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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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DOE OSTI2023

Optimizing liquid free ionomer binders for high-temperature polymer electrolyte membrane fuel cells for heavy duty vehicles

This report documents tech transfer from Penn State to Ionomer Solutions LLC for high-temperature polymer electrolyte membrane fuel cells. High-temperature polymer electrolyte membrane (HT-PEM) fuel cells are enticing power plants for heavy-duty vehicle (HDV) transportation because their elevated temperature operation fosters greater heat rejection through larger temperature differentials. In 2021, over 6 million battery electric light duty vehicles (LDVs) were sold. Conversely, only 19,000 LDVs using fuel cell power trains were sold in 2021. Given the meteoric rise of battery-based powertrains for LDVs and its projected growth, stakeholders for fuel cell technology for transportation have shifted their focus towards HDVs rather than LDVs given fuel cells specific and volumetric energy density advantage over batteries when the vehicle is large, heavy, and/or needs to move large distances before refueling.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Energy Consumption and Cost Reduction of Future Light-Duty Vehicles through Advanced Vehicle Technologies: A Modeling Simulation Study Through 2050

The U.S. Department of Energy’s (DOE’s) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) aim to develop sustainable, affordable and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate vehicle-level fuel savings potential is critical for understanding DOE’s impact. In this work, we simulated technologies funded by VTO and HFTO for light duty vehicles. The simulations were performed across: Multiple powertrain configurations (i.e., conventional, power-split, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles), Vehicle classes (i.e., compact car, midsize car, small sport utility vehicle [SUV], midsize SUV, and pickup trucks); and Fuels (i.e., gasoline, diesel, hydrogen, and battery electricity). These various technologies are assessed for six different timeframes: laboratory years 2015, 2020, 2025, 2030, and 2045. A delay of 5 years is assumed between laboratory year and model year (year technology is introduced into production). Finally, uncertainties are included for both technology performance and cost aspects by considering two cases: Low case, aligned with DOE technology manager estimates of expected original equipment manufacturer (OEM) improvements based on regulations, business as usual; and High case, aligned with aggressive technology advancements based on R&D targets developed through support by VTO & HFTO. These scenarios are not intended as predictions of future performances. The energy and cost impact of different technologies were estimated using Autonomie (www.autonomie.net), Argonne vehicle system simulation tool. Autonomie is a state-of-the-art vehicle system simulation tool used to assess the energy consumption, performance and cost of multiple advanced vehicle technologies across classes (from light to heavy duty), powertrains (from conventional to HEVs, FCEVs, PHEVs and BEVs), components and control strategies. Autonomie is packaged with a complete set of vehicle models for a wide range of vehicle classes, powertrain configurations and component technologies, including vehicle level and component level controls. These controls were developed and calibrated using dynamometer test data. Autonomie has been used to support a wide range of studies including analyzing various component technologies, sizing powertrains components for different vehicle requirements, comparing the benefits of powertrain configurations, optimizing both heuristic and route based vehicle energy control and predicting transportation energy use when paired with a traffic modeling tool such as POLARIS. This report documents the assumptions and estimates the vehicle-level energy consumption benefits and associated technology costs for the various types of light duty vehicles. All details of vehicle assumptions and simulation results are available in the spreadsheets accompanying this report.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

A Detailed Vehicle Modeling & Simulation Study Quantifying Energy Consumption and Cost Reduction of Advanced Vehicle Technologies Through 2050

The U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) aim to develop sustainable, affordable, and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate vehicle-level fuel savings potential is critical for understanding DOE’s impact. In this work, we simulated technologies funded by VTO and HFTO for light duty vehicles. The simulations were performed across: (1) Multiple powertrain configurations (conventional, power-split, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles); (2) Vehicle classes (compact car, midsize car, small sport utility vehicle [SUV], midsize SUV, and pickup trucks); and (3) Fuels (gasoline, diesel, natural gas, hydrogen, and battery electricity). These various technologies are assessed for six different timeframes: laboratory years 2015 (reference), 2020, 2025, 2030, and 2045. A delay of five years is assumed between laboratory year and model year (the year the technology is introduced into production).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Thick Electrode Design for Facile Electron and Ion Transport: Architectures, Advanced Characterization, and Modeling

