RUDN Journal of Ecology and Life SafetyRUDN Journal of Ecology and Life SafetyВестник Российского университета дружбы народов. Серия: Экология и безопасность жизнедеятельности2313-23102408-8919Peoples’ Friendship University of Russia named after Patrice Lumumba (RUDN University)5220510.22363/2313-2310-2026-34-3-364-375FNCQWCIndustrial EcologyПромышленная экологияResearch ArticleAssessment of production factors in the manufacturing of lithium-ion batteries: case study of Gelon LIB equipmentОценка производственных факторов при изготовлении литий-ионных аккумуляторов на примере оборудования фирмы Gelon LIBhttps://orcid.org/0000-0001-8732-219X2812-3782AkhtyamovRasul G.АхтямовРасул Гумерович

Ph.D. in Engineering (Candidate of Technical Sciences), Associate Professor, Department of Technosphere and Environmental Safety

кандидат технических наук, доцент, доцент кафедры техносферной и экологической безопасности

ahtamov.zchs@gmail.comhttps://orcid.org/0000-0003-4058-29685367-2937ShikhovtsevaAnna V.ШиховцеваАнна Владимировна

Junior Research Fellow, Laboratory of Solid-State Electrochemical Systems

младший научный сотрудник Лаборатории твердотельных электрохимических систем

dissovet04@icp.ac.ruhttps://orcid.org/0009-0003-9507-11855657-5774KaluginLeonid E.КалугинЛеонид Ермолаевич

Ph.D. in Chemistry (Candidate of Chemical Sciences), Engineer, Laboratory of Materials and Device Technologies for Electrochemical Power Sources

кандидат химических наук, инженер Лаборатории технологий материалов и устройств электрохимических источников энергии

kleo2712@yandex.ruhttps://orcid.org/0000-0002-3562-88055375-9184EvshchikElizaveta Yu.ЕвщикЕлизавета Юрьевна

Ph.D. in Chemistry (Candidate of Chemical Sciences), Senior Research Fellow, Laboratory of Solid-State Electrochemical Systems

кандидат химических наук, старший научный сотрудник Лаборатории твердотельных электрохимических систем

liza@icp.ac.ruEmperor Alexander I St. Petersburg State Transport UniversityПетербургский государственный университет путей сообщения Императора Александра IFederal Research Center for Problems of Chemical Physics and Medicinal Chemistry of the Russian Academy of SciencesФедеральный исследовательский центр проблем химической физики и медицинской химии Российской академии наук10092026343VOL 34, NO2 (2026)ТОМ 34, №2 (2026)36437510092026Copyright ©; 2026, Akhtyamov R.G., Shikhovtseva A.V., Kalugin L.E., Evshchik E.Y.Copyright ©; 2026, Ахтямов Р.Г., Шиховцева А.В., Калугин Л.Е., Евщик Е.Ю.2026Akhtyamov R.G., Shikhovtseva A.V., Kalugin L.E., Evshchik E.Y.Ахтямов Р.Г., Шиховцева А.В., Калугин Л.Е., Евщик Е.Ю.https://creativecommons.org/licenses/by-nc/4.0https://journals.rudn.ru/ecology/article/view/52205

The production of lithium-ion batteries (LIBs) is associated with a complex of hazardous factors at all technological stages. Existing studies are often fragmented and do not offer a holistic risk management system, which highlights the need to develop a comprehensive approach to ensuring safety and efficiency. The aim of this work is a systematic analysis of production risks at all stages of LIB manufacturing and the development of practical recommendations for creating an effective safety system, including technical, organizational, and personnel aspects. The research is based on a systematic analysis of the LIB production technological process. Methods of risk analysis, comparative assessment of manual and automated operations, and analysis of the technical characteristics of specialized equipment were used. The results are structured in the form of detailed risk assessment tables for each stage. Key hazards were identified and ranked: toxicity of chemical components (especially LiPF₆-based electrolyte), fire and explosion risks, nanoparticle exposure, and mechanical injuries. It has been established that the most hazardous operations involve the electrolyte, ultrasonic welding, and drying. A significant reduction in the risk of injuries and production defects during the transition from manual to automated assembly has been proven. Specific protective measures have been developed and systematized: engineering solutions (ventilation, interlocks), personal protective equipment (PPE) requirements, microclimate parameters, training programs, and the need for real-time monitoring systems. This article proposes a holistic, step-by-step approach to risk management in LIB production. The main conclusion is that safety and economic efficiency are achieved through a systematic combination of maximum automation of critical operations, implementation of multi-level monitoring, and comprehensive personnel protection. The presented recommendations form a ready-made basis for designing safe production lines.

Производство литий-ионных аккумуляторов (ЛИА) сопряжено с комплексом опасных факторов на всех технологических этапах. Существующие исследования часто фрагментарны и не предлагают целостной системы управления рисками, что актуализирует разработку комплексного подхода к обеспечению безопасности и эффективности. Цель исследования - системный анализ производственных рисков на всех этапах изготовления ЛИА, а также разработка практических рекомендаций по созданию эффективной системы безопасности, включающей технические, организационные и кадровые аспекты. Исследование основано на системном анализе технологического процесса производства ЛИА. Использованы методы анализа рисков, сравнительная оценка ручных и автоматизированных операций, анализ технических характеристик специализированного оборудования. Результаты структурированы в виде детализированных таблиц оценки рисков для каждого этапа. Выявлены и ранжированы ключевые опасности: токсичность химических компонентов (особенно электролита на основе LiPF₆), пожарно-взрывные риски, воздействие наночастиц и механические травмы. Установлено, что наиболее опасными являются операции с электролитом, ультразвуковой сваркой и сушкой. Доказано значительное снижение риска травматизма и производственного брака при переходе от ручной к автоматизированной сборке. Разработаны и систематизированы конкретные защитные меры: инженерные решения (вентиляция, блокировки), требования к СИЗ, параметры микроклимата, программы обучения и необходимость внедрения систем реального времени. Предложен целостный, поэтапный подход к управлению рисками в производстве ЛИА. Основной вывод заключается в том, что безопасность и экономическая эффективность достигаются через системную комбинацию максимальной автоматизации критических операций, внедрения многоуровневого мониторинга и комплексной защиты персонала. Представленные рекомендации формируют готовую основу для проектирования безопасных производственных линий.

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