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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

Comprehensive Assessment of On-And Off-Board Vehicle-To-Grid Technology Performance and Impacts on Battery and the Grid

This project defined, developed, and tested the open standards-based requirements, engineering design and system integration of on and off-vehicle Vehicle-to-Grid technologies both on the grid and on the PEV, to assess their effectiveness in implementing the use cases that create value for the grid, which in turn, can be passed on to the ratepayers and the PEV owners. The project comprised of three key categories of work and four key sub-areas of work. The three key categories were: On-Vehicle V2G, Off-Vehicle V2G, and impact of V2G operation on the battery capacity degradation. The four key sub-areas of work under each of these categories were: defining requirements, implementing the technology, performing system integration testing, and estimating the value of each of the grid services under specific assumptions, on a per-vehicle and on an aggregated basis. The technical implementation demonstrated the validity of standards-based approach to grid integration that led to interoperability, in addition to assessing the operational details with grid constraints imposed at the transformer level. The technology implementation also identified the subtle gaps in the standards definition to close the feedback loop on the accuracy of the standards as written, which are being implemented as revisions to the appropriate protocols. The battery impacts assessment developed a test cycle that the batteries from a real PHEV were subjected to for both the mobility-only and mobility with V2G specific energy cycling. While the battery impact results show a clear incremental degradation in response to additional throughput for V2G application purposes, the amount of additional kWh that can be made available without exceeding the end-of-life capacity definition of the battery at its 10-year warranty period was found to be significant. Given that the PEV battery being exercised during testing was a PHEV battery (smaller energy capacity), and 44% of its usable energy (i.e., SOC) was utilized daily for V2G applications, the EVs with much larger batteries will fare much better, either in terms of extracting more value in terms of incremental kWh for V2G, or in terms of relative incremental degradation of the capacity through the battery lifespan. Further, this battery was the second-generation Lithium-Ion chemistry circa 2015, which is at least two generations ago. Continual improvements in electrochemistry and manufacturing techniques as well as on-board capacity will enable the future batteries to provide even more energy for non-mobility-related services. Finally, the valuation of V2G energy services at the premise, distribution, and the ISO/market level was carried out for both the on-vehicle and off-vehicle cases, to understand both the GHG mitigation and operational efficiency improvements in quantitative terms. The analysis indicates that between $\$400$ and $\$1400$ per year of total value to the grid can be realized. When netted of costs to implement V2G either on or off-vehicle, the net value is available to be shared between the ratepayers and the EV owners. Over the life of the EV, therefore, this value becomes significant and can easily provide both ratepayer and EV owner benefits more than the cost of the equipment, either on or off-board, in addition to providing GHG mitigation benefits both on the grid and on the mobility sides. For these benefits to accrue, the key learnings from both the on- and off-vehicle V2G parts of the project indicate the need for at-scale demonstrations through involvement of real EV owners to validate both the technical feasibility, interoperability, as well as real grid benefits by performing extensive data collection and analysis. This will help inform the grid planners, the program designs, and tariff designers, as well as automotive and equipment manufacturers how best to create their products to maximize grid, ratepayer, and EV owner value.

30 DIRECT ENERGY CONVERSION↗

Impedance-Based State-of-Health Estimation for Lithium-Ion Battery Management Systems

This paper discusses an impedance-based state-of-health (SOH) estimation for lithium-ion battery management systems. Features obtained from the Nyquist plot of the electrochemical impedance spectroscopy (EIS) are utilized to estimate the SOH. Two commercial lithium-ion batteries were aged (cycled) in the laboratory to collect aging and impedance data. An algorithm for SOH estimation is presented and evaluated. The performance evaluation results show that the SOH features extracted from the Nyquist plot can be utilized for SOH estimation. Estimated SOH values can be then utilized in various battery management systems (BMS) functions such as for calibrating the available capacity, adjusting charging/discharging strategies, and protection.

