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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Surface modification of cathode material enhances electrochemical performance in dry-processed Li-ion battery electrodes

The transition to electric vehicles (EVs) is pivotal for achieving energy security and integrating grid stability, with lithium-ion batteries (LIBs) playing a central role in this transformation. However, the conventional wet electrode manufacturing relying on N-methyl-2-pyrrolidone (NMP) solvent is energy intensive and costly. Dry processing (DP) has emerged as a promising alternative, eliminating solvents and using polytetrafluoroethylene (PTFE) binder for electrode fabrications. Despite its advantages, DP faces a critical challenge: poor interfacial adhesion between the hydrophobic PTFE binder and the hydrophilic cathode active material (CAM), particularly LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811), which undermines electrode performance. Here, to address this, we introduced a novel vapor-phase trimethoxymethylsilane (TMMS) coating to hydrophobize the CAM surface, enhancing compatibility with PTFE. This surface modification significantly enhances binder – CAM interactions, enabling uniform mixing and robust electrode integrity without damaging the CAM particles. Our findings advance the feasibility of environmentally sustainable and cost-effective dry processing, representing a significant step toward sustainable battery manufacturing.

Choi, Junbin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2022

The impact of energy-efficiency upgrades and other distributed energy resources on a residential neighborhood-scale electrification retrofit

We report ambitious targets for carbon emissions reductions are highlighting new challenges for electrification strategies, leading to an increased focus on building load flexibility and energy management to complement the variability inherent in renewable energy generation. Over the next decade millions of existing homes could undergo electrification retrofits, and there is an urgent need to understand the potential impacts of electrifying major residential loads such as water and space heating on community load characteristics, resident energy bills, and the utility's distribution system. Behind-the-meter distributed energy resources (DERs), including efficiency measures, photovoltaics (PV), battery storage, managed electric vehicle (EV) charging, and controls such as home energy management systems (HEMS), can significantly alter a neighborhood's load profile and provide benefits to both the residents and the grid. We present a novel approach to characterizing the impact of a hypothetical neighborhood-scale residential retrofit program on individual homes' energy use profiles, associated utility bills, and the local distribution system. We modeled a mixed-fuel community of 30 single-family homes in Denver, Colorado, and compared the effects of retrofit scenarios ranging from conventional energy-efficiency upgrades to full electrification with and without more advanced DER technologies. We analyzed which packages of DERs most reliably enable demand flexibility in response to a time-of-use (TOU) rate for this and similar neighborhoods. Our buildings-to-grid co-simulation framework includes a generic secondary distribution feeder model to capture voltage profiles, transformer loading, and other grid impacts in each case. We also calculated the carbon emissions associated with energy use in the community. The methodology developed here can be broadly applied to community-scale beneficial electrification studies in other regions, climates, utility infrastructures, and building typologies to make specific, targeted recommendations based on quantified projections of energy demand in any given community. Our findings indicate that residential electrification can be achieved without negatively impacting the monthly utility bill, and that a combination of conventional energy-efficiency measures, PV, battery, controls, and managed EV charging to maximize a community's demand flexibility is a promising strategy. Adding DERs (especially PV) as part of efficient electrification produces much bigger savings than efficient electrification without DERs. A key barrier is that upgrades require upfront costs, and modest utility bill savings result in long payback periods.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

A High-Voltage High-Reliability Scalable Architecture for Electric Vehicle Power Electronics (Final Report)

This project developed and demonstrated new composite converter technologies that lead to high power density (> 20 kW/L) at power levels of 10s of kW, 100s of kW, or possibly higher, with fundamental advances in converter efficiency and Q that lead to substantial increases in mean time to failure (MTTF). These advantages were realized through development of new composite converter topologies that perform buck, boost, or other conversion functions and that are scalable to higher voltage and power levels through sharing of voltage and current stresses among multiple dissimilar partial-power converter modules. The project led to experimental demonstration of a125 kW multifunction electric vehicle power conversion system having in-creased dc bus voltage (950 V nominal, 1200 V peak) that interfaces a 200 V to 400 V battery pack, and that includes integrated level 2 wired charging and wireless charging functions. The project incorporated SiC MOSFET modules having switching frequencies in excess of 100 kHz, planar magnetics, a hierarchical control architecture that enables scaling to higher voltages and powers with additional converter modules, and a high-power density in excess of 20 kW/L. The research demonstrated how a more complex converter approach can increase mean-time-to-failure, even though the number of elements is increased. This is achieved through significant reduction of temperature rise through fundamentally superior converter circuit topologies. The research also demonstrated new high power planar magnetics that increase power density. The technology is appropriate to a variety of applications including EV power trains, EV charging, PV inverters, battery storage, and similar areas. These systems potentially can be manufactured in the U.S.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Direct Cathode Recycling of End-Of-Life Li-Ion Batteries Enabled by Redox Mediation

