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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Safe Electrolytes for Batteries

The demand for reliable and safe lithium-ion batteries (LIBs) for electric vehicles (EVs) and energy storage systems (ESS) necessitates the exploration of nonflammable phosphorus-based electrolytes as alternatives to the traditional flammable carbonate-based ones. However, integrating phosphorus-based electrolyte poses challenges, including capacity fading and compatibility issues with graphite material. Here, a high-throughput (HTP) electrochemical characterization method, similar to PH test paper, is introduced to fast screen compatible phosphorus-based electrolyte for use with graphite. Among 1,740 combinations of phosphorus-based electrolytes and graphite materials, 101 promising combinations are identified for further evaluation. These identified phosphorus-based electrolytes and graphite materials are evaluated and optimized in Li/Graphite half-cells and Graphite/LiFePO 4 (LFP) full-cells using commercial-level electrodes. The desolvation energy of a complex with one Li+ and four solvent molecules of phosphate or carbonate is calculated by density functional theory (DFT). Key parameters such as viscosity, ionic conductivity, and flammability of the electrolytes are thoroughly tested and optimized. The modified phosphate-dominant electrolyte (2 M LiFSI TEP/DME/EC (6/2/2, volume ratio) + 5 wt.% VEC + 5 wt.% FEC) demonstrates excellent thermal stability with lithiated graphite and showcases superior cycling performance in the Graphite/LFP full cell, surpassing prior research findings in phosphate-dominant electrolytes. By the rapid HTP screening and identification of compatible electrolyte-graphite combinations, this approach contributes to expediting the development of safer LIBs for EVs and ESS.

25 ENERGY STORAGE↗

DOE OSTI2024

Impact of Cooling Rate and Thermal Mass on Supercooling in a Salt-Hydrogel Complex for Thermal Energy Storage

Glauber’s salt is a promising phase change material for building thermal management because of its high latent heat, acceptable melting temperature of 32.3 °C for indoor air1,2. Despite these advantages, the practical application of Glauber’s salt in thermal energy storage systems is still challenging due to supercooling and phase segregation1–3. Here, we report the impact of temperature ramp rate and thermal mass on the supercooling of Glauber’s salt through the DSC and T-history experiment. The ramp rate effect was studied with a wide range of ramp rates in 1 to 10 °C/min in DSC and 1 to 4 °C/min in the T-history experiment. The thermal mass effect was investigated by comparing DSC and T-history experiment. The latent heat was also analyzed for different ramp rates and thermal mass conditions. The melting temperatures of Glauber’s salt from the two techniques were identical while freezing temperatures were different because of the thermal mass effect. During freezing in the T-history experiment, the latent heat was reduced by around 75% to the latent heat in melting due to supercooling and phase segregation. To overcome this bottleneck, we developed a novel hydrogel complex that reduces the supercooling and prevents phase segregation to maintain volumetric energy density for 100 cycles. Thermodynamic analysis accounting for composition shows that a higher salt composition can further enhance the volumetric energy storage density. For example, a 10% increase in the weight percentage of salt leads to about 50% enhancement in volumetric energy storage density. References: 1. D. R. Biswas, Solar Energy. 19, 99–100 (1977). 2. S. M. Hasnain, Energy Conversion and Management. 39, 1127–1138 (1998). 3. Byung Chul Shin, Sang Done Kim, P. Won-Hoon, Energy. 14, 921–930 (1989).

inorganic, thermodynamics↗

NASA NTRS2019

Electrified Aircraft Propulsion Systems: Potential Failure Modes and Failure Mitigation Strategies

