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At least 19 records

Using In Situ High-Energy X-ray Diffraction to Quantify Electrode Behavior of Li-Ion Batteries from Extreme Fast Charging

Extreme fast charging (XFC, =15 min charging time) of Li-ion batteries (LIBs) has been proposed as an immediate target to increase the commercial appeal of electric vehicles. However, XFC of LIBs is associated with the degradation of battery performance and safety concerns. Quantitative and simultaneous characterization of various components during cell degradation represents a major experimental challenge. In this work, we outline a methodology for the use of spatially resolved, high-energy X-ray diffraction as a quantitative, in situ method of mapping the degradation of LIBs. We use this approach to study the battery cell capacity loss, both locally (mm scale) and globally over the entire cell (cm scale). Specifically, our workflow allows us to quantify the total amount of plated Li on the anode, as well as its spatial correlation to the structural properties of the anode and cathode. The method complements existing optical methods to resolve the spatial heterogeneity of local degradation mechanisms such as Li plating and provides simultaneous insights into concomitant anode state-of-charge variability. We apply it to commercially relevant single-layer pouch cells with the graphite anode and the LiNi 0.5 Mn 0.3 Co 0.2 O 2 cathode. Our results show that Li plating occurs heterogeneously on the graphite anode and that it is spatially correlated to the extent of anode lithiation. In this work, we anticipate that the described workflow will allow for understanding multiscale degradation in energy-storage devices beyond LIBs, where quantitative analysis at a local and global length scale can be performed without the necessity to tear down the device, due to the applicability of high-energy X-rays to probe in situ degradation.

25 ENERGY STORAGE↗

Levelized cost of charging of extreme fast charging with stationary LMO/LTO batteries

Extreme DC fast charging for electric vehicles (EVs) could be competitive with the internal combustion engine refueling experience and enable longer-distance travel, which could help with EV adoption and decarbonization, but these systems have high capital costs and extremely variable high-power demands. Behind-the-meter systems (BTMS) could support extreme-fast-charging (XFC) stations to increase nationwide adoption of EVs. Here, this study examines the optimal break-even levelized cost of charging (LCOC) across 96 BTMS scenarios to enable low-wait XFC stations providing 200 miles of charge in 10 min. This research simulates LCOC via synthetic XFC-capable EV loads, machine-learned battery life models from testing data, and nonlinear optimal controls, co-minimizing complex utility costs and battery replacements. An aggregate optimal BTMS design treating each EV load as equal likely gives an optimal LCOC per utility rate, the average of which is $\$$0.59/kWh. In addition, the sensitivity of optimal and off-optimal design factors, the long-life LMO/LTO chemistry, and optimized controls are analyzed. The battery control model, based on battery stressors to compare chemistries, optimizes LMO/LTO resting state of charge and cycle depth without compromising cost reduction, which enables greater flexibility in operation. The LCOC savings due to replacement reduction are small, up to $\$$0.035/kWh (6%), with an average of $\$$0.02/kWh (3.5%). Compared with gasoline stations, the aggregate XFC station design achieves comparable speed, experience of service, and cost at $\$$3.81/gal gasoline, showing that EVs can replace gasoline vehicles even for longer-distance travel.

25 ENERGY STORAGE↗

Bilayer hybrid graphite anodes via freeze tape casting for extreme fast charging applications

Extreme fast charging (XFC) of lithium-ion batteries is critical for continuous market adoption of electric vehicles. However, mass transport limitations and sluggish kinetics lead to lithium plating in graphite anodes under fast charging conditions. One approach to address the mass transport limitation in graphite is to design low-tortuosity electrodes to enhance ionic transport. In this study, a bilayer hybrid structured electrode with directionally aligned channels was developed via freeze tape casting, which enables faster lithium ion diffusion through the graphite electrode. A scalable roll-to-roll process was designed in which slurry can be cast on any substrates for simple processing. Additionally, electrochemical impedance spectroscopy measurements indicated that the bilayer hybrid coating had both low tortuosity and short diffusion pathways, enabling XFC charging. Rate testing for the bilayer hybrid electrode indicated superior performance over the other coatings, exhibiting a ~20% improvement in the charge capacity compared with the conventional coating at 5C and 10 min total charging time. The bilayer hybrid electrode also demonstrated a 10% improvement in capacity retention compared with the conventional electrode after 1000 cycles at XFC conditions. This study demonstrates freeze tape casting as a scalable way to fabricate low-tortuosity electrodes for XFC applications.

