Prospects for reducing the processing cost of lithium ion batteries

A detailed processing cost breakdown is given for lithium-ion battery (LIB) electrodes, which focuses on: 1) elimination of toxic, costly N -methylpyrrolidone (NMP) dispersion chemistry; 2) doubling the thicknesses of the anode and cathode to raise energy density; and 3) reduction of the anode electrolyte wetting and SEI-layer formation time. These processing cost reduction technologies generically adaptable to any anode or cathode cell chemistry and are being implemented at ORNL. This paper shows step by step how these cost savings can be realized in existing or new LIB manufacturing plants using a baseline case of thin (power) electrodes produced with NMP processing and a standard 10–14-day wetting and formation process. In particular, it is shown that aqueous electrode processing can cut the electrode processing cost and energy consumption by an order of magnitude. Doubling the thickness of the electrodes allows for using half of the inactive current collectors and separators, contributing even further to the processing cost savings. Finally wetting and SEI-layer formation cost savings are discussed in the context of a protocol with significantly reduced time. These three benefits collectively offer the possibility of reducing LIB pack cost from $502.8 kW h −1 -usable to $370.3 kW h −1 -usable, a savings of $132.5/kWh (or 26.4%). • A comprehensive cost study on lithium-ion electrode processing is reported. • Advanced electrode processing can save up to $111/kWh-usable. • Reduced SEI-layer formation time can save an additional $22/kWh-usable. • These processing technologies are amenable to any anode or cathode chemistry. • Capital cost savings realized and cell processing bottlenecks addressed.