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DOE OSTI2021

Enhancing Distribution Grid Resilience Through Model Predictive Controller Enabled Prioritized Load Restoration Strategy: Preprint

Effective resilience improvement strategies enable the power grid to cope with disruptive extreme events. Most power grid outages are caused by disruptions in distribution grids. Motivated by the urgent need for power system resilience research, this paper proposes a priority-weighted optimal load restoration technique to enhance the resilience of distribution grids against extreme events. The proposed technique is based on smart distribution technology and framed as sequential multi-step decision process (MDP) and mixed integer linear program (MILP). It is formulated as optimal control problem with a model predictive control (MPC) approach. We applied the devised MILP-MPC-based load restoration technique to a simplified single-bus version of the IEEE 13-bus distribution system with integrated distributed energy resources (DERs) such as wind turbine, photovoltaic array, microturbine, and energy storage device. The technique executes a reducing and rolling horizon optimization in each control step in real-time using the forecasted information of the renewables, the fuel status of the microturbine and the state of charge of the energy storage device. We consider an extreme event which triggered outage of the upstream utility grid and caused islanded operation of the distribution grid. We demonstrated the effectiveness of the proposed MPC approach in restoring the distribution grid loads based on their priority during the main grid outage-caused islanded operation.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2021

Enhancing Distribution Grid Resilience Through Model Predictive Controller Enabled Prioritized Load Restoration Strategy

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2021

Cybersecurity for Grid Connected eXtreme Fast Charging (XFC) Station (CyberX) (Final Scientific/Technical Report)

This report summarizes the activities conducted under the DOE VTO funded project DE- EE0008451, where ABB Inc. (ABB), in collaboration with Idaho National Laboratory (INL), APS Global (APS), and XOS Trucks (XOS) pursued the development of a cyber-resilient extreme fast charging (XFC) management system. This project entitled Cybersecurity for Grid Connected eXtreme Fast Charging (XFC) Station (CyberX) focuses on a resilient architecture for smart charging EV Supply Equipment (EVSE) device control and Coordinated Anomaly Detection System (CADS) features that can be added at the charging site depot level to increase cybersecurity. The project was split into two budget periods focused first on developing the threat model and resilient control concepts and second on testing, improving, and validating those developed resilient control algorithms and features with a focus on key vulnerabilities identified during the threat assessment portion of the project. During the first budget period of the CyberX project, the ABB led team focused on activities to identify, model, and quantitatively prioritize high-impact attack scenarios with potential cyber-physical effects while also modeling and developing concepts for a resilient control system that could securely address integration of DERs and other resources with EV charging. Development of the security focused XFC management system (XMS) was accomplished first by offline simulation using a developed XFC station or depot with 480V input level and simulating measurement inputs to monitoring and control systems in concept development. A representative distribution grid model was developed supporting an EV charging site model with BESS and 6 general EV charging models. These EV charging models allowed multiple configurations of charging level, multiple connected protection and measurement devices, and simulation function to show general compromise of EV, BESS, and protection features based on parallel threat analysis. During the second budget period, the EV site and supporting systems model was developed in more detail and converted from offline model to real-time to real-time with EV charging hardware in the loop (HIL). The resilient control architecture developed as concept in the first part of the project was further tested and validated for integration of local energy resources and XFC charging station site equipment while maintaining cybersecure operating principles. The proposed resilient architecture for smart charging and cybersecurity features consists of two main concepts developed and tested within the project. The first concept is an XFC management system (XMS) consisting of a hardware gateway, software platform, and Supervisory Control and Data Acquisition (SCADA) or Distribution Management System integration components. The second concept is a Coordinated Anomaly Detection System (CADS) which forms a primarily software-related subsystem of the total CyberX solution focused on monitoring system measurements, estimation of measurement states, and predicting current at the utility point of interaction based on machine learning for anomaly detection.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

A Robust Numerical Treatment of Solid-Phase Diffusion in Pseudo Two-Dimensional Lithium-Ion Battery Models