25 ENERGY STORAGE↗

Sizing Energy Storage System for Energy Arbitrage in Extreme Fast Charging Station

This paper proposes a non-linear programming (NLP) model to optimally size the energy storage system (ESS) and obtain an optimal energy management for energy arbitrage of an extreme fast charging station (XFCS) for electric vehicles (EVs), with minimized total cost of XFCS operation and ESS investment. Different from most reported work on sizing the ESS for EV charging stations, this paper proposes a pragmatic approach to model the ESS life degradation and accurately count the ESS cycles. Moreover, this work incorporates the peak demand charges in the operational cost of the charging station which are often overlooked in the literature. The proposed model is formulated and solved using AIMMS. Finally, a thorough sensitivity analysis is performed to offer insights into how different input parameters impact the ESS sizing and savings from the energy arbitrage perspective.

25 ENERGY STORAGE↗

Deadband Voltage Control and Power Buffering for Extreme Fast Charging Station

Voltage fluctuation is one of the most common challenges that electric vehicle charging station (EVCS) may introduce to the power grid. Local reactive power compensation (Q-compensation) capability of bi-directional electric vehicle (EV) chargers can mitigate the steady-state voltage violations caused by the EV charging itself or changes in the neighboring loads. Power buffering, using energy storage system (ESS), can be utilized to address the voltage transients (sags and swells) as a result of EV charging at the EVCS. To address PI controller’s ‘hunting’ issue, this paper proposes a Q-sign triggered deadband voltage control (V-control) method at the point of common coupling (PCC). In addition, to ensure the ramp rate of EV charging is within the allowable limits set forth by the grid code, a ramp rate control is proposed that uses the ESS as a ‘power buffer’. Lastly, different from most reported work in the literature where no explicit limit of the power electronic converters (PECs) is considered, this work considers a reasonable apparent power capacity limit of the PECs when achieving the V-control. This limit also affects the amount of active power that can be obtained from the grid, and subsequently may require ESS to function as ‘load sharing’ device to provide supplemental active power to satisfy EV load. A case study simulated in MATLAB (interfaced with PLECS) is presented to demonstrate the effectiveness of the proposed approaches for EVCS operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Correlating the influence of porosity, tortuosity, and mass loading on the energy density of LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes under extreme fast charging (XFC) conditions

Extreme fast charging capabilities along with high energy density of Li-ion batteries are the key factors to increase the adoption of electric vehicles while eliminating the problem of range anxiety. The U.S Department of Energy has a goal of <12 min charging time with energy density of > 200 Wh kg -1 . A combined improvement in the electrode architecture, electrolyte properties, and separator membrane is necessary to achieve this goal. Cells with thin electrodes are capable of extreme fast charging at the expense of low energy density and high cost. Electrode engineering can maximize energy density. In this work, the influence of porosity, mass loading and charging protocols on capacity and energy density and electrode kinetics are investigated under extreme fast charging conditions. Increasing the mass loading from 11.5 mg cm -2 to 25 mg cm -2 compromises the rate performance due to the mass transport limitation and underutilization of thick electrodes. Furthermore, reducing the electrode porosity from 50% to 35% improves the rate performance ascribed to shorter Li ion diffusion length. Symmetric cells are cycled to verify the performance of the half cells, suggesting that Li metal plating is the rate limiting step under high current density.

