The future of battery production is in automated metrology technology

Lithium ion batteries can store energy efficiently for long periods of time, making this technology essential to many everyday devices, from mobile phones to electric vehicles.

Lithium ion cells are also the most common battery storage choice for grid operations today, supplying more than 90% of the world’s markets. In fact, 74% of the world’s mined lithium goes into battery production alone.

However, the available reserves of lithium that are required for battery manufacture are close to depletion, prompting the exploration of alternative battery chemistries that will be able to supplement or replace lithium in the near future.

Despite their advantages, many of these technologies cannot currently provide the required energy densities, compact form factor or affordability to rival lithium ion batteries, and some are also difficult to scale up for commercial production. This makes it ever more important to maximize the usage of available lithium stocks, and to reduce wastage as much as possible during the manufacturing process.

Making sense of the shortage

The reasons behind the lithium shortfall are multifaceted. First of all, contrary to what you may think, lithium is not a rare metal; it is simply buried deep in the Earth’s crust, making it hard to access.

New mines take many years to be brought online and environmental objectives are making it harder for companies to gain permission to explore potential new sites.

This means that, even though lithium is still plentiful in nature, new sources won’t be available for use in batteries for quite some time, creating a pressing need for technologies that will enhance process efficiencies and minimize the loss of existing raw material during battery fabrication.

To understand how we got to the current state, we need to go back sev- eral years. Between 2017 and 2020, the prices of lithium and lithium compounds plummeted by around 60%, hitting an all-time low worldwide, largely in reaction to a supply glut and a lack of demand.

This sudden drawdown forced miners to cut back on their lithium extraction operations and call off the exploration of new mines, with the result that today only a few active mines are bringing new material into circulation. Exploration for new lithium mines is once again on the increase, but it will be years before they contribute to the current supply.

This issue is being compounded by the fact that EVs — from scooters to aeroplanes — are rapidly gaining in popularity.

Of course, EVs rely on large rechargeable batteries for their power, and these are almost all lithium ion based at the moment. This rapid surge of interest in EVs over the last couple of years is therefore draining the existing stocks of lithium, with the trend only set to continue as EVs become more affordable.

The reduced mining capacity caused by the low prices of a few years ago is now limiting the industry’s ability to supply battery manufacturers with the raw material they need to ramp up their production and meet the needs of the growing EV market.

The combination of depleted supplies and low mining capacity has inevitably led to lithium and its compounds becoming incredibly expensive since the start of 2021.

For example, lithium carbonate is now 10x the cost it was at the beginning of 2020, at around $72,155 per tonne, with lithium hydroxide prices sitting even higher at $75,000 per tonne.

This sudden price hike is proving challenging for many battery manufacturers, forcing them to cut the amount of raw material they purchase and thereby limiting the quantity of lithium ion batteries they can produce for the EV market.

Fortunately, there is some scope for recycling to address some of this gap between supply and demand. However, there are currently no wide-scale systems in place to collect and process scrap materials such as used lithium ion batteries.

The absence of an effective recycling infrastructure means that, eventually, much of the lithium originally mined out of the ground goes right back where it came from, but locked away in landfill.

This adds up to a tremendous amount of lithium wastage every year. Reversing this trend and rescuing material that has already been thrown away would contribute to a much more sustainable, circular economy.

Optimizing Li usage in battery production

Suitable and widely available alternatives to lithium ion batteries are still some way away and, with supply constraints looming, better management of existing resources is critical. Improving the efficiency of the battery manufacturing process in order to reduce lithium wastage is key.

In particular, coating variations during the electrode coating process can both be detrimental to battery performance and reduce product yield, leading to lithium wastage.

The safety, longevity and cost-effectiveness of lithium ion batteries are dependent on achieving consistent coating uniformity for the anode and cathode during the manufacturing process.

In-line metrology systems can be used to provide automated measurement of the electrode coating throughout the entire production process. (Image 1).

