Techno-economic analysis for the preparation of Li-ion battery's ternary cathode material using flame spray pyrolysis

doi:10.19799/j.cnki.2095-4239.2023.0558

Abstract

Abstract:

The cost of cathode materials contributes to approximately 30% of the manufacturing cost of lithium-ion batteries and is the main influencing factor in the price of battery packs. The production of nickel-rich ternary cathode material, LiNi_0.8Co_0.1Mn_0.1O₂ (NCM811), using flame spray pyrolysis (FSP) has lower energy consumption and needs less production equipment, which could considerably reduce the manufacturing cost of the cathode material. The objective of the present study is to quantitatively evaluate the technical and economic feasibility of producing nickel-rich ternary cathode materials using flame spray pyrolysis. The mass, energy, and emission flow rate of the NCM811 production by FSP were evaluated, and the minimum cathode material selling price (MCSP) was obtained and compared with the traditional carbonate coprecipitation pathway. The mass and energy balance results showed that the FSP process can reduce 41% of CO₂ emissions, 85% of power consumption, and 29% of water consumption compared with the traditional pathway due to the advantages of compressing sintering time. The economic analysis results showed that the MCSP under breakeven conditions was 221.1 CNY/kg, about 18% lower than the current market price. The sensitivity analysis results showed that the price of raw materials was the most important factor. If the materials' prices were decreased by 25%, the NCM811 MCSP from FSP could achieve a price of 172.0 CNY/kg.

Key words: flame spray pyrolysis, techno-economic analysis, nickel-rich ternary cathode material, Li-ion battery

CLC Number:

TK-9

Wen DU, Junlei WANG, Yunfei XU, Shilong LI, Kun WANG. Techno-economic analysis for the preparation of Li-ion battery's ternary cathode material using flame spray pyrolysis[J]. Energy Storage Science and Technology, 2024, 13(1): 345-357.

