Energiespeichersysteme und Konzepte für die Umsetzung in ... · Energiespeichersysteme und...

Energiespeichersysteme und Konzepte für die Umsetzung in der Produktion

Frankfurt (Oder), Dec.2010

Dr. Rudolf Simon

M+W GroupStuttgart, Germany Phone +49 711 8804-1101

[email protected]

© M+W Group2 Battery Factories – Dec. 2010

M+W Group Scope of Business

Facility Operations

Consulting

Engineering, Procurement and Construction Management

Process Equipment Hook-up

Upgrade, Retrofit, Conversion

Compliance and Validation Automotive

Semiconductor

Photovoltaics

Energy

Batteries

Science and Research


Scope of Services

OperationConsulting Design Construction

Feasibility Studies

Programming

Manufacturing

Technology

Site Selection

Preliminary Design

Detail and Final Design

Permits / Environmental Compliance

Value Engineering

Project Management

General Contracting

Commissioning

Hook-up

Maintenance of Technical

Building Systems

Energy Management

Infrastructure Services

Commercial Services

Security Services

Consulting Services, Evaluation,

Programming

Planning and

Design

Construction Management

and Build

Facilities Services / Maintenance

Operation


Agenda

Anwendungen und Marktentwicklung

Anforderungen für Elektromobilität

Produktionstechnologien

Modulare Fabrik für Großserienfertigung

Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Lithium Battery Markets

Electric Grid ServicesTransportation

Uninterrupted Power SupplyHEV / PHEV / EV Grid Stabilization

Fuel

Economy

Reduced

Emissions

Energy Independence

Increase

Plant Efficiency

Increase

Grid Reliability

Energy Independence

Heavy-Duty Hybrids


Battery Type Comparison: „Ragone Plot“

Sou

rce:

SA

FT


Comparison of Weight per CapacityS

ourc

e: S

AFT


Forecast for Li-Ion Battery Market March 2010, IIT

10 B$

20 B$

30 B$

40 B$Worldwide rechargeable battery demand per year

Cop

yrig

ht ©

2009

-201

0 /II

T


200

Forecast - Automotive Battery Production

Note: Each

million

m²

of production

area

=> approx. 40

large scale

Factories

(each

1 GWh/a)

Forecast Production Area worldwide

0

1

2

3

4

5

2007 2009 2011 2013 2015 2017 2019 2021

Million m²

Mitsubishi

CAR

60 $/barrel

oil

110 $/barrel

oil

40

80

120

160

0

Factories

http://upload.wikimedia.org/wikipedia/de/5/56/Mitsubishi_Logo.svg


Agenda





Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Anforderungen an Batterien für Elektromobilität

Energiedichte in kWh/kg

Leistungsdichte in kW/kg

Lebensdauer

Kalendarische Lebensdauer

Zyklische Lebensdauer

Sicherheit

Kosten

1000 €/kWh >>> 200 €/kWh


Agenda





Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Design of Cells

Cylindrical

/ Prismatic

Cell Pouch

Cell

Trend


Battery Factory Modules

Electrode Production

Cell Assembly

Formation

Battery Pack Assembly

Bat

tery

Cel

l


Li-Ion-Cell Factory: Plant Layout Concept

Final Storage Formation Pre-

Formation

Agin

g

Res

ting

Deg

assi

ng

Ship

men

t

Cathode

Production

Anode Production

Dry

ing

Assembly

Elec

troly

teFi

lling

Mat

ater

ialP

repa

ratio

n

Slur

ryair lock


Li-Ion-Cell Factory: Process Steps


Formation

Agin

g

Res

ting

Deg

assi

ng

Ship

men

t

Cathode

Production

Anode Production

Dry

ing

Assembly

Elec

troly

teFi

lling

Mat

ater

ialP

repa

ratio

n

Slur

ryair lock

Coating Pressing Slitting Notching

M

ater

ial P

repa

ratio

n

Sl

urry

Mix

ing

El

ectr

olyt

e Lamination Tab welding Canning Sealing QC Steps Drying

Formation Degassing Final Storage QC Steps

Resting Pre-Formation Aging


Li-Ion-Cell Factory: Climate Zones


Formation

Agin

g

Res

ting

Deg

assi

ng

Ship

men

t

Cathode

Production

Anode Production

Dry

ing

Assembly

Elec

troly

teFi

lling

Mat

ater

ialP

repa

ratio

n

Slur

ryair lock

15% r.h.

