WS #B: Cells and modules

In the area of cells and modules, the focus is on the development and FID of battery components, battery cells, modules and innovative test methods.

Above-mentioned innovations in the field of raw and advanced materials as well as process innovations cumulate into this area dedicated to cells and modules and lead to technologically leading battery cells and modules generations.

In the area of battery cell components, innovative solutions for the solid-state technology will in particular be developed. It will include solutions to utilize solid-state electrolytes in combination with LiM. Fully solvent free electrode processes, cathode in particular, are equally part of the innovation as Co-free cathodes. Both will have a significant contribution to a far more sustainable battery cell production and will improve the CO2-eq footprint.

The innovative nature for the battery cells itself lies in the increase in energy density and power density taking into account economic and ecological aspects. It combines innovations from the material and process area with novel cell designs developed during the individual projects. The particular focus of the Integrated Project on cells and modules will be on a green manufacturing footprint: elimination of toxic solvents; reducing the CO2-eq equivalent during production; and more efficient processes (reversible formation, water based coating).

 

IPCEI Partner

ACC

Created in September 2020 Automotive Cells Company (ACC) is a new venture that brings together the expertise of three major companies, with highly complementary skills and experiences: Saft, PSA and Opel.

France

Saft specializes in advanced battery technology solutions for industry, from design and development to production, customization and service provision, and brings its expertise for battery R&D and industrialization. PSA (Stellantis) is a French multinational automobile company creating vehicles for Peugeot, Citroen, DS, Opel and Vauxhall and will make ACC benefit from its knowledge of the automotive market and its experience in mass production. Opel brings over a century of German industrial know-how to ACC. They've lead the way in creating robust, reliable vehicles since 1899.
This association demonstrates their desire to combine their know-how to create a global reference player for battery development and manufacturing for eV, and the European leader of automotive batteries enabling clean and efficient mobility for the greatest number.
ACC’s ambitions are to be a high-tech and innovative center of excellence, to be competitive, producing automotive batteries more affordable than ever, to act in a socially and environmentally responsible manner and to create highly qualified jobs and job opportunities also in its value chain.
ACC’s 4 main environmental and social levers for responsible battery manufacturing are: the lowest possible carbon footprint for its cells and modules in a continuous improvement approach, a sustainable supply chain with full traceability of the raw materials especially the strategic metals, eco-design of the products that will be recyclable, easy to repair and dismantle, and factories operated according to the best environmental management standards.

Description of the project
ACC’s project targets within the framework of „IPCEI on Batteries“ are research & development, prototype production and testing of highly innovative Lithium ion battery cell technologies and mass-production of battery cells and modules in 2 gigafactories. The project builds on R&D activities near Bordeaux (South of France) and on a testing plant in Nersac (South of France). The second phase of the project is the building of a Gigafactory for battery cells and modules in Billy-Berclau (North of France), with an expected start of production by mid-2023. And the third one is the construction of another Gigafactory in Kaiserslautern (Germany).
By 2030, ACC aim to produce one million batteries annually with at least 70% of its suppliers based in Europe.

www.acc-emotion.com

BMW

With its four brands BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial and mobility services.

Germany

The BMW Group production network comprises 31 production and assembly facilities in 15 countries; the company has a global sales network in more than 140 countries.

In 2019, the BMW Group sold over 2.5 million passenger vehicles and more than 175,000 motorcycles worldwide. The profit before tax in the financial year 2019 was € 7.118 billion on revenues amounting to € 104.210 billion. As of 31 December 2019, the BMW Group had a workforce of 126,016 employees.

The success of the BMW Group has always been based on long-term thinking and responsible action. The company has therefore established ecological and social sustainability throughout the value chain, comprehensive product responsibility and a clear commitment to conserving resources as an integral part of its strategy.

Description of the project
BMW’s project targets within the framework of „IPCEI on Batteries“ are design (including definition of cell chemistry), development, prototype production and testing of a highly innovative generation of Lithium ion battery cells. Therefore, several battery cells sample prototypes are built, tested and analyzed. The final target cell will be manufactured on the newly set-up battery cell pilot plant and as proof of concept fully validated as basis for subsequent industrialization by a European cell supplier.

Another significant part of the project is the design of an improved and innovative module and battery pack targeting substantial reduction of production time, cost reduction, increase of energy density (on module and pack level), but in particular leading to a significantly improved recycling ability (e.g. less complicated automated dismantling, optimization of material mix…) as a base of recirculation of materials into production process (circular economy).

www.bmwgroup.com

Endurance

Endurance SpA (Endurance), an Italy-based subsidiary of Endurance Overseas, the European holding company of the Endurance Group, active in the supply of engine and transmission components to European automotive OEMs.