Electrified aircraft propulsion (EAP) systems hold great potential for the reduction of aircraft fuel burn, emissions, and noise. Currently, NASA and other organizations are actively working to identify and mature technologies necessary to bring EAP designs to reality. A requirement for the development of any civil aircraft and its systems is to ensure that potential hazards in the design are identified and appropriately mitigated to ensure that the system is safe. During aircraft development, a system safety assessment that consists of a functional hazard assessment is conducted to identify all potential failure conditions of each function, and classify those failures according to the severity of their effects on the aircraft or its occupants. The more severe a function's failure condition classification, the greater the development assurance level required for the function to ensure that the probability of the hazard is acceptably low. Today, aircraft engines and their control systems receive type certificate approval as a stand-alone system to signify their airworthiness. However, the complex coupling and distributed nature of EAP designs are expected to place added challenges on the certification of these systems. This presentation will provide an initial high-level review of the potential failure modes and hazards posed by a generic EAP system along with potential mitigation strategies for those failures. The EAP system is assumed to be a hybrid design consisting of gas turbine engines, mechanical drives, electric machines, power electronics and distribution systems, energy storage devices, and motor driven propulsors. The functionality provided by each of these EAP subsystems will be discussed along with the potential failure modes they may encounter. This will include a discussion of coupled failure effects, where a fault in one EAP subsystem effects the operation of other subsystems in the architecture. Next, potential failure mitigation strategies are discussed including both software-based and hardware-based mitigation strategies. The presentation will conclude with an example evaluation of the potential failure modes and mitigation strategies for a concept EAP system proposed by NASA.

Simon, Donald L.↗

DOE OSTI2025

Mitigating Battery Cell Failure: Role of Ag‐Nanoparticle Fillers in Solid Electrolyte Dendrite Suppression

Abstract The development of solid‐state batteries (SSBs) with lithium Li metal anodes holds significant promise for enhancing the energy density and safety of next‐generation energy storage systems. However, their commercialization is hindered by challenges related to Li dendrite formation, which can lead to short circuits and battery failure. In this study, the role of Ag nanoparticles embedded within solid electrolytes (SE) is investigated in suppressing dendrite propagation. The results demonstrate that Ag nanoparticles effectively mitigate two key failure mechanisms: (1) dendrite growth within porous networks at low current densities and (2) stress intensification‐induced SE fracture at higher current densities (12 mA cm −2 ). Ex situ characterization using focused‐ion beam – scanning electron microscopy (FIB–SEM) and energy dispersive X‐ray spectroscopy (EDS,) reveals that Ag nanoparticles migrate alongside advancing Li dendrites, promoting homogeneous dendrite growth and reducing the likelihood of localized stress concentrations. Additionally, the incorporation of Ag nanoparticles is shown to facilitate a more uniform Li distribution toward the anode side, which can potentially enable the use of higher charging rates in SSBs. This study provides a new perspective on Li dendrite suppression and presents new opportunities for enhancing the performance and safety of SSBs.

Diallo, Mouhamad Said↗

DOE OSTI2026

DOE EV Data Collection - Facility Data

Facility data includes information on electricity consumption by larger-scale infrastructure, including buildings, solar arrays, and energy storage systems. Parameter definitions can be found in the data dictionary. If a connection between specific vehicle information and facility data exists, it will be available in the vehicle attributes table. Vehicle ID can be used as a key between vehicle data and vehicle attribute tables. Data is being uploaded quarterly through 2023 and subject to change until the conclusion of the project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Transition Metal Dichalcogenides as Effective Catalysts for High-Rate Lithium–Sulfur Batteries

In today’s renaissance of high energy density secondary batteries, lithium-sulfur (Li-S) batteries represent one of the most promising candidates for the next generation of renewable energy storage systems, due to sulfur’s high theoretical specific capacity of 1675 mAh g -1 and high earth abundance. However, despite decades of study, the issues associated with capacity fade via the polysulfide shuttle and sluggish kinetics remain. Through a rigorous and detailed electrochemical study of lithium polysulfides via rotating disk electrode voltammetry (RDE), we have investigated the kinetics of the redox reactions, and explored candidate catalysts to potentially overcome/mitigate the polysulfide shuttle effect. From these RDE studies, supported by comprehensive electronic-structure calculations of conversion-type surface reactions, we determined that WSe 2 can effectively catalyze the polysulfide redox reaction, though further studies are necessary to improve overall Li-S battery performance.

