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Economic Analysis of Manufacturing of
MWCNT Lithium-Ion Batteries
Ali Hakimian, Jacqueline Isaacs, Thomas Cullinane
Sagar Kamarthi, and K.M. Abraham
Santa Barbara, CANov 4, 2013
SNM-1120329
EEC-0832785
Outline
Introduction to Li-based batteries and markets
Manufacturing processes for CNT lithium-ion batteries
Economic assessment using process-based cost modeling
Results and sensitivity analyses
Summary
2
Lithium-Based Batteries
3
Lithium’s propertieso Lightest of all metals
o Provides largest specific
energy per weight
Li-ion batteries typeso Lithium cobalt oxide
o Lithium manganese oxide
o Lithium iron phosphate
New Li-ion batterieso Cathode: MWCNT + LiMnO
o Anode: graphite
Applicationso Laptops
o Cell phones
o Satellites
Lithium-ion cell / battery part Material Used
Anode active material Graphite
Anode substrate Copper
Cathode active material MWCNT + LiMnO
Cathode substrate Aluminum
Separator Polyethylene
Electrolyte solvent Organic carbonate &
lithium salt
Cell Configurations of CNT LiMnO Battery
This work investigates MWCNT- Lithium Manganese Oxide Batteries
The main application is satellites
Global Markets for Lithium-Ion Batteries
Market 2004 2008 2009 2014
Portable products
Computing 2200 2300 2200 2550
Communications 3450 4516 4245 4415
Tools 15 30 40 125
Other potable 530 730 650 620
Medical 65 150 160 185
Stationary applications
UPS 50 5 5 50
Military/ aerospace 70 180 180 200
Automotive and motive power
Industrial EV - - 5 6
EV and HEV - 15 18 450
Automotive - 2 2 40
Total 6380 7927 7505 8641
Global Projected Lithium-ion Batteries Market- $ millions
Source: BCC Research, Wellesley, MA USA Web: www.bccresearch.com
Lithium-ion batteries market
o 2004: $6.4 billion
o 2014: $8.6 billion
4
Global Production Capacity for CNTs
31413993
5197
6901
9258
12806y = 2294.9e0.281x
0
2000
4000
6000
8000
10000
12000
14000
2011 2012 2013 2014 2015 2016
CN
Ts
Pro
du
cti
on
Cap
ac
ity (
in M
T)
Year
5
Source: http://www.nanowerk.com/spotlight/spotid=23118.php
Production capacity
forecast (2014-2016) of
CNTs global market
shown
Significant CNTs market
share expected for
plastic composites,
electronics then energy
Benefits of CNTs in Li BatteriesProperty improvements with CNTs in Li-ion cells
o Increased electron and ion conductivity
o Greater battery efficiency and capacity
6
Cell Parameters LiMnO cell MWCNT LiMnO Cell % Cell Improved
Anode active material Graphite Graphite
Anode substrate Copper Copper
Cathode material LiMnO MWCNT LiMnO
Cathode substrate Aluminum Aluminum
Separator Polyethylene Polyethylene
Electrolyte solventOrganic carbonate &
lithium salt
Organic carbnate &
lithium salt
Nominal capacity 25 Ah 30 Ah
Dimensions95 mm w *140 mm ht * 28
mm thick
95 mm w *140 mm ht * 28
mm thick
Nominal weight 0.908 kg 0.908 kg
Cell type Prismatic Prismatic
Energy density 105 Wh/kg 125 Wh/kg
Power density 250 W/kg 2500 W/kg
20%
20%
900%
CNT Lithium-Ion Battery Life Cycle
Use
Device
Fabrication
Material Extraction
and Processing
End-of-Life (EOL)
Environment: air,
water, land
resources
7
Process Flow Chart for LiMnO Battery
Mixing
Coating & Drying
Calendaring
Cutting
Assembly
Filling
Sealing
NMP *
Anode AM
Cathode AM
Carbon black
PVDF *
Al sheet
Cu sheet
Separator
Electrolyte
Forming & Testing
Clean Room
Environment
* NMP: N-Methyl-2-pyrrolidone)
PVDF: Polyvinylidene fluoride
Final Assembly (Battery Pack)8
Without CNTs
Proposed Process Flow for MWCNT LiMnO Battery
Mixing
Coating & Drying
Calendaring
Cutting
Assembly
Filling
Sealing
Forming & Testing
NMP
Anode Am
Cathode AM
Carbon Black
PVDF
Al Sheet
Cu Sheet
Separator
Electrolyte
High Protection
Environment
Desired
Clean Room
Environment
MWCNT
Final Assembly (Battery Pack)
9
Detailed Process Showing Scrap Generation
Positive active
material
LiMnO
MWCNT
Conductive
diluent
Carbon black
Binder
PVDF
NMP
Negative active
material
Graphite
Binder
PVDF
NMP
Mixing
Coating
Drying
Calendaring
Slitting
Mixing
Coating
Drying
Calendaring
Slitting
Aluminum foil Copper foil
Winding
Insert separator
Bottom welding
Wetting
Sealing&welding
Forming&testing
Separator
Case
Electrolyte
