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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Technology Evaluation of the Yotta SolarLEAF: A Panel-Based Thermally Managed Battery Module

In 2019, the United States installed 13.3 gigawatts of solar energy production capacity. This demand for solar will continually increase as the phasing out of fossil fuels continue. As the demand for solar energy grows, so does the demand to store this generated energy. It is projected that by 2035 the global demand for stationary energy storage will reach the terawatt scale. So, scalable solutions with suitable thermal management systems are required to meet future demand. Yotta Solar has developed an ESS system, the Yotta LEAF, that provides solar energy storage without increasing the footprint of solar arrays. This is particularly useful in applications with limited space (e.g., building roof) and where large scale batteries require strong requirements for fire suppression systems. As part of the Wells Fargo Innovation Incubator (IN2), the National Renewable Energy Laboratory (NREL) has conducted a third-party technology validation of Yotta's alpha prototype. The report includes the objectives, technology description, methodology, and results from experiments conducted at the Thermal Transfer Facility (TTF) at NREL.

14 SOLAR ENERGY↗
DOE OSTI2022

Mitigation of Leakage and Water Ingress for a Promising Phase Change Material (PCM) Containing Polyethylene Glycol (PEG)

A promising and cost-effective phase change material (PCM) containing polyethylene glycol (PEG) 600, 800, and/or 1000 has been synthesized. It is shape stabilized using a sol-gel method and displays promising thermal properties. These properties make the PCMs good candidates for thermal batteries and other thermal energy storage applications in the building sector. However, PEG leakage is observed at elevated temperatures, and due to the hygroscopic nature of PEG, moisture ingress is also observed, which can have a significant effect on performance and durability. Thus, we have developed hydrophobic coatings to prevent PEG leakage and mitigate moisture ingress. The selected approach involves a secondary sol-gel process during which a thin layer formulated with hydrophobic precursors is deposited onto the surface of the PCM samples. Several coating formulations have been investigated, including formulations composed of tetraethyl orthosilicate (TEOS), diethoxy(dimethyl)silane (DEDMS), triethoxymethylsilane (TEMS), and n-octyltriethoxysilane (OTES). We find that this is effective at increasing hydrophobicity of the PCM substrates. It also decreases substrate leakage.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
DOE OSTI2022

Mitigation of Leakage and Water Ingress for a Promising Phase Change Material (PCM) Containing Polythylene Glycol (PEG): Preprint

A promising and cost-effective phase change material (PCM) containing polyethylene glycol (PEG) 600, 800, and/or 1000 has been synthesized. It is shape stabilized using a sol-gel method and displays promising thermal properties. These properties make the PCMs good candidates for thermal batteries and other thermal energy storage applications in the building sector. However, PEG leakage is observed at elevated temperatures, and due to the hygroscopic nature of PEG, moisture ingress is also observed, which can have a significant effect on performance and durability. Thus, we have developed hydrophobic coatings to prevent PEG leakage and mitigate moisture ingress. The selected approach involves a secondary sol-gel process during which a thin layer formulated with hydrophobic precursors is deposited onto the surface of the PCM samples. Several coating formulations have been investigated, including formulations composed of tetraethyl orthosilicate (TEOS), diethoxy(dimethyl)silane (DEDMS), triethoxymethylsilane (TEMS), and n- octyltriethoxysilane (OTES). We find that this is effective at increasing hydrophobicity of the PCM substrates. It also decreases substrate leakage.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
DOE OSTI2023

Nonintrusive thermal-wave sensor for operando quantification of degradation in commercial batteries

Abstract Monitoring real-world battery degradation is crucial for the widespread application of batteries in different scenarios. However, acquiring quantitative degradation information in operating commercial cells is challenging due to the complex, embedded, and/or qualitative nature of most existing sensing techniques. This process is essentially limited by the type of signals used for detection. Here, we report the use of effective battery thermal conductivity ( k eff ) as a quantitative indicator of battery degradation by leveraging the strong dependence of k eff on battery-structure changes. A measurement scheme based on attachable thermal-wave sensors is developed for non-embedded detection and quantitative assessment. A proof-of-concept study of battery degradation during fast charging demonstrates that the amount of lithium plating and electrolyte consumption associated with the side reactions on the graphite anode and deposited lithium can be quantitatively distinguished using our method. Therefore, this work opens the door to the quantitative evaluation of battery degradation using simple non-embedded thermal-wave sensors.

