Advances in Repurposing and Recycling of Post-Vehicle-Application Lithium-Ion Batteries

Increased electrification of vehicles has increased the use of lithium-ion batteries for energy storage, and raised the issue of what to do with post-vehicle-application batteries. Three possibilities have been identified: 1) remanufacturing for intended reuse in vehicles; 2) repurposing for non-vehicle, stationary storage applications; and 3) recycling, extracting the precious metals, chemicals and other byproducts. Advances in repurposing and recycling are presented, along with a mathematical model that forecasts the manufacturing capacity needed for remanufacturing, repurposing, and recycling. Results obtained by simulating the model show that up to a 25% reduction in the need for new batteries can be achieved through remanufacturing, that the sum of repurposing and remanufacturing capacity is approximately constant across various scenarios encouraging the sharing of resources, and that the need for recycling capacity will be significant by 2030. A repurposing demonstration shows the use of post-vehicle-application batteries to support a semi-portable recycling platform. Energy is collected from solar panels, and dispensed to electrical devices as required. Recycling may be complicated: lithium-ion batteries produced by different manufacturers contain different active materials, particularly for the cathodes. In all cases, however, the collecting foils used in the anodes are copper, and in the cathodes are aluminum. A common recycling process using relatively low acid concentrations, low temperatures, and short time periods was developed and demonstrated

Battery choice and management for New Generation Electric Vehicles

Different types of electric vehicles (EVs) have been recently designed with the aim of solving pollution problems caused by the emission of gasoline-powered engines. Environmental problems promote the adoption of new-generation electric vehicles for urban transportation. As it is well known, one of the weakest points of electric vehicles is the battery system. Vehicle autonomy and, therefore, accurate detection of battery state of charge (SoC) together with battery expected life, i.e., battery state of health, are among the major drawbacks that prevent the introduction of electric vehicles in the consumer market. The electric scooter may provide the most feasible opportunity among EVs. They may be a replacement product for the primary-use vehicle, especially in Europe and Asia, provided that drive performance, safety, and cost issues are similar to actual engine scooters. The battery system choice is a crucial item, and thanks to an increasing emphasis on vehicle range and performance, the Li-ion battery could become a viable candidate. This paper deals with the design of a battery pack based on Li-ion technology for a prototype electric scooter with high performance and autonomy. The adopted battery system is composed of a suitable number of cells series connected, featuring a high voltage level. Therefore, cell equalization and monitoring need to be provided. Due to manufacturing asymmetries, charge and discharge cycles lead to cell unbalancing, reducing battery capacity and, depending on cell type, causing safety troubles or strongly limiting the storage capacity of the full pack. No solution is available on the market at a cheap price, because of the required voltage level and performance, therefore, a dedicated battery management system was designed, that also includes a battery SoC monitoring. The proposed solution features a high capability of energy storing in braking conditions, charge equalization, overvoltage and undervoltage protection and, obviously, SoC information in order to optimize autonomy instead of performance or vice-versa

Towards Better Understanding of Failure Modes in Lithium-Ion Batteries: Design for Safety

In this digital age, energy storage technologies become more sophisticated and more widely used as we shift from traditional fossil fuel energy sources to renewable solutions. Specifically, consumer electronics devices and hybrid/electric vehicles demand better energy storage. Lithium-ion batteries have become a popular choice for meeting increased energy storage and power density needs. Like any energy solution, take for example the flammability of gasoline for automobiles, there are safety concerns surrounding the implications of failure. Although lithium-ion battery technology has existed for some time, the public interest in safety has become of higher concern with media stories reporting catastrophic cellular phone- and electric vehicle failures. Lithium-ion battery failure can be dangerously volatile. Because of this, battery electrochemical and thermal response is important to understand in order to improve safety when designing products that use lithium-ion chemistry. The implications of past and present understanding of multi-physics relationships inside a lithium-ion cell allow for the study of variables impacting cell response when designing new battery packs. Specifically, state-of-the-art design tools and models incorporate battery condition monitoring, charge balancing, safety checks, and thermal management by estimation of the state of charge, state of health, and internal electrochemical parameters. The parameters are well understood for healthy batteries and more recently for aging batteries, but not for physically damaged cells. Combining multi-physics and multi-scale modeling, a framework for isolating individual parameters to understand the impact of physical damage is developed in this work. The individual parameter isolated is the porosity of the separator, a critical component of the cell. This provides a powerful design tool for researchers and OEM engineers alike. This work is a partnership between a battery OEM (Johnson Controls, Inc.), a Computer Aided Engineering tool maker (ANSYS, Inc.), and a university laboratory (Advanced Manufacturing and Design Lab, University of Wisconsin-Milwaukee). This work aims at bridging the gap between industry and academia by using a computer aided engineering (CAE) platform to focus battery design for safety

