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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Analysis of an all-solid state nanobattery using molecular dynamics simulations under an external electric field

Present Li-ion battery (LIB) technology requires strong improvements in performance, energy capacity, charging-time, and cost to expand their application to e-mobility and grid storage. Li-metal is one of the most promising materials to replace commercial anodes such as graphite because of its 10 times higher specific capacity. However, Li-metal has high reactivity with commercial liquid electrolytes; thus, new solid materials are proposed to replace liquid electrolytes when Li-metal anodes are used. We present a theoretical analysis of the charging process in a full nanobattery, containing a LiCoO 2 cathode, a Li 7 P2S 8 I solid-state electrolyte (SSE), a Li-metal anode as well as Al and Cu collectors for the cathode and anode, respectively. In addition, we added a Li 3 P/Li 2 S film as a solid electrolyte interphase (SEI) layer between the Li-anode and SSE. Thus, we focus this study on the SEI and SSE. We simulated the charging of the nanobattery with an external voltage by applying an electric field. We estimated temperature profiles within the nanobattery and analyzed Li-ion transport through the SSE and SEI. Here, we observed a slight temperature rise at the SEI due to reactions forming $PS_{3}^{–}$ and $P_{2}S_{7}^{4}$$^{–}$ fragments at the interfaces; however, this temperature profile changes due to the charging current under the presence of the external electric field ε = 0.75 V Å –1 . Without the external field, the calculated open-circuit voltage (OCV) was 3.86 V for the battery, which is within the range of values of commercial cobalt-based LIBs. This voltage implies a spontaneous fall of available Li-ions from the anode to the cathode (during discharge). The charge of this nanobattery requires overcoming the OCV plus an additional voltage that determines the charging current. Thus, we applied an external potential able to neutralize the OCV, plus an additional 1.6 V to induce the transport of Li + from the cathode up to the anode. Several interesting details about Li + transport paths through the SSE and SEI are discussed.

25 ENERGY STORAGE↗
DOE OSTI2023

Chemical contributions to silicon anode calendar aging are dominant over mechanical contributions

Silicon (Si) anodes are a promising candidate for increasing the energy density of lithium (Li)-ion batteries for electric vehicles. However, they have recently been identified as having poor calendar life that is insufficient for commercial needs, in addition to the well-known issue of their poor cycle life resulting from large volume expansion. Here, a specially designed protocol with variable rest periods between intermittent cycling is used to evaluate the impact of the mechanical disruption of Si and solid electrolyte interphase (SEI) from cycling on calendar aging measurements. Si was found to undergo more mechanical degradation during calendar aging with intermittent cycling than graphite. However, Si anode capacity fade was still dominated by time, especially for rest periods greater than or equal to 1 month between cycling. Postmortem dQ/dV half-cell analysis indicated this was mainly due to Li inventory loss and an increase in electrode resistance. Isothermal microcalorimetry further demonstrated that Si passivation is more disrupted than graphite passivation with intermittent cycling and suggested that there may be a chemical buildup of a detrimental species in the electrolyte, leading to a large spike in heat after the Si and SEI are disrupted by cycling.

25 ENERGY STORAGE↗
DOE OSTI2020

Three-Dimensional Mapping of Resistivity and Microstructure of Composite Electrodes for Lithium-Ion Batteries

Nanoparticle silicon–graphite composite electrodes are a viable way to advance the cycle life and energy density of lithium-ion batteries. However, characterization of composite electrode architectures is complicated by the heterogeneous mixture of electrode components and nanoscale diameter of particles, which falls beneath the lateral and depth resolution of most laboratory-based instruments. In this work, we report an original laboratory-based scanning probe microscopy approach to investigate composite electrode microstructures with nanometer-scale resolution via contrast in the electronic properties of electrode components. Applying this technique to silicon-based composite anodes demonstrates that graphite, SiOx nanoparticles, carbon black, and LiPAA binder are all readily distinguished by their intrinsic electronic properties, with measured electronic resistivity closely matching their known material properties. Resolution is demonstrated by identification of individual nanoparticles as small as ~20 nm. Our technique presents future utility in multiscale characterization to better understand particle dispersion, localized lithiation, and degradation processes in composite electrodes for lithium-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Advanced Processing of Coal and Coal Waste to Produce Graphite for Fast-Charging Lithium-Ion Battery Anode

