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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 127 records · Page 7

Impact of electric vehicle battery recycling on reducing raw material demand and battery life-cycle carbon emissions in China

The rapid growth of electric vehicles (EVs) in China challenges raw material demand. This study evaluates the impact of recycling and reusing EV batteries on reducing material demand and carbon emissions. Integrating a national-level vehicle stock turnover model with life-cycle carbon emission assessment, we found that replacing nickel-cobalt-manganese batteries with lithium iron phosphate batteries with battery recycling can reduce lithium, cobalt, and nickel demand between 2021 and 2060 by up to 7.8 million tons (Mt) (67%), 12.4 Mt (96%), and 37.2 Mt (93%), respectively, significantly decreasing reliance on import. Moreover, battery recycling coupled with reuse can reduce carbon emissions by up to 6,532-6,864 Mt (36.0-37.9%), depending on four recycling methods employed. However, this reuse strategy delays battery recycling and risks lithium supply shortage, necessitating trade-offs between carbon reduction and material supply. Future technologies, such as lithium-sulfur and all-solid-state batteries, despite their energy efficiency, might exacerbate lithium shortage, underscoring the crucial need for increased lithium supply.

25 ENERGY STORAGE↗

Solid electrolyte for solid-state batteries: Have lithium-ion batteries reached their technical limit?

With increasing demand for electrical power on a distribution grid lacking storage capabilities, utilities and project developers must stabilize what is currently still intermittent energy production. In fact, over half of utility executives say “the most important emerging energy technology” is energy storage. Advanced, low-cost battery designs are providing promising stationary storage solutions that can ensure reliable, high-quality power for customers, but research challenges and questions lefts. Have lithium-ion batteries (LIBs) reached their technical limit? The industry demands are including high costs, inadequate energy densities, long recharge times, short cycle-life times and safety must be continually addressed. Safety is still the main problem on developing the lithium ion battery.The safety issue must be considered from several aspects, since it would become serious problems, such as an explosion in a Japan Airlines 787 Dreamliner’s cargo hold, due to the battery problem. The combustion is mainly due to the leakage or shortcut of the electrodes, caused by the liquid electrolyte and polymer separator. For this reason, the research on solid electrolyte for replacing the existing liquid electrolyte is very important. The materials used in existing lithium ion battery, such as a separator and liquid electrolyte must be replaced to new solid electrolytes, solid materials that exhibits high ionic conductivity. Due to these reasons, research on solid state ionics materials have been vastly growing worldwide, with the main aim not only to search new solid electrolyte to replace the liquid one, but also looking for low cost materials and environmentally friendly. A revolutionary paradigm is also required to design new stable anode and cathode materials that provide electrochemical cells with high energy, high power, long lifetime and adequate safety at competitive manufacturing costs. Lithium superionic conductors, which can be used as solid electrolytes, promise the potential to replace organic liquid electrolytes and thereby improve the safety of next-generation high-energy batteries. Li{sub 3}PO{sub 4} has been proved to be a good candidate for solid electrolyte, due to its easy in preparation, low cost, high melting temperature and good compatibility with the electrode materials. In the present work, Li{sub 3}PO{sub 4} has been prepared by wet chemical reaction, a simple method with the advantage of recycling a waste product H{sub 3}PO{sub 4}. The crystal structure has been characterized by both neutron and x-ray diffraction. The use of neutron scattering plays important role on observing the light atoms such as lithium ion. The x-ray diffraction results showed the crystal structure of orthorhombic phase P m n 21 (31), that belongs to the β-Li{sub 3}PO{sub 4}, with the lattice parameters are a = 6.123872, b = 5.250211, c = 4.876378. The conductivity of β-Li{sub 3}PO{sub 4} was around 10{sup −8} S/cm. Furthermore, the future application of the solid electrolyte layer in lithium ion battery will also be considered. It is concluded that the used of local resources on producing the solid electrolyte Li{sub 3}PO{sub 4} for lithium ion battery will give more added values to the researches and national industry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Battery Energy Storage Scenario Analyses Using the Lithium-Ion Battery Resource Assessment (LIBRA) Model

