📋 Case Study

Electrolyte Manufacturing for EV Batteries — BASF Ulsan Plant

HF generation during synthesis; 42% fluorine lost as CaF₂ sludge; high energy demand for cryogenic purification

🏗️ Project Overview

New LiPF₆ synthesis line with closed-loop fluorine management

🎯 Challenge

HF generation during synthesis; 42% fluorine lost as CaF₂ sludge; high energy demand for cryogenic purification

🔧 Design Approach

Adopted electrochemical fluorination with regenerative HF scrubbing; installed heat-integrated distillation with ceramic membranes

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Fluorine Recovery Rate

Recovered F / Input F × 100

Result: 98.7%

Reduces raw material cost and regulatory reporting burden

Specific Energy Consumption

kWh / kg LiPF₆

Result: 8.3 → 4.1

Key competitiveness lever in battery supply chain

📊 Results

HF emissions reduced by 99.4%; fluorine purchase costs down 31%; passed ISO 14067 carbon footprint verification

💡 Lessons Learned

• •Material compatibility (e.g., Ni–Mo alloys) is non-negotiable for HF service
• •Real-time fluorine mass balance monitoring prevents batch rejection

✅ Key Takeaways

• 1Material compatibility (e.g., Ni–Mo alloys) is non-negotiable for HF service
• 2Real-time fluorine mass balance monitoring prevents batch rejection