25 ENERGY STORAGE↗

DC Link Voltage Balancing of the Active Front-End for the Extreme Fast Charging Stations

One of the most important challenges of the extreme fast charging (XFC) stations is to balance the DC link voltages of the active front-end (AFE). The multilevel cascaded H-bridge (CHB) converter is a great topology for the AFE applications due to the high power density, low total harmonic distortion (THD), and a low number of active and passive components. In this paper, a technique is proposed for balancing DC-link capacitor voltages of a three-phase CHB converter, when a phase shiftPWM modulation technique is used on all cells of the converter. To reach this goal, the redundant states of the CHB converters are used for generating different AC voltage levels by sorting the voltages of the converters. The proposed voltage balancing technique uses the principles that are employed for the DC link voltage balancing of the low-frequency modulation techniques to balance the DC link voltages of the CHB converter. As shown in this paper, the DC link voltages of the CHB converter can accurately be balanced very fast without using PI controllers, which are used in the conventional DC link voltage balancing techniques. A controller also is proposed which will be used to control the dq currents of the CHB converter. To verify the advantages of the proposed technique, the simulation results of the proposed technique will be carried out in a three-phase 7-cell CHB AFE.

Grid-tied converters, cascaded H-bridge, DC link v↗

A MW scale charging architecture for supporting extreme fast charging of heavy-duty electric vehicles

Extreme fast charging of electric vehicles technologies is coming. Heavy duty electric vehicles (HD-EVs) are in development and are expected to have multipliers bigger in battery capacity compared to the light duty counterparts. To meet short charging times, MW charging will be necessary. This paper presents a MW scale extreme DC fast charger with a communication and control architecture for HD-EVs. The system is validated in a controller hardware in the loop platform.

Starke, Michael↗

Methodologies for Design, Characterization and Testing of Electrolytes that Enable Extreme Fast Charging of Lithium-ion Cells

Selection, testing and validation of electrolyte candidates for Li-ion cells are discussed, based on a 10-minute target for extreme fast charge (XFC). A combination of modeling and laboratory measurements create a timely and synergistic approach to identifying candidate electrolyte formulations. Multi-solvent systems provide a balanced set of properties, wherein lower molecular-weight solvents offer reduced viscosity, increased species diffusivity, and mitigation of concentration polarization at high charge rates. Carefully selected formulations can exhibit peak conductivity and usable conductivity range of two to three times that of the baseline EC-EMC (3:7, wt.) + LiPF 6 . Candidates are also chosen based on stability and longevity within the cell environment. Lab testing coincides with property predictions from the Advanced Electrolyte Model (AEM) and a macro-scale cell model. Furthermore, cell testing utilized coin and pouch cells having NMC532 or NMC811 cathodes with graphite electrodes. Results indicate combinations of low-molecular weight solvents are key for fast-charge electrolytes as they extend the useful conductivity range to both low and higher salt concentrations, and possess higher self-diffusivities compared to conventional solvents. This reduces impacts from concentration polarization. The choice of electrolyte also influences the tendency for lithium metal deposition at the anode, as showcased by experimental and modeling results herein.

25 ENERGY STORAGE↗

R&D Insights for Extreme Fast Charging of Medium- and Heavy-Duty Vehicles: Insights from the NREL Commercial Vehicles and Extreme Fast Charging Research Needs Workshop, August 27-28, 2019

As battery costs have declined and battery performance has improved, the applicability of vehicle electrification has expanded beyond passenger cars to the commercial vehicle sector. However, due to the larger batteries that would be needed for the medium- and heavy-duty (MDHD) sector, the electric charging capabilities to serve these larger commercial vehicles will need to be substantially more powerful than light-duty chargers. More specifically, such 'extreme fast charging' (XFC) will likely need to reach the megawatt scale to provide a full charge in less than 30 minutes in some applications. In addition, the combined cost of electrified vehicles and charging must be competitive with the costs of petroleum-based technologies and other alternatives to encourage widespread adoption of battery electric vehicles (BEVs) among MDHD fleets. Most of these fleets have a commercial mission and demand low total cost of ownership (TCO) (which motivates minimal refueling times) and high performance from their vehicles.