Meeting aggressive carbon emission goals will entail widespread deployment of renewable sources of electricity. Because these sources are variable, there is a need to develop scalable energy storage technologies. The U.S. Department of Energy is supporting efforts to increase U.S. manufacturing and recycling capabilities for LIBs and to decrease costs of stationary storage batteries. Many factors influence the domestic manufacturing and cost of stationary storage batteries, including availability of critical raw materials (lithium, cobalt, and nickel), competition from various demand sectors (consumer electronics, vehicles, and battery energy storage), resource recovery (recycling), government policies, and learning in the industry, among other factors. Understanding how these factors interact and identifying synergies and bottlenecks is important for developing effective strategies for the LIB stationary energy storage system. We developed the Lithium-Ion Battery Resource Analysis (LIBRA) model as a tool to help stakeholders better understand the following types of questions: What are the roles of R&D, industrial learning, and scaling of demand in lowering the cost of battery energy storage system production? How do the intersections between the EV and stationary storage sectors affect the battery supply chain? For various stationary storage and EV penetration scenarios, what volumes of critical materials might be required and what role can resource recovery play? What does expected demand for both EVs and stationary storage portend for mineral resources and overall mineral scarcity? The LIBRA model is developed using a System dynamics (SD) modeling approach to represent interactions across the segments of the battery materials supply chain. System dynamics models can capture the complex interactions and feedback between the various system components that influence supply and demand. The LIBRA model is comprised of several interacting modules that represent specific portions of the LIB supply chain. The model tracks the buildout of the domestic LIB industry over time (2020 - 2050) and in the context of competing demands for raw materials, recycling, and markets for LIBs. The LIBRA model represents major systemic feedback loops and delays across the supply chain. This report provides a complete documentation for the LIBRA model, including model assumptions, data, scenario analysis results, and sensitivity analysis of the model's input space.

25 ENERGY STORAGE↗

Supporting the Li-Ion Battery Supply Chain via PEV Battery Reuse

The electric vehicle market is growing rapidly and there is significant need for lithium ion batteries and their materials. There is growing concern about the supply chain issues of lithium ion batteries in the US as most of the materials and components come from overseas. The concern about supply chain would be even more of a concern as more lithium ion systems will be installed in the renewable grid. By 2025, it is estimated that 3.5 million used PEVs may be retiring worldwide with commutative capacity of around 150 GWh. The question is what the is best way to deal with these batteries: recycle them right away for re-introduction of valuable materials into the battery supply chain or reused and then recycle them. These batteries usually have between 70-80% of their original capacity and studies have shown second use of these batteries are technically and environmentally – the question has been the economic viability. Most of LIBs has been going into the growing electric vehicle market. Rather than using new LIBs in the future grid, the second-life batteries is a significant resource and could alleviate supply chain issues.

47 OTHER INSTRUMENTATION↗

Open‐Structured V 2 O 5 · n H 2 O Nanoflakes as Highly Reversible Cathode Material for Monovalent and Multivalent Intercalation Batteries

The high‐capacity cathode material V 2 O 5 · n H 2 O has attracted considerable attention for metal ion batteries due to the multielectron redox reaction during electrochemical processes. It has an expanded layer structure, which can host large ions or multivalent ions. However, structural instability and poor electronic and ionic conductivities greatly handicap its application. Here, in cell tests, self‐assembly V 2 O 5 · n H 2 O nanoflakes shows excellent electrochemical performance with either monovalent or multivalent cation intercalation. They are directly grown on a 3D conductive stainless steel mesh substrate via a simple and green hydrothermal method. Well‐layered nanoflakes are obtained after heat treatment at 300 °C (V 2 O 5 ·0.3H 2 O). Nanoflakes with ultrathin flower petals deliver a stable capacity of 250 mA h g −1 in a Li‐ion cell, 110 mA h g −1 in a Na‐ion cell, and 80 mA h g −1 in an Al‐ion cell in their respective potential ranges (2.0–4.0 V for Li and Na‐ion batteries and 0.1–2.5 V for Al‐ion battery) after 100 cycles.

Wang, Huali↗

Impact of automated battery sorting for mineral recovery from lithium-ion battery recycling in the United States

The United States has identified several lithium-ion battery materials as critical for reaching the national emission reduction targets that have been set in accordance with the 2015 Paris Agreement. However, with few natural resources available domestically, there is a rapidly growing focus on the development of a domestic recycling industry to recover these materials from end-of-life batteries. Here, we use the Lithium-Ion Battery Resources Assessment (LIBRA) system dynamics model to evaluate the impact of automated battery sorting technology in terms of the shares of cobalt and nickel that are recovered through recycling. Findings show that automated sorting has clear benefits over manual sorting methods by helping recyclers selectively process high-cobalt batteries. By maximizing cobalt recovery, recycling becomes more profitable and drives greater investment in recycling capacity, resulting in a higher share of nickel and cobalt recovered from EOL batteries over time.