25 ENERGY STORAGE↗
DOE OSTI2021

Modeling cell venting and gas-phase reactions in 18650 lithium ion batteries during thermal runaway

A numerical model is developed to study cell venting, internal pressure, and gas-phase dynamics behavior of 18650 Li-ion cells undergoing thermal runaway. A k-e Reynolds-Averaged Navier-Stokes (RANS) model is adopted to describe the turbulent flow out of the cells, while the fluid dynamics inside the cells is described by Darcy-Forchheimer's equation. Thermal abuse reactions and gas generation kinetics are described by a single-step lumped reaction model. Then, a series of computational fluid dynamics (CFD) simulations are conducted on a single 18650 cell at various states-of-charge (100%, 50%, 25%) to study detailed flow and thermal behavior as a function of quantity of gas generated during cell venting. Venting events are categorized into two stages: i) breaching of the cell container and ii) thermal runaway reactions. It is found that the cell response is dominated by the second stage since most of the gases are generated during thermal runaway. Also, the propensity for propagation is highly affected by state-of-charge (SOC). Cells at higher SOCs produce more heat and gas during the venting event, owing to higher mass and concentrations of reacting gases, and consequently reach higher internal cell pressures which increase the risk of side-wall breaching.

25 ENERGY STORAGE↗
DOE OSTI2022

High-Temperature Latent Heat Storage System using Transportable Heat Pipes for Versatile Integration with Emerging Microreactors

With the growing interest in the development of micro nuclear reactors and their application to microgrid, high-temperature thermal energy storage (TES) has also been receiving great attention as a technology to reinforce the energy utilization and profitability of this class of reactors. Given the importance and research needs of the TES technology, a research project is underway at Idaho National Laboratory (INL) to develop high-temperature TES that can be easily interfaced with emerging micro nuclear reactors. Currently under development is the Heat pipe-Integrated Thermal Battery (HITB), a novel latent heat storage design that enables flexible and robust integration with any design of currently considered micro nuclear reactors. The development of detailed design based on the proposed TES concept, HITB, requires not only development and validation of modeling and simulation capabilities, but also research that spans thermal performance analysis, component- and system-scale design optimization, and experimental demonstrations including high-temperature feasibility testing. The current research efforts (and plans) are divided into the following four areas: (i) Thermal and structural modeling and analysis at both system- and component-scales for evaluating performance and conducting design optimization, (ii) Small-scale experimental demonstrations for the key components of the proposed HITB design, (iii) Modelica-based dynamic model development for developing a control strategy under dynamic operation within integrated energy systems configuration, (iv) Integrated experimental testing and demonstration. This paper introduces the overall research efforts that have been and are being conducted to develop and demonstrate the novel design of the high-temperature latent heat storage device, HITB. The key design features, ongoing research efforts including the development of modeling and simulation capabilities, small-scale demonstrations of the HITB’s key functionalities prior to scaled-up experimental demonstration, are discussed. Then, this paper concludes with a remark on the future research plans for this project.

25 ENERGY STORAGE↗
DOE OSTI2023

Estimate long-term impact on battery degradation by considering electric vehicle real-world end-use factors

Many estimates of battery capacity degradation are based on accelerated lab tests that involve charge-discharge cycles or rely on data or electrochemical modeling. These methods are reasonable for technology benchmarking but rarely consider real-world end-use factors. To address this issue, this study develops the Battery Run-down under Electric Vehicle Operation (BREVO) model. It links the driver's travel pattern to physics-based battery degradation and powertrain energy consumption models. The model simulates the impacts of charging behavior, charging rate, driving patterns, and multiple energy management modules on battery capacity degradation. It finds that, over a 10-year timespan, firstly, for a random driver situated in the New England area, daily direct-current fast charging (60 kW) could lead to up to 22% less battery capacity when compared to daily Level-1 charging (1.8 kW). Second, the battery thermal management system can delay battery degradation by approximately 0.5% in the New England area. Third, warmer ambient temperatures enhance BEV battery usage. The model indicates that the battery capacity in the Los Angeles area is 6% higher than that in the New England area. The BREVO model provides crucial information for consumers and BEV manufacturers on range anxiety, BEV battery design, and decision support of battery warranty.

25 ENERGY STORAGE↗
DOE OSTI2022

Deformation and Fracture Behaviors of Cylindrical Battery Shell During Thermal Runaway

Thermal runaway is one of the catastrophic failure modes of lithium-ion cells. During thermal runaway in cylindrical cells, sidewall shell rupture has been identified as a contributing factor for thermal runaway propagation in battery packs. Herein, the deformation and fracture behaviors of the battery shell during thermal runaway are investigated based on in-situ and ex-situ characterization as well as physics-based modeling. The deformation and fracture modes of the battery shell with/without Carbon Fiber Reinforced Polymer (CFRP) sleeves are identified. In the simulation, the strain introduced by thermal expansion of the system is considered, as well as the thermal and strain rate effects on the plastic stage. The final cell shell modeling is validated by cell thermal runaway tests. Results reveal the quantitative relation between shell deformation behaviors and the pressure and temperature distribution. Both the experiment and model demonstrate the effectiveness of adding a tight-fitting CFRP sleeve around the cell in limiting the side-wall rupture of the shell. The use of CFRP tubes introduces a novel phenomenon in the context of uneven temperature distribution. Results shed light on the mechanistic analysis of a cell side-wall rupture during thermal runaway and provide essential guidance for the next-generation safe battery design.

