E E E E lectrical E lectrical E lectrical E lectrical E nergy - - PowerPoint PPT Presentation

E lectrical E nergy Storage for E lectrical E nergy Storage for E lectrical E nergy Storage for E lectrical E nergy Storage for Vehicles: Targets and Metrics Vehicles: Targets and Metrics Vehicles: Targets and Metrics Vehicles: Targets and Metrics

Ted J. Miller November 3 2009

Key Automotive Targets

• HEV (40kW battery full hybrid system example)

– High specific power: >2,000W/kg (<20kg battery) –

• 30C cranking capability: 5kW

– Extremely high shallow cycle life: 500k cycles – Long operating life: 15 years – High power/energy ratio: >20:1 – Cost: goal of $20/kW ($800) @ 100k/year

• PHEV (Ford Escape Plug-in Hybrid battery system example)

– Higher energy power battery: 10kWh / 25mi / 140kg / 95 liters – Requires full power over a wide temperature range – Both high deep (5,000) and shallow (500k) cycle life required – Must be fully abuse tolerant when packaged in the crash zone – Power/energy ratio: 5:1 to 15:1 – Cost: $1,000/kWh ($10-15k); goal = $200-300/kWh @100k/year

• EV (30kWh electric vehicle battery system example)

– High energy density: >120Wh/kg (30kWh / 100mi / 250kg battery) – High deep discharge cycle life: 3,000 cycles to 80-90% DOD – Power/energy ratio: 2:1 to 4:1 – Cost: $600/kWh ($18k) at volume; future high volume prospect = $300/kWh

• HEV (40kW battery full hybrid system example)

– High specific power: >2,000W/kg (<20kg battery) –

• 30C cranking capability: 5kW

– Extremely high shallow cycle life: 500k cycles – Long operating life: 15 years – High power/energy ratio: >20:1 – Cost: goal of $20/kW ($800) @ 100k/year

• PHEV (Ford Escape Plug-in Hybrid battery system example)

– Higher energy power battery: 10kWh / 25mi / 140kg / 95 liters – Requires full power over a wide temperature range – Both high deep (5,000) and shallow (500k) cycle life required – Must be fully abuse tolerant when packaged in the crash zone – Power/energy ratio: 5:1 to 15:1 – Cost: $1,000/kWh ($10-15k); goal = $200-300/kWh @100k/year

• EV (30kWh electric vehicle battery system example)

– High energy density: >120Wh/kg (30kWh / 100mi / 250kg battery) – High deep discharge cycle life: 3,000 cycles to 80-90% DOD – Power/energy ratio: 2:1 to 4:1 – Cost: $600/kWh ($18k) at volume; future high volume prospect = $300/kWh

USABC HE V Battery Requirements

FreedomCAR Goals Power-Assist Power-Assist Characteristics

Units

Minimum Maximum

Pulse Discharge Power (10s) kW 25 40 Max Regen Pulse (10s) kW 20 (50Wh pulse) 35 (97Wh pulse) Total Available Energy kWh 0.3 0.5 Round Trip Efficiency % >90 - 25Wh Cycle >90 - 50Wh Cycle Cycle Life for specified SOC Increments Cyc. 300k 25Wh Cycle (7.5 MWh) 300k 50Wh Cycle (15 MWh) Cold-cranking Power at -30°C (Three 2-sec pulses, 10-sec rests between) kW 5 7 Calendar Life Yrs 15 15 Max Weight kg 40 60 Max Volume liters 32 45 Production Price @ 100k units/yr $ 500 800 Maximum Operating Voltage Vdc ≤ 400 Max ≤ 400 max Minimum Operating Voltage Vdc ≥ 0.55xVmax ≥ 0.55 x Vmax Maximum Self Discharge Wh/d 50 50 Operating Temperature °C

• 30 to +52
• 30 to +52

Survival Temperature °C

• 46 to +66
• 46 to +66

FreedomCAR Goals Power-Assist Power-Assist Characteristics

Units

Minimum Maximum

Pulse Discharge Power (10s) kW 25 40 Max Regen Pulse (10s) kW 20 (50Wh pulse) 35 (97Wh pulse) Total Available Energy kWh 0.3 0.5 Round Trip Efficiency % >90 - 25Wh Cycle >90 - 50Wh Cycle Cycle Life for specified SOC Increments Cyc. 300k 25Wh Cycle (7.5 MWh) 300k 50Wh Cycle (15 MWh) Cold-cranking Power at -30°C (Three 2-sec pulses, 10-sec rests between) kW 5 7 Calendar Life Yrs 15 15 Max Weight kg 40 60 Max Volume liters 32 45 Production Price @ 100k units/yr $ 500 800 Maximum Operating Voltage Vdc ≤ 400 Max ≤ 400 max Minimum Operating Voltage Vdc ≥ 0.55xVmax ≥ 0.55 x Vmax Maximum Self Discharge Wh/d 50 50 Operating Temperature °C