25 ENERGY STORAGE↗

NASA NTRS2002

Solar Flight on Mars and Venus

Solar powered aircraft are of interest for exploring both Mars and Venus. The thin atmosphere of Mars presents a difficult environment for flying. It is clear that a new approach is needed. By making a totally solar airplane, we can eliminate many of the heavy components, and make an airplane that can fly without fuel. Using high efficiency solar cells, we can succeed with an airplane design that can fly for up to 6 hours in near-equatorial regions of Mars (4 hours of level flight, plus two hours of slow descent), and potentially fly for many days in the polar regions. By designing an airplane for a single day flight. In particular, this change means that we no longer have to cope with the weight of the energy storage system that made previous solar powered airplanes for Mars impractical). The new airplane concept is designed to fly only under the optimal conditions: near equatorial flight, at the subsolar point, near noon. We baseline an 8 kg airplane, with 2 kg margin. Science instruments will be selected with the primary criterion of low mass. Solar-powered aircraft are also quite interesting for the exploration of Venus. Venus provides several advantages for flying a solar-powered aircraft. At the top of the cloud level, the solar intensity is comparable to or greater than terrestrial solar intensities. The atmospheric pressure makes flight much easier than on planets such as Mars. The atmospheric pressure on Venus is presented. From an altitude of approximately 45 km (pressure = 2 bar), to approximately 60 km (pressure = 0.2 bar), terrestrial airplane experience can be easily applied to a Venus airplane design. At these flight altitudes, the temperature varies from 80 C at 45 km, decreasing to -35 C at 60 km. Also, the slow rotation of Venus allows an airplane to be designed for flight within continuous sunlight, eliminating the need for energy storage for nighttime flight. These factors make Venus a prime choice for a long-duration solar-powered aircraft. Fleets of solar-powered aircraft could provide an architecture for efficient and low-cost comprehensive coverage for a variety of scientific missions. Exploratory planetary mapping and atmospheric sampling can lead to a greater understanding of the greenhouse effect not only on Venus but on Earth as well.

Landis, Geoffrey A.↗

DOE OSTI2025

BESS Digital Assurance, Supply Chain Risk Management, and Emerging Regulation Session Two

The TADA BESS Supply Chain Workshops are designed to equip participants with the knowledge and tools necessary to address the evolving challenges at the intersection of battery energy storage systems (BESS), cybersecurity, and supply chain vulnerabilities. The workshops emphasize the application of Cyber-Informed Engineering (CIE) principles using INL’s procurement guide and the CIE-BAT tool. Attendees will develop risk-based security strategies and actionable compliance roadmaps tailored to their BESS projects. Additionally, the program fosters a collaborative network of practitioners and provides guidance on navigating emerging regulatory requirements, including FEOC rules under the OBBB framework, to assess and enhance organizational readiness. A comprehensive exploration of BESS cybersecurity supply chain risks, systematic vendor risk assessment through the BESS Procurement Guide, and practical application of the INL SCRM Chatbot for enhanced supply chain resilience. This is Session 2 of 3. (Full Version)

25 - ENERGY STORAGE↗

DOE OSTI2024

A Comprehensive Strategy for Grid Forming Control in DC Coupled Photovoltaic and Battery Energy Storage Inverters

This paper presents an integrated DC-DC and DCAC grid-forming control strategy for DC-coupled photovoltaic (PV) plus battery energy storage systems, considering the effect of DC link voltage variations caused by direct PV connections. A power reference algorithm determines power distribution between the PV and battery to the grid while observing device power ratings to prevent the over-rating of components and keep the battery's state of charge within an acceptable range. The simulated utility-scale model in MATLAB/Simulink illustrates its ability against extreme phase angle variation contingencies in the grid while controlled through grid-forming control with a fast dynamic on DC link voltage. The simulation results confirm the effectiveness of the proposed control in integrating PV plus battery configurations with grid forming control and maintaining reliable grid operation under severe grid disturbances.

battery, boost, control, energy storage, grid form↗

DOE OSTI2024

Approximate Dynamic Programming With Enhanced Off-Policy Learning for Coordinating Distributed Energy Resources