Development and experimental evaluation of the control system of a hybrid fuel cell vehicle

This work presents the development and experimental evaluation of a Fuel Cell Hybrid Vehicle, focusing on the control system. The main objective of this paper is to present a real vehicle which has been designed in order to demonstrate the feasibility of the use of hydrogen as an energy source for automotive applications. The paper describes the components that are integrated in the vehicle and presents several experimental results obtained during normal operation. A control system is designed and tested in order to perform all the operations related to the coordinated operation of the fuel cell, the intermediate electrical storage and the power train. Its main task is to compute the power that must be demanded to the fuel cell in real time. This computation is done in order to satisfy the power demand of the electric motor taking into account the state of charge of the batteries and the operating regime of the fuel cell. This is accomplished by manipulating the electronic converter which regulate the current that the fuel cell supplies to the batteries.Ministerio de Ciencia y Tecnología DPI2007-66718-C04-0

Improved thermal performance of a large laminated lithium-ion power battery by reciprocating air flow

The file attached to this record is the author's final peer reviewed version. The Publisher's final version can be found by following the DOI link.Thermal safety issues are increasingly critical for large-size laminated Lithium-Ion Batteries (LIBs). Despite a number of investigations conducted on the Battery Thermal Management System (BTMS) with reciprocating air-flow cooling, large laminated power LIBs are still not sufficiently investigated, particularly in the view of battery thermal characteristics. The present study investigates the thermal behaviors of an air-cooled NCM-type LIB (LiNi1−x−yCoxMnyO2 as cathode) from an experimental and systematic approach. The temperature distribution was acquired from different Depth of Discharge (DOD) by the infrared imaging (IR) technology. A reciprocating air-flow cooling method was proposed to restrict the temperature fluctuation and homogenize temperature distribution. Results showed that there was a remarkable temperature distribution phenomenon during the discharge process, the temperature distribution was affected by direction of air-flow. Forward air-flow (from current collector side to lower part of battery) was always recommended at the beginning of the discharge due to the thermal characteristics of the battery. After comprehensive consideration on battery temperature limit and cooling effect, the desired initial reversing timing was about 50% DOD at 3 C discharge rate. Different reversing strategies were investigated including isochronous cycles and aperiodic cycles. It was found that the temperature non-uniformity caused by heat accumulation and concentration was mitigated by reciprocating air-flow with optimized reversing strategy

Alleviating a form of electric vehicle range anxiety through On-Demand vehicle access

On-demand vehicle access is a method that can be used to reduce types of range anxiety problems related to planned travel for electric vehicle owners. Using ideas from elementary queueing theory, basic QoS metrics are defined to dimension a shared fleet to ensure high levels of vehicle access. Using mobility data from Ireland, it is argued that the potential cost of such a system is very low

Safety of Lithium Nickel Cobalt Aluminum Oxide Battery Packs in Transit Bus Applications

