FY 2014 Annual Progress Report - Energy Storage R&D This Document Highlights Work Sponsored by Agencies of the U.S
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MARCH 2015 2014 OFFICE OF VEHICLE TECHNOLOGIES FY 2014 Annual Progress Report - Energy Storage R&D This document highlights work sponsored by agencies of the U.S. Government. Neither the U.S. Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the U.S. Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the U.S. Government or any agency thereof. U.S. Department of Energy 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 Fiscal Year 2014 Annual Progress Report for Energy Storage R&D March 2015 Approved by David Howell, Hybrid Electric Systems Program Manager Vehicle Technologies Office, Energy Efficiency and Renewable Energy Table of Contents I. Introduction ............................................................................................................................................................... 1 I.A Vehicle Technologies Office Overview ............................................................................................................ 1 I.B Vehicle Technologies Battery R&D Overview ................................................................................................. 1 I.B.1 DOE Battery R&D Goals and Technical Targets .......................................................................................... 1 I.B.2 DOE Battery R&D Plans ............................................................................................................................... 2 I.B.3 Energy Storage R&D Programmatic Structure .............................................................................................. 3 I.B.4 Recent EV Everywhere Highlights ................................................................................................................ 5 I.B.5 Organization of this Report ........................................................................................................................... 7 II. Advanced Battery Development ........................................................................................................................... 11 II.A USABC Battery Development Projects ......................................................................................................... 15 II.A.1 EV Battery Development (Envia Systems) ................................................................................................ 15 II.A.2 Advanced High-Performance Batteries for Plug-In Hybrid Electric Vehicle Applications (JCI) .................. 19 II.A.3 Development of a High-Performance PHEV Battery Pack (LG Chem, MI) ................................................ 26 II.A.4 Development of a PHEV Battery (Xerion) .................................................................................................. 31 II.A.5 Energy Storage System for High Power LEESS PAHEV Applications (Maxwell Technologies) ................ 35 II.A.6 Development of 12V Start-stop Microhybrid Batteries (Saft) ..................................................................... 38 II.A.7 Development of 12V Start-stop Microhybrid Batteries (Leyden Energy) .................................................... 43 II.A.8 2012 EV Technology Assessment Program (SKI) ..................................................................................... 47 II.A.9 Multifunctional, Inorganic-Filled Separator Development for Large Format Li-ion Batteries (ENTEK) ................................................................................................................................................... 50 II.B Advanced Lithium Battery Cell Technology ................................................................................................. 53 II.B.1 Silicon-nanowire Based Lithium Ion Batteries for Vehicles with Double the Energy Density (Amprius) .................................................................................................................................................. 53 II.B.2 Development of Large Format Lithium-Ion Cells with Higher Energy Density (XALT Energy) ................... 56 II.B.3 Innovative Cell Materials and Designs for 300 Mile Range EVs (OneD Material) ...................................... 60 II.B.4 Advanced High-energy Li-ion Cell for PHEV and EV (3M) ........................................................................ 69 II.B.5 Solid Polymer Batteries for Electric Drive Vehicles (Seeo) ........................................................................ 74 II.B.6 Development of High-Energy Lithium-Sulphur Battery Cells (PSU) ........................................................... 76 II.B.7 Stand Alone Battery Thermal Management System (Denso) .................................................................... 83 II.C Low-cost Processing Research ..................................................................................................................... 87 II.C.1 Low Cost Lithium-ion Cell Manufacturing Project (JCI) ............................................................................. 87 II.C.2 Ultraviolet Curable Binder Lithium-ion Battery Project (Miltec UV International) ....................................... 96 II.C.3 High Capacity Alloy Anodes (Applied Materials) ...................................................................................... 100 II.C.4 Innovative Manufacturing and Materials for Low Cost Lithium-ion Batteries (Optodot Corporation) ....... 104 FY 2014 Annual Progress Report for Energy Storage R&D i Table of Contents II.C.5 Dry Process Electrode Fabrication (Navitas) ........................................................................................... 107 II.D Small Business Innovative Research Projects ........................................................................................... 111 III. Battery Testing, Analysis, and Design .............................................................................................................. 115 III.A Cost Assessments and Requirements Analysis ....................................................................................... 116 III.A.1 Core BatPaC Development and Implementation (ANL) .......................................................................... 116 III.A.2 Battery Ownership Model: A Tool for Evaluating the Economics of Electrified Vehicles and Related Infrastructure (NREL) ................................................................................................................ 121 III.A.3 PEV Battery Second Use (NREL) ........................................................................................................... 125 III.A.4 Battery Life Trade-Off Studies (NREL) ................................................................................................... 128 III.A.5 Battery Production and Recycling Materials Issues (ANL) ...................................................................... 132 III.B Battery Testing Activities ............................................................................................................................ 140 III.B.1 Battery Performance and Life Testing (ANL) .......................................................................................... 140 III.B.2 Battery Performance and Life Testing (INL) ........................................................................................... 143 III.B.3 Battery Abuse Testing (SNL) .................................................................................................................. 148 III.B.4 Battery Thermal Analysis and Characterization Activities (NREL) .......................................................... 155 III.C Battery Analysis and Design Activities ...................................................................................................... 161 III.C.1 Battery Multiscale Multidomain Framework & Modeling (NREL) ............................................................ 161 III.C.2 Computer Aided Engineering of Batteries – CAEBAT (NREL) ............................................................... 165 III.C.3 Computer Aided Engineering of Batteries Effort (ORNL) ........................................................................ 170 III.C.4 Development of Computer Aided Design Tools for Automotive Batteries (GM) ..................................... 174 III.C.5 Development of Computer Aided Design Tools for Automotive Batteries (CD-Adapco) ......................... 182 III.C.6 Development of Computer Aided Design Tools for Automotive Batteries (EC Power) ........................... 186 III.C.7 Coupling of Mechanical Behavior of Cell Components to Electrochemical-Thermal Models for Computer-Aided Engineering of Batteries Under Abuse (NREL, MIT, ANSYS) ..................................... 190 III.C.8 Mechanistic Modeling Framework for Predicting Extreme Battery Response: Coupled Hierarchical Models for Thermal, Mechanical, Electrical and (Electro)chemical Processes (SNL, ORNL, Col School of Mines) .................................................................................................................