This non-contact, non-destructive measurement equipment enables manufacturers to continuously monitor production through real-time analysis of coating uniformity, providing rapid detection of any defects. This allows issues to be identified as early as possible in the cell manufacturing process and traced back to their source, ensuring defective or out-of-specification material can be segregated before it is incorporated into the final product.

In-line metrology systems can be combined with automatic profile control (APC) to further reduce coating variability and raw material wastage through the elimination of human error.

Closing the loop between measurement and adjustment

Until recently, most optimization processes in battery production lines were performed manually, but this makes it difficult to regulate coating uniformity and reliably identify production line defects.

In-line coating measurement gauges represent a development in automated production, scanning moving reels of coated electrodes to monitor coating thickness in real-time to ensure that coating defects are detected. (Image 2).

Sensor selection is a key consideration when using in-line metrology during lithium ion battery manufacture.

A variety of sensor technologies are available for different applications, including beta and X-ray sensors for measuring coating weight during the coating process and confocal laser sensors for measuring coating thickness during the calendering process.

Sensor quality is determined by factors such as resolution, precision and beam size, and is crucial for precisely and reliably measuring defects during electrode production.

Following the scanning stage, the next step is to feed the collected data back into the production process. This helps to optimize the electrode coating procedure by modifying fabrication variables like slurry thickness or volume.

In manual workflows, sensor-generated data is made visible to machine operators, allowing them to make informed adjustments to the coating stage, whereas, in more advanced production lines, a feedback loop can be programmed to connect process measurement and control.

For example, electrode coating using automated slot-dies is controlled by thermal die bolts, which expand or reduce dispensing volumes based on downstream measurements. (Image 3).

Using APC algorithms to automatically fine-tune the thickness and uniformity of electrode coatings increases production speed and efficiency by eliminating common issues, such as high error frequency, delays, and raw material wastage.

This metrology solution also allows for data storage, recall and analysis, so that manufacturers can resolve future issues in production lines and keep up with the growing global demands for lithium ion batteries. (Image 4).

The outlook for the future

In 2020 it was calculated that lithium demand is on course to more than triple in the five years leading up to 2025, rising to a million tonnes and outpacing supply by an estimated 200,000 tonnes.

This spike is largely driven by the growing need for more EV and energy storage battery cells, as well as the global push towards carbon neutrality, with EVs expected to exceed 50% of total vehicle sales as early as 2030.

However, current mining operations cannot keep pace with this sudden uptick in demand due to a combination of factors, including lack of mine capacity and depleted reserves, which are helping to send the price of lithium sky-high.

Consequently, some manufacturers are now struggling to afford what lithium there is available on the market. There is also a lack of recycling, causing this precious element to be wasted in alarming quantities.

As a result, quickly and precisely detecting flaws in electrode coatings using in-line metrology solutions is becoming increasingly important for reducing the wastage of lithium and enhancing the efficiency and sustainability of battery manufacturing in the years to come.

ees Europe

June 13–16

Munich, Germany

Discover future-ready solutions for renewable energy storage and advanced battery technology at ees Europe! Europe’s largest, most international and most visited exhibition for batteries and energy storage systems is the industry hotspot for suppliers, manufacturers, distributors, and users of stationary electrical energy storage solutions as well as battery systems.

In 2023, more than 450 suppliers of products for energy storage technology and systems will be present at ees Europe and the parallel exhibitions of The smarter E Europe taking place in Munich.

The exhibition will be accompanied by a two-day energy storage conference.

Contact Solar Promotion GmbH

E: merz@solarpromotion.com www.ees-europe.com

Advanced Automotive Battery Conference Europe — AABC Europe

June 19–22, Mainz, Germany

Take part in this game-changing event where battery technologists from leading automotive OEMs and their key suppliers explore development trends and breakthrough technologies shaping the future of vehicle electrification.

As more European nations and international automotive OEMs invest in their commitment to vehicle electrification and eMobility, the 2023 AABC Europe event propels that momentum forward, presenting unparalleled coverage of the research and development that helps drive outcomes and supports the next generation of electric vehicle batteries.