The future of mass transportation is clearly moving toward the increased efficiency and greenhouse gas reduction of hybrid and electric vehicles. With the introduction of high-power/high-energy storage devices such as lithium ion battery systems serving as a key element in the system, valid safety and security concerns emerge. This is especially true when the attractive high-specific-energy and power-chemistry lithium nickel cobalt aluminum oxide (NCA) is used. This chemistry provides great performance but presents a safety and security risk when used in large quantities, such as for a large passenger bus. If triggered, the cell can completely fuel its own fire, and this triggering event occurs more easily than one may think. To assist engineers and technicians in this transfer from the use of primarily fossil fuels to battery energy storage on passenger buses, the Battery Application Technology Testing and Energy Research Laboratory (BATTERY) of the Thomas D. Larson Pennsylvania Transportation Institute (LTI) in the College of Engineering at The Pennsylvania State University partnered with advanced chemistry battery and material manufacturers to study the safety concerns of an NCA battery chemistry for use in transit buses. The research team ran various experiments on cells and modules, studying rarely considered thermal events or venting events. Special considerations were made to gather supporting information to help better understand what happens, and most importantly how to best mitigate these events and/or manage them when they occur on a passenger bus. The research team found that the greatest safety concern when using such a high-energy chemistry is ensuring passenger safety when a cell’s electrolyte boils and causes the ventilation of high-temperature toxic material. A cell-venting event can be triggered by a variety of scenarios with differing levels of likelihood. Also, though the duration of a venting event is relatively short, on the order of just a few seconds, the temperature of the venting material and cell is extremely high. During a venting event, the high-pressure, burning gases tend to burn holes in nearby packaging materials. Most interestingly, the team discovered that following a venting event the large-format cells tested immediately reached and remained at extremely high external skin temperatures for very long periods, on the order of hours. The majority of this report covers the testing designed to better understand how high-energy cells of this chemistry fail and what materials can be used to manage these failures in a way that increases passenger survivability

Enabling Development; design of a the Single Seat Wintec Electric Vehicle.(SSWEV)

The research project is related to the single seat three-wheel electric vehicle. Due to the high consumption of the oil in New Zealand (NZ) which have a direct impact on the economy, the authorities are now looking for an alternative source to power the vehicles and revolutionize the transport industry. There is another motive behind the development of electric vehicle (EV) which is linked with the environmental conditions of the country. The Internal Combustion Engine (ICE) vehicles increase the air pollution in the country and due to which the global warming has become a serious issue. To reduce the global warming effect and air pollution the electric vehicles have become a strong candidate or choice for the transportation. This project covers the electric vehicle in three parts: the Road Legal Status of EV in New Zealand, the Battery Electric System(BES), and Vehicle Design. There are some limitations which are associated with electric vehicles such as legislation does not encourage the people to purchase an electric vehicle, and the manufacturers are still interested in ICE vehicles. The research project proposes the desired policy for the EV in New Zealand. The possible design of the EV is proposed which is modeled in SolidWorks. Furthermore, the entire battery electric system and its management is included in the report which describes the proposed Battery electric system for single-seat electric vehicle. The primary goal in developing the battery electric system of the EV was to ensure that it has long driving range. The current EV are struggling to achieve the long driving range. The design selected for the EV is Reverse-trike. The unique features include the shifting of the centre of mass of the more extensive position. This design provides more stability and traction to the vehicle as the weight shift is towards the front wheels of the car

Car Industry developments – oil industry challenges

Automotive industry of Europe is one of the greatest economical powers, the „engine of Europe”. It employs directly 2.2 million people and 10 million in related industries and services. Combined turnover of automotive manufacturers reaches 700 billion EUR (retail another 520 billion EUR). The industry is the largest R&D investor in EU. On the other hand the transport sector carries a huge safety and environmental risk. Thanks to this fact the automotive industry is one of the most regulated sectors in the EU. As a result of these regulations: one average car built in 1970s produced as many pollutant elements as one hundred cars manufactured today. These achievements are based on struggles of both the auto and oil industry as parallel with technology development in car industry fuel quality developments achieved by the oil industry drove to a much “cleaner” fuel quality (unleaded sulphur free petrol, reduction of aromatics, benzene; sulphur free diesel, reduction of density, poly-aromatics, etc.). In the end of the 1990s, and especially for the last few years new challenges came into the focus of the auto and oil industry of the EU and the world. Concerns about high energy prices and price volatility, security of worldwide oil supply and climate change became a main policy agenda of the EU and the world. This new policy is reflected in new regulatory initiatives requiring cars using less energy more efficiently, emitting less carbondioxide and using growing proportion of renewable fuels. The European Commission declared the idea of “Cars for Fuels” instead of “Fuels for Cars”. This article discusses in detail the regulations and challenges that rose towards oil and car industry during the recent years. It describes the possible solutions in order to fulfil the requirements of the EU. After that a wide picture is presented without going into much detail on developments of the automotive industry. Developments are divided between vehicle level, engine level and fuel level technologies, also paying attention to technologies that are less known or rather futuristic