• 30 to +52
• 30 to +52

Survival Temperature °C

• 46 to +66
• 46 to +66

FreedomCAR Goals FreedomCAR Goals Power-Assist Power-Assist Power-Assist Power-Assist Characteristics Characteristics

Units Units

Minimum Minimum Maximum Maximum

Pulse Discharge Power (10s) Pulse Discharge Power (10s) kW kW 25 25 40 40 Max Regen Pulse (10s) Max Regen Pulse (10s) kW kW 20 (50Wh pulse) 20 (50Wh pulse) 35 (97Wh pulse) 35 (97Wh pulse) Total Available Energy Total Available Energy kWh kWh 0.3 0.3 0.5 0.5 Round Trip Efficiency Round Trip Efficiency % >90 - 25Wh Cycle >90 - 25Wh Cycle >90 - 50Wh Cycle >90 - 50Wh Cycle Cycle Life for specified SOC Increments Cycle Life for specified SOC Increments Cyc. Cyc. 300k 25Wh Cycle (7.5 MWh) 300k 25Wh Cycle (7.5 MWh) 300k 50Wh Cycle (15 MWh) 300k 50Wh Cycle (15 MWh) Cold-cranking Power at -30°C (Three 2-sec pulses, 10-sec rests between) Cold-cranking Power at -30°C (Three 2-sec pulses, 10-sec rests between) kW kW 5 7 Calendar Life Calendar Life Yrs Yrs 15 15 15 15 Max Weight Max Weight kg kg 40 40 60 60 Max Volume Max Volume liters liters 32 32 45 45 Production Price @ 100k units/yr Production Price @ 100k units/yr $ 500 500 800 800 Maximum Operating Voltage Maximum Operating Voltage Vdc Vdc ≤ 400 Max ≤ 400 Max ≤ 400 max ≤ 400 max Minimum Operating Voltage Minimum Operating Voltage Vdc Vdc ≥ 0.55xVmax ≥ 0.55xVmax ≥ 0.55 x Vmax ≥ 0.55 x Vmax Maximum Self Discharge Maximum Self Discharge Wh/d Wh/d 50 50 50 50 Operating Temperature Operating Temperature °C °C

• 30 to +52
• 30 to +52
• 30 to +52
• 30 to +52

Survival Temperature Survival Temperature °C °C

• 46 to +66
• 46 to +66
• 46 to +66
• 46 to +66

USABC PHE V Battery Goals

Characteristics at EOL (End of Life) High Power/Energy Ratio Battery High Energy/Power Ratio Battery Reference Equivalent Electric Range miles 10 40 Peak Pulse Discharge Power - 2 Sec / 10 Sec kW 50 / 45 46 / 38 Peak Regen Pulse Power (10 sec) kW 30 25 Available Energy for CD (Charge Depleting) Mode, 10 kW Rate kWh 3.4 11.6 Available Energy for CS (Charge Sustaining) Mode kWh 0.5 0.3 Minimum Round-trip Energy Efficiency (USABC HEV Cycle) % 90 90 Cold cranking power at -30°C, 2 sec - 3 Pulses kW 7 7 CD Life / Discharge Throughput Cycles/MWh 5,000 / 17 5,000 / 58 CS HEV Cycle Life, 50 Wh Profile Cycles 300,000 300,000 Calendar Life, 35°C year 15 15 Maximum System Weight kg 60 120 Maximum System Volume Liter 40 80 Maximum Operating Voltage Vdc 400 400 Minimum Operating Voltage Vdc >0.55 x Vmax >0.55 x Vmax Maximum Self-discharge Wh/day 50 50 System Recharge Rate at 30°C kW 1.4 (120V/15A) 1.4 (120V/15A) Unassisted Operating & Charging Temperature Range °C