battery casing↗
DOE OSTI2023

Safety perceptions of solid-state lithium metal batteries

Safety concerns hamper the wide application of lithium-ion batteries (LIBs) in the fields of electric vehicles and stationary energy storage. As the blame of the battery thermal runway was widely cast on the flowable, volatile, and flammable nature of liquid organic electrolytes, solid-state lithium batteries with solid and nonflammable electrolytes are highly praised for potentially better safety characteristics. Furthermore, solid-state lithium metal batteries (SS-LMBs) may become an ultimate solution for safe, high-energy density batteries. Whether SS-LMBs are safe enough to meet emerging demands remains unclear, as recent publications have presented serious safety concerns at both the material and device levels. In conclusion, this review summarizes recent investigations into SS-LMB safety, and systematic analysis and discussion are provided in this discussion of the safety concerns of SS-LMBs.

25 ENERGY STORAGE↗
DOE OSTI2022

Corrosion evaluation of metal foams in eutectic molten salts for high temperature latent heat energy storage application

High-temperature Thermal Energy Storage (TES) has drawn great attention as a technology that can increase the role and profitability of micro nuclear reactors in the decentralized clean energy market. Various research needs have been proposed by Idaho National Laboratory (INL) in "the Integrated Energy Systems: 2020 Roadmap" with the goal of utilizing the high temperature of 550 degrees or more generated in the 4th generation reactor to industrial purposes from the standpoint of integrated energy systems [1]. With the recent development of the 4th generation nuclear power plant, including micro nuclear reactor, there is a great deal of interest in researching how to efficiently couple a heat source to an industrial process through thermal processing. Texas A&M University (TAMU) and INL are currently collaborating to develop a novel latent heat storage design called HITB (Heat pipe-Integrated Thermal Battery). As part of the small-scale experimental demonstration research for HITB, a study for storage medium selection was conducted at TAMU. Eutectic salts have attracted interest as high-temperature heat storage medium for HITB. Especially, chloride molten salts and fluoride molten salts are considered promising candidates due to their high melting temperature, thermal stability, and high latent heat of fusion. Since eutectic salts have poor thermal conductivity in general, it is critical to distribute materials with high thermal conductivity evenly to facilitate the charging and discharging of heat. In this study, metal foam was considered in the HITB system to overcome the poor heat transfer characteristics of eutectic salts. In order to improve heat transfer, it is necessary to study materials with high thermal conductivity, corrosion resistant to molten salts, such as fins, extended surfaces, particles, microcapsulation, or foam structure. Porous structure of copper or aluminum can increase heat transfer area, form a thermal transfer network, and increase the effective thermal conductivity of thermal storage medium [2]. Since the melting temperature is required to be at least 450? in the current HITB design, various eutectic salts are being considered. FLiNaK and FLiBe, which are famous for fluoride salts, are good candidates, but due to the sharp rise in the price of LiF recently, they are excluded for economic reasons to be applied to large-capacity thermal energy storage. On the other hand, chloride salts are very cheap and easy to obtain, have a high melting temperature, and have a high latent heat of fusion, so they are recently in the spotlight as a phase change material. However, because of the hygroscopic nature of chloride salts, HCl gas due to impurity is easy to be released and is particularly vulnerable to corrosion. Chloride eutectic salts have been tested and suggested for metal alloys that are particularly resistant to corrosion, such as SS304, SS316, Hastelloy, Inconel 625, Incoloy 800H, which has low thermal conductivity, and is very expensive [3-6]. Porous materials with high thermal conductivity such as copper and aluminum have been tested for stability in fluids such as paraffin or water as metal foam or metal fin structures, but high temperature corrosion tests were not performed on various eutectic salts yet. Therefore, this study investigated the high temperature corrosion characteristics of metal alloys, such as C10100 foam, C10100 plate, 6101 alloy foam, and SS316 plate, while immersed in the candidate eutectic salts. A total of 20 tests for SS316 coupons and 10 tests for C10100 coupons were performed to ensure the repeatability of the present measurements. Since it is difficult to completely remove the salt inside metal foam due to the complex inner structure of the metal foam, only the surface condition was observed with a microscopy and scanning electron microscopy (SEM) image, except for measuring the corrosion rate and average mass loss.