The demand for lithium ion batteries continues to expand for powering applications such as portable electronics, grid-scale energy storage, and electric vehicles. As the application requirements advance, the innovation of lithium ion batteries toward higher energy density and power output is required. Along with the investigation of new materials, an important strategy for increasing battery energy content is to design electrodes with high areal loading to minimize the fraction of nonactive materials such as current collectors, separators, and packaging components, resulting in significant gains in energy content and the reduction of the system-level cost. However, the adoption of thick high areal loading electrodes has been impeded by sluggish charge transport and mechanical instability. With conventional slurry cast electrodes, battery function significantly deteriorates with increases in electrode thickness due to high cell polarization and the incomplete utilization of active materials. Thus, a consideration of approaches that facilitate an understanding and eventual adoption of high-loading electrodes is warranted to enable the deliberate advancement of next-generation batteries. Herein, this Account considers three aspects critical to the science and technology of thick high-loading electrodes. The first discussion covers recent approaches to the design and fabrication of high-loading electrodes. Ensuring electrical contact throughout the electrode is accomplished through the manipulation of conductive additives or using a conductive scaffold within the electrode. Ion transport can be facilitated through electrode design and fabrication approaches that deliberately control the electrode porosity and tortuosity. Second, advanced characterization methodologies are presented as the ability to determine the origins of transport limitations provide the insight needed to deliberately approach future designs. Spectroscopic and diffraction methods have been used to characterize the 2D and 3D pore structure and composition of the electrodes. Furthermore, operando methods that yield spatially and temporally resolved information regarding the progression of the electrochemical reaction are highlighted. The third aspect considered is the utilization of modeling. Physically based continuum models linked with the results of experimental characterization have been demonstrated and then allow the rapid simulation of a variety of deliberate electrode designs and their impacts on functional electrochemistry. Variables relevant to the designs can be tested by the model under a series of use conditions to identify those of most promise for a specific application. Finally, an outlook on future opportunities for high-loading battery electrode research is provided to inform and entice practitioners in the field to pursue these important directions of inquiry.

25 ENERGY STORAGE↗

DOE OSTI2021

Behind-the-Meter Storage [Slides]

This is an overview of the work happening with Behind-the-Meter Storage. NREL is the Project Lead for Behind-the-Meter storage. The goal of this research is to produce behind-the-meter battery solutions deployed at scale to meet the functional requirement of high-power electric-vehicle charging.

25 ENERGY STORAGE↗

DOE OSTI2024

Consumer-Oriented Energy Use and Range Metrics for Battery Electric Vehicles

The present study was motivated by a need to expand information for consumers offered through the FuelEconomy.Gov website. To that end, a power-based modeling approach has been used to examine the effect of steady-speed driving on estimated range for model year 2020 – 2023 battery electric vehicles (BEVs). This approach allowed rapid study of a broader range of BEV models than could be accomplished through vehicle tests. Publicly accessible certification test results and other data were used to perform a regression between cycle-average tractive power requirements and the resulting electrical power. Importantly, this regression enabled estimation of electric power and energy use over a range of steady highway speeds. These analyses in turn allowed projection of vehicle range at differing speeds. The projections agree within 6% with available 65 MPH manufacturer test data. Analyses of vehicles from model years 2020 – 2023 show that the 5-cycle range and energy use values from the window stickers of new vehicles are reasonable values for steady-speed driving at 65 MPH. Range decreases by a median value of approximately 15% for each 10 MPH increase in speed. The 5-cycle energy use (in kW-Hr / 100 miles) and energy economy (in miles / kW-Hr) derived from the 5-cycle energy use are reasonable estimates for 65 MPH steady speed driving. Energy economy decreases by about 0.5 miles / kW-Hr for every 10 MPH increase in speed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Transition Metal Oxide Powders Made from Flame Spray Pyrolysis for Li-Ion Batteries

In 2012 the U.S. Department of Energy introduced its EV Everywhere Grand Challenge, with a stated goal of enabling “plug-in electric vehicles (PEVs) that are as affordable and convenient for the American family as gasoline-powered vehicles by 2022.” This requires a reduction in battery costs from the current $500/kWh to around $125/kWh. Most approaches have been to eliminate vehicle weight through lightweighting and to improve the energy density of battery materials. But what if we were able to just make the materials cheaper instead? To this end we introduce a green, low-cost method of producing cathode materials using an integrated flame spray pyrolysis process.

