Digitalization of Battery Manufacturing: Current Status, Challenges, and Opportunities

As the world races to respond to the diverse and expanding demands for electrochemical energy storage solutions, lithium-ion batteries (LIBs) remain the most advanced technology in the battery ecosystem. Even as unprecedented demand for state-of-the-art batteries drives gigascale production around the world, there are increasing calls for next-generation batteries that are safer, more affordable, and energy-dense. These trends motivate the intense pursuit of battery manufacturing processes that are cost effective, scalable, and sustainable. The digital transformation of battery manufacturing plants can help meet these needs. This review provides a detailed discussion of the current and near-term developments for the digitalization of the battery cell manufacturing chain and presents future perspectives in this field. Current modelling approaches are reviewed, and a discussion is presented on how these elements can be combined with data acquisition instruments and communication protocols in a framework for building a digital twin of the battery manufacturing chain. The challenges and emerging techniques provided here is expected to give scientists and engineers from both industry and academia a guide toward more intelligent and interconnected battery manufacturing processes in the future.publishedVersio

Life cycle assessment (LCA) of a battery home storage system based on primary data

While the market for battery home storage systems (HSS) is growing rapidly, there are still few well-modelled life cycle assessment (LCA) studies available for quantifying their potential environmental benefits and impacts. Existing studies mainly rely on data for electric vehicles and often lack a thorough modelling approach, especially regarding the peripheral components. This paper presents a full cradle to grave LCA of a Lithium iron phosphate (LFP) battery HSS based on primary data obtained by part-to-part dismantling of an existing commercial system with a focus on the impact of the peripheral components. Additionally, alternative battery chemistries (Sodium ion battery (SIB) and two lithium nickel manganese cobalt oxides, (NMC811, and NMC622) are investigated under the consideration of the same periphery. This approach allows a comprehensive com parison between present and emerging cell chemistries that can be potentially considered for an HSS. The total greenhouse gas emissions of the HSS are 84 g CO2eq/KWh of electricity delivered over its lifetime in a residential PV application, or 31 g CO2eq/KWh over lifetime when excluding the use-phase impact. The peripheral components contribute between 37% and 85% to the total gross manufacturing impacts of the HSS, depending on the considered cell chemistry and the impact category. Especially the inverter plays an important role, and its impacts are significantly higher than those obtained when using the standard ecoinvent dataset, indicating that the contribution of power electronics might often be underestimated when using this dataset. In terms of cell chemistries, the considered SIB turns out to be not yet competitive with LIB chemistries due to its lower energy density and lifetime, but might become so when reaching similar lifetimes

Life cycle assessment (LCA) of a battery home storage system based on primary data

While the market for battery home storage systems (HSS) is growing rapidly, there are still few well-modelled life cycle assessment (LCA) studies available for quantifying their potential environmental benefits and impacts. Existing studies mainly rely on data for electric vehicles and often lack a thorough modelling approach, especially regarding the peripheral components. This paper presents a full cradle to grave LCA of a Lithium iron phosphate (LFP) battery HSS based on primary data obtained by part-to-part dismantling of an existing commercial system with a focus on the impact of the peripheral components. Additionally, alternative battery chemistries (Sodium ion battery (SIB) and two lithium nickel manganese cobalt oxides, (NMC811,and NMC622) are investigated under the consideration of the same periphery. This approach allows a comprehensive comparison between present and emerging cell chemistries that can be potentially considered for an HSS. The total greenhouse gas emissions of the HSS are 84 g CO2eq/KWh of electricity delivered over its lifetime in a residential PV application, or 31 g CO2eq/KWh over lifetime when excluding the use-phase impact. The peripheral components contribute between 37% and 85% to the total gross manufacturing impacts of the HSS, depending on the considered cell chemistry and the impact category. Especially the inverter plays an important role, and its impacts are significantly higher than those obtained when using the standard ecoinvent dataset, indicating that the contribution of power electronics might often be underestimated when using this dataset. In terms of cell chemistries, the considered SIB turns out to be not yet competitive with LIB chemistries due to its lower energy density and lifetime, but might become so when reaching similar lifetimes

Digitalization of Battery Manufacturing: Current Status, Challenges, and Opportunities

As the world races to respond to the diverse and expanding demands for electrochemical energy storage solutions, lithium-ion batteries (LIBs) remain the most advanced technology in the battery ecosystem. Even as unprecedented demand for state-of-the-art batteries drives gigascale production around the world, there are increasing calls for next-generation batteries that are safer, more affordable, and energy-dense. These trends motivate the intense pursuit of battery manufacturing processes that are cost effective, scalable, and sustainable. The digital transformation of battery manufacturing plants can help meet these needs. This review provides a detailed discussion of the current and near-term developments for the digitalization of the battery cell manufacturing chain and presents future perspectives in this field. Current modelling approaches are reviewed, and a discussion is presented on how these elements can be combined with data acquisition instruments and communication protocols in a framework for building a digital twin of the battery manufacturing chain. The challenges and emerging techniques provided here is expected to give scientists and engineers from both industry and academia a guide toward more intelligent and interconnected battery manufacturing processes in the future

Rechargeable Batteries of the Future—The State of the Art from a BATTERY 2030+ Perspective

