synergies and/or gaps.

During this event, CIDETEC research team presented one contribution with work developed within

GREENLION

“Advanced manufacturing processes for Low Cost Greener Li-Ion batteries" (ORAL

COMMUNICATION) by I. Cendoya,

GREENLION dissemination activ it ies

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June 2-4, La Rochelle (France)

Mat4Bat is an European project funded by the European Union 's Seventh Framework Programme

(FP7/2007-2013) under grant agreement n°608931. MAT4BAT builds-up its EVs battery strategy on

advanced materials and pilot line processes, proposing three novel concepts of cells initiating from

a state-of-the art combination of cell materials (NMC/Carbonate liquid electrolyte/Graphite).

MAT4BAT organized a summer school during which presentations, discussions and round tables

about the different research orientations chosen to develop next generations of Li-ion batteries for

electric vehicles were given

During this event, CIDETEC research team presented one contribution with work developed within

GREENLION

“Advanced manufacturing processes for Low Cost Greener Li-Ion batteries" (ORAL

COMMUNICATION) by I. Cendoya,

Workshop Mat4bat

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UPCOMING EVENTS

ECS Conference on Electrochemical Energy Conversion & Storage with SOFC–XIV

This is an event on electrochemical energy conversion/storage

materials, concepts, and systems, with the intent to bring

together scientists and engineers to discuss both fundamental

advances and engineering innovations. ECS Conference on

Electrochemical Energy Conversion & Storage with SOFC–XIV is

devoted to the following areas: Section A : Solid Oxide Fuel

Cells (SOFC-XIV)—All aspects of research, development, and

engineering of solid oxide fuel cells Section B : Batteries—A

wide range of topics related to battery technologies Section C :

Low Temperature Fuel Cells—Low-temperature fuel cells,

electrolyzers, and redox flow cells

July 26-31 2015 Glasgow, (UK)

http://www.electrochem.org/meetings/satellite/glasgow/

Battery Power 2015

Battery Power 2015 is an international conference highlighting

the latest developments impacting mobile and portable battery

systems for consumer and commercial products, including

power tools, smart phones, tablets, laptops and medical

devices - August 5-6, 2014, Denver, Colorado (USA) http://www.batterypoweronline.com/conferences/

ABAF-16 — Adanced Batteries, Accumulators and Fuel

Cells

Research and development of new materials for modern

electrochemical power sources such as lithium batteries, similar batteries, fuel cells and others including ionic liquids for mentioned purposes August 30 –September 4 2015 Brno, (Czech Republic)

http://www.aba-brno.cz

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http://www.electrochem.org/meetings/satellite/glasgow/

http://www.batterypoweronline.com/conferences/presentations/

http://www.batterypoweronline.com/conferences/

http://www.batteriesevent.com/site/GB/Conferences/index.php

http://www.batteriesevent.com/site/GB/Conferences/index.php

http://www.aba-brno.cz/

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Coordinator of the project :

IK4- CIDETEC

Parque Tecnológico de San Sebastián

2009 Donostia – San Sebastian (Gipuzkoa)

Spain

IN F O@ GRE E N L IO NP R O JE C T. E U

W W W .G RE E N LI O NP R O JE C T . E U

PARTNERS

16 Partners from 7 members states:

- 10 Industries (8 Large, 2 SME)

- 3 Research Institutes

- 3 Universities

AE 2014 Thermal Management System Symposium

The SAE 2014 World Congress & Exhibition assembles the best

talent in the automotive industry; experts, management

teams, engineers, and executives alike gather to collaborate

and address these current challenges, celebrate evolution and

achievement over the last 100+ years, and promote the

multitude of opportunities fundamental for a successful future

September 22-24, 2014, Denver, Colorado (USA)

http://www.sae.org/congress/

Batteries 2015

For 17 years, the Batteries event remains today one of the world's most attractive event and the meeting place of

technologies (lead acid, NiMH, Li-ion Post), applications (from micro batteries to large format batteries) and the value chain (chemists OEMs and end users)... During three days, the conference will gather 70 speakers and internationally known experts. October 7-9 , 2015 Nice (France) http://www.batteriesevent.com/

World of Energy Solutions Trade fair

The WORLD OF ENERGY SOLUTIONS is international trade fair

and conference – and thus an important platform for speeding

up the change to alternative energy sources. It addresses all

players involved in the manufacturing of battery and energy

storage systems for mobile and stationary implementation. All

areas are dealt with, from raw materials to turnkey battery

systems.

October 12-14, 2015 Messe (Germany)

http://www.messe-stuttgart.de/en/wes/

eCarTec

Along with the parallel measurement of MATEIALICA – Lightweight Design for new mobility and sMove 360° - connected drive,eCarTec Munich as the world’s largest trade

fair for electric and hybrid mobility depicts the complete range of topics.

October 20-22, 2015 Munchen(Germany)

http://www.ecartec.com/

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http://www.sae.org/congress/

http://www.batteriesevent.com/

http://www.messe-stuttgart.de/en/wes/

http://www.ecartec.com/

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Coordinator of the project :

IK4- CIDETEC

Parque Tecnológico de San Sebastián

2009 Donostia – San Sebastian (Gipuzkoa)

Spain

IN F O@ GRE E N L IO NP R O JE C T. E U

W W W .G RE E N LI O NP R O JE C T . E U

PARTNERS

15 Partners from 7 members states:

- 9 Industries (7 Large, 2 SME)

- 3 Research Institutes

- 3 Universities

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greenlion is a...international symposium on green chemistry – isgc 2015 may 3-7, la rochelle...

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