Herein this paper proposes an innovative approximate dynamic programming (ADP) method for distributed energy resource coordination with the loss of life of battery energy storage system (BESS) explicitly modeled. The dispatch policy is designed to account for both calendrical and cyclical aging effects on BESS, explicitly modeling the impacts of ambient temperature on BESS lifespan. The proposed ADP employs an adaptive critic method and enhanced off-policy deterministic policy gradient (DPG) strategy, addressing the limitations of the on-policy gradient-based ADP approaches, including inadequate exploration, low data usage, and computational complexity. In particular, a customized policy is proposed to guide the algorithm to explore some promising decisions and thereby improve exploration capability and learning efficiency compared to conventional DPG-based learning approaches, which may struggle to find a global optimum due to random noisy action-based exploration or require expert demonstration with extra effort. The proposed method is illustrated using the IEEE 123-node system and compared with the existing ADP methods to prove solution accuracy and demonstrate the effects of incorporating degradation models into control design. Case studies showed that the proposed ADP effectively coordinates DERs with a 10 times smaller optimization gap compared to existing methods, and the incorporation of the BESS life loss model ensures the expected lifespan and results in significant cost savings.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Thermodynamic Control of Interface Directs MnO 2 Nucleation Chemistry for Dense and Conformal Electrodeposition

Manganese dioxide (MnO 2 ) is widely recognized as a promising material for high-energy-density energy storage systems due to its broad applicability and facile electrodeposition. However, achieving uniform, thin, and high-mass-loading MnO 2 coatings on high-surface-area electrodes remains a significant challenge. Conventional electrodeposition methods typically yield nonuniform, thick layers with poor conductivity and limited material utilization, restricting their practical use. Here, we uncover a thermodynamically engineered vanadyl/pervanadyl (VO 2+ /VO 2 + ) interface that fundamentally reshapes MnO 2 electrodeposition chemistry, enabling highly uniform and dense coatings. Here, combining in situ AFM measurement, Classical Nucleation Theory, and Johnson–Mehl–Avrami–Kolmogorov modeling, we show that this interface reduces early-stage detectable MnO 2 island size by 35-fold and shifts the MnO 2 growth from diffusion-limited to reaction-limited progressive nucleation. This thermodynamically controlled interface yields highly dense and conformal MnO 2 films with record-high mass loading of 241 mg cm –2 (1607 mg cm –3 ) on 3D-printed graphene aerogels, without compromising porosity or inducing thickness gradient. As a prototype demonstration, the resulting MnO 2 electrodes deliver record-setting volumetric performance in both capacitors (106 F cm –3 ) and Zn//MnO 2 pouch cells (162 mAh cm –3 ). Beyond energy storage, our findings demonstrate the significance of thermodynamic interface control in MnO 2 nucleation chemistry for achieving dense and uniform coatings on various substrates, with implications for electrocatalysis, semiconductor processing, and advanced materials manufacturing.

Batteries↗

DOE OSTI2025

Sulfide electrolyte additive enables multi-ionic transfer pathways in alkaline iron redox

Traditional alkaline iron (Fe) batteries rely on the conversion reaction between Fe and Fe(OH) 2 but suffer from hydrogen generation upon Fe formation on charging. Fe 2+ /Fe 3+ redox is a promising anode reaction for alkaline Fe batteries, as it alleviates the formation of hydrogen gas during charging. However, achieving complete Fe 2+ /Fe 3+ redox with a one-electron transfer reaction is challenging due to the formation of electrochemically inert Fe 3 O 4 materials. Here, we demonstrate that an alkaline sulfide-containing electrolyte facilitates the reversible multi-ion transfer and transport pathways within (and beyond) the Fe 2+ /Fe 3+ redox system, including Fe(OH) 2 /Fe 3 O 4 conversion, intercalation of hydrosulfide into layered Fe(OH) 2 , and hydrogen deposition, mediated by hydroxyl ions, hydrosulfide anions, and protons, respectively. This multi-ionic charge storage mechanism delivers a compelling discharge capacity of up to 330 mA h g −1 , as determined by chronopotentiometry measurements at a current density of 0.1 A g −1 , exceeding the theoretical iron redox capacity solely relying on Fe 2+ /Fe 3+ redox (∼299 mA h g −1 ). Our study will highlight the potential of alkaline iron redox as a green anode reaction for various aqueous energy storage systems by utilizing a scalable and low-concentration hydrosulfide electrolyte additive.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Energy Northwest – Horn Rapids Solar and Storage: A Techno-economic Assessment

In 2017, as part of the second round of funding from the Washington State Clean Energy Fund, the Washington State Department of Commerce granted up to $\$3$ million in matching funds to develop an estimated $6.5 million project that deployed a 4-MW, 20-acre solar generating array of photovoltaic (PV) panels coupled with a 1 MW/4 MWh (nameplate capacity) lithium-iron-phosphate battery energy storage system (BESS) in Richland, Washington. The combination of PV and BESS will provide a predictable, renewable generating source and will also serve as a training ground for solar and battery technicians throughout the nation. This report documents the techno-economic assessment of the integrated system, including the definition of use cases and applications, collection and preparation of data and input parameters, development of modeling and optimization methods, case studies, and analysis results.