Al-Smadi, Mohammad↗

Unlocking the value of recycling scrap from Li-ion battery manufacturing: Challenges and outlook

The growing global trend toward mobile electrification is primarily driven by the rising popularity of electric vehicles, leading to an unprecedented surge in demand for lithium-ion batteries. As a result, the importance of battery recycling has become increasingly apparent. Battery recycling aims to recover valuable materials from both spent batteries and battery manufacturing scraps. By recycling these resources, the reliance on raw material extraction is reduced, which benefits resource conservation and minimizes the need for new mining operations. While significant attention has been given to the recycling of spent batteries, less emphasis has been placed on the recycling and recovery of battery scraps. However, it is important to recognize that many gigafactories are still taking steps to improve their manufacturing processes, and end-of-life batteries take approximately 10 years to become suitable for recycling, the manufacturing scraps will serve as the primary sources for recycling in this decade. This review delves into the progress in recycling technologies associated with battery manufacturing scraps, shedding light on the challenges, opportunities, and evolving perspectives surrounding battery manufacturing scrap recycling. In conclusion, we aim to contribute to the knowledge base of battery manufacturing scrap recycling and promote a more comprehensive understanding of the subject.

25 ENERGY STORAGE↗

Unraveling interphase-driven failure pathways in LiMn0.6Fe0.4PO4/graphite pouch cells

LiMnxFe1−xPO4 (LMFP) is a promising high-voltage, thermally stable, and earth-abundant cathode material, yet its practical application is limited by interphase instability and Mn dissolution. In this work, we systematically evaluate LiMn0.6Fe0.4PO4/graphite pouch cells using three electrolyte formulations including control carbonate electrolyte, control + 2 wt% vinylene carbonate (VC), and control + 2 wt% VC + 1 wt% 1,3,2-dioxathiolane 2,2-dioxide (DTD), to establish how electrolyte composition governs interphase chemistry and long-term degradation. Electrochemical testing shows that both additives are preferentially reduced prior to ethylene carbonate (EC) during cell formation, generating robust cathode-electrolyte interphase (CEI) and solid-electrolyte interphase (SEI) layers that suppress gas evolution and raise the first-cycle coulombic efficiency to 89.3%. Additionally, the dual-additive electrolyte delivers the most stable performance, retaining over 85% capacity after 600 cycles while minimizing impedance growth under long-term cycling at C/3 and 40 °C. Soft X-ray absorption spectroscopy confirms that VC + DTD effectively suppresses electrolyte oxidation at the cathode surface, and micro-X-ray fluorescence shows substantially reduced Mn dissolution and deposition on the graphite anode. Density functional theory simulations further provided insights into the structural and energetic influences of alkoxide species on the cathode surface, proposing a Mn2+ extraction mechanism. The combined experimental and computational findings establish a mechanistic link between electrolyte composition and interphase evolution, highlighting the effectiveness of electrolyte engineering for extending the operational lifetime of LMFP-based lithium-ion batteries.

Chak, Chanmonirath Michael↗

Physics-based Models, Machine Learning, and Experiment: Towards Understanding Complex Electrode Degradation

Degradation phenomena in Li-ion batteries are highly complex, coupled, and sensitive to use history and operating conditions. In this study, we show how tracking model parameters in continuum-level physics-based models, expedited by machine learning, can be useful in testing hypotheses for degradation mechanisms. An exemplary analysis using this approach is presented for a set of lithium trivanadate ( L i x V 3 O 8 ) cathodes cycled over a range of current rates. A simple cell revival process is combined with the parameter estimates over the course of cycling to extract valuable insights into cathode evolution and eliminate hypothesized degradation mechanisms for these cathodes. The presented approach is expected to be broadly applicable for degradation analysis of other electrodes.

25 ENERGY STORAGE↗

Avoiding thermal runaway in lithium-ion batteries using ultrasound detection of early failure mechanisms

Thermal runaway leading to catastrophic failure has slowed the adoption of lithium-ion batteries, highlighting the need for early warning systems. In this work, ultrasound is used to detect physical changes in 0.950 Ah Li-ion battery cells by inducing conditions associated with thermal runaway. Ultrasound signal features are extracted as the batteries are cycled under baseline conditions and subsequently subjected to constant current and voltage overcharges. Two conditions identifying failure are defined: a warning to detect the start of overcharge and an emergency stop (E-stop), to immediately take the battery out of service. Using changes in ultrasound signal features, consistent warning and stopping classifications are applied to all failure experiments. On average, a warning notification was issued after 15% of the overcharge time and an E-stop was triggered after 35% of total overcharge duration before failure. Further testing suggests that it is possible to avoid thermal runaway by reacting to intermediate, warning notifications prior to an immediate E-stop. In other words, not only can detection derived by ultrasound identify battery failure before a catastrophic event, but can also provide early, actionable warnings so that overcharges can be detected and corrected quickly enough so the battery does not need to be decommissioned.