Italy

Eneris

Eneris Groupa (Eneris), a Poland-based company, dedicated to innovations protecting environment (waste, water, energy) active, amongst other, in distributed energy and recycling, including batteries.

Poland

FAAM

FIB S.p.A., an Italy-based company, operating under the brand FAAM, is active in the design, production and recycling of cells, modules, and li-ion batteries for industrial, automotive, storage, and special applications.

Italy

FIB has already realized a pilot production of cells, modules, and li-ion batteries in Teverola (Italy) with a production capacity of 0.35GWh.
FIB is also active in the production and recycling of lead-acid batteries, as well as in the design and construction of plants for the recycling of end-of-life batteries.
FIB is part of Seri Industrial Group, a listed company on the Milan Stock Exchange (MTA) operating along the entire value chain of plastics (recycling, moulding, and extrusion) and batteries, that employs almost 1,000 people in 14 production plants in Italy, France, Poland, and China.

Project Description (Cells and modules WS)
The objective of the project is the design and development of beyond state-of-the-art Li-ion cells and modules, based on high-voltage, high energy, and safe active materials. Particular attention will be put on the environmental footprint, with a sustainable and efficient manufacturing process. The green manufacturing process will be carried out by eliminating toxic solvents and reducing the CO2- equivalent during production. Emphasis will be put on the battery cell and module design to be easily dismantled and recycled.
The project will be deployed in the Teverola (Italy) cluster area, where FIB is already running a 0.35GWh plant. The mission of FIB is to deploy the first Mediterranean Gigafactory.

Project Description (Recycling WS)
The objective of the project is the deployment of an industrial pilot line based on hydrometallurgical process for the recovery of the feedstock. This process, coupled with optimized logistics and integration with waste electrical and electronic equipment, will allow to reach a “zero waste” concept for the recovery of Li-ion battery materials. The collection, sorting and battery dismantling will be performed locally, based on local regulation, minimizing the transport of dangerous waste. Cell material recycling, after the deactivation and shredding, would be carried out in centralized plants, continuously fed, thus reducing energy consumption and emissions, and optimizing economics.

www.faam.com
www.seri-industrial.it

SEEL Swedish Electric Transport Laboratory

The Swedish Electric Transport Laboratory (SEEL) is a joint venture company owned and run by Chalmers and RISE. SEEL will establish and operate a test center for research and development in the field of electromobility.

Sweden

Chalmers University of Technology in Gothenburg conducts research and education in technology and natural sciences at a high international level. RISE is an independent, state-owned group of research institutes in Sweden, which offers unique expertise and over 100 testbeds and demonstration environments for future-proof technologies, products and services.

Description of the project
The project will establish three facilities with the aim to consolidate efficient knowledge development and improve the conditions for collaboration in the field of electrified transport in Sweden and Europe. The automotive, aerospace and maritime sectors plus other developers in relevant areas will gain a common platform on which to meet, and will benefit from the knowledge development and technology shift currently taking place. Researchers will at the same time gain access to advanced research infrastructure in the field of electromobility. The test center will be operational by 2023.

www.ri.se/en/test-demo/seel

VARTA

VARTA AG produces and markets an extensive battery portfolio from microbatteries, household batteries, energy storage systems to customer-specific battery solutions for a wide range of applications.

Germany

As the group’s parent company, it operates in the business segments ‘Microbatteries & Solutions’ and ‘Household Batteries’.
 
The Microbatteries & Solutions segment focuses on the OEM business for microbatteries and on the lithium-ion battery pack business.
 
As an innovation leader in the microbattery sector and for hearing-aid microbatteries, the operating subsidiaries VARTA Microbattery GmbH and VARTA Micro Production GmbH aspire to establish overarching future market innovations in the field of Lithium-Ion batteries.

The VARTA AG group currently employs almost 4,000 people. With five production and manufacturing facilities in Europe and Asia as well as sales centers in Asia, Europe and the USA, the operating subsidiaries of VARTA AG are currently active in over 75 countries worldwide.

Description of the project
The objective of the project is the research and development of beyond state of the art Lithium-Ion cell designs and recipes, sustainable and efficient manufacturing processes as well as the industrialisation of the latest innovations of Lithium-Ion technology in Europe.
 
In the course of the individual project, VARTA will develop and industrialize battery cells and the necessary manufacturing processes which will exceed the state-of-the-art. The goal is to supply the markets with significantly more powerful and efficient products compared to today. Applications in the areas of the Internet of Things (“IOT”) or medical technology will equally benefit as industrial applications and automotive.

The major objectives are the increase of energy and power density on cell and system level combined with highly efficient and sustainable manufacturing processes on large scale.

www.varta.com

Technology Fields

Overview of the the IPCEI Batteries RDI (Research, Development and Innovation) and FID (First Industrial Development) work streams