Battery-Cell-and-Pack-Assembly---2010-energy-stora

Formoreinformation1-877-EERE-INFO(1.877.337.3463)eere.energy.govDOE/EE-0382January2011annualprogressreport2010EnergyStorageR&DThisdocumenthighlightsworksponsoredbyagenciesoftheU.S.Government.NeithertheU.S.Governmentnoranyagencythereof,noranyoftheiremployees,makesanywarranty,expressorimplied,orassumesanylegalliabilityorresponsibilityfortheaccuracy,complete-ness,orusefulnessofanyinformation,apparatus,product,orprocessdisclosed,orrepresentsthatitsusewouldnotinfringeprivatelyownedrights.Referencehereintoanyspecificcommercialproduct,process,orservicebytradename,trademark,manufacturer,orother-wisedoesnotnecessarilyconstituteorimplyitsendorsement,recommendation,orfavoringbytheU.S.Governmentoranyagencythereof.TheviewsandopinionsofauthorsexpressedhereindonotnecessarilystateorreflectthoseoftheU.S.Governmentoranyagencythereof.U.S.DepartmentofEnergy1000IndependenceAvenue,S.W.Washington,D.C.20585-0121FISCALYEAR2010ANNUALPROGRESSREPORTFORENERGYSTORAGER&DJanuary2011ApprovedbyDavidHowell,HybridElectricSystemsTeamLeadVehicleTechnologiesProgram,EnergyEfficiencyandRenewableEnergyFY2010AnnualProgressReportiEnergyStorageR&DTableofContentsI.INTRODUCTION......................................................................................................................................................1I.AVehicleTechnologiesProgramOverview..........................................................................................................................1I.BEnergyStorageResearch&DevelopmentOverview............................................................................................................1I.B.1ProgrammaticStructure..............................................................................................................................1I.B.2SomeRecentHighlights..............................................................................................................................3I.B.3OrganizationofthisReport.........................................................................................................................4II.AMERICANRECOVERY&REINVESTMENTACT(ARRA)OF2009.............................................................9II.AIntegratedBatteryMaterialsProduction,CellManufacturing,andBatteryAssemblyFacilities....................................................10II.A.1Domesticadvancedbatteryindustrycreationproject(JohnsonControls,Inc.).......................................10II.A.2VerticallyIntegratedMassProductionofAutomotiveClassLithium-ionBatteries(A123Systems).....13II.A.3AcceleratingtheElectrificationofU.S.DriveTrains:ReadyandAffordableTechnologySolutionsforDomesticallyManufacturedAdvancedBatteries(ExideTechnologies)............................................................15II.A.4PHEVBatteryDevelopment(EastPennManufacturingCo.,Inc.).........................................................18II.BBatteryCellandPackAssemblyFacilities......................................................................................................................19II.B.1CellandBatteryManufacturingFacilityinMichigantoSupporttheEVandHEVMarkets(Kokam/Dow,MidlandBatteryPark)................................................................................................................19II.B.2DevelopmentofHigh-PerformancePHEVBatteryPack(LGChemMichiganInc.–formerlyknownasCompactPower,Inc.).........................................................................................................................................21II.B.3Lithium-ionCellProductionandBatteryPackAssembly(EnerDel)......................................................24II.B.4Li-IonBatteryPackManufacturing(GM)...............................................................................................26II.B.5Lithium-ionCellProductionandBatteryPackAssembly(SaftAmerica,Inc.)......................................29II.CBatteryMaterialsProductionFacilities..........................................................................................................................31II.C.1ManufacturingFacilitiesInitiativeforLithium-IonBatterySeparators(Celgard)..................................31II.C.2AdvancedCathodeMaterialsProductionFacility(TodaAmericaInc.)..................................................34II.C.3DomesticProductionofLithiumCarbonateandLithiumHydroxide(ChemetallFoote)........................37II.C.4High-VolumeManufacturingofLiPF6–ACriticalLithium-ionBatteryMaterial(Honeywell)............40II.C.5ConstructionofaLi-ionBatteryCathodeProductionPlant(BASF).......................................................42II.C.6NanoengineeredUltracapacitorMaterial(EnerG2,Inc.).........................................................................43II.C.7ExpansionofNovolyteCapacityforLithium-IonElectrolyteProduction(Novolyte)............................45II.C.8EstablishandExpandCommercialProductionofGraphiteAnodeBatteriesforHighPerformanceProductionofLi-ionBatteries(FutureFuel)..................................................................