Contact Cambridge Enertech www.advancedautobat.com/europe

International Automotive Recycling Conference — IARC

June 21 – 23

Geneva, Switzerland

IARC is the international platform for discussing the latest developments and challenges in circular economy and automotive recycling. We bring together up to 300 decision-makers from the automotive and recycling sector, especially car manufacturers, metal suppliers, plastic scrap traders, recyclers, shredder operators, policymakers and many more.

IARC 2023 gives you the unique opportunity to hear and exchange with industry leaders and pioneers such as ArcelorMittal, LKQ, EMR and Toyota in a privileged business environment.

Don’t miss this unique opportunity to get valuable industry insights and engage in the most inspiring discussions and unrivalled networking opportunities amongst the leading experts in the field of automotive recycling!

Contact ICM AG

E: info@icm.ch www.events.icm.ch/event/e2e5c27c-ff224918-b685-0b07aa604ddf/summary

Pb2023 — International Lead Conference

June 21 – 23

Athens, Greece

Pb2023 is the premier event for analysis, networking and discussions on all matters relating to lead, including mining, production, batteries, recycling and the environmental management of the metal and its compounds organised by the International Lead Association.

This year the Pb2023 programme includes the latest market trends and forecasts from world-renowned industry experts, a workplace lead exposure management workshop, together with all the latest updates on regulation, sustainability and advanced lead battery research from the Consortium for Battery Innovation.

Registration is now open — check our website www.pb2023.org

Contact

International Lead Association

Maura McDermott

E: McDermott@ila-lead.org www.pb2023.org

Battery Cells & Systems Expo

June 28 – 29

Birmingham, UK

Battery Cells & Systems Expo is a free to attend exhibition and conference showcasing international manufacturers, users and the entire supply chain working to increase battery performance, cost and safety. The show will bring together automotive OEM’s, electric utilities, battery cell manufacturers, system manufacturers and integrators along with the entire manufacturing supply chain.

Co-located with Vehicle Electrification Expo. The show will benefit from the rapid growth in the manufacturing of electric and hybrid vehicles in the UK along with the significant investments being made in domestic battery manufacture and research. Featuring a global list of exhibitors and speakers, the entire world of battery manufacturing and integration will gather in the heart of UK manufacturing, Birmingham.

Contact

Event Partners

Lana Fowler, event director

E: lana.fowler@event-partners.org www.batterysystemsexpo.com

International Flow Battery Forum

June 28 – 29

Brussels, Belgium

The International Flow Battery Forum is the leading event for the flow battery community. The IFBF promotes the most recent developments in the science, technology and deployment of flow batteries and its conferences cover a broad range of interests in research and commercial aspects of flow batteries.

IFBF conferences provide an ideal opportunity to promote products and develop business contacts.

Contact Swanbarton www.flowbatteryforum.com

Battery Recycling Conference

June 28 – 29

Messe Frankfurt, Germany

Battery Recycling Conference & Expo 2023 is the must-attend event for battery producers, recycling companies, critical raw material suppliers, and the entire battery supply chain to come together on a single platform.

This year’s cycle will showcase over 80 exhibitors in the free-to-attend exhibition, 100+ expert speakers at the conference and over 1,500 highquality participants. Furthermore, it will be complemented by two other industry-specific co-located events, E-Waste World and Metal Recycling Conference & Expos.

Contact

Transglobal Events

Peter Sarno, event director

E: peter@trans-globalevents.com www.batteryrecycling-expo.com

World Battery Industry Expo

August 8 – 10

Guangzhou, China

Committed to promoting global market trade and battery industrial chain, WBE has developed into a professional exhibition with the largest number of exhibitors in battery enterprises and the highest participation of professional visitors and foreign buyers.

Relying on its worldwide influence and thousands of overseas buyers, WBE provides exhibitors with highquality buyers resources to help enterprises get more business opportunities.

