Battery Testing, Analysis and Design - Energy

1 FY 2013 Annual Progress Report cxv Energy storage R&D Battery Testing, Analysis and Design Cost Assessments and Requirements Anlysis Battery Testing Activities Computer Aided Engineering of Batteries FY 2013 Annual Progress Report 117 Energy storage R&D IV. Battery Testing, Analysis , and Design The Battery Testing, Analysis , and Design activity supports several complementary but crucial aspects of the Battery development program. The activity s goal is to support the development of a domestic advanced Battery industry whose products can meet electric drive vehicle performance targets. Within this activity, Battery technologies are also evaluated according to USABC Battery Test Procedures. The manuals for the relevant PEV and HEV applications are available online.

2 A benchmark testing of an emerging technology can be performed to remain abreast of the latest industry developments. High-level projects pursued in this area include the following topics: Cost Assessments and Requirements Analysis . o Cost modeling. o Secondary and other Energy storage use and life studies. o Analysis of the recycling of core materials. o Requirements Analysis for PEVs and HEVs. Battery Testing Activities. o Performance, life and abuse testing of contract deliverables. o Performance, life and abuse testing of laboratory and university developed cells. o Performance, life and abuse testing of benchmark systems from industry. o Thermal Analysis , thermal testing and modeling. o Development of new test procedures. o Maintenance of current test procedures.

3 Computer Aided Engineering of Batteries. o development of tools for computer aided engineering of batteries. The rest of this section lists the projects which were active for the above three key areas during FY 2013. Energy storage R&D 118 FY 2013 Annual Progress Report Cost Assessments and Requirements Analysis Core BatPac Development and Implementation (ANL) Kevin G. Gallagher, Paul A. Nelson, Shabbir Ahmed & Dennis W. Dees Argonne National Laboratory 9700 South Cass Avenue Argonne, IL 60439-4837 Phone: (630) 252-4473; Fax: (630) 972-4520 E-mail: Collaborators: Ira Bloom, Argonne National Laboratory Wenquan Lu, Argonne National Laboratory Dan Santini, Argonne National Laboratory Fritz Kalhammer, Electric Power Research Institute Satish Rajagopalan, Electric Power Research Institute Joe McDonald, Environmental Protection Agency Aymeric Rousseau, Argonne National Laboratory Ram Vijayagopal, Argonne National Laboratory Start Date: October 2012 Projected End Date: September 2016 Objectives The objective of this task is to develop and utilize efficient simulation and Design tools for advanced lithium-ion batteries capable of predicting precise overall and component weights and dimensions, as well as cost and performance characteristics.

4 Technical Barriers The primary technical barrier to commercialization is the development of a safe cost-effective PHEV Battery with a 40 mile all electric range that meets or exceeds all performance goals. The major challenge specific to this project is accurately predicting the impact of promising new Battery materials on the performance and cost of advanced full-size lithium-ion batteries for transportation applications. Technical Targets Develop model for calculating total Battery mass, volume, & cost from individual components. Predict methods & materials that enable manufacturers to reach the necessary goals. Evaluate the interplay between performance and cost for advanced materials, such as anodes and cathodes, on total Battery pack cost.

5 Support policy making process of Government. Document and publicly distribute the model. Accomplishments Distribution of BatPaC and revised supporting 100+ page report began on November 15, 2012 from the website Over 600 independent downloads have occurred in FY2013 including those by major commercial entities, universities, and laboratories. This is more than double the number of downloads in the FY2012 for the previous version BatPaC Continued to support the EPA and DOT in refining BatPaC to enable use in the 2017-2025 rule making process for CAFE and GHG regulations. Identified and initiated critical BatPaC development pathway to support mid-term review of rule. Continually interacted with EERE-VTO program participants to quantify the effect of materials development on cost.

6 Particular focus was to support the ABR Voltage Fade program. Validated critical Design parameter target voltage efficiency at rated power by combing a two-time constant performance model into the Autonomie vehicle simulation tool. Heat generation under drive cycle conditions and net-present value of Battery was determined for a number of cases. Supported the Competitiveness program, PAINT learning curve initiative, IEA activities, and life cycle Analysis for transportation batteries. Gallagher ANL Core BatPac Development and Implementation FY 2013 Annual Progress Report 119 Energy storage R&D Introduction The penetration of lithium-ion (Li-ion) batteries into the vehicle market has prompted interest in projecting and understanding the costs of this family of chemistries being used to electrify the automotive powertrain.

7 Additionally, research laboratories throughout the DOE complex and various academic institutions are developing new materials for Li-ion batteries regularly. The performance of the materials within the Battery directly affects the end Energy density and cost of the integrated Battery pack. The development of a publicly available model that can project bench-scale results to real world Battery pack values would be of great use. The Battery performance and cost (BatPaC) model, represents the only public-domain, peer-reviewed model that captures the interplay between Design and cost of Li-ion batteries for transportation applications. Moreover, BatPaC is the basis for the quantification of Battery costs in EPA and NHTSA 2017-2025 Light-Duty Vehicle Technical Assessment.

8 This assessment is then used to determine what mileage ( , for CAFE) and CO2 emission standards are optimal from a cost-benefit Analysis . Approach BatPaC is the product of long-term research and development at Argonne through sponsorship by the Department of Energy . Over a decade, Argonne has developed methods to Design Li-ion batteries for electric-drive vehicles based on modeling with Microsoft Office Excel spreadsheets. These Design models provided all the data needed to estimate the annual materials requirements for manufacturing the batteries being designed. This facilitated the next step, which was to extend the effort to include modeling of the manufacturing costs of the batteries. The Battery pack Design and cost calculated in BatPaC represent projections of a 2020 production year and a specified level of annual Battery production, 10,000-500,000.

9 As the goal is to predict the future cost of manufacturing batteries, a mature manufacturing process is assumed. The model designs a manufacturing plant with the sole purpose of producing the Battery being modeled. The assumed Battery Design and manufacturing facility are based on common practice today but also assume some problems have been solved to result in a more efficient production process and a more Energy dense Battery . Our proposed solutions do not have to be the same methods used in the future by industry. We assume the leading Battery manufacturers, those having successful operations in the year 2020, will reach these ends by some means. Establishing the validity of the model calculation is important in justifying the conclusions drawn from exercising the model.

10 The Design assumptions and methodologies have been documented and reported in a number of formats. The most notable of those is the 100+ page public report that accompanies the model at the BatPaC webpage. The report and model have been subjected to a public peer-review by Battery experts assembled by the Environmental Protection Agency as well as many private reviews by vehicle original equipment manufacturers (OEMs) and cell suppliers. Changes have been made in response to the comments received during the peer-reviews. The peer-review comments are publicly available. The Battery pack price to the OEM calculated by the model inherently assumes the existence of mature, high-volume manufacturing of Li-ion batteries for transportation applications.