The ongoing surge of electric vehicle (EV) adoption forecasts an unprecedented amount of lithium-ion battery wastes in the near future. Since cathode materials have the highest economic and engineering values, it is essential to recycle and reuse the end-of-life (EOL) cathode materials. Here, we show that redox mediators can deliver lithium ions and electrons from a lithium source to the cathode, efficiently relithiate the EOL cathode materials, and make them ready for new battery production after a postheat treatment. We have found that some quinone-based redox mediators, especially 3,5-di-tert-butyl-o-benzoquinone (DTBQ), can shuttle the charges very fast between Li metal and EOL cathode. Reduction of DTBQ on lithium is evidenced by chemical changes of Li metal and DTBQ, and successful relithiation of the EOL cathode by the subsequent oxidation of DTBQ is verified by electrochemical and structural evaluations.

battery recycling↗
DOE OSTI2025

Design, Control, and Protection of a 13.2 kV, 1 MVA Solid State Transformer for Electric Vehicle Extreme Fast Charging Station

In this article, a medium-voltage (MV) ac-dc solid state transformer (SST) for electric vehicle (EV) extreme fast charging (XFC) station is proposed. The SST adopts a cascaded H-bridge (CHB)-based structure where the active front end (AFE) power stages are connected in input-series followed by dual active bridge (DAB) converters connected in an output-parallel configuration providing galvanic isolation through a high-frequency transformer (HFT). The SST is rated for 1 MVA and connects directly to a three-phase 13.2 kV MV ac grid through ac switchgear and outputs 750-V dc. At the dc bus, several dc/dc converters are connected, each of which can charge an EV based on its battery capacity. A novel decentralized control architecture of the SST is adopted in this work which simplifies the MV dc link voltage and module-level power balancing. In addition, the local and central protection designs of the SST are presented which identify and respond to the internal fault of the system. Finally, the experimental validations of the SST hardware prototype are presented up to the rated voltage. Furthermore, this article details the design and implementation of the MV SST addressing the challenges of an isolated MV class power converter for connecting directly to the MV ac grid with unique controller architecture, distributed protection framework, and SST constructional features.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Laboratory-Scale Coal-Derived Graphene Process (Final Report)

The Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphene from four U.S. domestic coal or coal wastes, including lignite from North Dakota, subbituminous coal from Wyoming, bituminous coal from Utah, and anthracite from Pennsylvania. The project was divided into two performance or budget periods (BPs), with BP1 comprising the up-front laboratory experiments to make graphene materials from coal beginning on May 1, 2020, to April 30, 2022. BP2 was conducted from May 1, 2022, to April 30, 2023, and was focused on analyzing the CDG process economic feasibility and the technical gaps for technological scale-up and commercialization. During this project, a few different coal-derived high-value products have been demonstrated, including graphite, graphene oxide (GO), reduced graphene oxide (rGO), and graphene quantum dots (GQDs). A new graphite microstructure was discovered and named “croissant graphite” because of the exterior morphological and textural resemblance to croissant food items sold in commercial groceries stores. The new graphite structure and the associated preparation from coal or coal waste feedstocks has been the subject of a U.S. patent application. The systematic experimental processes involving coal cleaning, upgrading, and conversion to high-value carbon products culminated into a developed upgraded coal-to-products (UCP) technology that is being pursued for potential fast-track commercialization, if funding is available. It is envisioned that commercialization of the UCP technology would increase consumption of U.S. domestic coals or coal wastes to make environmentally sustainable high-value products for the electronics industry, high-energy-storage applications, and clean energy technologies such as electric vehicle (EV) lithium-ion batteries (LIBs), for which graphite has become a critical mineral commodity. Croissant graphite microstructures, when observed by field emission scanning electron microscopy (FESEM), display wavy surface morphology and often grow from a base that is made of graphitized particles with honeycomb-like layers, which are believed to be graphene layers. While more studies are needed to fully ascertain the mechanisms of the croissant graphite microstructure formation, it is postulated that their growth may begin from curling of the graphene sheets into ribbon-like structures, and continuous growth and densification of the ribbon-like structures forms croissant microstructures. Additional studies are ongoing to evaluate the electrochemical performance of croissant graphite for LIB applications and to determine the experimental conditions necessary to tune on/off croissant formation so that it can be either optimized or suppressed depending on performance evaluation results. In addition to the discovery of croissant graphite, the graphitization process from the four coal ranks in general was successful. X-ray diffraction (XRD) analysis showed that the degree of graphitization (DoG) ranged from 12% to 80% in an early sample set, and further optimization on lignite coal produces a DoG of about 92%, which was spectacular to see as lignite is the lowest-rank coal. Thus, it is expected that the graphitization performance for higher-rank coals will be similar or better when optimized as well. The coal-derived graphite was used to make GO and rGO. Analytical characterization, e.g., by methods such as Raman spectroscopy, XRD, Fourier transform infrared (FTIR) spectroscopy and FESEM, showed that the sequence of converting the coal to graphite, exfoliating it to GO, and then chemically reducing the GO to rGO was successful. Although coal naturally contains aromatic compounds and some relatively small-sized condensed aromatic units, it does not contain graphene sheets. In the UCP process, the aromatic domains in the coals, particularly low-rank coals, are concentrated and condensed further into graphene sheets, which are ordered into a 3D stack during graphitization. The synthesized graphite is then unpacked by methods such as exfoliation to various graphene products. GQDs were synthesized from all four coal types, and their optical properties were demonstrated to be tunable by the coal precursor preprocessing treatments. In all four coal types, enhanced optical properties were observed for the produced GDQs with incremental improvements made to the coal precursors. GQDs produced from raw coal samples displayed lower ultraviolet–visible (UV–Vis) spectroscopy absorbance intensity compared to those obtained from cleaned and upgraded coal residues. The photoluminescence (PL) intensities also varied with pretreatment conditions and with the concentration of GQDs in aqueous solutions. GQDs obtained from anthracite show longer emission wavelengths and can be excited by visible light as opposed to GQDs derived from the other coal ranks. UV fluorescence 3D maps and spectra revealed that the emission wavelength at which the GQDs solutions display the highest intensity was slightly redshifted based on the coal precursor pretreatments. In low-rank coal (lignite and subbituminous) samples, two clusters were observed in the maps for GQDs, which may suggest that there are potentially two types of fluorophores in solution or two main size