25 ENERGY STORAGE↗

From K‐O 2 to K‐Air Batteries: Realizing Superoxide Batteries on the Basis of Dry Ambient Air

Abstract Although using an air cathode is the goal for superoxide‐based potassium‐oxygen (K‐O 2 ) batteries, prior studies were limited to pure oxygen. Now, the first K‐air (dry) battery based on reversible superoxide electrochemistry is presented. Spectroscopic and gas chromatography analyses are applied to evaluate the reactivity of KO 2 in ambient air. Although KO 2 reacts with water vapor and CO 2 to form KHCO 3 , it is highly stable in dry air. With this knowledge, rechargeable K‐air (dry) batteries were successfully demonstrated by employing dry air cathode. The reduced partial pressure of oxygen plays a critical role in boosting battery lifespan. With a more stable environment for the K anode, a K‐air (dry) battery delivers over 100 cycles (>500 h) with low round‐trip overpotentials and high coulombic efficiencies as opposed to traditional K‐O 2 battery that fails early. This work sheds light on the benefits and restrictions of employing the air cathode in superoxide‐based batteries.

Qin, Lei↗

Electrode Edge Effects and the Failure Mechanism of Lithium-Metal Batteries

Lithium (Li) metal with very high specific capacity makes it one of the ideal anode for high energy batteries. However, Li dendrite growth and the formation of isolated (or “dead”) Li during repeated Li plating/stripping processes lead to its low Coulombic efficiency (CE). In this work, we discovered for the first time that part of Li CE loss can be attributed to the edge effect of the copper (Cu) substrate electrode in a conventional Li||Cu cell configuration. The “dead” Li formed on the edge of Cu substrate was systematically investigated through scanning electron microscopy, energy dispersive X-ray spectroscopy, and two-dimensional X-ray photoelectron spectroscopy. In order to minimize the Li loss at the edge of the Cu exposed to pressure-free space, modified Li||Cu cell configuration with a Cu electrode smaller than Li metal is preferred. It was clearly demonstrated that using an electrode configuration with minimal open space or “pressure-free space” across electrodes can reduce “dead” Li accumulated during cycling and increase Li CE. This phenomena was also verified in Li metal batteries (Li||LiNi1/3Mn1/3Co1/3O2) and should be considered in the design of practical Li metal batteries.

Lee, Hongkyung↗

Energy and environmental aspects in recycling lithium-ion batteries: Concept of Battery Identity Global Passport

The emergence and dominance of lithium-ion batteries in expanding markets such as consumer electronics, electric vehicles, and renewable energy storage are driving enormous interests and investments in the battery sector. The explosively growing demand is generating a huge number of spent lithium-ion batteries, thereby urging the development of cost-effective and environmentally sustainable recycling technologies to manage end-of-life batteries. Currently, the recycling of end-of-life batteries is still in its infancy, with many fundamental and technological hurdles to overcome. Here in this paper, the authors provide an overview of the current state of battery recycling by outlining and evaluating the incentives, key issues, and recycling strategies. The authors highlight a direct recycling strategy through discussion of its benefits, processes, and challenges. Perspectives on the future energy and environmental science of this important field is also discussed with respect to a new concept introduced as the Battery Identity Global Passport (BIGP).

25 ENERGY STORAGE↗

Efficient thermal management of Li-ion batteries with a passive interfacial thermal regulator based on a shape memory alloy [A passive interfacial thermal regulator based on shape memory alloy and its application to battery thermal management]

The poor performance of lithium-ion batteries in extreme temperatures is hindering their wider adoption in the energy sector. A fundamental challenge in battery thermal management systems (BTMSs) is that hot and cold environments pose opposite requirements: thermal transmission at high temperature for battery cooling, and thermal isolation at low temperature to retain the batteries’ internally generated heat, leading to an inevitable compromise of either hot or cold performances. Here, we demonstrate a thermal regulator that adjusts its thermal conductance as a function of the temperature, just as desired for the BTMS. Without any external logic control, this thermal regulator increases battery capacity by a factor of 3 at an ambient temperature (T ambient ) of -20 °C in comparison to a baseline BTMS that is always thermally conducting, while also limiting the battery temperature rise to 5 °C in a very hot environment (T ambient = 45 °C) to ensure safety. The result expands the usability of lithium-ion batteries in extreme environments and opens up new applications of thermally functional devices.

25 ENERGY STORAGE↗

A strategically managed rechargeable battery system with a neutral methyl viologen anolyte and an acidic air-cathode enabled by a mediator-ion solid electrolyte

Redox flow batteries with organic electrode materials are attracting much attention. Previous research efforts have been focusing on liquid-phase electrodes on both the anode and cathode sides. Since batteries based on air cathodes can provide immense advantages, coupling a liquid organic electrode with a gaseous air cathode could offer multiple benefits in terms of cost, safety, and energy density. Herein we present a liquid–gaseous battery system with an aqueous methyl viologen (MV) anode and an air cathode. However, under the traditional battery operation principle with the same electrolyte at the anode and cathode, the resulting MV–air battery will not be able to provide a reasonable voltage for practical applications. In this study, the cell voltage of the MV–air chemistry is strategically manipulated by using an acidic cathode electrolyte (catholyte) and a neutral anode electrolyte (anolyte). To operate a battery with different electrolytes at the anode and cathode, a sodium-ion (Na + -ion) conductive solid-state electrolyte (Na-SSE) membrane is employed to physically and electrically separate the two electrodes. In this work, the shuttling of sodium ions via the Na-SSE balances the ionic charge transfer between the two electrodes and sustains the redox reactions at the air cathode and the MV anode.

