LITHIUM FERRO PHOSPHATE BATTERY PACK

(CAP: 50 NOS/DAY)
[EIRI/EDPR/4047] J.C.: 2180XL

INTRODUCTION

A lithium iron phosphate (LFP) battery is a type of lithium-ion battery that is

capable of charging and discharging at high speeds compared to other types of
batteries. It is a rechargeable battery consisting of LiFePO4 as its cathode
material; hence the name.

Lithium iron phosphate batteries have several distinctive features, including:

 Better power density

 Low discharge rate
 Flat discharge curve
 Less heating
 Higher number of charge cycles
 Increased safety

Lithium iron phosphate (LFP) batteries are also known as lithium ferrophosphate
batteries.

The first model of the lithium iron phosphate battery was made after the discovery
of phosphate as a cathode material for use in li-ion batteries in 1996.
Improvements in the coatings and usage of nano-scale phosphate have made this
type of battery more efficient.

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The major distinction that lithium iron phosphate batteries have from other li-ion
batteries is that LFP is capable of delivering a constant voltage and also has a
comparatively higher charge cycle, in the range of 2000-3000. LFP batteries are
environmentally safe and structurally stable. They have a lower energy density
and low discharge rate. They do not heat up easily and are relatively cooler than
other batteries. The chemistry of the battery saves it from thermal runaway, and
hence it is considered to be safe for home use.

Due to their constant voltage and safe discharge, LFPs have found applications in
cars, bicycles and solar devices. They are also used as replacements for costly
lead-acid starter batteries. They are well suited for applications that require high-
load currents and endurance. They are easy to store and carry due to their light
weight and ability to provide huge amounts of energy. They are widely used in
portable electronic devices like laptops and mobile phones.

A recent improvement over the original lithium iron phosphate cathode material
by MIT has allowed these batteries to be charged up to 100 times faster than the
previous speed. An improvised coating of an ion conductor onto the LFP has
enabled the acceleration of ions, and thus the charging time has been greatly
reduced.

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Lithium Iron Phosphate (LiFePO4)

Phosphate based technology possesses superior thermal and chemical stability

which provides better safety characteristics than those of Lithium-ion technology
made with other cathode materials. Lithium phosphate cells are incombustible in
the event of mishandling during charge or discharge, they are more stable under
overcharge or short circuit conditions and they can withstand high temperatures
without decomposing. When abuse does occur, the phosphate based cathode
material will not burn and is not prone to thermal runaway. Phosphate chemistry
also offers a longer cycle life.

Lithium Ion Cathode Chemistry Comparison (Used With Carbon Anodes)

Energy Density
Typical
Cathode
Voltage Thermal Stability
Material Gravimeric Volumetric
(V)
(Wh/Kg) (Wh/L)

Cobalt Oxide 3.7 195 560 Poor

Nickel Cobalt 3.6 220 600 Fair

Aluminum
Oxide (NCA)

Nickel Cobalt 3.6 205 580 Fair

Manganese
Oxide (NCM)

Manganese 3.9 150 420 Good

Oxide (Spinel)

Iron Phosphate 3.2 90-130 333 Very Good

(LFP)

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 CONTENTS

INTRODUCTION
LITHIUM IRON PHOSPHATE (LIFEPO4)
LITHIUM ION CATHODE CHEMISTRY COMPARISON (USED WITH
CARBON ANODES)
ADVANTAGES:
CONSTRUCTION OF LITHIUM FERRO PHOSPHATE BATTERY
CHARGING AND DISCHARGING PHENOMINA IN LI ION BATTERY
SAFETY FACTOR IN LITHIUM ION PHOSPHATE BATTERIES
CHARACTERSTICS OF LIFEPO4 BATTERIES
DIFFERENT SHAPES OF LITHIUM FERRO PHOSPHATE CELLS
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR BATTERY ASSEMBLING
ASSEMBLING PROCESS OF LITHIUM ION BATTERY
1. CELL SORTING:
2. MODULE ASSEMBLY:
3. PACK ASSEMBLY:
4. FINAL TESTING AND STORAGE:
EQUIPMENTS FOR AUTOMATIC ASSEMBLY
1. LINEAR WORKPIECE CARRIER TRANSFER SYSTEM
2. PRE-ASSEMBLY STATION
3. AUTOMATIC MODULE ASSEMBLY STATION
1. ASSEMBLY OF SECOND SIDE PLATE
2. AUTOMATIC LINE CHANGE
3. AUTOMATIC LASER WELDING STATION
MARKET POSITION
INDIA LITHIUM-ION BATTERY MARKET
DECREASING COST OF LITHIUM-ION BATTERIES - TO SUPPLEMENT
THE DEMAND
RENEWABLE-BASED ENERGY STORAGE - OPPORTUNITY FOR GROWTH
ELECTRIC VEHICLES & LITHIUM ION BATTERY MARKET, INDIA, 2017
CHANGING LANDSCAPE OF THE ENERGY SECTOR, INDIA, 2017-2030
INDIA LITHIUM-ION BATTERIES MARKET TO GROW AT OVER 35%
CAGR TILL 2020
INDIA LITHIUM-ION BATTERIES MARKET FORECAST AND
OPPORTUNITIES, 2020
KEY DEVELOPMENTS IN THE INDIA LITHIUM-ION BATTERY MARKET
INDIGENIZATION OF LITHIUM-ION BATTERY MANUFACTURING
A TECHNO-ECONOMIC FEASIBILITY ASSESSMENT

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GLOBAL LIB PRODUCTION AND PRICE TREND
LIB DEMAND IN INDIA: PROJECTIONS FOR 2030
ECONOMICS OF LIB MANUFACTURING: 50 GWH PLANT
ANALYSIS & RECOMMENDATIONS
BATTERY MARKET POSITION
GLOBAL CONTEXT AND IMPACT
KEY CHALLENGES TO SCALING INDIA’S BATTERY INDUSTRY
A. LOW MINERAL RESERVES
B. EARLY-STAGE BATTERY MANUFACTURING INDUSTRY
C. LACK OF COORDINATION AMONG STAKEHOLDERS
D. HIGH PERCEIVED RISK
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING

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PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF LIFEPO4 BATTERY PACK
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF LI ION FE PO4 CELL
CHINA SUPPLIERS FOR LIFEPO4 CELL
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ASSEMBLY LINE
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SUBMERSIBLE WATER PUMP
ADDRESSES OF PLANT & MACHINERY SUPPLIERS FOR LITHUM BATTERY

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 50 Nos/Day

Land & Building (1000 sq.mt.) Rs. 1.57 Cr
Plant & Machinery Rs. 35 Lac
Working Capital for 2 Months Rs. 5.30 Cr
Total Capital Investment Rs. 7.28 Cr
Rate of Return 36%
Break Even Point 51%

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