Contact Guangzhou Honest Exhibition Co., Ltd

E: grand.fi@grahw.com www.battery-expo.com

Oslo Battery Days

August 21 – 22

Oslo, Norway

The 5th Oslo Battery Conference will meet to discuss and provide a platform for technological innovations and business opportunities with the latest updates in that fields in Norway and abroad.

For the 2023 event we will offer a beautiful Fjord cruise that includes dinner, networking and a view of the Oslo skyline on the classic Norwegian boat MS Nobel.

Contact Shmuel De-Leon Energy

E: sigalit@sdle.co.il www.oslobatterydays.com

Intersolar Mexico

Mexico City, Mexico.

September 5 – 7

Intersolar Mexico serves as the industry’s go-to source for invaluable technology trends and premier B2B contacts in the promising Mexican solar market. It sits at the cross-section of photovoltaics, solar heating & cooling technologies, and energy storage.

Together, the two events will be the largest gathering of professionals in Mexico for international manufacturers and distributors looking to meet regional buyers in the fields of solar, renewable energy and cleantech.

More than 250 exhibitors and 13,000 visitors from over 35 countries are expected to participate in this year’s events.

Contact Solar Promotion International

E: info@solarpromotion.com https://www.intersolar.mx/organizers

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8TH International Secondary Lead and Battery Recycling Conference — Recycle100

September 4–5

Siem Reap, Cambodia

Fourteen years ago, the first Secondary Lead Conference was held in Macau, China, bringing together all aspects of the leadacid battery recycling and smelting industry. It has successfully brought the industry together to discuss, debate and learn.

Over that period, the battery recycling industry has continued to develop and now expanded into an exciting new phase, the recycling of lithium-ion batteries.

The conference will discuss the many technical and market aspects of the recycling industry of various battery chemistries. The conference’s overall themes will not change, as we will hear from some leading recycling, smelting and environmental speakers worldwide about the best methods for collecting, breaking, and recovering valuable elements.

Contact Conference Works — CW3 Events

E: events@conferenceworks.com.au www.recycle100.events

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20th Asian Battery Conference and Exhibition

— 20ABC

September 5–8

Siem Reap, Cambodia

The Asian Battery Conference has a long and proud history of bringing together the world’s leading battery industry C-level executives, marketers, technical staff and sales teams biennially to remain updated on new and emerging technologies, understand future directions, meet new suppliers, conduct business and network with industry peers.

An integral feature of the Asian Battery Conference is the exhibition. A true international opportunity, the exhibition sees the world’s major battery companies come together to showcase their capabilities and leverage off the considerable business developments and direct sales opportunities the conference provides.

The Asian Battery Conference has seen tremendous growth since its inception in 1986, not only in terms of the size of the event but more importantly its ability to act as an educator and business development tool for all the worlds key battery industry executives.

The importance of the Asian Battery Conference to the global battery industry can be demonstrated by the success of the past four conferences.

Contact Conference Works — CW3 Events

E: events@conferenceworks.com.au www.asianbatteryconference.com

International Congress for Battery Recycling — ICBR

September 6 – 8

Valencia Spain

ICBR 2023 is the international platform for reviewing the challenges faced by the Battery Recycling Industry on a global basis.

For 28 consecutive years, ICBR has brought together the international community of experts and decision makers of the entire Battery Recycling value chain, including battery recyclers and manufacturers, collection organizations, OEM’s, policymakers, materials and services providers and many more.

Contact ICM AG

E: info@icm.ch www.events.icm.ch/event/743ec9e5df9d-42e1-8e20-e13bafe7f6ed/summary

The Battery Show

North America

September 12 – 14

Novi, MI. USA

The Battery Show connects you with more than 8,000 engineers and executives, and more than 600 leading suppliers across the advanced battery supply chain.

A powerful end-to-end showcase, this leading global industry event covers today’s emerging advanced battery technology for the automotive, portable electronics, medical technology, military and telecommunications, and utility and renewable energy support sectors.

Explore the most comprehensive industry event in North America.