25 ENERGY STORAGE↗

DOE OSTI2024

Nondestructive Analysis of Commercial Batteries

Electrochemical batteries play a crucial role for powering portable electronics, electric vehicles, large-scale electric grids, and future electric aircraft. However, key performance metrics such as energy density, charging speed, lifespan, and safety raise significant consumer concerns. Enhancing battery performance hinges on a deep understanding of their operational and degradation mechanisms, from material composition and electrode structure to large-scale pack integration, necessitating advanced characterization methods. These methods not only enable improved battery performance but also facilitate early detection of substandard or potentially hazardous batteries before they cause serious incidents. Here, this review comprehensively examines the operational principles, applications, challenges, and prospects of cutting-edge characterization techniques for commercial batteries, with a specific focus on in situ and operando methodologies. Furthermore, it explores how these powerful tools have elucidated the operational and degradation mechanisms of commercial batteries. By bridging the gap between advanced characterization techniques and commercial battery technologies, this review aims to guide the design of more sophisticated experiments and models for studying battery degradation and enhancement.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Towards fast-charging high-energy lithium-ion batteries: From nano- to micro-structuring perspectives

Electric vehicles (EVs) have been playing an indispensable role in reducing greenhouse gas emissions for our modern society. However, current EVs are difficult to meet people’s diverse travel needs, especially in long endurance and fast-charging capacities. At the heart of this issue is the physicochemical limit of current lithium-ion batteries (LIBs), which are the core parts for powering the vehicles. Hence, LIBs with simultaneous high energy and power are critically required to further promote the development of EVs. Here, in this review, we first summarize the key electrochemical processes in electrochemical reactions which lead to the corresponding overpotentials in or between multiple battery components. Furthermore, numerical simulations are employed to quantitatively analyze the effects of versatile electrode parameters on electrochemical properties in high-energy NMC811//graphite systems. On the basis of the in-depth understandings from simulation, recent experimental efforts on designing electroactive materials and electrode architectures across multiple length scales are discussed. Among them, nano-structuring can promote local mass transport and stabilize the interfaces at the particle level, while micro-structuring can establish efficient pathways for charge carriers at the electrode level. Finally, we conclude that a tight feedback loop among structure engineering, characterization and simulation should be followed to speed up the understanding of the deficiencies existing in current electrode designs as well as point out the possible electrode optimization routes for next-generation fast-charging LIBs.

25 ENERGY STORAGE↗

DOE OSTI2021

Traveling Wave Relays for Distribution Feeder Protection with High Penetrations of Distributed Energy Resources

Increased penetration of power electronics interfaced Distributed Energy Resources (DER) like PV, electric vehicle and battery storage in the distribution system (both in numbers and sizes) may cause bi-directional power flows under normal operation. In addition, they contribute low fault current under short circuit conditions. These two changes can impact the proper operation of legacy protection systems. This can add additional challenges during weak grid and islanded operation. In this research, traveling wave (high frequency) signature based protection scheme is proposed for future distribution systems. Simulations are performed under different transient scenarios to provide insight into the high frequency signatures to show the traveling wave behavior. Finally, this paper discusses the importance of sensing and digital processing requirements for traveling-wave protection in distribution system.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2021

Traveling Wave Relays for Distribution Feeder Protection with High Penetrations of Distributed Energy Resources: Preprint

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2021

Traveling Wave Relays for Distribution Feeder Protection with High Penetrations of Distributed Energy Resources

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2008

Vehicle Technologies Program: Energy Storage R&D (2008 Annual Progress Report)

One of the primary objectives of the Energy Storage effort is the development of durable and affordable advanced batteries (and ultracapacitors) for use in a full range of vehicle applications, from start/stop to full-power HEVs, EVs, and PHEVs. The battery technology development activity spans three areas: system development of full battery systems; benchmark testing of emerging technologies in order to remain abreast of the latest industry developments; and Small Business Innovative Research (SBIR) to fund early-stage R&D for small businesses/entrepreneurs.

