Accelerating Electric Vehicle Adoption & Battery Design Kandler - - PowerPoint PPT Presentation

Figure Credit: Kenny Gruchalla and Francois Usseglio-Viretta, NREL

Kandler Smith

Electrochemical Energy Storage - Computational Modeling Team Lead National Renewable Energy Laboratory, Golden CO

Kandler.Smith@nrel.gov

Accelerating Electric Vehicle Adoption & Battery Design

Outline

• Transportation Electrification
• Battery Cost
• Lithium-based Chemistries – Today & Future
• DOE & NREL Research & Development

– Low/No Cobalt Cathodes – Recycling (RECELL) – Extreme Fast Charging (XCEL) – Behind the Meter Storage (BTMS) – Computer-Aided Engineering of Batteries (CAEBAT)

Batteries and Electrification

• New York International Auto Show: more than

40 electrified vehicles

• EPRI: Utilities are proposing ~$3.7B in EV

charging infrastructure

• CEO of Daimler Trucks North America: For

commercial vehicles “The beginning of the post internal combustion engine era”

2020 Chevy Bolt | Adam Jeffery | CNBC https://www.cummins.com/news/2018/04/23/cummins- puts-electrification-progress-display

Courtesy: Cunningham Brian, DOE, AMR, 2019

www.rivian.com

Energy Storage: Battery Cost Story – The Past

“Rapidly falling costs of battery packs for electric vehicles”, B. Nykvist and M. Nilsson; Nature, Climate Change; March 2015, DOI: 10.1038/NCLIMATE2564

95% conf. interval, whole industry 95% conf. interval, market leaders Publications, reports, and journals News items with expert statements Log fit of news, reports, and journals: 12 ÷ 6% decline Additional cost estimates without a clear method Market leader, Nissan Motors (Leaf) Market leader, Tesla Motors (Model S) Other battery electric vehicles Log fit of market leaders only: 8 ÷ 8% decline Log fit of all estimates: 14 ÷ 6% decline Future costs estimated in publications

2005 2010 2015 2020 2025 2030 2,000 1,600 1,800 1,400 1,200 1,000 800 600 400 200

2014 US$/kWh

DOE cost target $100/kWh w/ ultimate goal of $80/kWh 2012 DOE cost target $600/kWh 2018 DOE cost $197/kWh 2022 DOE cost target $100/kWh

Conventional Li-ion Chemistries

Samu Kukkonen, VTT Technical Research Centre of Finland (2014)

Anode/Cathode Combinations Decreasing Energy Density

Graphite/ LCO Graphite/ NCA Graphite/ NMC Graphite/ LMO-Blend Graphite/ LFP LTO/NMC Safety Energy Lifetime Charge Cost

Future Supply

LCO – Lithium Cobalt Oxide; NCA – Nickel Cobalt Aluminum; NMC – Nickel Manganese Cobalt LMO – Lithium Manganese Oxide; LFP – Lithium Iron Phosphate; LTO – Lithium Titanate Oxide

Energy Storage: Battery Cost Story – The Future

System Cost ($/kWh)

$200

$600 $500 $400

$300

$100

Year

2014 2020 2022 2024 2012 2016 2018 2026 $197/kWh Graphite/High Voltage NMC Silicon/High Voltage NMC 2028 2030

Lithium-Metal or Lithium/Sulfur

$320/kWh (5x excess Li, 10%S)

~$80/kWh

Graphite/High Voltage NMC

Silicon/High Voltage NMC Lithium-Metal & Li/Sulfur

• R&D Focus: Higher cathode

capacity (220+ mAh/g), low/no cobalt, recycling, fast charge

• R&D Focus: Higher anode

capacity (1000+ mAh/g), cycle/calendar life, fast charge

• R&D Focus: Solve cycle life/

catastrophic failure issues, reduce excess lithium, reduce excess electrolyte, reduce lithium metal cost

Courtesy: Cunningham Brian, DOE, AMR, 2019

Conventional to Next-Gen Li-ion Chemistries – DOE R&D

Energy Storage: DOE R&D Portfolio

CHARTER: Develop battery technology that will enable large market penetration of electric drive vehicles

