Energiespeichersysteme
Rudolf Simon
und Konzepte für die
Umsetzung in der Produktion
Frankfurt (Oder), Dec.2010
Dr.
M+W Group
Stuttgart, Germany
Phone +49 711 8804-1101
batteries@mwgroup.net
www.mwgroup.net
M+W Group Scope of Business
Consulting Semiconductor

Engineering, Procurement and

Photovoltaics
Construction Management

Process Equipment Hook-up Energy

Upgrade, Retrofit, Conversion Batteries

Compliance and Validation Automotive

Facility Operations Science and Research

2 Battery Factories – Dec. 2010 © M+W Group

Scope of Services

Consulting Design Construction Operation

Consulting Services, Planning Construction Facilities Services /

Evaluation, and Management Maintenance
Programming Design and Build Operation
 Feasibility Studies  Preliminary Design  Project  Maintenance
 Programming  Detail and Management of Technical
Final Design  General Contracting Building Systems
 Manufacturing
Technology  Permits /  Commissioning  Energy
Environmental Management
 Site Selection  Hook-up
Compliance  Infrastructure
 Value Engineering Services
 Commercial
Services
 Security Services

3 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

4 Battery Factories – Dec. 2010 © M+W Group

Lithium Battery Markets

Transportation Electric Grid Services

HEV / PHEV / EV Heavy-Duty Hybrids Grid Stabilization Uninterrupted Power Supply

 Fuel Economy  Increase Plant Efficiency

 Reduced Emissions  Increase Grid Reliability
 Energy Independence  Energy Independence

5 Battery Factories – Dec. 2010 © M+W Group

 Battery Type Comparison:
„Ragone Plot“
Source: SAFT

6 Battery Factories – Dec. 2010 © M+W Group

 Comparison of Weight per Capacity
Source: SAFT

7 Battery Factories – Dec. 2010 © M+W Group

 Forecast for Li-Ion Battery Market
March 2010, IIT

Worldwide rechargeable battery demand per year

40 B$

30 B$

20 B$

10 B$
Copyright ©2009-2010 /IIT

8 Battery Factories – Dec. 2010 © M+W Group

 Forecast - Automotive Battery Production

Forecast Production Area worldwide

Factories Million m²
200 5 110 $/barrel oil

160 4

Mitsubishi

120 3

80 2
CAR

40 1 60 $/barrel oil

0 0
2007 2009 2011 2013 2015 2017 2019 2021

Note: Each million m² of production area => approx. 40 large scale Factories (each 1 GWh/a)

9 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

10 Battery Factories – Dec. 2010 © M+W Group

Anforderungen an Batterien
für Elektromobilität

 Energiedichte in kWh/kg
 Leistungsdichte in kW/kg
 Lebensdauer
 Kalendarische Lebensdauer
 Zyklische Lebensdauer

 Sicherheit
 Kosten
 1000 €/kWh >>> 200 €/kWh

11 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

12 Battery Factories – Dec. 2010 © M+W Group

Design of Cells

Trend

Cylindrical / Prismatic Cell Pouch Cell

13 Battery Factories – Dec. 2010 © M+W Group

Battery Factory Modules

Electrode Production
Cell

Cell Assembly

Formation
Battery

Battery Pack Assembly

14 Battery Factories – Dec. 2010 © M+W Group

Li-Ion-Cell Factory:
Plant Layout Concept
Mataterial Preparation air lock

Anode Production

Electrolyte
Drying

Filling
Slurry

Assembly

Cathode Production

Degassing
Shipment

Pre-

Resting
Final Storage Formation

Aging
Formation

15 Battery Factories – Dec. 2010 © M+W Group

Li-Ion-Cell Factory:
Process Steps
Mataterial Preparation
Material Preparation air lock