25 ENERGY STORAGE↗

DOE OSTI2025

Spontaneous sodium ion storage behaviors of reduced graphene oxide anodes exceeding 100% Coulombic efficiency by modulated ion solvation

Rechargeable batteries are essential energy storage devices that power portable devices and electrical vehicles throughout the world. In general, it is thought that the electrochemical performance of rechargeable batteries is mostly determined by the electrodes within them and that the electrolyte plays a relatively passive role. However, ion transport and storage can be greatly influenced by the electrolyte solution structure, specifically, ion solvation within the bulk and ion desolvation across the electrode/electrolyte interfaces. Herein, we studied the role of the electrolyte as an active component of electrochemical energy storage devices. We found that with an appropriate electrolyte formulation, ion storage in disordered carbonaceous anode materials can occur spontaneously without externally supplied electrical energy. Reduced graphene oxide (RGO) in an ether-based electrolyte demonstrates ‘spontaneous' ion storage behaviors of adsorbing and inserting the solvated ions utilizing facilitated permeability and wettability of RGO, which results in Coulombic efficiency of ~145% due to additional charging capacity of ~180 mAh g -1 during electrochemical processes. The unexpected spontaneous ion storage behavior was extensively investigated using a combination of electrochemical analyses and diagnostics, advanced characterizations, and computational simulation. In conclusion, we believe the spontaneous ion storage behavior offers a new way to further improve the energy efficiency of practical rechargeable batteries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Composite Cathode Architectures Made By Freeze-Casting for All Solid State Lithium Batteries (CRADA Final Report)

As part of a Battery 500 seedling project, MBRDNA partnered with LBNL and Montana State University (MSU) to develop solid-state batteries based on an Al-substituted LLZO (Li 7 La 3 Zr 2 O 12 ) ceramic ion-conductor. All solid-state lithium batteries are attractive contenders for use as power sources for electric vehicles because of their potential for better safety and higher energy density than state-of-the-art lithium-ion batteries, although they are still at early stages of development. Al-substituted LLZO is one of the most promising solid electrolytes for battery applications based on high ionic conductivity, a wide operating voltage window, and apparent stability vs. reduction by lithium. However, difficulties with processing thin (< 20 $\textit{um}$ and dense LLZO membranes have hampered development of devices based on this material. It is non-compressible and must be sintered at high temperatures to densify components. It is also difficult to maintain contact between the active cathode material and LLZO in the composite cathodes, which is critical for successful operation. This research project aimed to use novel processing methods to overcome these issues. The end result was the first ever-reported truly all solid-state battery based on LLZO operating at room temperature without application of exogenous pressure. During the course of the project, we also identified a number of issues that need to be addressed to improve the technology readiness level of this battery.

25 ENERGY STORAGE↗

DOE OSTI2023

High-energy, High-power Solid-state Li-ion Battery (SSLiB) Cells Based on High-voltage 5V Electrode for Electric Drive Vehicle Applications

Explore the source record for details and available documents.

25 ENERGY STORAGE↗

DOE OSTI2021

Electric Vehicle Basics

Electric vehicles (EVs) use electricity as their primary fuel or to improve the efficiency of conventional vehicle designs. EVs include all-electric vehicles, also referred to as battery electric vehicles (BEVs), and plug-in hybrid electric vehicles (PHEVs). In colloquial references, these vehicles are called electric cars, or simply EVs, even though some of these vehicles still use liquid fuels in conjunction with electricity. EVs are known for providing instant torque and a quiet driver experience. Other types of electric-drive vehicles not covered here include hybrid electric vehicles, which are powered by a conventional engine and an electric motor that uses energy stored in a battery, and fuel cell electric vehicles, which use a propulsion system similar to electric vehicles, where energy stored as hydrogen is converted to electricity by the fuel cell.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Guest Editorial Special Issue on Emerging Topics of Power Electronics Interfaced Battery Energy Storage System

No doubt, battery energy storage systems have been the enabling solution to balance generation and consumption of power systems with high-penetration renewable energy resources, long-range electric vehicles, and various smart devices. Upon the battery has been manufactured, the rest of implementation issues become how to interface battery and related systems, how to regulate the charging/discharging power, and how to keep battery energy storage systems (BESSs) safe, reliable, and long-term service. In this editorial, we discuss how power electronic converters and associated control and optimization, which can maximize the value of BESSs, are devoted to provide cost-effective, efficient, and even revolutionary technologies.

25 ENERGY STORAGE↗