Figures/Tables 17

Fig. 1

Fig. 2

Fig. 3

Table 1

Fig. 4

Table 2

Table 3

Fig. 5

Table 4

Table 5

Fig. 6

Table 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

References 47

1	刘卓然, 陈健, 林凯, 等. 国内外电动汽车发展现状与趋势[J]. 电力建设, 2015, 36(7): 25-32.
	LIU Z R, CHEN J, LIN K, et al. Domestic and foreign present situation and the tendency of electric vehicles[J]. Electric Power Construction, 2015, 36(7): 25-32.
2	洪吉超, 梁峰伟, 杨京松, 等. 新能源汽车产业及其技术发展现状与展望[J]. 科技导报, 2023, 41(5): 49-59.
	HONG J C, LIANG F W, YANG J S, et al. New energy vehicle industry and technology development status[J]. Science & Technology Review, 2023, 41(5): 49-59.
3	AGENCY I E. Global EV Outlook 2023[M]. OECD, 2023.
4	WOOD D L, LI J L, DANIEL C. Prospects for reducing the processing cost of lithium ion batteries[J]. Journal of Power Sources, 2015, 275: 234-242.
5	胡国荣, 杜柯, 彭忠东. 锂离子电池正极材料: 原理、性能与生产工艺[M]. 北京: 化学工业出版社, 2017.
	HU G R, DU K, PENG Z D. Cathode materials for lithium ion batteries[M]. Beijing: Chemical Industry Press, 2017.
6	栗志展, 秦金磊, 梁嘉宁, 等. 高镍三元层状锂离子电池正极材料: 研究进展、挑战及改善策略[J]. 储能科学与技术, 2022, 11(9): 2900-2920.
	LI Z Z, QIN J L, LIANG J N, et al. High-nickel ternary layered cathode materials for lithium-ion batteries: Research progress, challenges and improvement strategies[J]. Energy Storage Science and Technology, 2022, 11(9): 2900-2920.
7	STROBEL R, PRATSINIS S E. Flame aerosol synthesis of smart nanostructured materials[J]. Journal of Materials Chemistry, 2007, 17(45): 4743-4756.
8	RICHARDS W D, TSUJIMURA T, MIARA L J, et al. Design and synthesis of the superionic conductor Na₁₀SnP₂S₁₂[J]. Nature Communications, 2016, 7: 11009.
9	YI E, TEMECHE E, LAINE R M. Superionically conducting β''-Al₂O₃ thin films processed using flame synthesized nanopowders[J]. Journal of Materials Chemistry A, 2018, 6(26): 12411-12419.
10	LIU S Y, ZHOU C, WANG Y, et al. Ce-substituted nanograin Na₃Zr₂Si₂PO₁₂ prepared by LF-FSP as sodium-ion conductors[J]. ACS Applied Materials & Interfaces, 2020, 12(3): 3502-3509.
11	KIM J H, YI J H, KO Y N, et al. Electrochemical properties of nano-sized LiNi_1/3Co_1/3Mn_1/3O₂ powders in the range from 56 to 101 nm prepared by flame spray pyrolysis[J]. Materials Chemistry and Physics, 2012, 134(1): 254-259.
12	WANG Y, ROLLER J, MARIC R. Morphology-controlled one-step synthesis of nanostructured LiNi_1/3Mn_1/3Co_1/3O₂ electrodes for Li-ion batteries[J]. ACS Omega, 2018, 3(4): 3966-3973.
13	ERNST F O, KAMMLER H K, ROESSLER A, et al. Electrochemically active flame-made nanosized spinels: LiMn₂O₄, Li₄Ti₅O₁₂ and LiFe₅O₈[J]. Materials Chemistry and Physics, 2007, 101(2/3): 372-378.
14	CHEW S Y, PATEY T J, WASER O, et al. Thin nanostructured LiMn₂O₄ films by flame spray deposition and in situ annealing method[J]. Journal of Power Sources, 2009, 189(1): 449-453.
15	WASER O, BÜCHEL R, HINTENNACH A, et al. Continuous flame aerosol synthesis of carbon-coated nano-LiFePO₄ for Li-ion batteries[J]. Journal of Aerosol Science, 2011, 42(10): 657-667.
16	KADOMA Y, KIM J M, ABIKO K, et al. Optimization of electrochemical properties of LiFePO₄/C prepared by an aqueous solution method using sucrose[J]. Electrochimica Acta, 2010, 55(3): 1034-1041.
17	YAMADA M, BI D Y, KODERA T, et al. Mass production of cathode materials for lithium ion battery by flame type spray pyrolysis[J]. Journal of the Ceramic Society of Japan, 2009, 117(1369): 1017-1020.
18	OGIHARA T, KODERA T, MYOUJIN K, et al. Preparation and electrochemical properties of cathode materials for lithium ion battery by aerosol process[J]. Materials Science and Engineering: B, 2009, 161(1/2/3): 109-114.