populations. The ability to tune the properties of GQDs based on processing methods can be exploited to make GQDs for various optical display or optoelectronics applications. The results also highlight the importance of removing coal-borne impurities to improve the quality of the coal precursor for preparation of graphene products. Coal and/or coal wastes preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. The preprocessing methods involve high specific-gravity separations, mineral acid cleaning (no hydrofluoric acid), and subsequent upgrading by reducing the coal-borne heteroatom (nitrogen, sulfur, and oxygen) content using proprietary chemical agents. Analytical characterization revealed that the preprocessing steps were successful, with ash reductions that range from 38% to 80% and residual ash content that was below the 5 wt% initial target. Based on proximate and ultimate analysis, the heteroatom reduction reactions produced upgraded coal residues with the oxygen content reduced by 8% to 24%, with additional reductions in the nitrogen and sulfur contents. An initial assessment of the waste streams from the UCP process shows very small to negligible environmental impact due to CO 2 , NO x , and SO x because most process steps are performed under inert atmosphere with argon. Consequently, reactive oxygen environments that tend to create these species are avoided. The inorganic and potentially hazardous species are released into aqueous waste streams that are easy to handle for proper disposal. The liquid waste streams were found to contain low-level concentrations of rare-earth elements (REEs), which could be concentrated and recovered as value-added by-products. Additionally, the volatile and gaseous fractions from carbonization and heat treatment contain useful organic compounds that can also be recovered as potential valuable by-products. Thus, the UCP technology is considered an environmentally sustainable and promising emerging technology for making high-value products from coal and coal wastes, with potential additional value-added by-products. Analysis of potential markets for the coal-derived carbon products shows a strong demand in both niche market sectors and across a wide variety of other industrial sectors. Graphite is currently considered a critical mineral commodity that has a large and growing demand in the LIB industry for EV applications. Based on data from Fortune Business Insights (2022) and Marketwatch (2023) reports, the average global graphite market is projected to reach about 33 billion by 2028, growing at a compound annual growth rate (CAGR) of about 7%, with much of this growth expected to be in the LIB industry. GO and rGO have strong market potentials in various application areas, such as coatings for anticorrosion, anti-icing, and antimicrobial protection, thermal barriers, wear resistance, sensors, additive manufacturing such as 3D inks, and others. GQDs are the emerging key player in the bioimaging, photovoltaics, and light-emitting diodes (LEDs) applications, with the potential to replace traditional semiconductor quantum dots (SQDs), which are based on metallic systems that are more toxic and more expensive. Biomedical applications of GQDs are becoming more attractive because of low to no toxicity and extremely low cost compared to SQDs. The major challenges for scale-up and commercialization of coal-derived carbon products such as graphene vary from the inherent attributes of graphene itself to reluctance to accept graphene in new manufacturing processes because of the uncertainty of the unknown. The 2D nature of graphene materials with a thickness of one atom presents significant challenges to proper handling/processing, and process scale-up becomes difficult because it requires high-end, expensive equipment, even for routine handling and analysis for quality assurance and control. Pristine graphene can also be extremely difficult to work into other matrices, thus hindering downstream processibility, especially at large scale. Currently, the cost of graphene and graphene products is still high and presents an economic risk that tends to slow down investment in scaling up emerging technologies. The lack of a standard for graphene materials for quality assurance and quality control poses a great challenge not only for the markets but also for commercialization efforts. A first-look economic feasibility analysis of the UCP technology provided valuable information that suggests the UCP process would be feasible, especially when it is scaled to a pilot scale and could be more competitive at the full scale. Graphitization was found to be the most energy-consuming and most capital-intensive step in the overall process. In small laboratory- and bench-scale experiments, labor is a significant contributor to the total process costs. Although these energy, capital, and labor constraints contribute to a higher selling price for the product, a preliminary economic model suggests that the process would be feasible at large scale when the process is fully integrated, optimized, and automated.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Diversifying the Materials and Technologies for the Future of Energy Storage