14 SOLAR ENERGY↗

DOE OSTI2020

Tin asymmetric membranes for high capacity sodium ion battery anodes

Sodium-ion batteries have attracted tremendous research attention as promising candidates for next generation energy storage systems due to low-cost and high abundancy. Furthermore, comparing to current Li-ion battery technology, limitations on the anode side seriously hinder the cell performance since sodium does not easily intercalate into graphite materials. Here, tin nanoparticles embedded in various asymmetric membrane structures were developed to leverage the high capacity of tin (847 mA h g -1 based on Na 15 Sn 4 ) and accommodate the significant volume expansion for long cycle life. It was demonstrated 762 mA h g -1 reversible capacity at 50 mA g -1 and stable cycling performance over 100 cycles with 92.1% capacity retention at 100 mA g -1 can be achieved for the tin asymmetric membrane electrode synthesized using polysulfone and tin tert-butoxide precursor.

25 ENERGY STORAGE↗

DOE OSTI2024

Adaptive Protection and Validated Models to Enable Deployment of High Penetrations of Solar PV (PV-MOD)

The availability and validation of various PV models in commercial tools differ, with some models not yet thoroughly validated for advanced inverter functionalities and reliable performance under weak system conditions. Many existing models do not fully incorporate new inverter control functions, which can affect system stability. The increasing deployment of solar PV and other inverter-based resources (IBRs), including distributed energy resources (DERs), is influencing the reliable operation of protection schemes in distribution systems and microgrids. Emerging adaptive protection schemes (APS) offer new opportunities for protecting these systems during varying configurations and DER operating conditions, though their demonstration and validation remain limited. Adaptive protection schemes face similar challenges, as they are typically designed for specific configurations. There is a growing need for tools and methodologies to streamline the deployment of adaptive protection for safe and reliable DER integration. The project main objective was to develop and validate high-fidelity generic models of solar PV facilities for stability, protection, EMT, and QSTS analyses. This objective was achieved, and these models can now be integrated into commercial software tools, enabling utilities, vendors, and developers to study high-penetration PV systems more confidently. The project also demonstrated advanced applications of these models, including the design and deployment of adaptive protection schemes in high-penetration field applications and microgrids, supporting grid safety and reliability. Several milestones were reached by the end of the project. A sophisticated inverter test plan was developed, and inverters representative of the North American marketplace were selected. EPRI and NREL tested various inverters, conforming to IEEE standards. Improvements were made to existing generic models of IBR units, IBR plants, and aggregated feeders for various analyses. The first generic electromagnetic transient (EMT) model for a solar PV plant was developed, conforming to IEEE Std 2800™-2022 and validated against laboratory measurements of a 2.2 MVA large-scale battery energy storage system (BESS) inverter. That model was then used to produce reference responses illustrating examples of validated and verified IBR plant models that pass or fail tests for technical minimum capability and performance as specified in the IEEE standard. The developed, tested, and validated generic models can be used for transmission planning, stability assessments, expansion planning, and evaluating potential future IBR interconnection requirements. They can also support interconnection screens and conformity assessments of IBR plants, including solar PV. The project significantly contributed to the ongoing standardization and model-based representation and verification of IBR responses. The project further addressed challenges of common distribution protection schemes with increasing