Scrap Scrap
Scrap
Defective cells
Final assembly Scrap
10
Models for Process-Based Cost Analysis
Customized models constructed to track variable and
fixed costs for manufacturing processes
Detailed cost assessment for manufacturing costs
Ability to explore effect of input parameters on costs
11
Four Scenarios Explored for Worker Safety Four different environmental health and safety (EHS) scenarios
explored in manufacturing process
o Base case
o Low EHS protection
o Medium EHS protection
o High EHS protection
Different levels of personal protection equipment (PPE)o Gloves
o Gowns
o Respirators
Different ventilation systems
o General exhaust ventilation (GEV)
o Local exhaust ventilation (LEV)• Blower
• Ductwork
• Hood
• Filter
o Clean room ventilation: calculation for air change method
CFM = [Space volume (cu.ft) * air change rate (AC p/hr) ] /60
12
8-h TWA Recommended Exposure
Limit for CNTs = 1 µg/m3 in 2013
Low EHS vs. High EHS Practices
13
EHS Standards Options Low High
Ventilation
1- General exhaust ventilation (GEV) X X
2- Local exhaust ventilation (LEV) Xa. Blower Xb. Ductwork Xc. Hood Xd. Filter X
Personal protection equipment
1- Latex gloves X2- Nitrile gloves X3- Disposable respirators X4- Respirators with HEPA filters X5- Tyvek suits X X
Administrative Controls
1- Air monitoring equipment X X
CNT LiMnO Battery Manufacturing Assumptions
CNT LiMnO battery contains 5 modules
each with 20 cells
Production volumeo Total production volume = 160,000 cells/yr
or 1600 battery/yr
o 1-2 workers per line (automated facility)
Cycle timeo One cell without forming step: 0.0125 hrs
o One cell with forming step: (48) hrs
Process line and machine numberso Adjusted to desired production volume
Dedicated and non-dedicated machines
10% defect rate
14
Operation data estimating the cost
of CNT LiMnO battery
Battery production volume 1600 Battery/year
Production volume 160000 Cells/year
Total production volume 174989 Cells/year
Process yield 90% %
Final assembly yield 98% %
Hours per day 8 hrs
Scheduled downtime 0.5 hrs
Interest rate 10%
Building life 30 years
Days per Year 250 days
Energy cost 0.15 $/KWh
Labor cost 25 $/hr
indirect labor rate 20 $/hr
% Indirect labor added on 15% %
Auxiliary equipment rate 10% %
Installation equipment rate 2% %
Tools rate 25% %
Fixed overhead rate 40% %
Maintenance Rate 5% %
Machine dedicated 0
Building cost 73 $/sq. ft
Total Time per year 1875 hrs
Process yield
Energy cost
Labor cost
Input Parameters for Cost Model
CNT Li-ion Cell
ParametersInput Information
Anode active material Graphite
Anode substrate Copper
Cathode active material CNT LiMnO
Cathode substrate Aluminum
Separator Polyethylene
Electrolyte solventOrganic carbonate &
lithium salt
Nominal capacity 25 Ah
Dimensions95 mm w *140 mm ht *
28 mm thick
Nominal weight 0.908 kg
Cell type Prismatic
Life cycle > 800 cycles
Specific energy 105 Wh/kg
CNT Li-ion Battery
(100 cells)
% of
Battery
weight
Anode 14.7%
Anode current collector 2.5%
Cathode 22.1%
Cathode current collector 1.0%
Electrolyte 10.4%
Separator 15.0%
Cell container 1.6%
Module container 10.1%
Pack container and BMS 36.4%
15
Economic Credits for Recycling Scrap
Cathode
production
Anode
production
Electrode
assembly
CNT
lithium-ion
cell
{95% conversion,
5% scrap}
{95% yield}
{95% conversion,
5% scrap}
{90% yield}
Battery
module &
pack
assembly
{98% yield}
Battery Scrap Generated for Each Process Step
Cathode scrap / cell
LiMnO
Aluminum sheet
Carbon black
MWCNT
NMP
Anode scrap / cell
Carbon (graphite)
Copper sheet
NMP
Assembly scrap / cell
LiMnO
Total aluminum
Total Carbon (graphite)
Copper
Separator
MWCNT
NMP
CNT Li-ion cell scrap
LiMnO
Total aluminum
Total carbon (graphite)
Copper
Separator
Electrolyte
MWCNT
Battery assembly scrap
Total aluminum
Total copper Total steel
16
Base Case Cost Results:
CNT LiMnO Battery Manufacturing
17
Variable Costs $/Year $/Battery Percent
Raw Material $ 6,610,996 $4,131 25.22%
Labor $ 6,348,739 $3,967 24.22%
Energy $ 8,907,283 $5,567 33.98%
Total Variable Cost $20,998,924 $13,124 83.41%
Fixed Costs $/Year $/Battery Percent Investment
Main Machine Cost $1,702,012 $1,063 6.49% $7,290,930,999.
