Sergei Mishin, measurement solutions sales director OEM Europe, explains how automation technology is essential to optimised, precise and safe production of anodes, cathodes and electrolytes.
Global electric vehicle (EV) sales are growing and accounted for 10% of all new cars sold in 2022, but reports suggest that EV sales must increase to approximately 60% by 2030 to align with the net-zero emissions by 2050 target. The advancement of lithium-ion battery technology has been central to the emergence of electric vehicles. Over the last two decades, lithium battery manufacturers and the manufacturers of EV battery components including anodes, cathodes and electrolytes have worked extremely closely to develop materials that enhance the performance and safety of lithium-ion batteries. For component manufacturers it is essential to implement manufacturing processes and technologies that ensure consistent and assured production quality and safety, while at the same time minimising costly rework that impacts throughput and profitability. The continuity of the manufacturing process means that errors or impurities taking place at an early stage will accumulate, resulting in much larger consequences further down the production line. Quality needs to be monitored at every stage – from raw materials through to cell assembly – to maintain production efficiency and minimise waste.
Optimised production is also extremely important, not only to ensure quality despite raw material variation and maximise throughput, but also to provide manufacturers with the flexibility to meet customer requests for different battery component types and proprietary recipes. Typically, manufacturing is based on batch processes. Batch control provided by Emerson’s DeltaV Batch Analytics software is designed specifically for this type of application. The key feature of this solution is that by learning from the past, the software is able to predict production outcomes. Multi-variate analysis of the process is performed based on models generated from a compilation of historical batches. Faults or deviations in the batch process are detected and identified in real time, giving operations the ability to take corrective action before a negative impact on production occurs. Should process parameters deviate from norms, it can evaluate whether the batch will still meet specifications and quality requirements or will fall outside specified parameters and require rework or disposal. This means decreased costs, reduced cycle times, increased yield, reduced waste, reduced variability and improved reliability.
Advanced measurement
Ensuring recipe consistency and production quality starts with accurate, reliable and repeatable measurements. Within a batch reactor application these need to monitor the addition of both raw materials and additives. Reactor heating and cooling, pressure control, overfill prevention and equipment condition monitoring rely on flow, temperature, level, pressure and analytical measurements. Precise control of material added to reactors and mixers is critical. Emerson’s Micro Motion™ Coriolis meters are ideally suited for these applications because they measure mass flow of the liquid or slurry rather than volume, ensuring measurement accuracy. Cathode precursor pH measurement accuracy is critical to the final shape of colloids impacting quality, but the sulfides and hydrofluoric acid present a very tough environment and reduce sensor life, whilst oil layers on the sensor make measurement difficult. The Rosemount RBI pH/OPR sensor is highly chemical-resistant and designed for string layer resistance, ensuring measurement certainty and reducing maintenance requirements. It’s important to understand the levels in reactors and mixing tanks to prevent damage to agitators caused by low level and protect against overfilling that presents safety issues. It can be difficult to accurately measure the level of metal slurry in a tank with an agitator that creates turbulence, changing the density of materials, which affects differential pressure-based level measurements, and viscous materials that would coat contacting technologies. Rosemount non-contacting radar level transmitters are well suited for these applications, as they can cope with these challenges. Their high sensitivity and unique software ensure that their performance is not affected by weak signals and turbulent conditions, while a process seal antenna protects against the corrosive media and high condensation levels.
Ensuring stable control and safety
Uneven chemical additives can lead to chemical waste and raw material inconsistencies creating costly product scrap. Reliable, precise and very smooth control is also essential to ensure process control strategies are implemented correctly. Typically, these applications are very challenging for valves, with abrasive and corrosive chemicals, slurries and powders flowing through the production process. Corrosion impacts the reliability and performance of valves, creating unstable flow control and also the possibility of leaks that create safety hazards for plant and workers. To maintain reliable operations and prevent safety and environmental issues, it is essential to ensure material compatibility. Emerson not only offers an extensive range of control valves suitable for severe service applications, but has the expertise to work with customers to select the appropriate technology and anti-corrosive materials to ensure high performance over an extended lifetime. For example, Fisher™ valves with hardened and ceramic trims provide good wear resistance, while Fisher vee-ball with its V-notch ball provides a non-clogging control solution. Emerson’s Clarkson bi-directional valves feature a leak-free shut-off and are suitable for low and medium density slurries at low pressure (<10 bar) and high pressure (<20 bar). For powder handling applications, Keystone™ F990 valves feature a special design with a split body and one-piece disc-shaft that produces a high flow capacity and simplifies maintenance. For manufacturers keen to focus resources on maintaining efficient production and continued product development, Emerson’s leading measurement, control and electrical technologies, combined with a global network of application experts, and engineering solution services, make the company the ideal partner in this rapidly developing market. Emerson is uniquely positioned to be able to provide process control systems, a complete range of advanced measurement solutions and the world’s most comprehensive range of final control technology.
To discover how Emerson’s products and services can improve product quality, plant reliability and safety for EV battery component manufacturers visit Emrsn.co/IM1906