It is increasingly important to meet the growing global energy demand driven by factors such as population growth, electrification, and the rapid development of emerging economies, while minimizing the environmental harm caused by carbon dioxide emissions. Although fossil fuels remain an abundant and inexpensive energy source, there is a global consensus on the critical importance of addressing climate change and an increasing urgency to reduce carbon dioxide emissions without hindering economic growth. This challenge is particularly daunting due to the significant transformations required in electricity generation systems, transportation, and industrial processes. A significant portion of our energy still comes from burning fossil fuels, which poses harmful effects on the environment. Transitioning to renewable energy sources like solar and wind is essential, as these sources provide a low-carbon pathway for power generation and have become increasingly cost-competitive with fossil fuels. However, they face the inherent challenge of intermittency. Thus, energy storage systems (ESS) are essential not only to address this issue but also to accommodate the increasing adoption of electric vehicles (EVs). Lithium-ion batteries (LIBs) are still the predominant ESS used for these applications; however, they suffer from issues related to scarce and harmful resources, safety, and socio-economic impacts. This underscores the need for alternative energy storage systems beyond LIBs. Here, in this review, we discuss the diversification, repurposing, and recycling of ESS to meet the projected energy demand while minimizing environmental harm.

batteries↗
DOE OSTI2026

OCHRE

OCHRE™ uses a variety of input data sources to run time-series simulations. Building models can be taken from the ResStock™ database or generated using the Building Energy Optimization Tool (BEopt™) or other OpenStudio-HPXML workflows. EV charging profiles can be taken from datasets used in NLR's 2030 National Charging Network project. Weather data can be taken from the National Solar Radiation Database or EnergyPlus® weather files. There are no public datasets with OCHRE outputs at this time. However, a recent project dataset on water heater and EV demand flexibility can be requested. OCHRE is a Python-based energy modeling tool designed to model flexible loads in residential buildings. OCHRE includes detailed models and controls for flexible devices including HVAC equipment, water heaters, EVs, solar PV, and batteries. It is designed to run in co-simulation with custom controllers, aggregators, and grid models.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Geochemical characterization of lithium deposition in fossil energy wastes

Lithium is a critical mineral used in rechargeable batteries for electric vehicles (EVs) and future modernization of electric grids with sensitive supply chains that are subject to volatility. Therefore, methods to recover lithium from domestic unconventional sources are actively being pursued in the United States. Herein, we report on the lithium recovery potential from four fossil energy waste feedstocks: oil and gas drill cuttings (sample number n = 16); oil and gas produced waters (n > 200) from Marcellus, Bakken and Permian basins; coal byproducts (n>20), such as coal ash; and acid mine drainage treatment solids (AMD solids). Select solid samples underwent sequential extraction to explore lithium hosting phases and simple organic and inorganic acid extraction to explore lithium recovery potential. Our preliminary results found lithium concentrations up to 440 mg/kg in select AMD treatment solids and up to 300 mg/L in Marcellus Shale produced waters, demonstrating these sources have lithium yield potentials comparable to conventionally mined lithium ores and brines. Sequential extractions revealed that lithium is mostly associated with clay and silicate phases in shale drill cuttings, whereas lithium resides in Fe,Mn-oxide reducible phases in AMD solids. Further, the lithium content in produced waters has a strong linear relationship with total dissolved solid (TDS) levels in three separate oil and gas basins. At the same TDS level, Marcellus Shale produced waters contain more lithium compared to Bakken Shale and Permian Basin waters, with higher percentages of Ca and Mg, major cations that might impact lithium recovery efficiencies. Our study demonstrates the heterogeneity of lithium hosts from different fossil energy wastes. Characterization results will inform future lithium recovery from these different feedstocks.

Stuckman, Mengling↗
DOE OSTI2023

Energy Cost Analysis and Operational Range Prediction Based on Medium- and Heavy-Duty Electric Vehicle Real-World Deployments across the United States

While the market for medium- and heavy-duty battery-electric vehicles (MHD EVs) is still nascent, a growing number of these vehicles are being deployed across the U.S. This study used over 2.3 million miles of operational data from multiple types of MHD EVs across various regions and operating conditions to address knowledge gaps in total cost of ownership and operational range. First, real-world energy cost savings were determined: MHD fleets should experience energy cost savings each year from 2021 to 2035, regardless of vehicle platform, with the greatest savings seen in transit buses (up to USD 4459 annually) and HD trucks (up to USD 3284 annually). Second, to help fleets across various geographies throughout the U.S. assess the suitability of EVs for their year-round operating needs, operational range was modeled using the XGBoost algorithm (R2: 70%) given 22 input features relevant to vehicle efficiency. Finally, this paper recommends (1) that MHD fleets apply energy-saving practices to minimize the impacts of cold temperatures and high congestion levels on vehicle efficiency and range, and (2) that local hauling fleets select trucks with a nominal range nearly double the expected maximum daily range to account for range losses under local, urban driving conditions.