Contact

Informa Markets

E: registration.ime@informa.com www.thebatteryshow.com

Battery Tech Expo Sweden

September 27 – 28

Gothenburg, Sweden

The Battery Tech Expo Nordic 2023 will bring together the latest technologies and services involved in the battery technology covering battery storage, battery management systems, fuel cell technology, lithium-ion batteries to name a few.

The event will welcome senior decision makers and users from across the power industry who share a professional interest in the technology and science of battery technology.

Held in Gothenburg, the hub of battery technology industry of Sweden, the event will provide a unique opportunity to showcase the latest technological products and services from within the industry.

Contact 10fourmedia

E: david.reeks@104-media.com www.batterytechexpo.se

The Battery Show India

October 4 – 6

Greater Noida, India

The Battery Show portfolio brings together engineers, business leaders, top industry companies, and innovative thinkers to discover groundbreaking products and create powerful solutions from across the globe.

From raw materials to components, find what you need to power your next project at the Battery Show India. The exhibition brings together more than 200+ brands showcasing the latest solutions across the transportation, stationary, portable and industrial sectors.

Contact Informa Markets www.thebatteryshowindia.com

Batteries Event

October 10 – 13

Lyon, France

The Batteries Event will cover aspects of the circular economy chain, starting from the production of the battery through raw materials, cell manufacturing, use and safety, management and applications, going through market trends, research and development, new technologies and finally closing the loop with a focus on recycling, second life and regulations.

International battery industry key players such as OEM, cell and pack manufacturers, end users, experts, researchers and recyclers will come together to discuss and exchange on new chemistries, manufacturing process, battery components, battery second life, recycling, regulation, future expectations and innovations.

Contact AVICENNE Energy www.batteriesevent.com

Fenibat

October 15 – 17

Londrina, Brazil

FENIBAT will gather in Londrina, Paraná, Brazil, from October 15 – 17, 2023 the Brazilian and Latin American battery and lead recycling industry and its suppliers. Its objective is to disseminate new products, services and technologies from all countries of the world to the South American market, as well as the exchange of information and knowledge.

Contact Fenibat

Jayme Gusmao, event director

E: gusmao@fenibat.com www.fenibat.com

Battery Tech Expo, Prague

October 18

Prague, Czech Republic

Central Europe is rapidly emerging as a key location in the Battery Technology landscape. With a well-established and rapidly developing automotive industry, and a growing number of gigafactories both in operation and planned to come on-stream, the next few years will see a rapid expansion in battery production capacity in the region.

The Battery Tech Expo, Prague is perfectly located to showcase the Battery Technology supply chain in the Central Europe Hub — highlighting the Czech Republic, Slovakia, Hungary and Poland, whilst remaining within easy reach of the German, French and Italian automotive centres of excellence.

Contact 10fourmedia

David Reeks, event director

E: david.reeks@104-media.com www.batterytechexpocentraleurope.com

Battery Safety Summit

November 6 – 7

Tysons Corner, Virginia, USA

The Annual Battery Safety Summit will bring together the key players from around the world to present the latest R&D advancements for integrating and implementing LIB safety to meet ever-increasing energy demands.

With constantly increasing market demands for higher energy density cells globally, it is critical that advances in chemistry and engineering for next generation batteries have a significant focus on safety.

Accurate testing, modelling and battery management systems are critical for predicting and controlling the complex electrochemical, thermal, and mechanical behavior of LIBs.

Contact Cambridge Enertech

E: ce@cambridgeenertech.com www.cambridgeenertech.com/batterysafety www.ees-events.com

Energy Storage Events

—

The Leading Exhibition Series for Batteries and Energy Storage Systems

■ JUNE 14–16, 2023, MUNICH, GERMANY EUROPE’S LARGEST EXHIBITION FOR BATTERIES AND ENERGY STORAGE SYSTEMS www.ees-europe.com

■ AUGUST 29–31, 2023, SÃO PAULO, BRAZIL SOUTH AMERICA’S HOT SPOT FOR BATTERIES AND ENERGY STORAGE SYSTEMS www.ees-southamerica.com