The University of North Dakota (UND) Energy & Environmental Research Center (EERC), in collaboration with the UND Center for Process Engineering Research (CPER), conducted a project to validate two technologies capable of converting North Dakota lignite and lignite coal waste to high-quality graphite for fast-charging lithium-ion battery (LIB) anode. The project was conducted over about 3 years from April 7, 2022, to July 6, 2025. The two technological paths pursued in this project include path A – direct conversion of coal or coal waste to graphite by the upgraded carbon ores to products (UCOP) process being developed at the EERC and path B – lignite-derived coal tar pitch (CTP) conversion to graphite (CTP2G) process being developed at CPER. The results from this project validate the two technological approaches and are expected to be an integral part of a portfolio of emerging technologies for making high-quality graphite not only from North Dakota lignite, but from all ranks of U.S. domestic coal and coal waste resources. The quality of the graphite produced by these technologies is high enough for various applications, including batteries for the fast-growing electric vehicle industry, energy storage applications, electric arc furnace electrodes for steel production, and graphene production, among others. Although the two technologies can produce high-quality graphite, they are fundamentally different in that the UCOP technology provides a direct path to transform coal to graphite, while the CTP2G technology needs to go through a CTP intermediate and a coking process for the intermediate, which requires a special facility to accomplish. For application in the industry, the UCOP process is designed to be more flexible, with feedstock to include potentially any carbonaceous material such as all coal ranks and biochar, while the CTP2G process is designed to utilize CTP as the starting precursor. The key project accomplishments include the following: • Successful preparation of high-quality synthetic graphite from North Dakota lignite coal/coal wastes and lignite-derived CTP. • Patent application has been filed for the UCOP process and an internal invention disclosure has been filed for the CTP2G process. • The produced graphite performs better than a commercial battery-grade sample in LIB coin cells, especially fast-charging capability, stability, and long-duration cycling. • Coin-type Li-ion half-cells with CTP2G graphite showed excellent performance, with >370 mAh/g capacity, >90% initial coulombic efficiency, and 93%/67% retention at 1C/2C rate, which outperforms commercial graphite in charging speed, stability, and cycling. • Results of fabricated 18650 cells were consistent with the observations in coin cells. • Preliminary techno-economic analysis (TEA) estimates for the UCOP technology indicate a manufacturing cost of about $\$$39/kg based on 50-metric ton/year capacity. • Preliminary TEA estimates for the CTP2G technology indicate a market price of about $\$$7107/ton ($\$$7/kg) based on 22,000-ton/year production capacity.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Magnetohydrodynamic Control of Interfacial Degradation in Lithium-Ion Batteries for Fast Charging Applications

Interfacial anodic degradation in graphitic materials under fast charging conditions causes severe performance loss and safety hazard in lithium ion batteries. We present a novel method for minimizing the growth of these aging mechanism by application of an external magnetic field. Under magnetic field, paramagnetic lithium ions experience a magnetohydrodynamic force, which rotates the perpendicularly diffusing species and homogenizes the ionic transport. This phenomenon minimizes the overpotential hotspots at the anode/separator interface, consequently reducing SEI growth, lithium plating, and interfacial fracture. In situ electrochemical measurements indicate an improvement in capacity for lithium cobalt oxide/graphite pouch cell (20 mAh) charged from 1–5 C under an applied field of 1.8 kG, with a maximum capacity gain of 22% at 5C. Post-mortem FE-SEM and EDS mapping shows that samples charged with magnetic field have a reduced lithium deposition at 3C and a complete suppression of interfacial fracture at 5C. At 5C, a 24% reduction in the lithium content is observed by performing XPS on the anodic interfacial film. Finally, fast charging performance under variable magnetic field strengths indicate a saturation behavior in capacity at high fields (>2 kG), thereby limiting the field and consequent energy requirements to obtain maximum capacity gain under extreme conditions.

electromagnetism↗
DOE OSTI2021

Review—The Lithiation/Delithiation Behavior of Si-Based Electrodes: A Connection between Electrochemistry and Mechanics

Silicon is a promising alternative anode material to graphite because of its high gravimetric and volumetric energy densities. However, severe capacity fading is observed in Si electrodes, and it is a result of mechanical changes of Si, such as volume changes, stress or fracture. Furthermore, these mechanical behaviors are strongly coupled with the electrochemistry of the Li-Si alloying reaction in Si-based electrodes, including both thermodynamics and kinetics. Therefore, the electrochemical properties of Si-based electrodes are strongly dependent on the control of the mechanics of Si during lithiation/delithiation. As such, it is very important to understand the correlation between electrochemistry and mechanics. Here, we review lithiation/delithiation behaviors of various types of Si-based electrodes, applying a fundamental understanding of electrochemistry and mechanics and the correlation between them.