25 ENERGY STORAGE↗

Calibration-free analysis of Li isotope ratios using laser ablation and laser absorption spectroscopy

We introduce a rapid, calibration-free, all-optical method for high-precision lithium isotope ratio measurements in solid materials using laser ablation combined with tunable laser absorption spectroscopy. A new asynchronous acquisition method is used to acquire time-resolved, high-resolution spectra of the 6Li and 7Li D1 and D2 transitions near 671 nm. Isotope ratios and atomic column densities are extracted from measured spectra via a physics-based fitting model including hyperfine structure. Under 1 Torr air, spectra recorded = 0.75 ms after plasma onset exhibit narrow linewidths corresponding to Doppler temperatures = 400 K, enabling resolution of the isotope peaks with high signal-to-noise ratios. Analysis of LiAlO2 samples with varying 6Li:7Li ratios demonstrates isotopic precisions of 0.6–1.7% for spectra acquired in 30 s. Isotope ratios determined from the spectral fits show accuracy within –0.3% to –1.7% of reference ICP-MS measurements without requiring calibration to external standards. By eliminating sample preparation and enabling spatially resolved isotopic mapping, this method offers a rapid analysis approach to lithium isotope determination in solid materials relevant to nuclear energy, safeguards, and geochemistry.

Phillips, Mark C.↗

Savannah River National Laboratory – General Fusion 2023 INFUSE Report (Rev.1)

This report describes the results from an INFUSE research project, where Savannah River National Laboratory (SRNL) in collaboration with General Fusion (GF) used process modeling to understand and optimize commercial power plant (CPP) fuel cycle designs based on parameters provided by GF. The study primarily focused on two candidate fuel cycles with different blanket materials, one with a lead lithium eutectic (LLE) blanket and the other with a pure lithium (Li) blanket. LLE benefits from a low melting point, favorable neutronics, and lower reactivity, but liquid lithium has the potential for higher tritium breeding ratios (TBR) and does not poison the plasma as a high Z contaminant. It was found that the main differences between LLE and Li designs are the extraction technologies required to remove tritium from the blanket and the amount of tritium and its distribution within the facility. More than 80% of the in-process tritium inventory for the LLE design is contained in the isotope separation system, while for the Li design, over 60% of the in-process tritium inventory is contained within the blanket material. This is due to significant tritium retention by Li. For the Li blanket, the burden of tritium processing rests on the blanket extraction technology rather than the traditional exhaust processing route. Thus, the blanket extraction technology is a main driver of tritium inventory in the Li system and determines the subsequent interface with the tritium processing plant.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Characterization of Glass Fiber Separator Material for Lithium Batteries

Characterization studies were carried out on a glass fiber paper that is currently employed as a separator material for some LiSOCl2 primary cells. The material is of the non-woven type made from microfilaments of E-type glass and contains an ethyl acrylate binder. Results from extraction studies and tensile testing revealed that the binder content and tensile strength of the paper were significantly less than values specified by the manufacturer. Scanning electron micrographs revealed the presence of clusters of impurities many of which were high in iron content. Results of emission spectroscopy revealed high overall levels of iron and leaching, followed by atomic absorption measurements, revealed that essentially all of this iron is soluble in SOCl2.

Subbarao, S.↗

Building Environmental Justice and Equity into the Development of Critical Mineral Industries