Qiu, Yin (ORCID:0009000900948794)↗
DOE OSTI2026

UL 1741SC Conformance Development, Evaluation, and Proposal [Slides]

V2G AC is a type of grid interconnection by mobile battery that transforms an EV into a DER with the potential to stabilize the grid and lower costs for electricity. UL 1741SC is a critical new standard to enable grid interconnection of V2G AC-capable vehicles, by defining requirements for V2G AC-intended EVSEs as a gatekeeper between the grid and the EV to support grid safety, such as through redundant voltage trip (namely oversight). EVSE manufacturers need a clear set of conformance test cases and criteria by which to evaluate their equipment and confirm the compliance with UL 1741SC, so that the EVSEs performs as intended for the grid safety. Hence, NLR identified necessary conformance tests and performed the tests identified to understand the maturity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Recovery of High Value Anode Materials for a Closed Loop Li-ion Battery Recycling Process (Final Report)

Battery Resourcers’ goal with this Small Business Innovative Research Phase 1 project was to produce high quality and high purity graphite generated from its Li-ion battery recycling technology. Battery Resourcers’ technology recovers cathode material from a broad spectrum of Li-ion battery regardless of size, shape or chemistry. In Battery Resourcers existing model, the graphite is recovered to be used as a reductant and therefore the battery materials cost or recycling cost is not lowered by the recovery of the graphite. Currently, Battery Resourcers is piloting its lithium ion battery recycling process and the recovered LiNi 0.33 Mn 0.33 Co 0.33 O 2 (NMC111) or LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC111) cathode materials have shown that they can outperform existing commercial NMC111 cathode materials while being produced at a projected lower cost. Battery Resourcers and its subcontractor WPI have demonstrated the same success with the recovered graphite for anode materials. The success of this award will enable Battery Resourcers offer lowest cost anode materials while reducing the carbon footprint of the battery industry. This will potentially lower the cost of EV by lowering the upfront cost of the battery and the end of life disposal costs. The technical objectives of this Phase 1 research project are to purify the recovered graphite from Battery Resourcers leaching process and demonstrate it is viable to be used in new electric vehicle lithium ion batteries. This project demonstrated that Battery Resourcers can recover graphite with less than 2% impurities. To separate the graphite from other materials Battery Resourcers will employed new filtering techniques and chemical processing methods.

25 ENERGY STORAGE↗
DOE OSTI2024

Optimal hybrid power plants for electric vehicle charging demand

Transmission constraints, increasing motivations to decarbonize, and concerns over peak electric vehicle (EV) load impacts on local grids have driven electric customers to consider behind-the-meter, hybrid power plant generation and storage at the distributed-grid level for EV charging. In this study, we develop capabilities to optimize hybrid power plant component capacities for EV charging. We then demonstrate these capabilities in a case study for Boulder, Colorado, using public EV charging data as well as wind and solar resource data. Our results show system designs that balance the cost of energy with load-meeting and peak shaving performance. Within the case study, systems designed for wind, solar photovoltaic (PV), and storage resulted in lower cost of energy than those optimized for PV and storage only. This indicates that in areas where wind resource exists, hybrid power plants that include wind, PV, and battery assets can better meet EV charging loads (including peak loads that are prone to overloading local grids) than PV and battery assets alone. Future work to address limitations in this paper include extending cost modeling to include performance losses (e.g., based on operations or weather) and charging station costs to estimate levelized cost of charging, and quantifying uncertainty and error in our aggregation methods for estimating EV charging loads at the hourly timescale.

14 SOLAR ENERGY↗
DOE OSTI2024

Investigation of Nonflammable Electrolytes for Behind-the-Meter Storage Batteries

Behind-the-Meter Storage (BTMS) is a battery-based, stationary energy storage system that is connected to the residential or industrial customer's side of the electrical grid utility service meter. BTMS systems enable consumers to (A) economically schedule charging and usage of stored energy, (B) store and use energy from on-site generation, especially from inconstant, renewable sources like solar and wind, and (C) avoid overloading the grid during peak hours via supplementation with stored energy. BTMS battery performance requirements and general priorities differentiate from other applications, like EVs, which has prompted the development of batteries with tailored electrode and electrolyte materials. These materials prioritize low cost, avoiding critical materials; longevity, achieving 8000 cycle and 20-year shelf lives; and importantly, high safety. Nonflammable electrolytes show promise to improve safety by mitigating thermal runaway, yet often come with sacrifices to battery performance. In this presentation (1) primary categories of nonflammable electrolytes will be discussed; (2) a rational design of experiment will be presented for efficient performance evaluation of several nonflammables electrolyte in BTMS-relevant battery chemistry, Li4Ti5O12- and LiNi0.90Mn0.10O2; and (3) preliminary results will be presented.