25 ENERGY STORAGE↗
DOE OSTI2022

Phase Transfer‐Mediated Degradation of Ether‐Based Localized High‐Concentration Electrolytes in Alkali Metal Batteries

Abstract Localized high‐concentration electrolytes (LHCEs) have attracted interest in alkali metal batteries due to the advantages of forming stable solid‐electrolyte interphases (SEIs) on anodes and good chemical/electrochemical stability. Herein, a new degradation mechanism is revealed for ether‐based LHCEs that questions their compatibility with alkali metal anodes (Li, Na, and K). Specifically, the ether solvent reacts with alkali metals to generate solvated electrons (e s − ) that attack hydrofluoroether co‐solvents to form a series of byproducts. The ether solvent essentially acts as a phase‐transfer reagent that continuously transfers electrons from solid‐phase metals into the solution phase, thus inhibiting the formation of stable SEI and leading to continuous alkali metal corrosion. Switching to an ester‐based solvating solvent or intercalation anodes such as graphite or molybdenum disulfide has been shown to avoid such a degradation mechanism due to the absence of e s − .

Chen, Xiaojuan↗
DOE OSTI2022

Phase Transfer‐Mediated Degradation of Ether‐Based Localized High‐Concentration Electrolytes in Alkali Metal Batteries

Abstract Localized high‐concentration electrolytes (LHCEs) have attracted interest in alkali metal batteries due to the advantages of forming stable solid‐electrolyte interphases (SEIs) on anodes and good chemical/electrochemical stability. Herein, a new degradation mechanism is revealed for ether‐based LHCEs that questions their compatibility with alkali metal anodes (Li, Na, and K). Specifically, the ether solvent reacts with alkali metals to generate solvated electrons (e s − ) that attack hydrofluoroether co‐solvents to form a series of byproducts. The ether solvent essentially acts as a phase‐transfer reagent that continuously transfers electrons from solid‐phase metals into the solution phase, thus inhibiting the formation of stable SEI and leading to continuous alkali metal corrosion. Switching to an ester‐based solvating solvent or intercalation anodes such as graphite or molybdenum disulfide has been shown to avoid such a degradation mechanism due to the absence of e s − .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

LiH formation and its impact on Li batteries revealed by cryogenic electron microscopy

Little is known about how evolved hydrogen affects the cycling of Li batteries. Hypotheses include the formation of LiH in the solid-electrolyte interphase (SEI) and dendritic growth of LiH. Here, we discover that LiH formation in Li batteries likely follows a different pathway: Hydrogen evolved during cycling reacts to nucleate and grow LiH within already deposited Li metal, consuming active Li. We provide the evidence that LiH formed in Li batteries electrically isolates active Li from the current collector that degrades battery capacity. We detect the coexistence of Li metal and LiH also on graphite and silicon anodes, showing that LiH forms in most Li battery anode chemistries. Last, we find that LiH has its own SEI layer that is chemically and structurally distinct from the SEI on Li metal. Our results highlight the formation mechanism and chemical origins of LiH, providing critical insight into how to prevent its formation.

25 ENERGY STORAGE↗
DOE OSTI2022

Li-Ion Battery Electrode Contact Resistance Estimation by Mechanical Peel Test

Li-ion battery electrode electronic properties, including bulk conductivity and contact resistance, are critical parameters affecting cell performance and fast-charge capability. Contact resistance between the coating and current collector is often the largest electronic resistance in an electrode and is affected by chemical, microstructural, and interfacial variations. Direct measurements of contact resistance and bulk conductivity have proven to be challenging. In their absence, a mechanical electrode peel test is often used to compare adhesion and electrical contact resistance. However, using a micro-flexible-surface probe, contact resistance can be directly determined. Here, this work compares contact resistance and mechanical peel strength of multiple commercial-grade HE5050 and NCM523 cathodes and graphite and silicon anodes. It was found that peel strength correlates well with contact resistance in a carefully curated data set (p < 0.05) and in some situations may be a good metric to estimate electrical properties. However, there were distinct outliers in the data set, indicating that peel strength may not accurately reflect electrical properties when there is significant variation in electrode composition. These results illustrate the value of the micro-flexible-surface probe in quantifying contact resistance and bulk conductivity to better understand how battery composition and processing steps affect microstructure and resulting cell performance.

