Periodic Reporting for period 1 - GIGABAT (Sustainable and digitalized GIGAfactory for BATtery production with made-in-Europe machinery)
Okres sprawozdawczy: 2023-07-01 do 2024-12-31
Europe urgently needs to expand its battery manufacturing capacity to meet the growing demand for electric vehicles (EVs) and renewable energy storage. This expansion is crucial for achieving the EU’s 2030 climate and energy goals, which focus on emission reductions, energy efficiency, and transitioning to a circular economy. A strong and sustainable battery industry will reduce reliance on external suppliers, ensuring Europe’s technological and industrial independence.
The GIGABAT project addresses critical gaps in Europe’s battery value chain, particularly in large-scale cell manufacturing. With demand expected to grow from 60 GWh to 900 GWh by 2030, scaling up production presents challenges, including the need for energy-efficient technologies, optimized production processes, and integrated local supply chains. GIGABAT aims to develop and validate GEN3b (Li-ion) battery technologies tailored to the needs of emerging gigafactories. Specifically, GIGABAT will focus on the development of new, energy-efficient cell manufacturing machinery, the seamless optimization and integration of multiple battery production processes, and the digitalization of Europe’s battery production facilitiesto improve efficiency and sustainability.
A key focus of the project is promoting sustainability through recycling, sector coupling, and integrating circular economy principles into gigafactory designs. Additionally, GIGABAT will drive digital transformation in battery manufacturing, using advanced technologies to streamline production, reduce costs, and increase competitiveness.
The project is expected to strengthen Europe’s global position in battery production, reduce the carbon footprint of manufacturing, and secure a resilient and competitive supply chain. By fostering collaboration among academia, technology centers, and industry leaders, GIGABAT will support innovation, create high-quality jobs, and stimulate regional economic growth.
Through its advancements, GIGABAT will play a vital role in aligning the European battery industry with the EU’s Green Deal objectives, ensuring long-term sustainability, industrial resilience, and strategic independence.
The GIGABAT project addresses critical gaps in Europe’s battery value chain, particularly in large-scale cell manufacturing. With demand expected to grow from 60 GWh to 900 GWh by 2030, scaling up production presents challenges, including the need for energy-efficient technologies, optimized production processes, and integrated local supply chains. GIGABAT aims to develop and validate GEN3b (Li-ion) battery technologies tailored to the needs of emerging gigafactories. Specifically, GIGABAT will focus on the development of new, energy-efficient cell manufacturing machinery, the seamless optimization and integration of multiple battery production processes, and the digitalization of Europe’s battery production facilitiesto improve efficiency and sustainability.
A key focus of the project is promoting sustainability through recycling, sector coupling, and integrating circular economy principles into gigafactory designs. Additionally, GIGABAT will drive digital transformation in battery manufacturing, using advanced technologies to streamline production, reduce costs, and increase competitiveness.
The project is expected to strengthen Europe’s global position in battery production, reduce the carbon footprint of manufacturing, and secure a resilient and competitive supply chain. By fostering collaboration among academia, technology centers, and industry leaders, GIGABAT will support innovation, create high-quality jobs, and stimulate regional economic growth.
Through its advancements, GIGABAT will play a vital role in aligning the European battery industry with the EU’s Green Deal objectives, ensuring long-term sustainability, industrial resilience, and strategic independence.
-Definition of gigafactory specifications and requirements for all manufacturing steps driven by gigafactory partner’s needs.
-Confirmation of viability of set-up including homogenizer in different mixing systems. Confirmation of slurry processability in stirred media mill continuous-mixing technology. For both mixing subtasks, preliminary operational optimization aligned with gigafactory needs was achieved successfully.
-Integration of manufactured IR emitter technology with varied wavelengths, reflectors, and power in the project pilot lines together with weight sensors to track electrode thickness. Cathode and anode drying activities at both lab and pilot scales combining infrared (IR) radiation and convective drying techniques have already started.
-Foundation for designing a roll-to-roll (R2R) post-drying machine aiming to integrate IR and convective drying for more efficient electrode production has been completed. Desing and simulation work for the roll-to-roll system has already started.
-Calendering machine concept finalized except for the surface quality control system to monitor electrode defects (currently ongoing). Calendering process was successfully modelled using both physics informed neural networks and data driven machine learning models.
-Definition of technical specifications required to design an inline burr-check vision system for electrodes in roll-to-roll machines.
-Patent filling of multiple tecnnical developments related to cell assembly and formation: innovative electrode stacking system, innovative vacuum sealing mask, flexible compression tray and flexible aging tray.
-Design completion of several technical developments related to cell assembly and formation: innovative electrode stacking group, innovative cell formation for blade cells, Design and construction of Gen1, Gen2 and Gen 3 cell formation prototypes for prismatic cells.
-Development of a beta version formation model for Gr/NMC chemistry across various electrolyte compositions
-Full characterisation of bulk powder raw materials used in battery manufacturing for transportation, storage, dosing, and handling.