deployment of DER by developing, validating, and demonstrating adaptive protection schemes (APS) that can improve the reliable and safe integration of DER into distribution systems. New APS were designed using improved DER models for three common distribution systems: a radial feeder, a meshed network, and a microgrid. Modeling and hardware-in-the-loop (HIL) testing of the APS were conducted, successfully showing their effectiveness and selectivity. Proof-of-concept field demonstration was achieved for two APS, i.e., one on a radial feeder and another one in a microgrid. Field demonstration could not be achieved for the APS on a meshed network, primarily due apprehension of one utility partner and also due to limited access to the protective algorithms in the network protectors. Guidelines developed from the lessons learned in the project lay out the general process followed in the design, installation, and commissioning of APS for various distribution systems. Distribution utility partners’ apprehension about field demonstration of the new APS were addressed—with varying success—by taking a stepped risk-management approach of modeling of a wide range of sensitivities first, performing in-depth proof-of-concept testing in the laboratory including HIL next, and finally deliberately implementing and commissioning the actual protection equipment and algorithms into parts of—or in parallel operation to—the three real distribution systems. Future work should include pilot projects that further show the acceptable performance of the developed APS before these schemes be rolled out more widely. Inclusion of both utility and original equipment manufacturers (OEMs) in future projects could increase chances of successful field demonstration. Despite challenges in achieving the field demonstration goal of the project for all three APS, the research significantly contributed to the innovation of adaptive protection solutions for scalable and reliable DER integration into distribution systems. This project significantly enhances the understanding of the impact of using appropriate inverter models on distribution and transmission (T&D) systems. By addressing the limitations of existing generic models, the project introduces high-fidelity models for stability, protection, electromagnetic transient (EMT), and quasi-static time series (QSTS) analyses. These models, integrated into commercial software tools, enable utilities, vendors, and developers to confidently study high-penetration PV systems. The project also demonstrates advanced applications, including adaptive protection schemes (APS) for distribution systems and microgrids, ensuring grid safety and reliability. The technical effectiveness and economic feasibility of the methods are evident through the development and validation of sophisticated inverter test plans and the selection of representative inverters. Testing by EPRI and NREL on retail, commercial, and utility-scale inverters, conforming to IEEE standards, underscores the robustness of the models. Improvements to existing generic models for various analyses further enhance their validity and applicability. The project also identifies gaps in common distribution protection schemes and designed new APS using improved DER models, demonstrating their effectiveness through modeling and hardware-in-the-loop (HIL) testing. The project’s benefits to the public are manifold. By advancing the standardization and model-based representation of IBR response, it supports transmission planning, stability assessments, and future IBR interconnection requirements. The generic models can facilitate better communication between transmission planners and developers, supporting expected IBR plant capability and performance. Additionally, the development of APS for radial feeders, meshed networks, and microgrids supports the integration of distributed energy resources (DERs) into distribution systems, enhancing grid reliability and safety. The project’s emphasis on thorough testing and simplicity in design ensures practical and scalable solutions for DER integration.