Solid-phase diffusion in active materials of lithium-ion batteries significantly affects charging and safety-related behavior of lithium-ion batteries. Therefore, it is essential to develop an efficient and robust numerical algorithm for solving solid-phase diffusion equations in physics-based battery models. In this work, we discuss the origins of numerical instabilities that can occur when solving the solid-phase diffusion equations using iterative methods. Then, in order to resolve such issues, we propose a simple numerical treatment to the surface flux term of discretized solid-phase diffusion equations. To demonstrate its numerical robustness, the proposed method is implemented into a pseudo two-dimensional (P2D) physics-based battery model and simulations are conducted at wide ranges of operating conditions. Even with extremely poor initial guesses for the Li+ concentrations of the active materials, computations using the proposed method do not diverge and the their computational speeds are comparable to those with conventional initial guesses. Comprehensive tests of the proposed method are also performed with a dynamic current profile based on US06 driving profile and a multi-stage charging profile with very high initial C-rate (12C).

battery modeling↗

DOE OSTI2022

Optimal economic dispatch policy for prosumer with energy storage considering self-consumption demand

This paper analyzed the effects of self-consumption demand on the joint economic dispatch of prosumers (energy consumers who are also producers), particularly for prosumers with both energy storage and distributed energy sources (DERs). Studies in the existing literature on the economic dispatch scheduling policy of energy storage, mostly from the perspective of electricity merchants, do not address the impacts of self-consumption demand. However, due to the intermittent and high levels of uncertainty regarding DERs generation and the dynamic demand of the prosumer, production and consumption are not always simultaneous; there are two possible scenarios in each period depending on whether DERs generation can meet prosumers' self-consumption or not. Incorporating the self-consumption demand will pose modeling challenges since these two scenarios cannot occur simultaneously in each period, and different scenarios require different decisions for prosumers. Further, this paper analyzed the two scenarios separately to find the optimal storage scheduling strategy, and the results were combined to get the optimal global solution. We focused on prosumers' economic decision-making while considering self-consumption demand and the physical constraints of a battery based on dynamic programming. Our study showed that the feasible state of charge (SOC) range of storage can be segmented into several sub-ranges by SOC reference points under the above two scenarios. As a result, a prosumer's optimal scheduling can be uniquely and conveniently selected based on the sub-ranges within which the current SOC falls. The results, therefore, provided multistage decision-making guidance for prosumers with energy storage.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Understanding particle size effect on fast-charging behavior of graphite anode using ultra-thin-layer electrodes

Extreme fast charging (≤ 15 min) of lithium-ion batteries is highly desirable to accelerate mass-market adoption of electric vehicles. However, significant capacity fading, as well as safety issues due to the lithium plating caused by the fast charging rate, limit its implementation. In this study, we investigated the fast-charging capability of graphite materials with various particle sizes. To eliminate the Li + ion concentration gradient effect across the thickness of the electrode, ultra-thin-layer graphite electrodes were developed to investigate the "real" fast-charging capability of graphite at the particle level. Electrochemical assessments as well as microscopic characterizations revealed that smaller particles exhibited superior fast-charging performance, featuring enhanced capacity reversibility, faster charging rate, and less lithium plating under the same fast-charging conditions. It is shown that small-particle graphite (mean radius of 3.3 μm) could withstand a 4C charge (to 80 % state-of-charge) without plating, with minimal plating occurring at 6C. Thicker particles exhibited plating at lower C-rates. Since the experimental data could not directly explain whether intra-particle diffusion limitations or interfacial reaction limitations dominated the plating mechanism, the pseudo-2-dimensional model was used to evaluate the most likely plating mechanism. The model suggested that particle-level diffusion is the dominant mechanism contributing to plating at high rates. Finally, this work provides comprehensive insights into the particle size effects on fast-charging capability, offering a better understanding of fast-charging behavior and valuable guidance for designing optimal electrode architecture for high-rate lithium-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2026

CoEx Electrode Structuring for High Energy and Fast Charging Lithium-Ion Batteries