19	OLJACA M, BLIZANAC B, DU PASQUIER A, et al. Novel Li(Ni_1/3Co_1/3Mn_1/3)O₂ cathode morphologies for high power Li-ion batteries[J]. Journal of Power Sources, 2014, 248: 729-738.
20	ZHANG J N, SINGH G, XU S Q, et al. A scalable approach of using biomass derived glycerol to synthesize cathode materials for lithium-ion batteries[J]. Journal of Cleaner Production, 2020, 271: 122518.
21	ZHANG J N, XU S Q, HAMAD K I, et al. High retention rate NCA cathode powders from spray drying and flame assisted spray pyrolysis using glycerol as the solvent[J]. Powder Technology, 2020, 363: 1-6.
22	ABRAM C, SHAN J N, YANG X F, et al. Flame aerosol synthesis and electrochemical characterization of Ni-rich layered cathode materials for Li-ion batteries[J]. ACS Applied Energy Materials, 2019, 2(2): 1319-1329.
23	ZANG G Y, ZHANG J N, XU S Q, et al. Techno-economic analysis of cathode material production using flame-assisted spray pyrolysis[J]. Energy, 2021, 218: 119504.
24	ZHANG J N, MULDOON V L, DENG S L. Accelerated synthesis of Li(Ni_0.8Co_0.1Mn_0.1)O₂ cathode materials using flame-assisted spray pyrolysis and additives[J]. Journal of Power Sources, 2022, 528: 231244.
25	中华人民共和国工业和信息化部. 镍钴锰酸锂: YS/T 798—2012[S]. 北京: 中国标准出版社, 2012.
	Ministry of Industry and Information of the People's Republic of China. Lithium nickel cobalt manganese oxide: YS/T 798—2012[S]. Beijing: Standards Press of China, 2012.
26	谭青, 冯雅晨. 我国烟气脱硝行业现状与前景及SCR脱硝催化剂的研究进展[J]. 化工进展, 2011, 30(S1): 709-713.
	TAN Q, FENG Y C. Present status and perspective of China's flue gas denitration industry and research progress of SCR catalysts[J]. Chemical Industry and Engineering Progress, 2011, 30(S1): 709-713.
27	AHMED S, NELSON P A, GALLAGHER K G, et al. Cost and energy demand of producing nickel manganese cobalt cathode material for lithium ion batteries[J]. Journal of Power Sources, 2017, 342: 733-740.
28	中华人民共和国工业和信息化部. 电池级碳酸锂: YS/T 582—2013[S]. 北京: 中国质检出版社, 2013.
	Ministry of Industry and Information of the People's Republic of China. Battery grade lithium carbonate: YS/T 582—2013[S]. , 2013.
29	中华人民共和国工业和信息化部. 电池用硫酸镍:HG/T 5919-2021[S]. 北京:中国标准出版社, 2021.
	Ministry of Industry and Information Technology of the People's Republic of China. Nickel sulfate fir battery materials: HG/T 5919-2021[S]. Beijing:Standards Press of China, 2021.
30	中华人民共和国工业和信息化部. 电池用硫酸钴:HG/T 5918-2021[S]. 北京:中国标准出版社, 2021.
	Ministry of Industry and Information Technology of the People's Republic of China. Cobalt sulfate fir battery materials: HG/T 5918-2021[S]. Beijing:Standards Press of China, 2021.
31	中华人民共和国工业和信息化部. 电池用硫酸锰:HG/T 4823-2015[S]. 北京:中国标准出版社, 2015.
	Ministry of Industry and Information Technology of the People's Republic of China. Manganese sulfate fir battery materials: HG/T 4823-2015 [S]. Beijing:Standards Press of China, 2015.
32	杨利新. 三元和富锂正极材料的热力学性质计算模型研究[D]. 兰州: 兰州理工大学, 2019.
	YANG L X. Model for the calculation of the thermodynamic properties of ternary and lithium-rich cathode materials[D]. Lanzhou: Lanzhou University of Technology, 2019.
33	陈家俊. 三元锂离子动力电池系统全生命周期研究[D]. 广州: 广州大学, 2023.
	CHEN J J. Study on the whole life cycle of ternary lithium-ion power battery system[D].Guangzhou: Guangzhou University, 2023.
34	中国有色金属工业协会, 中国有色金属学会. 绿色设计产品评价技术规范镍钴锰氢氧化物:TCNIA 0046-2020 [S]. 北京:冶金工业出版社, 2020.
	China Non-Ferrous Metals Industry Association, The Nonferrous Metals Society of China. Technical specification for green-design product assessment—Nickel cobalt manganese composite hydroxide: TCNIA 0046-2020 [S]. Beijing: Metallurgical Industry Press, 2020.