-Investigation at lab-scale of all process routes (mechanical, thermal and solvent-based) for direct scrap recycling to select the method of choice based on the recycled material quality and expected practicality, e.g. toxicity and environmental effects.
- Design a virtual formation area for a gigafactory through a discrete event simulation model paradigm. AI algorithms were later used to optimize tray allocation with a focus on reducing energy consumption.
-Development of scalable, process-specific energy models for key battery production stages were conducted, providing a foundation for data collection for gigafactories overall process and energy optimization.
-Completion of a study on raw material sourcing for lithium-ion battery production, focusing on identifying European suppliers and gaining insights into supply chain challenges and bottlenecks at the European level.
-A literature review and first screening LCA study conducted providing early insights and eco-design guidelines applied to gigafactories.
-Framework for absolute sustainability published and applied to derive sustainability targets for battery gigafactories.
-Confirmation of viability of set-up including homogenizer in different mixing systems. Confirmation of slurry processability in stirred media mill continuous-mixing technology. For both mixing subtasks, preliminary operational optimization aligned with gigafactory needs was achieved successfully.
-Integration of manufactured IR emitter technology with varied wavelengths, reflectors, and power in the project pilot lines together with weight sensors to track electrode thickness. Cathode and anode drying activities at both lab and pilot scales combining infrared (IR) radiation and convective drying techniques have already started.
-Foundation for designing a roll-to-roll (R2R) post-drying machine aiming to integrate IR and convective drying for more efficient electrode production has been completed. Desing and simulation work for the roll-to-roll system has already started.
-Calendering machine concept finalized except for the surface quality control system to monitor electrode defects (currently ongoing). Calendering process was successfully modelled using both physics informed neural networks and data driven machine learning models.
-Definition of technical specifications required to design an inline burr-check vision system for electrodes in roll-to-roll machines.
-Patent filling of multiple tecnnical developments related to cell assembly and formation: innovative electrode stacking system, innovative vacuum sealing mask, flexible compression tray and flexible aging tray.
-Design completion of several technical developments related to cell assembly and formation: innovative electrode stacking group, innovative cell formation for blade cells, Design and construction of Gen1, Gen2 and Gen 3 cell formation prototypes for prismatic cells.
-Development of a beta version formation model for Gr/NMC chemistry across various electrolyte compositions
-Full characterisation of bulk powder raw materials used in battery manufacturing for transportation, storage, dosing, and handling.
-Investigation at lab-scale of all process routes (mechanical, thermal and solvent-based) for direct scrap recycling to select the method of choice based on the recycled material quality and expected practicality, e.g. toxicity and environmental effects.
- Design a virtual formation area for a gigafactory through a discrete event simulation model paradigm. AI algorithms were later used to optimize tray allocation with a focus on reducing energy consumption.
-Development of scalable, process-specific energy models for key battery production stages were conducted, providing a foundation for data collection for gigafactories overall process and energy optimization.
-Completion of a study on raw material sourcing for lithium-ion battery production, focusing on identifying European suppliers and gaining insights into supply chain challenges and bottlenecks at the European level.
-A literature review and first screening LCA study conducted providing early insights and eco-design guidelines applied to gigafactories.
-Framework for absolute sustainability published and applied to derive sustainability targets for battery gigafactories.
Several significant technical achievements have been made throughout the project, as outlined in the previous section. However, the following advancements have already surpassed the current state-of-the-art as of M18 of the project:
- Based on the the foundation work for the development of a fully Europe-designed roll-to-roll (R2R) post-drying machine, the calculations and technical layout of the R2R E-dryer that has started is considering results obtained with chemistries that are more challenging to postdry than those typically used in current gigafactories, opening opportunities for innovative beyond-state-of-the-art equipment in new gigafactories.
- Novel developments of technologies related to cell assembly and formation: electrode stacking system, innovative vacuum sealing mask, flexible compression tray and flexible aging tray, all currently with patent-pending status.
- Novel design developments of multiple technologies related to cell assembly and formation: innovative electrode stacking group, innovative cell formation for blade cells, design and construction of Gen1, Gen2 and Gen 3 cell formation prototypes for prismatic cells.
- Based on the the foundation work for the development of a fully Europe-designed roll-to-roll (R2R) post-drying machine, the calculations and technical layout of the R2R E-dryer that has started is considering results obtained with chemistries that are more challenging to postdry than those typically used in current gigafactories, opening opportunities for innovative beyond-state-of-the-art equipment in new gigafactories.
- Novel developments of technologies related to cell assembly and formation: electrode stacking system, innovative vacuum sealing mask, flexible compression tray and flexible aging tray, all currently with patent-pending status.
- Novel design developments of multiple technologies related to cell assembly and formation: innovative electrode stacking group, innovative cell formation for blade cells, design and construction of Gen1, Gen2 and Gen 3 cell formation prototypes for prismatic cells.