This project was a collaboration between SRI International (SRI) and Oak Ridge National Laboratory (ORNL) focused on advancing SRI’s CoEx technology for printing of battery electrodes with structured porosity, specifically for improving fast charging performance. Prior work funded by the Vehicle Technologies Office (VTO) served as proof-of-concept for CoEx printing, with the scope limited to demonstrating that CoEx structuring in the cathode would improve discharge performance. In that work, a thick cathode was paired with an anode produced through conventional means (i.e. it had no structuring), and the baseline comparison was a cell with conventionally produced cathode and anode of similar loading, along with a lower loaded cell that was intended to represent cells of typical loading. The result of that work showed that the CoEx cells had higher energy density than the thin baseline cells, due to the thicker electrode layers, and had much higher power density than the thick baseline cells at higher discharge rates, because the CoEx cathode had higher performance than the conventional cathode. In this project, we proposed to extend the CoEx technology to structure both the anode and cathode of a lithium ion battery, resulting in at least a 20% increase in energy density under fast charging conditions, while reducing costs by 15% and cutting energy usage during production.

25 ENERGY STORAGE↗

DOE OSTI2025

Quantitative and mechanistic insights into proton dynamics for fast energy storage

Proton conduction in hydrogen-bond-rich protic electrolytes enables fast mass and charge transport, crucial for electrochemical energy storage and power conversion. Such transport can give proton-based batteries exceptional rate capability and low-temperature operation beyond other working ions. Here we show that in phosphoric acid (H 3 PO 4 ) electrolytes, vehicular and structural proton transport coexist, and their contributions to conductivity can be quantitatively distinguished. We link structural diffusion directly to hydrogen-bond strength, enabling the precise tuning of proton migration. Guided by this, we reveal a double conductivity peak from regulated structural diffusion. The optimal electrolyte (5.8-M H 3 PO 4 ) achieves high overall (232.9 mS cm −1 ) and structural (164.9 mS cm−1) conductivity. A MoO 3 ‖CuFe-TBA battery with this electrolyte outperforms a deep-eutectic benchmark (8.3-M H 3 PO 4 ), delivering >17,474 W kg −1 at room temperature and retaining 15.1 Wh kg −1 at −75 °C. These findings provide a framework for designing advanced protic electrolytes across electrochemical systems.

Li, Ziyue [Fudan University, Shanghai (China, Peop↗

DOE OSTI2022

Operando detection of Li plating during fast charging of Li-ion batteries using incremental capacity analysis

A major challenge that limits fast charging of Li-ion batteries is lithium (Li) plating on the graphite electrode. Furthermore, it remains challenging to detect and diagnose Li plating in operando during charging. In this work, incremental capacity (IC) analysis is applied while charging graphite-NMC pouch cells over a range of rates from C/2 to 4C. Three-electrode pouch cell measurements and post-mortem SEM imaging was performed to demonstrate that the onset of Li plating is correlated with a specific IC peak. IC analysis was also applied to study the fast-charge performance of multi-layer pouch cells with 3-D anode architectures. The results demonstrate that: 1) IC curves have a characteristic peak that is an indicator of Li plating during fast charging, which grows in magnitude as charging rate increases; 2) the plating IC peak correlates with the voltage minimum of the graphite anode, indicating a transition from intercalation to plating; 3) the plating IC peak is sensitive to small amounts of Li plating; 4) IC analysis can be applied to study Li plating in novel cell architectures; 5) the plating IC peak evolves during extended fast-charge cycling, which is a result of reduced Li plating as the Li inventory decreases.

25 ENERGY STORAGE↗

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 OSTI2023

Battery Charge Curve Prediction via Feature Extraction and Supervised Machine Learning

Real-time onboard state monitoring and estimation of a battery over its lifetime is indispensable for the safe and durable operation of battery-powered devices. In this study, a methodology to predict the entire constant-current cycling curve with limited input information that can be collected in a short period of time is developed. A total of 10 066 charge curves of LiNiO 2 -based batteries at a constant C-rate are collected. With the combination of a feature extraction step and a multiple linear regression step, the method can accurately predict an entire battery charge curve with an error of < 2% using only 10% of the charge curve as the input information. The method is further validated across other battery chemistries (LiCoO 2 -based) using open-access datasets. The prediction error of the charge curves for the LiCoO 2 -based battery is around 2% with only 5% of the charge curve as the input information, indicating the generalization of the developed methodology for predicting battery cycling curves. The developed method paves the way for fast onboard health status monitoring and estimation for batteries during practical applications.