25 ENERGY STORAGE↗
DOE OSTI2023

Bio-Based Phase Change Materials (PCMs) for Thermal Energy Storage (Final Scientific/Technical Report)

The goal of this project is to develop a novel bio-based phase change material (PCM) derived from squid ring teeth (SRT) proteins, and design a prototype heat exchanger based on these bio-based PCMs for energy storage and dynamic heat exchange for building thermal energy storage systems. The PCMs, derived from SRT proteins, will demonstrate room temperature energy storage capacities and switchable thermal conductivities that redefine the current state-of-the-art (SOA) for building thermal energy storage. Further, in a single material and with a single manufacturing processes, our proposed thermal battery will be developed with “on demand” thermal conductivity for rapid charging/discharging but superior insulation during energy storage periods. More specifically, our bio-based PCMs have demonstrated: 1) the potential for increased energy storage capacity (i.e., greater than paraffines at room temperature); 2) tunability in thermal conductivity with the largest thermal conductivity switching ratios for an intrinsic material reported to date, and 3) a 100% recyclable and biodegradable PCM with low volatility and toxicity and scalability in its manufacture for both residential and commercial applications. The already established ability for roll-to-roll processing of these non-toxic, non-flammable SRT composites along with their carbon-neutral manufacturing processes that has been pioneered by our team make this solution a disruptive and impactful technology to redefine the current SOA of energy storage technologies. The outcomes of this effort have been: 1) the identification of new bio-based PCM that establishes a new SOA for thermal conductivity and energy storage density at room temperature and 2) the development of a new experimental technique to measure the energy storage density via latent heat measurements during melting of thin films. This new technique can be applied to thin films (as thin as < 1 micrometer), and represents a novel approach for thin film energy storage density measurements. Dynamic thermal energy storage is the missing technology that will enable a grid- interactive efficient building (GEB). For a “smart” building capable of connecting with the power grid, the media must be inexpensive and possess thermal switching capabilities to control the time-dependent heat flow into (and out of) the PCM on demand. Unique to the material system in this program, programmable SRT-based PCM show improvements as compared to traditionally used PCMs, and thus its technical performance will represent a leap forward for the future GEB concept.

25 ENERGY STORAGE↗
DOE OSTI2021

LIM1TR: Lithium-Ion Modeling with 1-D Thermal Runaway (V.1.0)

LIM1TR (Lithium-Ion Modeling with 1-D Thermal Runaway) is an open-source code that uses the finite volume method to simulate heat transfer and chemical kinetics on a quasi 1-D domain. The target application of this software is to simulate thermal runaway in systems of lithium-ion batteries. The source code for LIM1TR can be found at https://github.com/ajkur/lim1tr. This user guide details the steps required to create and run simulations with LIM1TR starting with setting up the Python environment, generating an input file, and running a simulation. Additional details are provided on the output of LIM1TR as well as extending the code with custom reaction models. This user guide concludes with simple example analyses of common battery thermal runaway scenarios. The corresponding input files and processing scripts can be found in the “Examples” folder in the on-line repository, with select input files included in the appendix of this document.

25 ENERGY STORAGE↗
DOE OSTI2026

Gaps in PV-Coupled Battery Modeling

With the rapid increase in battery attachment rates for PV systems and the continued qualification of storage for the ITC under OBBB, accurately characterizing PV-coupled batteries is becoming increasingly critical for the PV industry. This presentation will explore the key gaps in current best practices for modeling PV-coupled battery storage, including challenges such as battery thermal conditioning, the influence of dispatch strategies on battery value, the limitations of oversimplified degradation and performance models, and the absence of a centralized database containing sufficient battery parameters for accurate modeling. For behind-the-meter applications, we will also address issues like mismatched solar resource and load profiles, as well as uncertainties in future utility rates. Where applicable, we will quantify the impacts of these gaps on the accuracy and uncertainty of modeling efforts and highlight ongoing research aimed at addressing these challenges.

14 SOLAR ENERGY↗
DOE OSTI2022

A Comprehensive Numerical and Experimental Study for the Passive Thermal Management in Battery Modules and Packs

Cooling plates in battery packs of electric vehicles play critical roles in passive thermal management systems to reduce risks of catastrophic thermal runaway. In this work, a series of numerical simulations and experiments are carried out to unveil the role of cooling plates (both between cells and a bottom plate parallel to the cell stack) on the thermal behavior of battery modules and packs under nail penetrations. First, we investigated the role of side cooling plates on the thermal runaway propagation mitigation in battery modules (1S3P) and packs (3S3P) by varying the key parameters of the side cooling plates, such as plate thicknesses, thermal contact resistances, and materials. Then, three important factors for passive thermal management systems are identified: (i) thermal mass of side cooling plates, (ii) interfacial thermal contact resistances, and (iii) the effective heat transfer coefficients at exterior surfaces. The roles of bottom cooling plates on thermal runaway propagation mitigation in 1S3P and 1S5P battery modules are numerically investigated by comparing the thermal behavior of the modules with only side cooling plates and with both side and bottom cooling plates.

25 ENERGY STORAGE↗