25 ENERGY STORAGE↗
DOE OSTI2022

Carbon Anode Material from Biomass Pyrolysis Oil

Lithium-ion batteries (LIB) are an important component of electric vehicles and sodium-ion batteries (SIB) are an attractive alternative for grid electric storage. We are investigating a novel approach to synthesizing the carbon anode materials for these batteries from biomass pyrolysis oil as part of conversion processes to produce biofuels. Graphite is used as anode material in LIB and is exclusively produced from petroleum residue or mined mineral carbon. We have synthesized drop-in graphite by coking the heavy residual oil from the distillation of catalytic fast pyrolysis oil and by catalytic graphitizing raw pyrolysis oil. XRD and Raman spectroscopies were used to verify the production of high purity crystalline graphite. Figure 1 shows typical XRD spectra of the bio-graphite compared to commercial material as well as the charge/discharge cycle. Graphite particle sizes and morphologies were adjusted to improve performance using jet milling and carbon coating. The bio-graphite delivered a high capacity (335 mAh/g) when tested in a graphite half-cell. Full cell coin cell experiments were also conducted to verify the observations from half-cell testing. The high value of graphite (>$9/kg) can positively impact the economics of biofuels production and can be an important part of a future circular carbon economy. We have also investigated synthesizing hard carbon from pyrolysis oil for use as anode material in SIB. These batteries are not commercially mature but have great promise in grid storage and use earth abundant elements. We have demonstrated that pyrolysis oil can be used to synthesize hard carbon, which was subsequently be used in SIB experiments. This material achieved a sodium-ion capacity of 250 mAh/g and a first cycle efficiency of 78%, with opportunities to further optimize this performance from optimizing the composition of the pyrolysis oil to shaping the hard carbon particles. As with graphite, hard carbon is a high value (> $10/kg) material that could facilitate biofuels production.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
DOE OSTI2024

Sucrose‐Based Dense, Pure, and Highly‐Crystalline Graphitic Materials for Lithium‐Ion Batteries

At present, most synthetic graphite materials commonly used as anode active ingredients in lithium-ion cells are produced by graphitization of petroleum cokes. The carbon footprint associated with synthetic graphite production is significant. Thus, bio-derived and cheap precursors, such as saccharides, would be an attractive alternative for the sustainable production of graphitic carbons. However, they are non-graphitizing at temperatures as high as 3000 °C, preserving the curved, fullerene-like structure of graphene layers and microporosity. Consequently, many lithium ions are consumed during the formation of solid electrolyte interphase films and passivated in the nanovoids. Here, a method for the production of pure, crystalline, graphitic materials based on sucrose disposed of microporosity is presented, which also works with a variety of saccharides and other organic precursors of hard carbons—generally considered incapable of such transformation. This process employs catalytic graphitization by Si particles at high temperatures. Finally, the electrochemical response of such derived sucrose-based graphite in Li-ion half-cells demonstrated its feasibility to serve as an anode active material for rechargeable Li-ion batteries.

Si particles↗
DOE OSTI2025

Highly crystalline, low-ash, graphite from coal using an Fe 2 O 3 -based catalytic process with recovery and reuse of catalyst and process acid

This study presents a sustainable process for producing highly crystalline, low-ash graphite from sub-bituminous coal using an Fe 2 O 3 -based catalytic method. The process integrates coal mineral removal, catalyst regeneration, and reagent recycling into a closed-loop system. Acid-soluble Fe-residue and mineral impurities are eliminated from the solid graphite through HCl treatment, followed by hydrolytic distillation to regenerate Fe 2 O 3 and recover HCl for reuse. Coal-derived silica is removed with a KOH rinse, yielding low-ash graphite suitable for high-performance applications. The closed-loop catalytic graphitization, where the recovered Fe 2 O 3 and HCl are used in subsequent graphitization runs, produces graphite with a degree of graphitization exceeding 95%. The L a and L c crystallite sizes reach 65–78 nm and 44–48 nm, respectively, with BET surface areas of 4–10 m 2 /g and an ash content below 0.1 wt.%. Lithium-ion battery testing reveals that anodes fabricated with this graphite deliver an initial discharge capacity between 384.5 and 421.2 mAh/g, averaging 395.0 ± 19.1 mAh/g, along with initial coulombic efficiencies of 85.0–89.1%. After 100 discharge–charge cycles at 0.25C, reversible capacities remain between 358.8 and 369.7 mAh/g, while coulombic efficiency stays above 99.9%. The findings highlight that coal can serve as a viable precursor for high-quality graphite production under relatively mild conditions, avoiding the need for extreme temperatures or aggressive reagents such as hydrofluoric acid, commonly employed in conventional processes. This work demonstrates both technical feasibility and environmental benefits, emphasizing its potential to support large-scale, sustainable graphite production for applications such as lithium-ion batteries.