• 30 to +52
• 30 to +52

Survival Temperature Range °C

• 46 to +66
• 46 to +66

Maximum System Production Price @ 100k units/yr $ $1,700 $3,400

Requirements of End of Life Energy Storage Systems for PHEVs

USABC E V Battery Goals

Parameter (units) of fully burdened system Mid-Term Goal Minimum Goals for Long Term Commercialization Long Term Goal Power Density (W/liter) 250 460 600 Specific Power - Discharge, 80% DOD/30 sec. (W/kg) 150 300 400 Specific Power - Regen, 20% DOD/10 sec. (W/kg) 75 150 200 Energy Density - C/3 Discharge rate (W•h/liter) 135 230 300 Specific Energy - C/3 Discharge rate (W•h/kg) 80 150 200 Specific Power/Specific Energy Ratio 2:1 2:1 2:1 Total Pack Size (kW•h) 40 40 40 Life (Years) 5 10 10 Cycle Life - 80% DOD (Cycles) 600 1000 to 80% DOD 1600 to 50% DOD 2670 to 30% DOD 1000 Power & Capacity Degradation (% of rated spec) 20 20 20 Ultimate Price - 10,000 units @ 40 kW•h ($/kW•h) 150 <150 ($75/kWh Desired) 100 Operating Environment (° ° ° °C)

• 30 to +65
• 40 to +50

20% Performance Loss (10% desired)

• 40 to +85

Normal Recharge Time (hours) 6 6 (4 desired) 3 to 6 High Rate Charge 40-80% SOC in 15 minutes 20-70% SOC in <30 minutes @ 150W/kg (<20min @ 270W/kg desired) 40-80% SOC in 15 minutes Continuous discharge in 1 hour - No failure (% of rated capacity) 75 75 75

USABC E nergy Storage Goals

FreedomCAR Energy Storage Goals Characteristics Units Start-Stop M-HEV P-HEV Low Power High Power Low Power High Power Comm. Long Term Discharge Power kW 6 for 2 sec 13 13 for 10 sec 25 for 10 sec 40 25 for 10 sec 50 Specific Power-Dischg 80% DOD/30 sec W/kg 300 400 Regen Pulse kW N/A 8 for 2 sec 18 20 for 10 sec 35 30 for 5 sec 60 Specific Power-Regen 20% DOD/10 sec W/kg 150 200 Engine-off Accessory Load kW Recharge Rate kW 2.4 2.6 4.5 Power Density W/l 460 600 Available Energy Wh 250 @ 3kW 300 700 300 500 1500 3000 Specific Energy - C/3 Discharge Rate Wh/kg 150 200 Energy Density - C/3 Discharge Rate Wh/l 230 300 Specific Power/Specific Energy Ratio Total Pack Size kWh Energy Efficiency on Load Profile % Cycle Life (to specific usage profiles) cycle Calendar Life year Cold-start at -30C kW 5 for 2 sec 7 Maximum Weight kg 10 25 35 40 60 40 65 Maximum Volume liter 9 20 28 32 45 32 50 Production Price at 100k units/year $US 150 260 360 500 800 500 1000 Production Price at 10k units/year $/kWh 150 100 Maximum Operating Voltage Vdc Minimum Operating Voltage Vdc Maximum Self-discharge Wh/d Operating Temperature Range C

• 30-+65 -40-+85

Survival Temperature Range C

• 30 to +52
• 46 to +66
• 30 to +52
• 46 to +66
• 30 to +52
• 46 to +66

>0.55xVmax 27 >0.55xVmax 50 20 50 8 at 21V minimum for 2 sec 5 for TBD min 400 48 440 2:1 40 15 15 15 10 300k 450k TBD 1000-80% DOD 3 for 5 min 90 90 90 HEV (Power-Assist) 42-Volt Fuel Cell Vehicle Battery EV

Automotive Battery E lectrochemistry

• Present and near-term designs
• Future designs

– Higher power, higher energy, lower cost lithium ion – High energy metallic lithium

• Present and near-term designs
• Future designs

– Higher power, higher energy, lower cost lithium ion – High energy metallic lithium

Type Abbrev. Potential Anode Separator Cathode Electrolyte Key Attributes lead-acid PbA 2.0V lead polyolefin glass mat lead-oxide sulfuric acid high power low cost nickel/metal- hydride NiMH 1.2V metal-hydride alloy polypropylene nickel-oxide potassium hydroxide long life durability lithium-ion Li-Ion 3.6V 2.4V carbon lithium-titanate polyolefin metal-oxide metal- phosphate carbonates and lithium salt high energy design flexibility lithium-polymer Li-Poly 3.6V 2.4V carbon lithium-titanate polyolefin metal-oxide cabonates, lithium salt, and ploymer high energy planar design