2022 GOAL: $150/kWh(useable)

Critical materials-free with recycled materials and capable of fast charge

Energy Storage R&D

Battery Testing, Design, & Analysis Battery Development Applied Battery Research (ABR) Battery Materials Research (BMR)

Courtesy: Cunningham Brian, DOE, AMR, 2019

Li-Based Chemistry Selection for Higher Energy Density

J.-M. Tarascon and M. Armand, Nature Vol. 414, p. 359 (2011)

Cathodes Anodes

Desire large potential difference between anode and cathode… …and high capacity

Li-ion Cell Configurations

Photo Credit: NREL-Dirk Long Photo Credit: https://en.wikipedia.org/wiki/List_of_battery_sizes Photo Credit: http://ewi.org/ultrasonic-metal- welding-for-lithium-ion-battery-cells/ Photo Credit: http://sustainablemfr.com/energy-efficiency/lowering- costs-lithium-ion-batteries-ev-power-trains#lithium

• Cylindrical:
• Jellyroll
• Hard can
• Prismatic:
• Wound or stacked layers
• Soft pouch or hard can

Battery Packs in Some EVs

http://autogreenmag.com/tag/chevroletvolt/page/2/

Chevy Volt Nissan Leaf

http://inhabitat.com/will-the-nissan-leaf-battery-deliver-all- it-promises/ http://www.caranddriver.com/news/car/10q4/2012_mitsubi shi_i-miev_u.s.-spec_photos_and_info- auto_shows/gallery/mitsubishi_prototype_i_miev_lithium- ion_batteries_and_electric_drive_system_photo_19

i-MiEV

http://www.metaefficient.com/cars/ford-focus-electric- nissan-leaf.html

Ford Focus Tesla Model S

https://hackadaycom.files.wordpress.com/2 014/09/tesla-batt.jpg?w=800

http://www.ibtimes.com/articles/79578/20101108/sb- limotive-samsung-sdi-chrysler-electric-car.htm

Fiat 500 EV

NREL Transportation RD&D Activities & Applications

Illustration by NREL

Advanced Energy Storage

Development, Testing, Analysis Thermal Characterization/Management Life/Abuse Testing/Modeling Computer-Aided Engineering Electrode Material Development

Advanced Power Electronics and Electric Motors

Thermal Management Thermal Stress and Reliability

Infrastructure

Vehicle-to-Grid Integration Integration with Renewables Charging Equipment & Controls Fueling Stations & Equipment Roadway Electrification Automation

Vehicle and Fleet Testing

MD/HD Dynamometer Testing MDV & HDV Testing/Analysis Drive Cycle Analysis/Field Evaluations Technology Performance Comparisons Data Collection, Storage, & Analysis Analysis & Optimization Tools

Regulatory Support

EPAct Compliance Data & Policy Analysis Technical Integration Fleet Assistance

Advanced Combustion/Fuels

Advanced Petroleum and Biofuels Combustion/Emissions Measurements Vehicle & Engine Testing

Vehicle Thermal Management

Integrated Thermal Management Climate Control/Idle Reduction Advanced HVAC

Vehicle Deployment/Clean Cities

Guidance & Information for Fleet Decision Makers & Policy Makers Technical Assistance Online Data, Tools, Analysis

DUMMY

• Lower cost of

batteries

• Lower

environmental impacts

• Increase USA’s

energy security DOE Approach to Circular Economy for Lithium-ion batteries

Realizing Next- Generation Cathodes for Li-Ion Batteries: Low-Cobalt Cathodes

• The objective of this

Argonne National Lab (ANL) led project is to realize high-capacity, high- energy cathodes with stabilized long-term performance.

• The project is developing

lithiated transition-metal (TM) oxides, in concert with strategies to minimize/ eliminate cobalt as well as particle surface- engineering efforts to mitigate the effects of surface reactivity.

• NREL is exploring Co-free

cathode materials and advanced electrolytes to stabilize nickel-rich surfaces. Developed Epitaxial High Nickel Cathodes Model Electrodes Understand how surface chemistry affects electrochemical reactivity at NMC surfaces using AFM/SECM

MISSION: Minimize the cost of recycling lithium ion batteries to ensure future supply availability of critical materials and decrease energy usage

Lithium Ion Battery Recycling R&D Center (ANL lead)

Direct recycling minimizes steps back to use

Decrease the cost of recycling lithium-ion batteries to ensure future supply of critical materials and decrease energy usage compared to raw material production

Existing Li-Ion Recycling Methods

Recycling Prize Focused on Five Areas

Why is Extreme Fast Charging (XFC) Important?

