SafyrOPC for Giga Factories
How to secure the production of Li-ion batteries for electric vehicles
Around 4,000 fires were caused by battery thermal runaway, a risk that can escalate rapidly in high-energy storage systems. At the same time, particle build-up remains a hidden threat across industries, contributing to 25% of equipment failures. Together, these figures highlight a critical need for smarter monitoring solutions that can detect and prevent hazards before they lead to costly—or dangerous—incidents.
Production under high tension
However, there are inherent risks in manufacturing Li-ion batteries. The materials used react with oxygen and humidity, generating explosive gases such as hydrogen, and dangerous gases such as hydrogen fluoride. What’s more, the use of toxic metals, notably cobalt in powder form, represents a danger to workers and the environment. One of the major problems to be solved is the formation of dendrites in battery cells, may cause thermal runaway and ignition or explosion of the battery. This phenomenon, caused by the growth of metallic structures between the electrodes,is amplified by the presence of contaminating particles during the assembly of battery components.
Fine particles at stake
With ISO 14644, control requirements are the same as for cleanrooms
FAQ
Q: What are the major issues involved in producing batteries for gigafactories?
The production of lithium-ion batteries, particularly for electric vehicles, poses major challenges in terms of safety and quality.
- Risk of thermal runaway: Caused by overheating of the battery cells, thermal runaway can lead to fires and explosions, representing a major hazard.
- Dendrite formation : The formation of dendrites, accentuated by the presence of pollutant particles, can cause short circuits and shorten battery life.
- Particle pollution: The presence of particles in the electrolyte can also affect battery capacity and production consistency. What’s more, the use of toxic metals such as cobalt and manganese exposes workers to health risks.
Q: How do cleanrooms contribute to battery production in gigafactories?
Cleanrooms are controlled environments where contamination by airborne particles is minimized. They play a crucial role in the production of lithium-ion batteries by :
- Reducing the risk of fire and explosion: By limiting the presence of particles that can aggravate the formation of dendrites, cleanrooms help minimize the risk of thermal runaway.
- Improving battery quality: Cleanroom production controls particle contamination in the electrolyte, increasing battery capacity and life.
- Protecting workers’ health: By maintaining a low concentration of harmful particles in the air, cleanrooms protect workers from the risk of exposure to toxic metals.
Q: How is air quality monitored in gigafactories?
Real-time monitoring of air quality is essential to guarantee an optimal production environment in gigafactories.
- Continuous monitoring systems: Sensors such as the Safyr OPC, using NextPM technology, enable continuous monitoring of particle concentration in the air.
- Laboratory analysis: In the event of a pollution peak or unusual event, further laboratory analysis can be carried out to identify the chemical composition of particles and take corrective action.
- Biological monitoring: In the event of potential exposure to toxic substances, biological monitoring of workers can be set up to assess the impact on their health and take the necessary measures.