HE V Battery Advancement

Escape Battery Module Fusion HEV Battery Pack

Cell Count - 17% Weight - 23% Cell Power +28%

Escape HEV Battery Pack Fusion Battery Module

Advanced Automotive Batteries

500 1000 1500 2000 2500 3000 3500 20 40 60 80 100 120 140 160 Specific Energy (Wh/kg) Specific Power (W/kg)

NiMH High Power

Fuel E nergy Density

Gasoline Gas + NiMH PbA Battery NiMH Battery Li-Ion Battery Gas ICE Gas + PbA Gas + Li-Ion 10 20 30 40 10 20 30 40 50 Gravimetric Energy Density (MJ/kg) Volumetric Energy Density (MJ/l)

E volutionary vs. Revolutionary

(M. Winter - University of Münster)

E V Battery Cost

• USABC long term goal of $100/kWh

– 40kWh battery system assumed ($4k) – $150/kWh commercialization target

• Consumer secondary cell cost of $300/kWh
• Achieving a battery cost of less than $10k

– High volume cost prospect is $300/kWh – Long term potential to $250/kWh – Resulting energy is 33-40kWh – EV range of 100-200 miles

• 500 mile range would require at least 100kWh

– USABC long term cost goal would need to be achieved – Much higher energy density (Wh/liter) a critical must – Charger and infrastructure power require ≥ ≥ ≥ ≥ 3x upgrade

• USABC long term goal of $100/kWh

– 40kWh battery system assumed ($4k) – $150/kWh commercialization target

• Consumer secondary cell cost of $300/kWh
• Achieving a battery cost of less than $10k

– High volume cost prospect is $300/kWh – Long term potential to $250/kWh – Resulting energy is 33-40kWh – EV range of 100-200 miles

• 500 mile range would require at least 100kWh

– USABC long term cost goal would need to be achieved – Much higher energy density (Wh/liter) a critical must – Charger and infrastructure power require ≥ ≥ ≥ ≥ 3x upgrade

Production E V Battery E xamples

• Ford EV

– 23kWh battery and 100 mile range

• Mitsubishi MiEV

– 16kWh battery and 100 mile range

• Nissan Leaf

– 25kWh battery and 100 mile range

• BMW Mini EV

– 35kWh battery and 150 mile range

• Ford EV

– 23kWh battery and 100 mile range

• Mitsubishi MiEV

– 16kWh battery and 100 mile range

• Nissan Leaf

– 25kWh battery and 100 mile range

• BMW Mini EV

– 35kWh battery and 150 mile range

Food for thought . . .

• Circa 1991 USABC EV battery price goal

determination

– ICE cost competitiveness assumed – Average 1991 gas price was $1.10/gal. – Resultant USABC EV battery price goal was $100/kWh

• A generalized formula of $100/kWh of battery per

$1.10/gallon of gasoline may be assumed

– Average October 2009 gas price is $2.72/gallon – Resultant battery price is $250/kWh

• This is slightly less than the present commodity price for

consumer (laptop, cell phone, PDA, etc.) Li-Ion batteries

• Bottom line: Threshold may have been reached

which makes battery energy storage a viable option

• Circa 1991 USABC EV battery price goal

determination

– ICE cost competitiveness assumed – Average 1991 gas price was $1.10/gal. – Resultant USABC EV battery price goal was $100/kWh

• A generalized formula of $100/kWh of battery per

$1.10/gallon of gasoline may be assumed

– Average October 2009 gas price is $2.72/gallon – Resultant battery price is $250/kWh

• This is slightly less than the present commodity price for

consumer (laptop, cell phone, PDA, etc.) Li-Ion batteries

• Bottom line: Threshold may have been reached

which makes battery energy storage a viable option

But, predictability is poor

U.S. Gasoline Price (1990-2009)

0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50

Aug- 90 Jul- 91 Jul- 92 Jun- 93 Jun- 94 May- 95 May- 96 Apr- 97 Apr- 98 Mar- 99 Mar- 00 Feb- 01 Feb- 02 Jan- 03 Jan- 04 Dec- 04 Dec- 05 Nov- 06 Nov- 07 Oct- 08 Oct- 09

Gasoline Price ($/gal)

Automotive Adoption Metrics

Hierarchy of Needs:

1. Must work

• Performance, life and robustness

2. Must fit (Wh/liter)

• Package without compromising crash performance

and expected interior utility

3. Must be cost effective

• Life of vehicle performance
• Cost of fuel influence
• Cost of carbon influence
• Value based on power and/or energy density
• Value based on degree of uniformity

4. Must be mass effective (Wh/kg and W/kg)

Hierarchy of Needs:

1. Must work

• Performance, life and robustness

2. Must fit (Wh/liter)

• Package without compromising crash performance

and expected interior utility

3. Must be cost effective

• Life of vehicle performance
• Cost of fuel influence
• Cost of carbon influence
• Value based on power and/or energy density
• Value based on degree of uniformity

4. Must be mass effective (Wh/kg and W/kg)

t1

What will be most valued?

