Set Up a Lithium Ion (Lifepo4) Cell Manufacturing Plant

Introduction

Lithium ions pass from the negative electrode (anode) to the positive electrode (cathode) during discharge and from the cathode to the anode during charge in lithium-ion batteries. Because of their high energy-to-weight ratios, lack of memory effect, and slow self-discharge when not in use, lithium-ion batteries are widely used in portable consumer electronics.

The cathode of lithium iron phosphate is iron phosphate, and the anode is graphite. It has a nominal voltage of 3.20V or 3.30V and a specific energy of 90/120 watt-hours per kilogram. Lithium iron phosphate has a charge rate of 1C and a discharge rate of 1-25C.

Benefits of Lithium Ion (Lifepo4) Cell

Compared to lead-acid batteries and other lithium batteries, lithium iron phosphate batteries (LiFePO4 or LFP) have a number of advantages. To name a few advantages, the battery has a longer life cycle, requires no maintenance, is extremely stable, is lightweight, and has improved discharge and charge performance. While LiFePO4 batteries are not the cheapest on the market, they are the best investment you can make due to their long life cycle and lack of maintenance.

Manufacturing Of Lithium Ion (Lifepo4) Cell

Layers of porous electrodes on aluminium and copper current collector foils make up lithium ion batteries (Daniel 2008). To ensure battery protection and avoid the risk of anode overcharging, each electrode pair's capacity must be balanced (which can result in lithium metal plating and short circuiting) or excessive cathode discharge (which can result in a collapse of the crystal structure and loss of vacancies for lithium to intercalate, dramatically reducing capacity).

The theoretical potential of graphite is 372 Ah/kg, which is double that of currently usable lithium ion NMC cathodes. As a result, in balanced lithium ion batteries, the cathodes are usually twice as thick as the anodes.

The quest for high-capacity cathodes was prompted by this inherent error in the cell design, which causes problems with mass transport and kinetics.

In order to increase the energy density of battery cells, inactive materials are being reduced. Increase the thickness of the electrodes, for example, to minimize the current collector, but this causes transport issues and necessitates a highly engineered porosity in the electrode.

Market Outlook

The global lithium ion battery market exceeded USD 40 billion in 2019 and is expected to rise at a rate of over 15% until 2026. The lithium ion battery industry will benefit from the rising demand for electric vehicles as a result of ongoing concerns about the pollution levels. In 2019, the automotive sector accounted for the bulk of market share.

Lithium iron phosphate, lithium cobalt oxide, and manganese oxide batteries are just a few of the common lithium ion battery chemistries that have seen widespread use in a variety of applications. The implementation of favorable policies to facilitate the use of electric vehicles, as well as increased economies of scale and overcapacity in component production, has significantly reduced the cost per kWh of batteries, improving the lithium ion battery demand outlook.

Government Policies

The government approved the production-linked incentive (PLI) scheme in advance chemistry cell (ACC) battery manufacturing and ten other industries on November 11, 2020. The scheme's battery strategy aims to improve producers' foreign competitiveness, increase exports, achieve economies of scale, and develop cutting-edge products.

This is part of an attempt to encourage the use of electric vehicles (EVs), which have been hampered in India by high battery costs and a lack of supporting infrastructure. Battery imports account for more than half of the cost of an electric vehicle in India.

The government has suggested that local manufacturing facilities be built in order to minimize costs and promote competition.

The government has made it clear that it wants to drive India toward clean energy and transportation, as evidenced by the ambitious target of 450 GW of renewable energy production by 2020. Apart from promoting EVs, there has been a notable drive for renewable energy to be available around the clock, which includes energy storage like ACC batteries.

The proposed battery policy is output-based rather than input-based, which is one of the scheme's key features. The subsidy is based on the amount of production generated and the amount of value added by private companies. Only private companies would be eligible for a government subsidy if they achieve a 60 percent value addition within five years of the project's start date, which is when full-scale development is planned.