25 ENERGY STORAGE↗

Multi-layered Energy Management Framework for Extreme Fast Charging Stations Considering Demand Charges, Battery Degradation, and Forecast Uncertainties

To achieve a cost-effective and expeditious charging experience for extreme fast charging station (XFCS) owners and electric vehicle (EV) users, the optimal operation of XFCS is crucial. It is however challenging to simultaneously manage the profit from energy arbitrage, the cost of demand charges, and the degradation of a battery energy storage system (BESS) under uncertainties. This paper, therefore, proposes a multi-layered multi-time scale energy flow management framework for an XFCS by considering long- and short-term forecast uncertainties, monthly demand charges reduction, and BESS life degradation. In the proposed approach, an upper scheduling layer (USL) ensures the overall operation economy and yields optimal scheduling of the energy resources on a rolling horizon basis, thereby considering the long-term forecast errors. A lower dispatch layer (LDL) takes the short-term forecast errors into account during the real-time operation of the XFCS. Per the latest research, monthly demand charges can be as high as 90% of the total monthly bills for EV fast charging stations; to this end, this paper takes the first attempt at the reduction of demand charges cost by considering the trade-off between the energy cost and monthly demand charges. Contrasting literature, this work allocates an energy reserve in the BESS stored energy to deal with the impact of short-term forecast errors on the optimized real-time operation of the XFCS. Moreover, degradation modeling considers the trade-off between short-term benefits and long-term BESS life degradation. As a result, case studies and a comparative analysis prove the efficacy of the proposed framework.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Developing extreme fast charge battery protocols – A review spanning materials to systems

Extreme fast charging (XFC) has become a focal research point in the lithium-battery community over the last several years. As adoption of electric vehicles increases, fast charging has become a key driver in enhancing consumer recharge experience. Recently, the research community has made significant improvements in developing charge protocols to support XFC. New charge protocol designs derived using a combination of advanced, physically derived models, and electrochemical and secondary characterization methods, increase charge acceptance and decrease aging. By coordinating these methods and modifying protocols to account for different material constraints, including lithium plating and cathode particle degradation, novel charge protocols have increased the energy accepted during charging by over 25% in 10 min and increased the charge acceptance prior to a constant-voltage step by approximately 3x. Here, we review several charge-protocol advances, aging factors which are enhanced by XFC and advances which will enable adoption of XFC capable vehicles. These advances include implementing machine learning and other detection algorithms to reduce and classify lithium plating, which is known to significantly degrade cell performance and reduce cell life. The review concludes by discussing full-system fast charge requirements, including electric vehicle service equipment needs for implementing XFC protocols.

25 ENERGY STORAGE↗

Optimal Sizing of PV and Energy Storage in an Electric Vehicle Extreme Fast Charging Station

This paper proposes an optimization model for the optimal sizing of photovoltaic (PV) and energy storage in an electric vehicle extreme fast charging station considering the coordinated charging strategy of the electric vehicles. The proposed model minimizes the annualized cost of the extreme fast charging station, including investment and maintenance cost of PV and energy storage, cost of purchasing energy from utility and demand charge. The decision variables are capacity of invested PV and the power and energy ratings of invested energy storage. To further reduce the annualized cost of the extreme fast charging station, the charging strategy of electric vehicles are integrated into the optimization model and coordinated with the power output of PV and charging/discharging of energy storage. Results of numerical simulations indicate that investment of PV and energy storage could help reduce the annualized cost of the extreme fast charging station significantly. Meanwhile, the impacts of various parameters on the optimal solution are investigated by sensitivity analysis.

