Material Flow Simulation in Lithium-Ion Battery Cell Manufacturing as a Planning Tool for Cost and Energy Optimization

Lithium-ion batteries are seen as a key technology for powering electric vehicles and energy storage. Still, their high cost and energy-intensive manufacturing process remain a significant barrier to wider adoption. Due to the high moisture sensitivity of certain processed materials, the operation of dry rooms is required, constituting a critical contributor to cost and energy consumption in lithium-ion battery production. As the operating costs for these dry rooms strongly depend on the volume and adjusted humidity of the air, it is vital to choose an appropriate operation strategy already in the planning and designing phase of the factories. In this regard, simulation tools can effectively support the planning process by providing predictive information on the production system. The simulation model presented in this paper offers an approach to optimize the material and energy consumption associated with the production of lithium-ion batteries while also considering current material-related production challenges regarding moisture. By calculating a time-resolved material flow, the model enables to identify individual process times and storage durations depending on the chosen production layout. This allows for a material-specific dimensioning of the buffers and supports the dry room design. Hence, the data generated by the model can serve as a basis for planning more cost-and energy-efficient production environments.