• Hybrids

– Power density and retained energy

• NiMH > 4,000W/liter and 140Wh/liter
• Li-Ion > 6,000W/liter and 150Wh/liter

– Increase power density valued

• 8 - 10kW/liter with at least 150Wh/liter
• Plug-in Vehicles

– Energy density and power retained

• Li-Ion > 300Wh/liter and > 1,000W/liter

– Increased energy density valued

• 500 – 600Wh/liter with at least 1,000W/liter
• Hybrids

– Power density and retained energy

• NiMH > 4,000W/liter and 140Wh/liter
• Li-Ion > 6,000W/liter and 150Wh/liter

– Increase power density valued

• 8 - 10kW/liter with at least 150Wh/liter
• Plug-in Vehicles

– Energy density and power retained

• Li-Ion > 300Wh/liter and > 1,000W/liter

– Increased energy density valued

• 500 – 600Wh/liter with at least 1,000W/liter

Ford Li-Ion Battery Research

E lectrochemical Modeling

(10C Discharge Pulse Results @ intermediate SOC)

0.85 0.95 1.05 1.15 1.25 1.35 10 20 30 40 50 60 70 80 90

Distance from Cu foil, microns LiPF6 concentration, mol/l

40 s 46 s 0 s and >100 s 42 s 60 s 40.6 s 0.4 s 1 s 5 s 10.2 s

Negative Separator Positive

(D. Bernardi - Ford)

Li-Ion E lectrode Degradation

• Electrode degradation studies via Raman
• Surface and cross section mapping
• In-situ characterization during cell cycling
• Electrode degradation studies via Raman
• Surface and cross section mapping
• In-situ characterization during cell cycling

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8

1200 1300 1400 1500 1600 1700 Raman shift / cm-1 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Counts

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8

1200 1300 1400 1500 1600 1700 Raman shift / cm-1 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Counts

(J. Remillard and J. Nanda - Ford)

Lithium Intercalation Model

• First principles model of graphite voltage vs. staging
• Explains limited ion mobility at high vs. low Li conc.
• First principles model of graphite voltage vs. staging
• Explains limited ion mobility at high vs. low Li conc.

Equilibrium, increased and decreased graphite interlayer distance at beginning of charge

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 1 1.5 2 2.5 3

Diffusion distance

inter-plane distance -10% inter-plane distance +10%

+/- 10%

Equilibrium, increased and decreased graphite interlayer distance at beginning of charge

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 1 1.5 2 2.5 3

Diffusion distance

inter-plane distance -10% inter-plane distance +10%

+/- 10%

Li diffusion between two Li sites at end

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 Diffusion distance

inter-plane distance +10%

+/- 10%

Li diffusion between two Li sites at end

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 Diffusion distance

inter-plane distance +10%

+/- 10%

(G. Ceder, et al. – MIT)

High E nergy Battery Research

• High Energy Li-Ion Composite Anode

– Silicon-carbon material – Potential to double existing capacity

• Lithium-Air (Oxygen) Technology

– Metallic lithium plating model – Lithium plating modeling, experimentation and validation – O2 cathode catalyst synthesis and characterization – High throughput materials investigations – Air electrode design and analysis – Large format cell design evaluation

• Solid State Battery Technology

– Solid state electrode conduction and ionic conductivity experimentation and analysis – Predictive model development and validation

• High Energy Li-Ion Composite Anode

– Silicon-carbon material – Potential to double existing capacity

• Lithium-Air (Oxygen) Technology

– Metallic lithium plating model – Lithium plating modeling, experimentation and validation – O2 cathode catalyst synthesis and characterization – High throughput materials investigations – Air electrode design and analysis – Large format cell design evaluation

• Solid State Battery Technology

– Solid state electrode conduction and ionic conductivity experimentation and analysis – Predictive model development and validation

Lithium Dendrite Formation

Cycle 1 Cycle 8 Cycle 13 Cycle 4

(M. Karulkar - Ford)

Lithium Plating Model

(M. Karulkar - Ford)

Solid State E lectrode Conductivity

(A. Sastry – U of M)