35	中国有色金属工业协会, 中国有色金属学会. 绿色设计产品评价技术规范镍钴锰酸锂:TCNIA 0047-2020 [S]. 北京:冶金工业出版社, 2020..
	China Non-Ferrous Metals Industry Association, The Nonferrous Metals Society of China. Technical specification for green-design product assessment—Lithium nickel cobalt manganese oxide: TCNIA 0046-2020 [S]. Beijing: Metallurgical Industry Press, 2020.
36	PARSONS S, ABELN F, MCMANUS M C, et al. Techno-economic analysis (TEA) of microbial oil production from waste resources as part of a biorefinery concept: assessment at multiple scales under uncertainty[J]. Journal of Chemical Technology & Biotechnology, 2019, 94(3):701-711.
37	刘晓君. 技术经济学[M]. 北京: 高等教育出版社, 2014.
	LIU X J. Technological economics[M]. Beijing: Higher Education Press, 2014.
38	北京当升材料科技股份有限公司. 江苏当升新型动力锂电正极材料产业化开发项目可行性研究报告[R]. 北京:当升科技, 2016.
	Beijing Easpring Material Technology Co., Ltd. Feasibility Study Report on the Project of Power Lithium Battery Positive Electrode Materials in Jiangsu[R]. Beijing: Easpring Material Technology Co., Ltd., 2016.
39	北京当升材料科技股份有限公司. 常州5万吨锂电新材料产业基地项目可行性研究报告[R]. 北京:当升科技, 2018.
	Beijing Easpring Material Technology Co., Ltd. Feasibility Study Report on the Project of Power Lithium Battery Positive Electrode Materials in Changzhou[R]. Beijing: Easpring Material Technology Co., Ltd., 2018.
40	乳源东阳光磁性材料有限公司. 乳源东阳光磁性材料有限公司年产1万吨新能源用锂离子电池正极材料建设项目竣工环境保护验收监测报告[R]. 韶关:乳源东阳光磁性材料有限公司, 2017.
	Ruyuandong Sunshine Magnetic Material Co., Ltd. Environmental protection acceptance monitoring report on the completion of the construction project of lithium-ion battery cathode materials for new energy with an annual output of 10000 tons[R]. Shaoguan: Ruyuandong Sunshine Magnetic Material Co., Ltd., 2017.
41	住建部,财政部. 关于印发《建筑安装工程费用项目组成》的通知[S]. 建标〔2013〕44号, 2013.
	Ministry of Housing and Urban Rural Development of the People's Republic of China, Ministry of Finance of the People's Republic of China. Notice on issuing the composition of construction and installation engineering cost items[S]. Jianbiao[2013]44, 2013.
42	国家发展改革委, 建设部. 建设项目经济评价方法与参数(第三版)[M]. 北京:中国计划出版社, 2006.
	National Development and Reform Commission, Ministry of Housing and Urban Rural Development of the People's Republic of China. Economic evaluation methods and parameters for construction projects (Third Edition)‍[M]. Beijing: China Planning Press, 2006.
43	Mann MK, Spath PL. The net CO₂ emissions and energy balances of biomass and coal-fired power systems[C]. Proceedings of the fourth biomass conference of the Americas. Oakland, California: Cite seer:1999, 379-385.
44	刘行, 叶康涛, 陆正飞. 加速折旧政策与企业投资——基于"准自然实验"的经验证据[J]. 经济学(季刊), 2019, 18(1): 213-234.
	LIU G, YE K T, LU Z F. Accelerated depreciation policy and firm investment—Evidence from a quasi-natural experiment in China[J]. China Economic Quarterly, 2019, 18(1): 213-234.
45	Chew VK, Minato N, Nakano M. Business system model of battery swapping management for transportation fleet and energy storage system[C]. Proceedings pf the 33rd international conference of the system. Dynamics Society; 2015.
46	刘宝权. 设备管理与维修[M]. 北京: 机械工业出版社, 2012.
	LIU B Q. Plant maintenance engineering[M]. Beijing: China Machine Press, 2012.
47	杨航, 郑成航, 金侃, 等. 燃煤电厂选择性催化还原脱硝系统运行成本[J]. 浙江大学学报(工学版), 2017, 51(2): 363-369.
	YANG H, ZHENG C H, JIN K, et al. Analysis on operation cost of SCR system in coal-fired power plant[J]. Journal of Zhejiang University (Engineering Science), 2017, 51(2): 363-369.