25 ENERGY STORAGE↗

Development of Aluminum/Air Battery as High-Capacity Primary Battery Energy Source for SUSAN Electrofan Project

High-capacity, high-performance, and safe battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. These battery technologies, including both secondary (i.e., rechargeable) batteries for hybrid/electric propulsion and primary batteries (i.e. non-rechargeable or single-use) for backup/emergency use in case of turbine engine failure, are important and vital components in SUSAN concept design. This paper is focused on aluminum (Al)-air battery, which is considered to be the most promising candidate to meet the energy goal of primary batteries for SUSAN project. However, there are challenges for Al-air batteries, including aluminum self-corrosion with hydrogen (H2) gassing and sluggish kinetics of oxygen reduction reaction (ORR) in air-cathode. In this paper, the preliminary results on investigation of electrolytes and additives on controlling aluminum self-corrosion/H2 gassing suppression and the study of air-cathode design for ORR improvement are presented and discussed.

James Wu↗

Life-cycle analysis of battery metal recycling with lithium recovery from a spent lithium-ion battery

Demand for critical materials (nickel, cobalt, manganese [NCM], and lithium) for use in batteries is increasing rapidly due to the expansion of the battery-electric vehicles market. Battery metal recycling (BMR) is an important technology that can potentially realize environmental and economic benefits in cathode active material (LiNi x Mn y Co z O 2 ) production using recycled materials. While current major battery recycling technologies recover cathode materials (NCM) and other metals (steel, aluminum, copper, etc.) from the spent battery, the lithium (Li) recovery rate is less than 1% in the world. In this study, we analyze the environmental benefits of a BMR process that recovers lithium in the form of lithium hydroxide monohydrate (LiOH∙H 2 O) along with other cathode materials. Using life-cycle analysis (LCA), we evaluate the life-cycle greenhouse gas (GHG) emissions, criteria air pollutant emissions, and water consumption of the new BMR technology in terms of lithium hydroxide production and cathode active material production. The LCA results show that the life-cycle GHG emissions recycled LiOH are 37–72% lower than those of virgin LiOH production from Chilean brine and Australian ore, respectively. In addition, the life-cycle GHG emissions of NCM811 produced using the recycled materials are 40–48% lower compared to virgin cathode active material production. Furthermore, recovering lithium from the spent batteries reduces associated air pollutant emissions and water consumption relative to using the virgin materials or materials from other recycling technologies without LiOH recovery.

25 ENERGY STORAGE↗

Voltage-Based Strategies for Preventing Battery Degradation under Diverse Fast-Charging Conditions

Maintaining safe operating conditions is a key challenge for high-performance lithium-ion battery applications. The lithium-plating reaction remains a risk during charging, but limited studies consider the highly variable charging conditions possible in commercial cells. Here we combine pseudo-2D electrochemical modeling with data visualization methods to reveal important relationships between the measurable cell voltage and difficult-to-predict Li-plating onset criteria. An extensively validated model is used to compute Li plating for thousands of multistep charging conditions spanning diverse rates, temperatures, states-of-charge, and cell aging. Here we observe an empirical cell operating voltage limit below which plating does not occur across all conditions, and this limit varies with the battery state-of-charge and aging. A model sensitivity analysis also indicates that, when comparing two charging voltage profiles, the capacity difference at 4.0 V correlates well with the difference in the plating onset capacity. These results encourage simple strategies for Li-plating prevention that are complementary to existing battery controls.

25 ENERGY STORAGE↗

Electrolyte additive enabled fast charging and stable cycling lithium metal batteries

Batteries using lithium (Li) metal as anodes are considered promising energy storage systems because of their high energy densities. However, safety concerns associated with dendrite growth along with limited cycle life, especially at high charge current densities, hinder their practical uses. Here we report that an optimal amount (0.05 M) of LiPF6 as an additive in LiTFSI-LiBOB dual-salt/carbonate-solvent-based electrolytes significantly enhances the charging capability and cycling stability of Li metal batteries. In a Li metal battery using a 4-V Li-ion cathode at a moderately high loading of 1.75mAh cm(-2), a cyclability of 97.1% capacity retention after 500 cycles along with very limited increase in electrode overpotential is accomplished at a charge/discharge current density up to 1.75 mA cm(-2). The fast charging and stable cycling performances are ascribed to the generation of a robust and conductive solid electrolyte interphase at the Li metal surface and stabilization of the Al cathode current collector.

25 ENERGY STORAGE↗