25 ENERGY STORAGE↗

DOE OSTI2022

Transforming Energy Through Sustainable Mobility: Expanding Low-Carbon Transportation R&D Solutions

As the nation's premier laboratory for cutting-edge transportation decarbonization research and development solutions, the National Renewable Energy Laboratory (NREL) pioneers the creation and deployment of sustainable mobility technologies and strategies, with a focus on slashing transportation sector greenhouse gas emissions and combatting climate change. Trucks, planes, cargo ships, and other difficult-to-decarbonize vehicles are part of this essential transition for the transportation sector, which is currently the nation's largest source of the greenhouse gas emissions. NREL provides the scientific building blocks needed to spur innovation through multifaceted analysis, research, and engineering. This work acts as a catalyst to help industry bring affordable, high-performance, energy-efficient, and low-emission modes of transport and related infrastructure to market sooner. Our researchers collaborate closely with academic, government, and industry partners to design better batteries, drivetrains, and engines. They develop technologies for high-power charging, thermal management, energy storage, and power electronics. They are also reimagining fuels and combustion while creating sustainable lightweight materials. Unbiased expert guidance - backed by credible data and analysis, tools, and scientific rigor - empowers partners to make informed decisions about sustainable transportation. NREL recognizes that communities with limited mobility options face reduced access to employment opportunities, health care, and education, lowering overall quality of life. Alongside partners, NREL experts are creating transportation solutions that meet community-identified needs and increase mobility equity in historically underserved and overburdened communities. Rather than providing a one-size-fits-all solution, we take an interdisciplinary approach to mobility equity that considers the needs and challenges of diverse groups, maximizing benefits at the individual, community, and societal levels.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Revealing causes of macroscale heterogeneity in lithium ion pouch cells via synchrotron X-ray diffraction

Heterogeneous battery performance is a critical issue for maximization of cell lifetime capacity and safety. Using high energy synchrotron X-ray diffraction, the influence of charge rate, voltage limit, uneven stack pressure, and gas generation on the lithium transport properties was quantified in single-layer graphite/LiNi 0.5 Mn 0.3 Co 0.2 O 2 pouch cells. A freshly formatted cell tracked in operando during initial fast charge cycles indicated variable position-dependent performances, while lateral mapping showed a significant fast charge (6C) heterogeneity compared to slow charge (C/2). Pressure effects were non-dominant compared to charge rate. Maps of previously aged and rested cells indicate that lateral heterogeneity slowly equilibrates at rest, but regenerates upon further cycling at fast charge rate. Furthermore, an unformatted cell was mapped at charge and discharge during its first formation cycle to analyze the effect of byproduct gases on the heterogeneous lithium transport. Gas was observed as randomly interspersed “bubbles” which locally hindered lithium intercalation and caused significant heterogeneity. Electrode architectures and charging protocols that promote homogeneous intercalation are critical for predictable high-performance and long-life batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Testing of Participant's Power Electronics Component for Circuit Performance and Efficiency (CRADA Final Report)

The "Solar SEED Smart Controller is a charge control device to condition solar power to load voltage with or without Battery (also called a "DC Power Platform") invented by David Gibbs and T4D Labs Inc. T4D Inc. and the SEED Smart Controller invention were selected for American Made Challenges Solar Prize, which includes voucher for NREL to provide technical assistance.