The development of new batteries has historically been achieved through discovery and development cycles based on the intuition of the researcher, followed by experimental trial and error—often helped along by serendipitous breakthroughs. Meanwhile, it is evident that new strategies are needed to master the ever-growing complexity in the development of battery systems, and to fast-track the transfer of findings from the laboratory into commercially viable products. This review gives an overview over the future needs and the current state-of-the art of five research pillars of the European Large-Scale Research Initiative BATTERY 2030+, namely 1) Battery Interface Genome in combination with a Materials Acceleration Platform (BIG-MAP), progress toward the development of 2) self-healing battery materials, and methods for operando, 3) sensing to monitor battery health. These subjects are complemented by an overview over current and up-coming strategies to optimize 4) manufacturability of batteries and efforts toward development of a circular battery economy through implementation of 5) recyclability aspects in the design of the battery

Rechargeable Batteries of the Future-The State of the Art from a BATTERY 2030+Perspective

The development of new batteries has historically been achieved through discovery and development cycles based on the intuition of the researcher, followed by experimental trial and error-often helped along by serendipitous breakthroughs. Meanwhile, it is evident that new strategies are needed to master the ever-growing complexity in the development of battery systems, and to fast-track the transfer of findings from the laboratory into commercially viable products. This review gives an overview over the future needs and the current state-of-the art of five research pillars of the European Large-Scale Research Initiative BATTERY 2030+, namely 1) Battery Interface Genome in combination with a Materials Acceleration Platform (BIG-MAP), progress toward the development of 2) self-healing battery materials, and methods for operando, 3) sensing to monitor battery health. These subjects are complemented by an overview over current and up-coming strategies to optimize 4) manufacturability of batteries and efforts toward development of a circular battery economy through implementation of 5) recyclability aspects in the design of the battery

A Roadmap for Transforming Research to Invent the Batteries of the Future Designed within the European Large Scale Research Initiative BATTERY 2030+

This roadmap presents the transformational research ideas proposed by “BATTERY 2030+,” the European large-scale research initiative for future battery chemistries. A “chemistry-neutral” roadmap to advance battery research, particularly at low technology readiness levels, is outlined, with a time horizon of more than ten years. The roadmap is centered around six themes: 1) accelerated materials discovery platform, 2) battery interface genome, with the integration of smart functionalities such as 3) sensing and 4) self-healing processes. Beyond chemistry related aspects also include crosscutting research regarding 5) manufacturability and 6) recyclability. This roadmap should be seen as an enabling complement to the global battery roadmaps which focus on expected ultrahigh battery performance, especially for the future of transport. Batteries are used in many applications and are considered to be one technology necessary to reach the climate goals. Currently the market is dominated by lithium-ion batteries, which perform well, but despite new generations coming in the near future, they will soon approach their performance limits. Without major breakthroughs, battery performance and production requirements will not be sufficient to enable the building of a climate-neutral society. Through this “chemistry neutral” approach a generic toolbox transforming the way batteries are developed, designed and manufactured, will be created. © 2022 The Authors. Advanced Energy Materials published by Wiley-VCH GmbHpublishedVersio

A Roadmap for Transforming Research to Invent the Batteries of the Future Designed within the European Large Scale Research Initiative BATTERY 2030+

This roadmap presents the transformational research ideas proposed by “BATTERY 2030+,” the European large-scale research initiative for future battery chemistries. A “chemistry-neutral” roadmap to advance battery research, particularly at low technology readiness levels, is outlined, with a time horizon of more than ten years. The roadmap is centered around six themes: 1) accelerated materials discovery platform, 2) battery interface genome, with the integration of smart functionalities such as 3) sensing and 4) self-healing processes. Beyond chemistry related aspects also include crosscutting research regarding 5) manufacturability and 6) recyclability. This roadmap should be seen as an enabling complement to the global battery roadmaps which focus on expected ultrahigh battery performance, especially for the future of transport. Batteries are used in many applications and are considered to be one technology necessary to reach the climate goals. Currently the market is dominated by lithium-ion batteries, which perform well, but despite new generations coming in the near future, they will soon approach their performance limits. Without major breakthroughs, battery performance and production requirements will not be sufficient to enable the building of a climate-neutral society. Through this “chemistry neutral” approach a generic toolbox transforming the way batteries are developed, designed and manufactured, will be created. © 2022 The Authors. Advanced Energy Materials published by Wiley-VCH Gmb

A Roadmap for Transforming Research to Invent the Batteries of the Future Designed within the European Large Scale Research Initiative BATTERY 2030+

This roadmap presents the transformational research ideas proposed by “BATTERY 2030+,” the European large-scale research initiative for future battery chemistries. A “chemistry-neutral” roadmap to advance battery research, particularly at low technology readiness levels, is outlined, with a time horizon of more than ten years. The roadmap is centered around six themes: 1) accelerated materials discovery platform, 2) battery interface genome, with the integration of smart functionalities such as 3) sensing and 4) self-healing processes. Beyond chemistry related aspects also include crosscutting research regarding 5) manufacturability and 6) recyclability. This roadmap should be seen as an enabling complement to the global battery roadmaps which focus on expected ultrahigh battery performance, especially for the future of transport. Batteries are used in many applications and are considered to be one technology necessary to reach the climate goals. Currently the market is dominated by lithium-ion batteries, which perform well, but despite new generations coming in the near future, they will soon approach their performance limits. Without major breakthroughs, battery performance and production requirements will not be sufficient to enable the building of a climate-neutral society. Through this “chemistry neutral” approach a generic toolbox transforming the way batteries are developed, designed and manufactured, will be created. © 2022 The Authors. Advanced Energy Materials published by Wiley-VCH Gmb