Accelerating Electric Vehicle Adoption & Battery Design Kandler - PowerPoint PPT Presentation

Accelerating Electric Vehicle Adoption & Battery Design Kandler Smith Electrochemical Energy Storage - Computational Modeling Team Lead National Renewable Energy Laboratory, Golden CO Kandler.Smith@nrel.gov Figure Credit: Kenny Gruchalla and Francois Usseglio-Viretta, NREL

Outline • Transportation Electrification • Battery Cost • Lithium-based Chemistries – Today & Future • DOE & NREL Research & Development – Low/No Cobalt Cathodes – Recycling (RECELL) – Extreme Fast Charging (XCEL) – Behind the Meter Storage (BTMS) – Computer-Aided Engineering of Batteries (CAEBAT)

Batteries and Electrification • New York International Auto Show: more than 2020 Chevy Bolt | Adam Jeffery | CNBC 40 electrified vehicles • EPRI: Utilities are proposing ~$3.7B in EV charging infrastructure • CEO of Daimler Trucks North America: For commercial vehicles “The beginning of the post internal combustion engine era” https://www.cummins.com/news/2018/04/23/cummins- puts-electrification-progress-display www.rivian.com Courtesy: Cunningham Brian, DOE, AMR, 2019

Energy Storage: Battery Cost Story – The Past “ Rapidly falling costs of battery packs for electric vehicles ”, B. Nykvist and M. Nilsson; Nature, Climate Change; March 2015, DOI: 10.1038/NCLIMATE2564 2,000 95% conf. interval, whole industry 95% conf. interval, market leaders 1,800 Publications, reports, and journals News items with expert statements 1,600 Log fit of news, reports, and journals: 12 ÷ 6% decline Additional cost estimates without a clear method 2014 US$ / kWh 1,400 Market leader, Nissan Motors (Leaf) 2012 DOE cost Market leader, Tesla Motors (Model S) target $600/kWh 1,200 Other battery electric vehicles Log fit of market leaders only: 8 ÷ 8% decline 1,000 Log fit of all estimates: 14 ÷ 6% decline Future costs estimated in publications 800 2018 DOE cost DOE cost target $100/kWh $197/kWh 600 w/ ultimate goal of $80/kWh 2022 DOE cost target 400 $100/kWh 200 2005 2010 2015 2020 2025 2030

Conventional Li-ion Chemistries Anode/Cathode Combinations Decreasing Energy Density Graphite/ Graphite/ Graphite/ Graphite/ Graphite/ LTO/NMC LCO NCA NMC LMO-Blend LFP Safety Energy Lifetime Charge Samu Kukkonen, VTT Technical Research Centre of Finland (2014) Cost Future Supply LCO – Lithium Cobalt Oxide; NCA – Nickel Cobalt Aluminum; NMC – Nickel Manganese Cobalt LMO – Lithium Manganese Oxide; LFP – Lithium Iron Phosphate; LTO – Lithium Titanate Oxide

Energy Storage: Battery Cost Story – The Future Graphite/High Voltage NMC $ 600 • R&D Focus: Higher cathode Graphite/High Voltage NMC capacity (220+ mAh/g), low/no System Cost ($/kWh) $ 500 cobalt, recycling, fast charge Silicon/High Voltage NMC $ 400 Silicon/High Voltage NMC Lithium-Metal or $320/kWh (5x excess Li, 10%S) Lithium/Sulfur • R&D Focus: Higher anode $300 capacity (1000+ mAh/g), $197/kWh cycle/calendar life, fast charge $200 Lithium-Metal & Li/Sulfur $ 100 • R&D Focus: Solve cycle life/ ~$80/kWh catastrophic failure issues, reduce excess lithium, reduce excess 2012 2014 2016 2018 2020 2022 2024 2026 2028 2030 electrolyte, reduce lithium metal Year cost Courtesy: Cunningham Brian, DOE, AMR, 2019

Conventional to Next-Gen Li-ion Chemistries – DOE R&D

Energy Storage: DOE R&D Portfolio CHARTER: Develop battery technology that 2022 GOAL: $150/kWh (useable) will enable large market penetration of Critical materials-free with recycled materials and electric drive vehicles capable of fast charge Energy Storage R&D Battery Materials Applied Battery Battery Battery Testing, Research (BMR) Research (ABR) Development Design, & Analysis Courtesy: Cunningham Brian, DOE, AMR, 2019

Li-Based Chemistry Selection for Higher Energy Density J.-M. Tarascon and M. Armand, Nature Vol. 414, p. 359 (2011) Cathodes Desire large potential difference between anode and cathode… Anodes …and high capacity

Li-ion Cell Configurations • Cylindrical: • Prismatic: • Jellyroll • Wound or stacked layers • Hard can • Soft pouch or hard can Photo Credit: http://sustainablemfr.com/energy-efficiency/lowering- Photo Credit: http://ewi.org/ultrasonic-metal- costs-lithium-ion-batteries-ev-power-trains#lithium welding-for-lithium-ion-battery-cells/ Photo Credit: https://en.wikipedia.org/wiki/List_of_battery_sizes Photo Credit: NREL-Dirk Long