14 SOLAR ENERGY↗

DOE OSTI2022

Quantifying Heterogeneities: Degradation During Fast Charge

This presentation investigates limitations in extreme fast charging due to local heterogeneities. This work covers research done by one of six thrusts within the large DOE fast charging program. Length scales investigated span from cm to microns. Novel techniques used include higher energy XRD, in-situ tomography, neutron tomography, and in-situ AFM. The team has compared local SOC heterogeneity at mm length scale with microstructure mapping and not found a strong correlation. Presentation outlines future work needed to understand underlying cause of observed heterogeneity.

degradation↗

DOE OSTI2022

High Current-Density-Charging Lithium Metal Batteries Enabled by Double-Layer Protected Lithium Metal Anode

The practical application of lithium (Li) metal anode (LMA) is still hindered by non-uniformity of solid electrolyte interphase (SEI), formation of "dead" Li, and continuous consumption of electrolyte although LMA has an ultrahigh theoretical specific capacity and a very low electrochemical redox potential. Herein, we report a facile protection strategy for LMA using a double layer (DL) coating that consists of a polyethylene oxide (PEO)-based bottom layer which is highly stable with LMA and promotes uniform ion flux, and a cross-linked polymer-based top layer which prevents solvation of PEO layer in electrolytes. Li deposited on DL-coated Li (DL@Li) exhibits a smoother surface and much larger size than that deposited on bare Li. The LiF/Li 2 O enriched SEI layer generated by the salt decomposition on top of DL@Li further suppresses the side reactions between Li and electrolyte. Driven by the abovementioned advantageous features, the DL@Li||LiNi 0.6 Mn 0.2 Co 0.2 O 2 cells demonstrate capacity retention of 92.4% after 220 cycles at a current density of 2.1 mA cm -2 (C/2 rate) and stability at a high charging current density of 6.9 mA cm -2 (1.5C rate). These results indicate that the DL protection is promising to overcome the rate limitation of LMAs and high energy-density Li metal batteries.

25 ENERGY STORAGE↗

DOE OSTI2023

Particle size effect of graphite anodes on performance of fast charging Li-ion batteries

Charging energy-dense lithium-ion batteries (LIBs) with thick graphite electrodes at high current densities are typically accompanied by poor performance and safety issues. The root cause is the onset of Li plating at the surface of graphite when lithiated to a high capacity within a short time period. Here, we investigated the behavior of graphite electrodes with various particle sizes under fast charge operations. Results from the electrochemical characterization on graphite electrodes exhibit the superiority of smaller particles over bigger particles in terms of suppressing the onset of Li plating and growth of plated Li particles. Observations from scanning electron microscopy also corroborate the presence of plated Li in electrodes with big graphite particles and its absence in graphite electrodes with small particles, when the cells were lithiated to 90% of the state of charge (SOC). Further, the improved performance of cells with the small particles might be associated with the low Li-ion concentration at the surface of graphite and thus reduced overpotential in graphite electrodes. The simulated results revealed that, compared to bigger particles, smaller particles have lower surface intercalation at any given cell SOC, which may significantly reduce the overpotential in the graphite electrodes and mitigate the onset of Li plating. This agrees well with experimental observations.

25 ENERGY STORAGE↗

DOE OSTI2020

Numerical Modeling and Parametric Study of a Dual Purpose Underground Thermal Battery

Buildings’ thermal energy systems for providing space heating/cooling consume a considerable amount of electricity nationwide. Integrating thermal energy storage with buildings’ thermal systems has the potential to shave the peak electric demand and to overcome the mismatch between the intermittent renewable power and the fluctuating daily demand for electricity. A novel dual-purpose underground thermal battery (DPUTB) has been developed to provide diurnal thermal energy storage in conjunction with a dual-source heat pump (DSHP)system. A two-dimensional numerical model is developed to simulate the transient performance of the DPUTB. This model has similar accuracy as a detailed three-dimensional model developed with commercial heat transfer and fluid dynamics simulation program but with 1000 times faster computational speed. A parametric study is performed to identify a design of the DPUTB that can provide 14 kWh thermal storage capacity for each charging and discharging cycle. A system simulation has been developed to assess the performance of the designed DPUTB when it is integrated with a DSHP for conditioning a typical residential building in summer and winter. Simulation results indicate that the DPUTB can meet all the design requirements in both summer and winter with the simple rule-based control strategy and the overall integrated DPUTB and DSHP system can shift the electric load for meeting the thermal demand from the peak hours to off-peak hours during a day, which would result in considerable energy cost savings if a Time of Use electricity tariff is applicable.

25 ENERGY STORAGE↗