Any new technology that emerges in the next ten years will be eligible for a subsidy as well. Next, the government has set aside 570 billion (US$7.7 billion) for the car industry over the next five years as part of the programme. In fact, ACC manufacturing industries have been allocated 180 billion (US$2.4 billion) in advance. The government would pay the producer a fixed subsidy (as determined by the private entity's bid) for a period of ten years, subject to discounting over time. Economies of scale and lower production prices will be factored into the discounting.

Key Players:-

· BYD Company Ltd.

· A123 Systems LLC,

· K2 Energy

· Electric Vehicle Power System Technology Co., Ltd.

· Bharat Power Solutions

· OptimumNano Energy Co., Ltd.

· LiFeBATT, Inc.

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Other Fixed Assets Furniture & Fixtures Pre-operative and Preliminary Expenses Technical Knowhow Provision of Contingencies
Working Capital Requirement Per Month Raw Material Packing Material Lab & ETP Chemical Cost Consumable Store
Overheads Required Per Month And Per Annum Utilities & Overheads (Power, Water and Fuel Expenses etc.) Royalty and Other Charges Selling and Distribution Expenses
Salary and Wages	Turnover Per Annum
Share Capital Equity Capital Preference Share Capital
Annexure 1:: Cost of Project and Means of Finance
Annexure 2:: Profitability and Net Cash Accruals Revenue/Income/Realisation Expenses/Cost of Products/Services/Items Gross Profit Financial Charges Total Cost of Sales Net Profit After Taxes Net Cash Accruals
Annexure 3 :: Assessment of Working Capital requirements Current Assets Gross Working. Capital Current Liabilities Net Working Capital Working Note for Calculation of Work-in-process
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Annexure 6 :: Profitability ratios D.S.C.R Earnings Per Share (EPS) Debt Equity Ratio
Annexure 7 :: Break-Even Analysis Variable Cost & Expenses Semi-Var./Semi-Fixed Exp. Profit Volume Ratio (PVR) Fixed Expenses / Cost B.E.P
Annexure 8 to 11:: Sensitivity Analysis-Price/Volume Resultant N.P.B.T Resultant D.S.C.R Resultant PV Ratio Resultant DER Resultant ROI Resultant BEP
Annexure 12 :: Shareholding Pattern and Stake Status Equity Capital Preference Share Capital
Annexure 13 :: Quantitative Details-Output/Sales/Stocks Determined Capacity P.A of Products/Services Achievable Efficiency/Yield % of Products/Services/Items Net Usable Load/Capacity of Products/Services/Items Expected Sales/ Revenue/ Income of Products/ Services/ Items
Annexure 14 :: Product wise domestic Sales Realisation	Annexure 15 :: Total Raw Material Cost
Annexure 16 :: Raw Material Cost per unit	Annexure 17 :: Total Lab & ETP Chemical Cost
Annexure 18 :: Consumables, Store etc.,	Annexure 19 :: Packing Material Cost
Annexure 20 :: Packing Material Cost Per Unit	Annexure 21 :: Employees Expenses
Annexure 22 :: Fuel Expenses	Annexure 23 :: Power/Electricity Expenses
Annexure 24 :: Royalty & Other Charges	Annexure 25 :: Repairs & Maintenance Exp.
Annexure 26 :: Other Mfg. Expenses	Annexure 27 :: Administration Expenses
Annexure 28 :: Selling Expenses	Annexure 29 :: Depreciation Charges – as per Books (Total)
Annexure 30 :: Depreciation Charges – as per Books (P & M)	Annexure 31 :: Depreciation Charges - As per IT Act WDV (Total)
Annexure 32 :: Depreciation Charges - As per IT Act WDV (P & M)	Annexure 33 :: Interest and Repayment - Term Loans
Annexure 34 :: Tax on Profits	Annexure 35 ::Projected Pay-Back Period And IRR