Auxiliary Equipment $170,201 $107 0.65% 0
Installation Cost $34,040 $21 0.13% 0
Tools $425,503 $266 1.62% 0
Building Cost $41,506 $26 0.16% $354,780
Fixed Overhead $1,891,906 $1182 7.22% 0
Maintenance Cost $85,100 $54 0.32% 0
Total Fixed Cost $4,350,270 $2,718 16.59% $7,291,285,779
Total Cost $26,216,291 $16,385 100.0%
Total Cost - Scrap Revenue $26,072,882 $16,296
Base Case: Cost Break Downs
Material 25.2%
Labor 24.2%
Energy 34.0%
Main Machine
Cost 6.5%
Auxiliary Equipment
0.6%
Installation Cost0.1% Tools
1.6%
Building0.2%
Fixed Overhead
7.2%
Maintenance Cost0.3%
Mixing19.0%
Coating & Baking6.0% Calendaring
1.9%
Cutting0.2%
Cell Assembly
0.9%
Filling2.6%
Sealing0.1%
Forming & Testing
66.0%
Battery Pack Assembly
3.3%
18
CNT Lithium-Ion Battery Variable&
Fixed Cost DivisionCNT Lithium-Ion Battery Production
Steps Cost Division
Sensitivity Analysis Shows Cost Drivers
-40%
-30%
-20%
-10%
0%
10%
20%
30%
40%
-50% -40% -30% -20% -10% 0% 10% 20% 30% 40% 50%
MWCNT cost
Process yield (cell inspection)
%C
ha
ng
e o
f C
os
t Cycle time(forming step)
Base Case
% Change
Labor cost
Electricity cost
Electricity cost, highest impact on total cost, followed by cycle time of forming
Process yield (cell inspection), only parameter with negative slope
19
Cost Results with the Stochastic Parameters
Process yield Triangular distribution
(80%, 90%,100%)
Energy cost Normal distribution
(0.15, 0.01)
Labor cost Triangular distribution
(20,25,30)
Cost of MWCNT Normal distribution
(5000,500)
Cycle time (forming step) Triangular distribution
(24,48,72)
Develop a simulation model
Generate numbers for the stochastic
parameters (1000 iterations)
Calculate the cost range of the CNT battery
Safety Scenarios $/Battery
No EHS [$20,370 , $13,144]
Low EHS [$20,499 , $13,330]
Medium EHS [$20,547 , $13,378]
High EHS [$20,690 , $13,419]
20
Summary Process-based cost models techniques implemented to scale-up
MWCNT LiMnO battery fabrication
Model cost outputs verified with related mfg producer
Costs calculated for each process step CNT LiMnO battery
Variables costs : material cost, energy cost, and labor cost
Fixed costs such as: machine cost, building cost, and maintenance cost
Process-based cost modeling techniques can be applied to manufacturing of
any other devices or materials
A Monte Carlo simulation model developed and random numbers for the
stochastic parameters generated to calculate the range of total cost for
different EHS levels
This model created to analyze the economic aspect of satellite batteries. It
can be applied to any batteries for any purposes like cars
21