battery↗
DOE OSTI2020

Well-to-wheels greenhouse gas and air pollutant emissions from battery electric vehicles in China

Electric vehicles (EVs) play a crucial role in addressing climate change and urban air quality concerns. China has emerged as the global largest EV market with 1.2 million EVs sold in 2018. This study established a novel life cycle energy use and emission inventory collecting up-to-date data including the electricity generation mix, emission controls in the power and industrial sectors, and the energy use in the fuel transport to estimate the well-to-wheels (WTW) greenhouse gas (GHG), and air pollutant emissions for battery electric vehicles (BEVs) and gasoline passenger vehicles in China. The results show that an average BEV has 35% lower WTW GHG emissions than an average gasoline car. BEVs reduce volatile organic compounds (VOCs) and nitrogen oxides (NOX) emissions by 98% and 34%, respectively, but have comparable or slightly higher primary fine particulate matter (PM2.5) and sulfur dioxide (SO2) emissions. Compact and small-size vehicles generally have lower GHG and air pollutant emissions than mid- and large-size vehicles. Class A vehicles contribute the most in the absolute amount of GHG and air pollutant emissions and therefore have the biggest potential for emission reduction. Our results suggest that global policymakers should continue to promote the transition to clean power sources, emission control, and fuel economy regulations, which are critical to enhancing emission mitigation benefits of BEVs. We also suggest EV development strategies should be formulated targeting vehicle class with the biggest emission mitigation potentials.

Air pollutant emissions↗
DOE OSTI2023

Revealing the Mechanism Behind Sudden Capacity Loss in Lithium Metal Batteries

Rechargeable Li-metal batteries (LMBs) are attractive energy storage candidates for electric vehicles (EVs) because they offer higher energy density than batteries built with intercalation electrodes. However, one of the main barriers to the commercial deployment of LMBs has been their relatively short cycle life. Re-designing the electrolyte system shows promise in achieving acceptable cycle life, but even so, the resulting cells display a challenging end-of-life (EOL) behavior: a sudden capacity loss. Herein, we report a new method for analyzing voltage profiles during cycling to distinguish between the capacity loss originating from the loss of cathode capacity vs growth in cell resistance. Further, this analysis reveals that sudden capacity loss was preceded by acceleration in the rate of growth of cell resistance, and cycling of multiple cells showed that this phenomenon is sensitive to the initial quantity of electrolyte in the cells. In contrast, the cathode capacity degraded at a constant rate independent of the electrolyte quantity. Combining this evidence with post-analysis of harvested electrolyte and electrodes, we conclude that neither the loss of active lithium nor the loss of active cathode material was the primary source of sudden capacity loss; instead, consumption and decomposition of electrolyte causes the drastic capacity loss at EOL.

25 ENERGY STORAGE↗
DOE OSTI2022

Accelerated Degradation in a Quasi-Single-Crystalline Layered Oxide Cathode for Lithium-Ion Batteries Caused by Residual Grain Boundaries

The rapidly growing demand of electrical vehicle (EV) requires high-energy-density lithium-ion batteries (LIBs) with excellent cycling stability and safety performance. However, conventional polycrystalline high-Ni cathodes severely suffer from intrinsic chemo-mechanical degradation and fast capacity fade. The emerging single-crystallization strategy offers a promising pathway to improve the chemo-mechanical stability, however, the single-crystallinity of the cathode is not always guaranteed and residual grain boundaries (GBs) could persist in nonideal synthesis conditions, leading to the formation of ‘quasi’ single-crystalline (QSC) cathodes. So far, there is a lack of understanding of the influence of these residual GBs on the electrochemical performance and structural stability. Herein, we investigate the degradation pathway of a QSC high-Ni cathode through transmission electron microscopy and X-ray techniques. The residual GBs caused by insufficient calcination time, dramatically exacerbate the cathode’s chemo-mechanical instability and cycling performance. Our work offers important guidance for the next-generation cathodes for long-life LIBs.

25 ENERGY STORAGE↗