14 SOLAR ENERGY↗

DOE OSTI2025

Anion sublattice design enables superionic conductivity in crystalline oxyhalides

Solid-state batteries are attractive energy storage systems as a result of their inherent safety, but their development hinges on advanced solid-state electrolytes (SSEs). Most SSEs remain largely confined to single-anion systems (e.g., sulfides, oxides, halides, and polymers). Through mixed-anion design strategy, we develop crystalline Li 3 Ta 3 O 4 Cl 10 (LTOC) and its derivatives with excellent ionic conductivities (up to 13.7 millisiemens per centimeter at 25°C) and electrochemical stability. The LTOC structure features mixed-anion spiral chains, consisting of corner-shared oxygen and terminal chlorine atoms, which induces continuous “tetrahedron-tetrahedron” Li-ion migration pathways with low energy barriers. Additionally, LTOC demonstrates holistic cathode compatibility, enabling solid-state batteries operation at 4.9 volts versus Li/Li + and low temperature, down to −50°C. In conclusion, these findings describe a promising class of superionic conductors for high-performance solid-state batteries.

Zhao, Feipeng [Western University, London, ON (Can↗

DOE OSTI2022

Experimental Investigation of a Phase Change Material Charged Finned-Tube Heat Exchanger

Understanding different thermal performance aspects of phase change material heat exchangers (PCM-HX) is critical for designing future energy-efficient thermal energy storage systems. This paper presents an experimental performance analysis of a vertically oriented annular finned-tube PCM-HX in a cylindrical container tested under six different melting and solidification test conditions, varied by heat transfer fluid’s (HTF) inlet temperatures and flow directions. The PCM-HX structure with 20 evenly spaced fins was 3D printed in aluminum, and the PCM-HX container was 285 mm in height. The PCM-HX average porosity was 89.7%, where the PCM mass was 246.4 g. Water served as the HTF, and a PCM with a nominal phase change temperature of 35 °C was selected. Instead of opaque conventional insulation sheets, a combination of air-and-argon-filled see-through insulation cylinders was assembled with the PCM-HX to visualize the phase-change phenomena, while minimizing the uncertainties due to heat loss. In total, there were 78 T-type thermocouples installed in the test section which allows a more precise assessment of thermal mass and heat loss, which are often neglected in similar studies found in the literature. We validated the reliability of the test facility as the repeated test results had negligible deviations under the same test conditions. The energy balances between the estimated theoretical and experimentally calculated PCM storage, considering heat loss and thermal mass, were within ±9% deviation for all test conditions. From the experimental investigations, we made several following observations. It was found that the melting pattern of the finned-tube PCM-HX with small gaps between the container wall and the fins was largely affected by the HTF flow directions, unlike the typical straight annular tube PCM-HX. For effective charging and discharging processes, a combination of upward melting and downward solidification is recommended to shorten the test duration. However, an upward solidification should be considered to minimize the cavity formation between the fins caused by the PCM volume contraction during the solidification process.

25 ENERGY STORAGE↗

DOE OSTI2023

Lithium-Ion Battery Diagnostics Using Electrochemical Impedance via Machine-Learning

Diagnosing battery states such as health, state-of-charge, or temperature is crucial for ensuring the safety and reliability of electrochemical energy storage systems. While some states, such as temperature, may be measured using cheap sensors, accurate diagnosis of battery health metrics usually requires time-consuming performance measurements, making them infeasible for use in real-world operation. These health metrics can be measured during lab-testing and then estimated on-line using predictive life models or via state observer algorithms such as Kalman filters, but these predictive methods should be supplemented by actual measurement of battery health whenever possible to ensure reliability. Rapid measurement of battery health may be done by various types of fast diagnostic techniques such as electrochemical impedance spectroscopy (EIS), which can be performed in only a few minutes and require only a fraction of the energy and power needed for a full charge and discharge measurement. But there is a substantial challenge for estimating battery health using EIS data, as EIS is sensitive to cell temperature, state-of-charge, current, and resting time in addition to health. Thus, utilizing EIS data to predict battery capacity requires correcting for all these additional variables, a task that is extremely difficult to handle analytically. This talk utilizes machine-learning methods to estimate the effectiveness of battery capacity prediction from EIS data, leveraging a data set of hundreds of EIS measurements recorded at varying temperature and state-of-charge throughout a 500-day aging study of 32 commercial, large-format NMC-Graphite lithium-ion batteries. Using EIS as input to machine-learning models is complicated by the nonlinear response of impedance to battery health, temperature, and state-of-charge, as well as the collinearity between the impedance response at neighboring frequencies, which can easily lead to overfit models. To train robust models, features from EIS data need to be extracted from the data or some subset of critical frequencies selected. Many approaches for extracting and selecting features from EIS data from electrochemical analysis and machine-learning fields were identified for analysis: using the entire raw spectra; selection of one, two, or many frequencies from the entire spectra; selecting interesting points from the EIS measurement using domain knowledge; fitting EIS with an equivalent-circuit model; calculating statistics on the raw impedance values; and reducing the dimensionality of the data using unsupervised linear (principal component analysis) and non-linear (uniform manifold approximation and projection) methods. These approaches were rigorously compared using a machine-learning pipeline approach, training linear, Gaussian process, and random forest regression models and quantifying performance using cross-validation as well as a held-out test set. An artificial neural network model trained on the raw spectra was also tested. Promising pipelines were fine-tuned via Bayesian hyperparameter optimization using cross-validation loss and training with class-specific weights to counter data set imbalance. The most reliable method for utilizing impedance in this work was the selection of two optimal frequencies through an exhaustive search, resulting in about 2% mean absolute error on test data for both Gaussian process and random forest model architectures. Interrogation of a variety of models reveals critical frequencies of 100 Hz and 103 Hz for this data set, though the optimal set of frequencies is not necessarily intuitive, i.e., the best performing models are not simply those that use impedance at frequencies that have the highest correlation to the relative discharge capacity. The best performing model is an ensemble model, which is able to predict battery capacity with 1.9% mean absolute error for unseen cells using impedance recorded at a variety of temperatures and states-of-charge.

battery↗