Anode Production
 Lamination

Electrolyte
 Coating

Electrolyte
 Pressing  Tab welding

Drying

Filling
Slurry Mixing
Slurry

 Slitting  Canning
Assembly
 Sealing
 Notching
 QC Steps
Cathode Production


 Drying


Degassing
Shipment

 Formation  Resting
Pre-

Resting
Final Storage  Degassing Formation

Aging
 Pre-Formation
 Final Storage  Aging
Formation
 QC Steps

16 Battery Factories – Dec. 2010 © M+W Group

Li-Ion-Cell Factory:
Climate Zones
Mataterial Preparation air lock

Anode Production

Electrolyte
Drying

Filling
0,1%
Slurry

15% r.h. < Assembly

1% r.h.
r.h.
Cathode Production

Degassing
Shipment

Pre-

Resting
Final Storage Formation

Aging
cooling heating Formation
cooling

17 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

18 Battery Factories – Dec. 2010 © M+W Group

Factory Concept:
Buildings and Facilities
Powder Delivery & Solvent Fire Fighting
Slurry Mixing Area Storage Facilities

y C e nt er
Energ de
c t r o
Ele duction
Pro nd Cell bly
ral a ssem
ectrical C e nt
y A
El
m a t i on, li t
Uti lding
For ing & Bui
Test e
i p m ent Offic
Sh

Explosion-proof Transport
Wall Elements Corridor

19 Battery Factories – Dec. 2010 © M+W Group

Factory Concept:
Production Areas

Powder site Electrode

Slurry Mixing Production

Cell
Assembly
Shipment

Final Electrolyte
Storage Filling

Formation

Aging Pre-Formation

20 Battery Factories – Dec. 2010 © M+W Group

Factory Concept – Phase I:
Capacity 400-600 MWh/a

Shipment Material
Preparation
Slurry
Final
Storage

Cathode Production

Anode Production
Formation
CUB

Degassing
Drying
Aging

Pre- Assembly
Formation

Resting Electrolyte

21 Battery Factories – Dec. 2010 © M+W Group

Factory Concept – Phase II:
Capacity 1200-1800 MWh/a
Energy
Center

Shipment Shipment Shipment Material Material Material

Preparation Preparation Preparation
Slurry Slurry Slurry
Final Final Final
Storage Storage Storage

Cathode Production
Cathode Production

Cathode Production
Anode Production

Anode Production

Anode Production
Formation Formation Formation
CUB

Degassing Degassing Degassing

Drying Drying Drying
Aging Aging Aging

Pre- Pre- Pre- Assembly Assembly Assembly

Formation Formation Formation

Resting Resting Resting Electrolyte Electrolyte Electrolyte

22 Battery Factories – Dec. 2010 © M+W Group

Factory Concept – Phase III:
Capacity 1600-2400 MWh/a
Energy
Center

Shipment Shipment Shipment Shipment Material Material Material Material

Preparation Preparation Preparation Preparation
Slurry Slurry Slurry Slurry
Final Final Final Final
Storage Storage Storage Storage

Cathode Production
Cathode Production

Cathode Production

Cathode Production
Anode Production

Anode Production

Anode Production

Anode Production
Formation Formation Formation Formation
CUB

Degassing Degassing Degassing Degassing

Drying Drying Drying Drying
Aging Aging Aging Aging

Pre- Pre- Pre- Pre- Assembly Assembly Assembly Assembly

Formation Formation Formation Formation

Resting Resting Resting Resting Electrolyte Electrolyte Electrolyte Electrolyte

23 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

24 Battery Factories – Dec. 2010 © M+W Group

Most Relevant Energy Flows

Coating Drying
Heating
Heat

~ 100°C
Solvents Evaporation
Air Condition

Air Drying Assembly

Air Condition

Formation

Charging
Electricity

Rest
~ 60°C
Discharging Heating

25 Battery Factories – Dec. 2010 © M+W Group

Process Control

Business Management
Level
ERP

Factory Management
Level MES / MIS

Process Control
Level DCS / SCADA

PLC, Sensors, Actuators

Field Level

26 Battery Factories – Dec. 2010 © M+W Group

Agenda

 Anwendungen und Marktentwicklung

 Anforderungen für Elektromobilität
 Produktionstechnologien
 Modulare Fabrik für Großserienfertigung
 Optimierte Anlagen- und Gebäudetechnik
 Cost-of-Ownership Modell

27 Battery Factories – Dec. 2010 © M+W Group

Total Cost of Ownership Model

I. Production Capacity

2010 2011 2012 2013 2014 2015

Cell Performance [W h/Cell] 80 80 80 80 80 80
Uptime [%] 0 0 50 75 87 90
Yield [%] 0 0 70 84 90 92

 Investment Cost Cycle Time

Operating weeks
Days per W eek
Shifts
[sec]
[weeks/a]
[days/week]
[shift/day]
0
0
0
0
0
0
0
0
1,80
50
6
3
1,80
50
6
3
1,80
50
6
3
1,80
50
6
3
Hours per Shift [hour/shift] 0 0 8 8 8 8