序号	反应方程式	初始温度/℃	反应温度/℃
1	4LiNO₃ → 2Li₂O + 4NO₂(g) ↑ + O₂(g) ↑	25	600
2	2Ni(NO₃)₂ → 2NiO + 4NO₂(g) ↑ + O₂(g) ↑	25	310
3	Mn(NO₃)₂ → MnO₂ + 2NO₂(g) ↑	25	230
4	2Co(NO₃)₂ → 2CoO + 4NO₂(g) ↑ + O₂(g) ↑	25	450
5	CO(NH₂)₂ → HCNO + NH₃(g) ↑	25	160

序号	工序	设备名称	数量/台(套)	设备单价/万	投资额/万	额定功率/kW
1a	预混料阶段	吨包投料站	3	13.5	40.5	9.7
1b		精密称重设备	6	28.3	169.8	0.1
1c		搅拌混料设备	3	35.0	105.0	65.0
2a	火焰喷雾热解阶段	雾化设备	10	10.0	100.0	0.1
2b		火焰喷雾热解燃烧器	10	40.0	400.0	0.2
2c		天然气增压机	1	76.5	76.5	160
2d		空气压缩机	30	0.6	18.0	10
3	烧结阶段	烧结推板窑	2	900.0	1800.0	320
4	粉碎阶段	气流粉碎系统	3	300.0	900.0	200
5	合批阶段	螺旋混料合批机	4	73.1	292.4	2.2
6	除铁阶段	电磁除铁机	4	80.0	320.0	15
7	封包装阶段	封装机	2	55.00	110.00	2
8a	辅助生产设备	料仓、阀件、安全筛	1	650.0	650.0	0.2
8b		车间收尘系统	10	18.0	180.0	50
8c		料仓破拱设备	15	3.3	49.5	1.9
8d		气力输送系统	4	86.3	345.2	50
8e		外轨循环线	2	322.1	644.2	30
8f		仓顶除尘器	6	6.8	40.8	15
8g		SCR烟气脱硝塔	1	68.0	68.0	100

序号	参数名称	数值	单位
1	折现率	20	%
2	企业所得税税率	25	%
3	增值税税率	13	%
4	增值税附加税税率	13	%
5	名义贷款利率	4.95	%
6	项目建设期	2	年
7	贷款年限	10	年
8	项目总投资贷款占比	20	%
9	折旧期限	8	年
10	回收残值	5	%
11	项目建设期	2	年
12	项目试运营期	1	年
13	生产运营期	20	年
14	项目年生产天数	320	天
15	试运营期可变成本支出	75	生产经营期的…%
16	试运营期固定成本支出	100	生产经营期的…%
17	试运营期产能	3000	吨/年
18	生产经营期产能	6000	吨/年
19	设备寿命	10	年
20	临修、小修和中修费用	3	设备原值的…%
21	大修时间间隔	3	年
22	大修费用	30	设备原值的…%
23	生产线设备使用寿命	10	年

序号	名称	费用/万	占比/%
1	项目建设投资	13456.1	78.8
2	建设期利息	936.7	5.5
3	流动资金	2691.2	15.7
4	项目总投资	17084.0	100.0

序号	一级名称	二级名称	费用/万
1a	设备购置费用	设备购置费用	6309.9	46.9
2a	建筑安装工程投资	设备安装费用	856.5	6.4
2b	建筑安装工程投资	建筑工程费用	3299.3	24.5
3a	其他建设投资	土地购置费用	637.6	4.7
3b		建设其他费用	498.7	3.7
3c		招投标费用	35.0	0.3
3d		未来经营费用	93.7	0.7
4a	预备费	基本预备费	1096.1	8.1
4b	预备费	涨价预备费	633.0	4.7
5	建设投资		13459.8	100.0