Catalytic graphitization↗
DOE OSTI2022

Performance of Lithium-Ion Batteries with 3D Printed Anodes and Compressible Carbon Structures

Carbon scaffolds have been shown to improve the performance of Li metal anodes in Li-ion batteries by acting as conductive hosts for Li metal plating and stripping. The scaffolds provide a more uniform electric field, and their 3D geometry enables smaller diffusion paths for the Li ions. In this project, several different types of carbon lattices were 3D printed, mechanically tested, and analyzed in coin cells. Planar and 3D printed graphite coatings were evaluated as the baseline, since graphite is a common anode material. The results showed that implementing a 3D graphite lattice into a coin cell improved the Li plating and stripping efficiency compared to the planar coating. However, since graphite can intercalate Li ions, other carbon materials were also explored that should act as better hosts for Li plating/stripping. To improve the compressibility of these non-graphite carbon scaffolds, five different carbon ink formulations were 3D printed in lattice configurations. SEM imaging and compression testing showed that both the final dimensions and the compressibility of the carbon lattices depended on the type of carbon precursors used. The two most suitable compositions were found to be those made with graphene oxide-resorcinol formaldehyde and graphene oxide-ammonium hydroxide. In the future, these formulations will be further refined to increase their mechanical strength, and their performance as scaffold hosts for Li metal anodes will be evaluated in coin cells.

25 ENERGY STORAGE↗
DOE OSTI2026

From Pyrolysis Oil to Advanced Biographite Anode: Unravelling Biocoke Structural Evolution and Delayed Coking Effects

Catalytic graphitization of biomass-derived carbon offers a promising route to produce biographite as a sustainable alternative to petroleum-based synthetic graphite for lithium-ion battery (LIB) anodes. This study investigates the physicochemical properties of biocokes produced from pyrolysis oil at carbonization temperatures ranging from 150 degrees C to 500 degrees C. Using an iron (Fe) catalyst, graphitization was performed at 1500 degrees C, significantly lower than the ~3000 degrees C required for conventional synthetic graphite. The effects of introducing an intermediate-temperature hold (400 degrees C-600 degrees C) prior to graphitization were evaluated, simulating a "delayed coking" process to enable the coproduction of sustainable aviation fuels (SAFs). Chemical structure evolution during biocoke formation was analyzed, and proposed mechanisms are presented. Biographites produced via the delayed coking pathway exhibited high crystallinity and excellent electrochemical performance in both half-cell and full-cell LIB configurations. The full cells exhibited an initial discharge capacity close to the theoretical capacity of the NMC622 cathode (175 mAh/g at 4.2 V), and high capacity retention (~88%) after 150 cycles. Notably, the graphitic and electrochemical properties remained stable across the range of intermediate hold temperatures. These findings provide a foundation for optimizing temperature parameters in delayed coking systems to enable scalable, integrated production of biographite and SAFs from pyrolysis oil.

09 BIOMASS FUELS↗
DOE OSTI2024

Low-Temperature Production of Battery Grade Graphite from Coal with Recovery and Reuse of the Catalyst

Synthetic graphite is made predominantly from a petroleum-derived needle coke using the Acheson method. This involves heating the needle coke at elevated temperatures of ~ 3000 °C for more than 7 days. High-temperature heating is the most technically challenging, expensive, and energy-intensive aspect of graphite manufacturing. We will present a strategy for synthesizing high-quality battery-grade graphite powder from coal using a low-temperature catalytic graphitization process. The use of a catalyst drops the processing temperatures to 1500 °C and processing times to a few hours. The graphite produced with this process has been tested as a battery anode and has been shown to outperform anodes made with commercially sourced graphite materials. We will also present a sustainable method to recover and reuse the catalyst and acid used to retrieve the catalyst. This overcomes a long-standing technical hurdle associated with using catalysts for manufacturing graphite.

Kim, Ki-Joong↗