The global transition toward low-carbon energy not only means an increase in demand for clean electricity and renewable resources, but also an increase in demand for the critical minerals (CMs) and rare earth elements (REEs) that these technologies rely upon. Indeed, low-carbon energy technologies, such as those used for wind turbines and electric vehicle motors, require significantly more lithium, nickel, cobalt, manganese, graphite, and other CMs than fossil-based energy technologies. The growing demand for new forms of low- carbon energy will necessitate a proportional scale-up of CM and REE extraction and processing. Presently, the majority of extraction and processing activities for CMs and REEs are concentrated in very few countries, primarily in China and the Global South. CM and REE supply chain activities conducted in or controlled by these countries are commonly associated with widespread and well- documented human rights abuses and environmental degradation. As a result of concerns related to supply chain security, worker welfare, and the overall need for additional sources of CMs and REEs, governments worldwide have begun to explore policy pathways for the development of new supply chains. The development of new supply chains for CMs and REEs re s a multifold opportunity to accelerate the global deployment of low-carbon energy fleets, reduce global carbon emissions, build political resilience—and also to enhance policy objectives of environmental justice and equity in the clean energy transition. Fulfilling these policy objectives requires energy producers to navigate a maze of global supply chain policies designed to shape and accelerate the growth of new markets. In the United States, for instance, President Biden recently implemented fiscal and trade policies that incentivize both domestic and global reliance on U.S.-produced CMs and REEs, leveraging key relationships in Asia and Europe to ensure the accelerated buildout of the U.S. supply chain. The Biden Administration’s framework also emphasizes that new supply chains for CMs, REEs, and other low-carbon energy pathways must generate benefits for marginalized and disadvantaged communities, build energy equity, and contribute to the Biden Administration’s vision of environmental justice. present CM and REE supply chains include several stages, including mining, processing, transport, utilization, and disposal, each of which involves different environmental justice considerations and potential injustices. This study explores how technical innovation, paired with responsible community engagement and empowerment, can help inform the development of energy equity and environmental justice at all stages of new supply chains. The study highlights these opportunities on a broad scale. We also lend a specific focus to research at the University of Wyoming School of Energy Resources that aims to guide the development of CM and REE industries in communities with high economic dependence on coal and other fossil fuel industries, identifying pathways to grow a U.S. domestic supply chain by producing CMs from coal, coal by-products, and coal waste streams. These production pathways represent a potential new supply for CMs across the U.S. and elsewhere, thereby enhancing national security and accelerating the widespread deployment of low-carbon energy technologies, while also generating alternative applications for remaining coal reserves and aiding in a just transition for rural energy-producing communities.

Gerace, Selena↗

ϵ-VOPO 4 cathode for lithium ion batteries

The epsilon polymorph of vanadyl phosphate, ε-VOPO 4 , made from the solvothermally synthesized H 2 VOPO 4 , is a high density cathode material for lithium-ion batteries optimized to reversibly intercalate two Li-ions to reach the full theoretical capacity at least 50 cycles with a coulombic efficiency of 98%. This material adopts a stable 3D tunnel structure and can extract two Li-ions per vanadium ion, giving a theoretical capacity of 305 mAh/g, with an upper charge/discharge plateau at around 4.0 V, and one lower at around 2.5 V.

25 ENERGY STORAGE↗

ϵ-VOPO 4 cathode for lithium ion batteries

The epsilon polymorph of vanadyl phosphate, ε-VOPO 4 , made from the solvothermally synthesized H 2 VOPO 4 , is a high density cathode material for lithium-ion batteries optimized to reversibly intercalate two Li-ions to reach the full theoretical capacity at least 50 cycles with a coulombic efficiency of 98%. This material adopts a stable 3D tunnel structure and can extract two Li-ions per vanadium ion, giving a theoretical capacity of 305 mAh/g, with an upper charge/discharge plateau at around 4.0 V, and one lower at around 2.5 V.

25 ENERGY STORAGE↗

ε-VOPO 4 cathode for lithium ion batteries

The epsilon polymorph of vanadyl phosphate, ε-VOPO 4 , made from the solvothermally synthesized H 2 VOPO 4 , is a high density cathode material for lithium-ion batteries optimized to reversibly intercalate two Li-ions to reach the full theoretical capacity at least 50 cycles with a coulombic efficiency of 98%. This material adopts a stable 3D tunnel structure and can extract two Li-ions per vanadium ion, giving a theoretical capacity of 305 mAh/g, with an upper charge/discharge plateau at around 4.0 V, and one lower at around 2.5 V.

Siu, Carrie↗

Innovations Driven by Advanced Characterization to Strategize Critical Mineral Production and Beneficial Reuse from Fossil Energy Waste