cooling

0,1% r.h.< 1% r.h.

coolingheating


Agenda





Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Factory Concept: Buildings and Facilities

Solvent Storage

ShipmentShipment

ElectrodeElectrode

Production

and and CellCellAssemblyAssembly

CentralCentralUtilityUtility

BuildingBuilding

Energy CenterEnergy Center

Office

Fire Fighting Facilities

Explosion-proof Wall Elements

Transport Corridor

Powder Delivery & Slurry Mixing Area

ElectricalElectrical

Formation,Formation,

TestingTesting &&


Factory Concept: Production Areas

Powder

siteSlurry

Mixing

Electrode Production

Cell Assembly

Formation

Pre-Formation

Electrolyte Filling

Aging

Final Storage

Shipment


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

Material Preparation

Slurry

Cathode

Production

Assembly

Resting

Pre- Formation

Aging

Degassing

Shipment

Electrolyte

CUB

Anode Production

Formation

Final Storage

Drying


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


Slurry

Cat

hode

Prod

uctio

nAssembly

Resting

Pre- Formation

Aging

Degassing

Shipment

Electrolyte

CUB

Energy Center

Ano

de P

rodu

ctio

n

Formation

Final Storage

Drying


Slurry

Cat

hode

Prod

uctio

n

Assembly

Electrolyte

Ano

de P

rodu

ctio

n

Drying

Slurry

Cat

hode

Prod

uctio

n

Assembly

Electrolyte

Ano

de P

rodu

ctio

n

Drying


Resting

Pre- Formation

Aging

Degassing

Shipment

Final Storage

Formation

Resting

Pre- Formation

Aging

Degassing

Shipment

Final Storage

Formation


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


Slurry

Cat

hode

Prod

uctio

nAssembly

Resting

Pre- Formation

Aging

Degassing

Shipment

Electrolyte

CUB

Energy Center

Ano

de P

rodu

ctio

n

Formation

Final Storage

Drying


Slurry

Cat

hode

Prod

uctio

n

Assembly

Electrolyte

Ano

de P

rodu

ctio

n

Drying

Slurry

Cat

hode

Prod

uctio

n

Assembly

Electrolyte

Ano

de P

rodu

ctio

n

Drying


Slurry

Cat

hode

Prod

uctio

n

Assembly

Electrolyte

Ano

de P

rodu

ctio

n

Drying


Resting

Pre- Formation

Aging

Degassing

Shipment

Final Storage

Formation

Resting

Pre- Formation

Aging

Degassing

Shipment

Final Storage

Formation

Resting

Pre- Formation

Aging

Degassing

Shipment

Final Storage

Formation


Agenda





Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Most Relevant Energy FlowsH

eat

Solvents

Evaporation

Coating

Air Drying

Heating

Drying

Air Condition

Charging

Formation

Discharging Heating

Rest

Air Condition

Assembly

Ele

ctric

ity

~ 100°C

~ 60°C


Process Control

Business Management Level

Factory Management Level

Process Control Level

Field Level

DCS / SCADA

ERP

PLC, Sensors, Actuators

MES / MIS


Agenda





Optimierte Anlagen-

und Gebäudetechnik

Cost-of-Ownership

Modell


Total Cost of Ownership Model

Investment Cost Labour Cost Utility Cost Material Cost Maintenance

Cost

Total Cost

Capacity Uptime Yield

Production Capacity Parameters

I. Production Capacity

2010 2011 2012 2013 2014 2015Cell Performance [Wh/Cell] 80 80 80 80 80 80Uptime [%] 0 0 50 75 87 90Yield [%] 0 0 70 84 90 92Cycle Time [sec] 0 0 1,80 1,80 1,80 1,80Operating weeks [weeks/a] 0 0 50 50 50 50Days per Week [days/week] 0 0 6 6 6 6Shifts [shift/day] 0 0 3 3 3 3Hours per Shift [hour/shift] 0 0 8 8 8 8