 Labour Cost Cells/a

Output/a
2.1 Investment Cost
[Cells]
[MWh]
0
0
0
0
5.006.400
401
9.072.000
726
11.275.200
902
11.923.200
954

 Utility Cost
2.1.1 Depreciation 2010 2011 2012 2013 2014 2015

Facility Investment (Building) [M€] 2,51 2,505 2,505 2,505 2,505 2,505
Facility Investment (Facilities) [M€] 2,96 2,96 2,96 2,96 2,96 2,96
Process Equipment [M€] 0,00 35,04 35,04 35,04 35,04 35,04

 Material Cost
Licence [M€] 0,00 1,40 1,40 1,40 1,40 1,40

2.1.2 Interest Expense [M€]

2,68 14,79 15,87 14,11 12,34 10,58

 Maintenance Cost
Total Investment Cost [M€] 5,64 54,19 55,28 53,51 51,75 49,99
2.4 Labour Cost

Direct Labour Cost 2010 2011 2012 2013 2014 2015

Operators/shift [Staff] 0 0 66 66 66 66
Technicians/shift [Staff] 0 0 7 7 7 7
Sum Direct Labour Cost/a [M€] 0 0 8,586 8,586 8,586 8,586

 Total Cost Indirect Labour Cost

Overhead Staff/day [Staff] 0 0 30 30 30 30
Management Staff/day [Staff] 0 0 16 16 16 16
Engineers & Technicians Staff/day [Staff] 0 0 35 35 35 35
Maintenance Staff/day [Staff] 0 0 10 10 10 10
Sum Indirect Labour Cost/a [M€] 0 0 5,36 5,36 5,36 5,36

 Capacity Summary
Total Operators
Total Technicians
[Staff]
[Staff]
0
0
0
0
198
21
198
21
198
21
198
21
Total Indirect Staff [Staff] 0 0 91 91 91 91

 Uptime
Sum of Employees [Staff] 0 0 310 310 310 310

Staff Cost/a [M€/a] 0,00 0,00 13,95 13,95 13,95 13,95

Staff Cost/Cell [€/Cell] 2,79 1,54 1,24 1,17

 Yield
Staff Cost/Wh [€/Wh] 0,035 0,019 0,015 0,015
2.7 Maintenance Cost

Investment Percentage 2010 2011 2012 2013 2014 2015

Site [M€] 4,00 1% 0,04 0,04 0,04 0,04 0,04
Fab [M€] 76,77 2% 1,54 1,54 1,54 1,54 1,54
Process Equipment [M€] 195,30 3% 5,86 5,86 5,86 5,86

 Production Capacity Maintenance Cost

Cost per Utility Unit

[M€] 0,00 1,58 7,43 7,43 7,43 7,43

 Parameters
2010 2011 2012 2013 2014 2015
Gas [€/m³] 0,00 0,00 1,10 1,10 1,10 1,10
Electricity [€/kW h] 0,00 0,00 0,12 0,12 0,12 0,12
Heat [€/kW h] 0,00 0,00 0,06 0,06 0,06 0,06
Potable W ater [€/m³] 0,00 0,00 1,19 1,19 1,19 1,19
Industrial Water [€/m³] 0,00 0,00 1,20 1,20 1,20 1,20
Disposal Water [€/m³] 0,00 0,00 195,00 195,00 195,00 195,00
Σ Utility cost per Unit [€/Utility Unit] 0,00 0,00 198,67 198,67 198,67 198,67

28 Battery Factories – Dec. 2010 © M+W Group

Li-Ion Cell Factory:
Production Parameters (20 Ah Cell)

Production Capacity

[MWh/a] [Cells/a]
1.200 14.000.000

12.000.000
1.000

10.000.000
800

8.000.000
600
6.000.000

400
4.000.000

200
2.000.000

0 0
2010 2012 2014 2016 2018 2020 2022 2024

[MWh] [Cells]

29 Battery Factories – Dec. 2010 © M+W Group

Li-Ion Cell Factory:
Total Net Investment

Investment Licence Net Working

Total Net Investment
Fee Capital
Real Estate 2% 6% Facility Investment
Investment Investment Licence Net Working 22%
1% Fee Capital
Real Estate
Process Integration 2% 6% Facility Investment
Investment
Support 1% 22%
6%Process Integration
Support
6%