Critical minerals (CM), such as rare earth elements (REE), cobalt, nickel, and lithium, have important uses in modern electronics and advanced manufacturing, yet are vulnerable to potential supply chain disruptions. Relatively abundant and readily available fossil energy (FE) wastes, such as coal combustion ash, acid mine drainage (AMD) and treatment solids (AMD solids), and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters) are under consideration as CM feedstocks. The National Energy Technology Laboratory (NETL) has studied CM resources for various FE wastes as part of the U.S. Department of Energy’s mission of bolstering the domestic CM supply, and makes the data available to the public on EDX at sites such as the NEWTS group. Advanced characterization utilizing synchrotron x-ray techniques coupled with laboratory extractions has been performed to identify CM hosting phases in these FE wastes to inform CM recoverability mechanisms. Novel methods to selectively recover CMs while co-producing other valuable byproducts have been developed. Successful examples discussed here include: (1) The identification of REE/Co/Ni/Sc binding and hosting phases in select FE waste (coal combustion ash and AMD solids), resulting in the development of a patented CM step-extraction process, (2) coupled production of functional sorbents from these extraction wastes and for CM recovery. A pilot-scale testing to evaluate the patent’s technical feasibility for extracting REE from coal ash on a barrel scale has been successfully performed. Additionally, (3) evaluation and measurements of brine geochemistry from U.S. O&G produced waters has informed a high Li recovery potential from Marcellus Shale produced water. NETL researchers have been developing tailored pre-treatment processes, an innovative and highly durable lithium sorbent, and geochemical model guided precipitation to accelerate Li production from the Marcellus Shale produced waters. These innovations driven by characterization are integral for maximizing and advancing the potential for CM recovery while offsetting the cost and environmental footprint for FE waste management.

critical mineral processing↗

Enabling fast discharge of Li-ion batteries via electrolyte formulations for urban air mobility applications

High-power discharge requirements are critical for lithium-ion batteries (LIBs) used in electric Vertical Takeoff and Landing (eVTOL) vehicles that are increasingly considered in urban mobility. This investigation places a particular emphasis on understanding the impact of electrolytes on discharge processes and rate capability. We aim to compare the discharge behavior of LiBs using a conventional electrolyte (Gen 2: 1.2 M LiPF 6 in EC:EMC) and the dual salt LiTFSI-LiBOB-based electrolyte. Here we carefully examine the profiles of charging and discharging, the behavior during extended cycles, impedance spectroscopy results, and the characteristics of the electrode surface. Our research findings demonstrate the complex relationship between the composition of electrolytes and the specific high-power discharge requirements of electric vertical takeoff and landing (eVTOL) systems. This research highlights the importance of customizing electrolyte compositions to optimize energy storage density while simultaneously enabling higher power extraction to enhance performance in short-range electric aviation.

25 ENERGY STORAGE↗

Ultrasonic Nondestructive Diagnosis of Cylindrical Batteries Under Various Charging Rates

Lithium-ion batteries have been used increasingly as electrochemical energy storage systems for electronic devices and vehicles. It is important to accurately estimate the state of charge (SoC) of a battery management system to control the battery operation to optimize performance, lifetime, and safety. The current work experimentally leverages ultrasonic diagnostic technology to investigate the SoC of lithium-ion batteries during the charge/discharge processes. A cylindrical-type nickel-cobalt-aluminum (NCA)–based 2500mAh 20A (INR18650-25R) battery was used for ultrasonic measurements with various charge/discharge rates of C/10.4, C/5.2, and C/1.3 at constant currents. The ultrasonic signals were analyzed for extracting wave velocity and wave attenuation. For all the testing rates, wave velocity increased in the charge process and decreased in the discharge process. Further, velocity profiles corresponding to lower rates of C/10.4 and C/5.2 exhibited primary peaks at the maximum SoCs, whereas the absolute wave velocity of C/1.3 rate showed primary peaks that occurred slightly after the SoC peak, indicating a delayed maximum Young's modulus. The wave attenuation computed for the C/10.4 rate had local maxima in the charge and discharge processes and depicted negative correlations with SoC, ranging from 0% to 18%, and positive correlations with SoC from 18% to 85%. On the other hand, the wave attenuation curves of the C/1.3 rate showed no local peaks and had negative correlations with SoC, ranging from 0% to 28%, and positive correlations with SoC ranging from 28% to 53%.

25 ENERGY STORAGE↗

Tracking Flows of End-of-Life Battery Materials and Manufacturing Scrap

This paper defines terms such as “recycling rate” that enable the characterization of flows of battery materials and expands the terminology to accommodate the description of complex product recycling. It also estimates the maximum percentage of U.S. demand for critical elements that could be satisfied by recycling as demand continues to grow, and it defines and estimates the recycling rate for lithium-ion batteries. Finally, it clarifies the role of manufacturing scrap as the domestic U.S. supply chain is built up. It concludes that recycling will be important in the long term, but growth still requires that new material be extracted to supply additional material.

25 ENERGY STORAGE↗