Accelerating Electric Vehicle Adoption & Battery Design

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

Kandler Smith

Electrochemical Energy Storage - Computational Modeling Team Lead

National Renewable Energy Laboratory, Golden CO

[email protected]

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)

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”

y

Bo

lt |

A

da

m

Je

ffe

ry

| CN

BC

https://www.cummins.com/news/2018/04/23/cummins-puts-electrification-progress-display

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 U

S$

/

kW

h

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

Sy

st

em C

os

t (

$/

kW

h)

$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

~$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

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)

Li-Based Chemistry Selection for Higher Energy Density

Cathodes

Anodes

Desire large

potential difference

between anode

and cathode…

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

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

Realizing

Next-Generation

Cathodes for

Li-Ion

Batteries:

Low-Cobalt

Cathodes

•

The objective of this

Argonne National Lab

(ANL) led project is to

realize 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

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

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%

of 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

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

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

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

c

_e

_c

_s

MSMD

CAEBAT1

CAEBAT2-3

Mechanical Abuse

3D Simulation Microstructure Tomography, Analysis, Stochastic Reconstruction

+XFC

*Computer-Aided Engineering of Batteries Program

+TARDEC

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 byU.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.