• DC Fast Charging Increases BEV

Utility

– Yearly electric vehicle miles (eVMT) traveled increases with use of 50 kW fast charging – Nearly 25% more miles driven annually when DCFC used for 1-5%

• f total charging events

Source: McCarthy, Michael. “California ZEV Policy Update.” SAE 2017 Government/Industry Meeting, Society of Automotive Engineers, 25 January 2017, Walter E. Washington Convention Center, Washington, DC. Conference Presentation.

Level 1 (110V, 1.4kW) Level 2 (220V, 7.2kW) DC Fast Charger (480V, 50kW) Tesla SuperCharger (480V, 140kW) XFC (1000V, 400kW) Range Per Minute of Charge (miles)

0.082 0.42 2.92 8.17 23.3

Time to Charge for 200 Miles (min)

2143 417 60 21.4 7.5

• EV Service Equip (EVSE)

Comparison

– XFC should be able to charge a BEV in less than 10 minutes and provide approximately 200 additional miles of driving range

Thick graphite electrodes increase energy density but decrease XFC

• Greater EV driving range needs energy-dense electrodes
• Slow transport of Li+ ions in electrolyte + graphite limitations  Li plating side reaction

Increasing Li deposition on graphite electrodes as a function of capacity loading (electrode thickness)

• Lithium may or may not removed during the following discharge cycle
• Stranded lithium can be a safety issue

Advanced electrolytes, electrode architectures and elevated temperature all can enable fast charging of 250 Wh/kg graphite-based Li-ion batteries

Courtesy: Michelbacher, Chris; DOE, AMR, 2017

NREL | 20

Partnership with the U. S. Department of Energy Buildings Technology Office and Solar Energy Technology Office

Behind-the-Meter Storage Project

Goal: To produce behind-the-meter storage solutions to enable high-power electric-vehicle charging coupled to a grid interactive efficient building.

• Focus on specific end user outcomes
• Minimize cost of energy to user
• Buildings are the largest electrical users.
• EVs will be charged at buildings.
• Demand charges need to be eliminated.
• Grid impacts minimized.
• Integration of PV is/will be common.
• Both electrons and heat need to be stored.
• New batteries are needed
• New thermal storage are needed

NREL | 21

Physics of Li-Ion Battery Systems in Different Length Scales

Li diffusion in solid phase Interface physics Particle deformation & fatigue Structural stability Charge balance and transport Electrical network in composite electrodes Li transport in electrolyte phase Electronic potential & current distribution Heat generation and transfer Electrolyte wetting Pressure distribution

Atomic Scale Particle Scale Electrode Scale Cell Scale System Scale

System operating conditions Environmental conditions Control strategy

Module Scale

Thermal/electrical inter-cell configuration Thermal management Safety control Thermodynamic properties Lattice stability Material-level kinetic barrier Transport properties

Many disparate disciplines involved in battery R&D. Computational models effectively communicate tradeoffs and accelerate R&D and design.

NREL | 22

ce cs

MSMD CAEBAT1 CAEBAT2-3

Parameter ID Mechanical Abuse 3D Simulation Microstructure Tomography, Analysis, Stochastic Reconstruction

+XFC

*Computer-Aided Engineering of Batteries Program

+TARDEC

Bullet Penetration

Computer- Aided Engineering for Batteries: Tools for Industry

DOE’s Vehicle Technologies Office established Computer-Aided Engineering for Batteries (CAEBAT) in 2010 to develop experimentally validated software design tools to accelerate battery product development time and reduce cost. Commercial CAEBAT modeling tools are widely used across industry.

www.nrel.gov

Thank You! Questions?

This work was authored in part by the National Renewable Energy Laboratory, operated by Alliance for Sustainable Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding provided by U.S. Department of Energy Vehicle Technologies Office. The views expressed in the article do not necessarily represent the views of the DOE or the U.S. Government. The U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for U.S. Government purposes.