Liu, Guodong↗

Sensitivity and reliability of key electrochemical markers for detecting lithium plating during extreme fast charging

Lithium plating is one of the key challenges for enabling extreme fast charging (XFC, ≤10 to 15 min charging at ≥6C) in graphite-based lithium-ion batteries. Significant R&D effort has been focused on how to mitigate Li plating. Parallel effort is also being devoted to developing methods to detect Li plating when and if it happens during fast charging. In that regard, electrochemical (EC) signature-based detection techniques are less resource intensive, more convenient, and more practical from an end-user application perspective. However, a comprehensive understanding of key plating related EC signatures for extreme fast charging is presently unavailable. In particular, there exist distinct issues of unreliability with key plating-related EC signatures—e.g., incremental capacity (dQ.dV -1 ), differential OCV (dOCV.dt -1 ), end of lithiation (EOL) rest voltage—at XFC conditions, and the underlying reasons have not been explored and identified methodically. Using a comprehensive test matrix and XFC conditions with Li/graphite half cells, this article highlights the unreliability issues associated with the EC Li plating diagnostics and explains the underlying root cause. This study finds distinct sensitivity and unreliability issues with plating related dQ.dV -1 , dOCV.dt -1 , and EOL rest voltage signatures with charging rates. Furthermore, the complex interaction between graphite and plated Li that happens through multiple competing mechanisms —Li stripping and chemical intercalation— at different charging rates is at the core of the sensitivity and unreliability issue.

25 ENERGY STORAGE↗

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

The pursuit of batteries capable of extreme fast charging (XFC), that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion battery technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, and vehicle light weighting is driving these metals towards near-critical status in the medium term. This study introduced metalized polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate (PET) film – named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in LIBs. We have utilized current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared to traditional metal foil counterparts. We conducted an extensive evaluation of their mechanical and electrical properties, including in-plane and through-plane resistivities, affirming their suitability for the roll-to-roll battery manufacturing process. Additionally, a novel XFC testing protocol was employed to thoroughly assess the cells' (both half and full-cell) performance across various C-rates and under long-term tests. These advancements have the potential to enhance energy density to 280 Wh/kg at the electrode level under 10-minute charging at 6C. Through testing, including a novel XFC protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, we have demonstrated the superior performance of these metalized polymer films. Notably, mPET/Cu and mPET/Al foils exhibited comparable capacities to conventional cells under XFC, with the mPET cells showing a 27% improvement in energy density at 6C and maintaining significant energy density after 1000 cycles. This study underscored the potential of mPET foils to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of LIBs in EV applications. Moreover, our results suggest that there is potential to enhance the performance of mPET foils, especially mPET/Al, by optimizing the manufacturing process to achieve higher conductivity.

99 GENERAL AND MISCELLANEOUS↗

Heat Generation Concerns Associated with Extreme Fast Charging

Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. Incorrect thermal management designs for extreme fast charging conditions could result in cells reaching abuse temperatures and potentially sending the cells into thermal runaway. Furthermore, the cell and module design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and how to potentially measure the internal temperatures of a battery. Thermal management is not a limiting condition with regards to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

ADVANCED PROPULSION SYSTEMS↗

Grid-Enhanced, Mobility-Integrated Network Infrastructures for Extreme Fast Charging (GEMINI-XFC)

Increasing vehicle electrification will require extensive use of extreme fast charging (XFC), especially for larger vehicles. Uncoordinated XFC can create grid challenges, particularly at the distribution level. Two strategies can support widespread XFC: gold-plate the grid (i.e., upgrade all systems to enable worst-case, fully coincident loads) or use integrated planning to codesign a smart system based on advanced controls that leverage load flexibility and distributed energy resources. With the right design and control, XFC can simultaneously support both mobility and grid operations. Fully realizing the potential of XFC, however, will require unprecedented coordination among the charging infrastructure, grid, and vehicles. GEMINI-XFC combines high-fidelity grid and transport modeling at an unprecedented level of resolution and codesigns a smart system based on advanced controls that leverage load flexibility and distributed energy resources to optimize the integration of extreme fast charging (XFC) across a full regional scale with individual customer resolution.

ADVANCED PROPULSION SYSTEMS↗