Battery Packs in Some EVs Nissan Leaf Fiat 500 EV Chevy Volt http://www.ibtimes.com/articles/79578/20101108/sb- http://autogreenmag.com/tag/chevroletvolt/page/2/ http://inhabitat.com/will-the-nissan-leaf-battery-deliver-all- limotive-samsung-sdi-chrysler-electric-car.htm it-promises/ i-MiEV Ford Focus Tesla Model S https://hackadaycom.files.wordpress.com/2 http://www.caranddriver.com/news/car/10q4/2012_mitsubi http://www.metaefficient.com/cars/ford-focus-electric- shi_i-miev_u.s.-spec_photos_and_info- nissan-leaf.html 014/09/tesla-batt.jpg?w=800 auto_shows/gallery/mitsubishi_prototype_i_miev_lithium- ion_batteries_and_electric_drive_system_photo_19

NREL Transportation RD&D Activities & Applications Vehicle Thermal Management Vehicle Deployment/Clean Cities Regulatory Support Integrated Thermal Management Guidance & Information for Fleet Decision EPAct Compliance Climate Control/Idle Reduction Makers & Policy Makers Data & Policy Analysis Advanced HVAC Technical Assistance Technical Integration Online Data, Tools, Analysis Fleet Assistance Infrastructure Vehicle-to-Grid Integration Integration with Renewables Charging Equipment & Controls Fueling Stations & Equipment Roadway Electrification Automation Advanced Combustion/Fuels Advanced Petroleum and Biofuels Combustion/Emissions Measurements Vehicle & Engine Testing Vehicle and Fleet Testing MD/HD Dynamometer Testing Advanced Energy Storage MDV & HDV Testing/Analysis Advanced Power Electronics Development, Testing, Analysis Drive Cycle Analysis/Field Evaluations and Electric Motors Thermal Technology Performance Characterization/Management Thermal Management Comparisons Life/Abuse Testing/Modeling Thermal Stress and Reliability Data Collection, Storage, & Analysis Computer-Aided Engineering Analysis & Optimization Tools Illustration by NREL Electrode Material Development

DOE Approach to Circular Economy for Lithium-ion batteries  Lower cost of batteries  Lower environmental impacts  Increase USA’s energy security DUMMY

• The objective of this Argonne National Lab Developed Epitaxial High Nickel Cathodes Model Electrodes (ANL) led project is to realize high-capacity, high- energy cathodes with stabilized long-term Realizing Next- performance. • The project is developing Generation lithiated transition-metal Cathodes for (TM) oxides, in concert with strategies to Li-Ion minimize/ eliminate cobalt as well as particle surface- Batteries: Understand how surface chemistry affects electrochemical engineering efforts to reactivity at NMC surfaces using AFM/SECM mitigate the effects of Low-Cobalt surface reactivity. Cathodes • NREL is exploring Co-free cathode materials and advanced electrolytes to stabilize nickel-rich surfaces.

Lithium Ion Battery Recycling R&D Center (ANL lead) MISSION : Minimize the cost of recycling lithium ion batteries to ensure future supply availability of critical materials and decrease energy usage

Existing Li-Ion Recycling Methods Decrease the cost of recycling lithium-ion batteries to ensure future supply of critical materials and decrease energy usage compared to raw material production Direct recycling minimizes steps back to use

Recycling Prize Focused on Five Areas

Why is Extreme Fast Charging (XFC) Important? • DC Fast Charging Increases BEV Utility – Yearly electric vehicle miles (eVMT) traveled increases with use of 50 kW fast charging – Nearly 25% more miles driven annually when DCFC used for 1-5% of total charging events Level 1 Level 2 DC Fast Tesla XFC ( 110V, ( 220V, Charger ( 480V, SuperCharger ( 1000V, • EV Service Equip (EVSE) 1.4kW ) 7.2kW ) 50kW ) ( 480V, 140kW ) 400kW ) Comparison Range Per Minute of – XFC should be able to charge 0.082 0.42 2.92 8.17 23.3 Charge a BEV in less than 10 minutes ( miles ) and provide approximately 200 Time to additional miles of driving Charge for 2143 417 60 21.4 7.5 range 200 Miles ( min ) Source: McCarthy, Michael. “California ZEV Policy Update.” SAE 2017 Government/Industry Meeting, Society of Automotive Engineers, 25 January 2017, Walter E. Washington Convention Center, Washington, DC. Conference Presentation.

Thick graphite electrodes increase energy density but decrease XFC • Greater EV driving range needs energy-dense electrodes Slow transport of Li + ions in electrolyte + graphite limitations  Li plating side reaction • Increasing Li deposition on graphite electrodes as a function of capacity loading (electrode thickness) • Lithium may or may not removed during the following discharge cycle • Stranded lithium can be a safety issue Advanced electrolytes, electrode architectures and elevated temperature all can enable fast charging of 250 Wh/kg graphite-based Li-ion batteries Courtesy: Michelbacher, Chris; DOE, AMR, 2017