Factory Automation
8%
Factory Automation
8%

Process Equipment
Process Equipment
55% 55%

30 Battery Factories – Dec. 2010 © M+W Group

Li-Ion Cell Factory:
Cost Development

[€/kWh]
TCO per kWh
450

400

350

300
Other Cost
250 Maintenance Cost
Utility Cost
200
Material Cost
150 Labour Cost
Investment Cost
100

50

0
2010 2012 2014 2016 2018 2020 2022 2024

31 Battery Factories – Dec. 2010 © M+W Group

Li-Ion Cell Factory:
Cost Development

[€/kWh]
TCO per kWh
450

400 Ex
pe
cte
350
d Ma
rk
et
300 P ric
e Other Cost
250 Maintenance Cost
Utility Cost
200
Material Cost
150 Labour Cost
Investment Cost
100

50

0
2010 2012 2014 2016 2018 2020 2022 2024

32 Battery Factories – Dec. 2010 © M+W Group

 Lithium-Ion Batteries:
Cost Forecast
Source: McKinsey Quarterly 2009, 3

33 Battery Factories – Dec. 2010 © M+W Group

Battery Factory Network

FhG-ISI, Karlsruhe, D (New Technologies) • RWTH Aachen, D • INRETS, F (Transports and Infrastructure) • Festo,
D (Handling) • Schiller-Automation, D (Handling) • Manz, D (Line Automation) • Sick, D (Sensors and Tracking) •
Material Equipment
Schubert, D (Handling) • MFI Prozessautomation, D (Automation) • Wonderware-Invensys, D (MES) • PC-Soft, D
(MES) • SMC-Pneumatik, D (Accessories) • ILS-Technology, USA (Testequipment) • Vaisala, FI (Dry Room Sensors)
Suppliers Suppliers
• Hirano, JP, (Production) • Coatema, D (Coater, Calander) • A-Pro, KO (Coater) • Arcotronics, I (Assembly, Filling) •
HarroHöfliger, D (Assembly, Filling) • Asada Iron Works, JP (Slurry) • Hisec, JP () • Maccor, (Formation) • Digatron, D
(Formation) • Itec, (Assembly) • Voith, D (Slurry) • Vakumix, D (Slurry) • Netsch, D (Slurry) • Innovative Machines,
USA (Calander) • IKA, (Calander) • Yuri-Roll-Presses, JP (Calender) • Kampf, D (Calander) • Pink, D (Dryer) •
Heraeus, D (Dryer) • Saueressig, D (Calander) • Hybar, (Electrolyte Filling) • Vötsch, D (Formation) • Siemens, D
(QC) • Toshiba, JP (QC) • MGL, CN (Coater, Assembly) • Chemetall, D (Electrode Materials) • Südchemie, D
R&D Technology
(LiFePO4) • BASF, D (Electrode Materials) • Evonik, D (Separators) • Merck, D (Electrolyte) • Alutec, D (Tabs, Cans)
Institutes Experts
• TeECon, D • ZSW, Ulm, D (Chemistry, Production) • FhG-ISIT, Itzehoe, D (Production) • ISEA, Aachen, D (Battery
Quality and Operation) • INES-CEA, Grenoble, F (Application) • ISET,D • FVA, D (Industy Association) • ZBT
Duisburg, D (Layer Technology) • FhG-ISE, Gelsenkirchen, D • FhG-ICT, Pfinztal, D (Chemical Technology) • KIT,
Karlsruhe, D • FhG-IPA, Stuttgart, D (Production Technology) • University of Munster, D • Voith, D (Slurry) • Vakumix,
D (Slurry) • Netsch, D (Slurry) • Innovative Machines, USA (Calander) • IKA, (Calander) • Yuri-Roll-Presses, JP
(Calender) • Kampf, D (Calander) • Pink, D (Dryer) • Heraeus, D (Dryer) • Saueressig, D (Calander) • Hybar,
(Electrolyte Filling) • Vötsch, D (Formation) • Siemens, D (QC) • Toshiba, JP (QC) • ZSW, Ulm, D • TeECon, D •

Owner
Technology Provider

34 Battery Factories – Dec. 2010 © M+W Group

Thank You…..

35 Battery Factories – Dec. 2010 © M+W Group