■ JANUARY 17–19, 2024, GANDHINAGAR, INDIA INDIA‘S LEADING ELECTRICAL ENERGY STORAGE EXHIBITION www.ees-india.in

■ APRIL 16–18, 2024 – DUBAI INTERSOLAR & EES MIDDLE EAST DUBAI WORLD TRADE CENTER www.intersolar.ae

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Battery Experts Forum

November 7 – 9

Darmstadt, Germany

The Battery Expert Forum is the largest battery conference in Europe. The forum offers an unparalleled platform for exchanging information on the latest developments in battery technology, presenting innovative products and services, and making valuable business contacts through renowned exhibitors, a comprehensive conference program and first-class trade visitors. In addition to the conference, there is also a trade exhibition where companies can showcase their latest products and services.

Contact Battery Experts Forum

E: info@battery-experts-forum.com www.battery-experts-forum.com

London EV Show

November 28 – 30

London, UK

The next edition of the London EV Show will once again bring the entire EV value chain under one roof to network with major industry players and identify numerous business opportunities in a hypercompetitive EV market.

The event aims to enable a large showcase of the new EV models & innovative solutions, a powerful speaker line-up and an enthused audience of policymakers, business

SAVE THE DATE

Future Battery Forum

November 27 – 28

Berlin, Germany + Online

The management conference brings together the entire value system of battery technologies: Across various industries more than 300 users, battery system and cell manufacturers and their suppliers will spend two days exchanging information, making new contacts and enriching each other.

Contact IPM AG

E: fbf@ipm.ag www.futurebattery.eu leaders, investors, thought leaders and a wide range of end-users.

Contact Valiant Business Media

E: info@londonevshow.com www.londonevshow.com

Expo for Decarbonised Industries

November 28 – 30

Düsseldorf, Germany

All you need for climate-friendly, secure and economical energy supply in your company: The Expo for Decarbonized Industries > ENERGY STORAGE (decarbXpo) bundles the most comprehensive range of energy storage systems, solutions for decarbonization in industry and commerce, and a high-quality forum and conference program into one event.

Directly from the organizer of leading global industry trade shows. Supported by research institutes, sector and industry associations.

Contact

Caroline Markowski, Messe Dusseldorf

E: markowskic@messe-duesseldorf.de www.decarbxpo.com

Advanced Automotive Battery Conference USA — AABC USA

December 11 – 14

San Diego, California, USA

AABC was founded more than twenty years ago to review the status of automotive battery technology and provide informed glimpses into the future.

The 2023 program will uncover the underlying technical and business issues that will impact the pace and path of vehicle electrification worldwide.

Join us to network with chief battery technologists from leading automotive OEMs, who will share their development trends and projected battery needs, as well as their key suppliers who will present their latest offerings and roadmaps for the future.

Contact Cambridge Enertech

E: ce@cambridgeenertec.com www.advancedautobat.com/us

Intersolar North America

January 17 – 19

San Diego, California, USA

Intersolar North America and Energy

Storage North America is the premier U.S.-based conference and trade show focused on solar, energy storage, and EV charging infrastructure. .

Join 6,000+ energy leaders and 300+ exhibitors in Long Beach, CA, to help shape the next phase of our clean energy transformation.

Contact Diversified Communications

E: ISNAinfo@divcom.com www.intersolar.us

The Smarter E India

— ees India

January 17 – 19

Gujarat, India

The market potential for electrical energy storage in India is expected to be tremendous in the future – especially driven by incoming policies for the e-mobility industry.

With the great success and support of ees Europe, Europe’s largest exhibition for batteries and energy storage, ees India becomes the most powerful energy storage exhibition in India.

The exhibition is the industry hotspot for suppliers, manufacturers, distributors and users of stationary electrical energy storage solutions. Covering the entire value chain of innovative battery and energy storage technologies – from components and production to specific user applications.

Contact Solar Promotion International

E: info@solarpromotion.com www.thesmartere.in/en/ees-india

Gujarat, India