Cells/a [Cells] 0 0 5.006.400 9.072.000 11.275.200 11.923.200Output/a [MWh] 0 0 401 726 902 9542.1 Investment 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 2,505Facility Investment (Facilities) [M€] 2,96 2,96 2,96 2,96 2,96 2,96Process Equipment [M€] 0,00 35,04 35,04 35,04 35,04 35,04Licence [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

Total Investment Cost [M€] 5,64 54,19 55,28 53,51 51,75 49,992.4 Labour Cost

Direct Labour Cost 2010 2011 2012 2013 2014 2015Operators/shift [Staff] 0 0 66 66 66 66Technicians/shift [Staff] 0 0 7 7 7 7Sum Direct Labour Cost/a [M€] 0 0 8,586 8,586 8,586 8,586

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

SummaryTotal Operators [Staff] 0 0 198 198 198 198Total Technicians [Staff] 0 0 21 21 21 21Total Indirect Staff [Staff] 0 0 91 91 91 91Sum of Employees [Staff] 0 0 310 310 310 310

Staff Cost/a [M€/a] 0,00 0,00 13,95 13,95 13,95 13,95Staff Cost/Cell [€/Cell] 2,79 1,54 1,24 1,17Staff Cost/Wh [€/Wh] 0,035 0,019 0,015 0,0152.7 Maintenance Cost

Investment Percentage 2010 2011 2012 2013 2014 2015Site [M€] 4,00 1% 0,04 0,04 0,04 0,04 0,04Fab [M€] 76,77 2% 1,54 1,54 1,54 1,54 1,54Process Equipment [M€] 195,30 3% 5,86 5,86 5,86 5,86

Maintenance Cost [M€] 0,00 1,58 7,43 7,43 7,43 7,43

Cost per Utility Unit2010 2011 2012 2013 2014 2015

Gas [€/m³] 0,00 0,00 1,10 1,10 1,10 1,10Electricity [€/kWh] 0,00 0,00 0,12 0,12 0,12 0,12Heat [€/kWh] 0,00 0,00 0,06 0,06 0,06 0,06Potable Water [€/m³] 0,00 0,00 1,19 1,19 1,19 1,19Industrial Water [€/m³] 0,00 0,00 1,20 1,20 1,20 1,20Disposal Water [€/m³] 0,00 0,00 195,00 195,00 195,00 195,00Σ Utility cost per Unit [€/Utility Unit] 0,00 0,00 198,67 198,67 198,67 198,67


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

Production Capacity

0

200

400

600

800

1.000

1.200

2010 2012 2014 2016 2018 2020 2022 2024

[MWh/a]

0

2.000.000

4.000.000

6.000.000

8.000.000

10.000.000

12.000.000

14.000.000[Cells/a]

[MWh] [Cells]


Li-Ion Cell Factory: Total Net Investment

Total Net Investment

Process Equipment55%

Factory Automation8%

Process Integration Support

6%

Real Estate Investment

1%

Investment Licence Fee2% Facility Investment

22%

Net Working Capital

6%

Process Equipment55%

Factory Automation8%

Process Integration Support

6%

Real Estate Investment

1%

Investment Licence Fee2% Facility Investment

22%

Net Working Capital

6%


Li-Ion Cell Factory: Cost Development

TCO per kWh

0

50

100

150

200

250

300

350

400

450

2010 2012 2014 2016 2018 2020 2022 2024

[€/kWh]

Other CostMaintenance CostUtility CostMaterial CostLabour CostInvestment Cost


Li-Ion Cell Factory: Cost Development

TCO per kWh

0

50

100

150

200

250

300

350

400

450

2010 2012 2014 2016 2018 2020 2022 2024

[€/kWh]

Other CostMaintenance CostUtility CostMaterial CostLabour CostInvestment Cost

Expected Market Price


Lithium-Ion Batteries: Cost Forecast

Source: McKinsey Q

uarterly

2009, 3


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) •

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) •

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 (LiFePO4) •

BASF, D (Electrode

Materials) •

Evonik, D (Separators) •

Merck, D (Electrolyte) •

Alutec, D (Tabs, Cans) •

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 •

Battery Factory Network

R&D Institutes

Material Suppliers

Equipment Suppliers

Technology Experts

OwnerTechnology Provider


Thank You…..

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