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The Parker Ranch installation in Hawaii
NYBEST Symposium
U.S. DOE Vehicle Battery R&D Update
March 11, 2015Troy, New York
David HowellHybrid & Electric Systems Program ManagerVehicle Technologies Office
U.S. Department of Energy1000 Independence AvenueWashington DC 20585
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US DOE EDV Battery R&D:Funding & Key Events
72%
$0
$20
$40
$60
$80
$100
$120
$140
$160
1993 1995 1997 1999 2001 2003 2005 2007 2009 2011
FY B
udge
t ($ x
milli
on)
Battery Selected asPrimary R&D Path
Transition to High-energyLi-ion Battery R&D
ARRA PHEV Battery Manufacturing Initiative
Li-ion HEV BatteryCommercializedJCI-Mercedes
NiMH Battery Commercialized and Li-ion Main R&D Focus Ultracap R&D Restart
Fiscal Year
High Energy Li-ionLi-ion High Power (for HEVs)NiMH & other
Partnership for a New Generation of Vehicles FreedomCar & Fuel Partnership US Drive
•3M Company•A123 Systems•AMS•Amtek•ARNL •Celgard•Compact Power •Delphi •Duracell•Electrovaya•EnerDel•JCI •Johnson
Controls -SAFT
•Johnson Controls
•K2 Energy Solutions
•Leyden Energy•Polystor•Quallion LLC•SAFT•SK Innovation•SRI •Ultralife•UMT•Valence •Varta
Li-ion Participants National Labs•Argonne•Berkley•Idaho•Oak Ridge•Brookhaven
NiMH Participants•Ovonic•GM Ovonic•SAFT •Texaco Ovonic•Electro Energy
•AEG•Bollore•Electrofuel•EPRI •Exide Corp.•Hydro-
Quebec
•Norvik•Maxwell•PolyPlus•Silent Power•SionPower•W.R. Grace
Other Participants Li-ion PHEV Battery
CommercializedLGChem-GM
3
EERE-VTO Battery Technology Highlights
Chevrolet VoltLithium-ion Polymer Battery Cell
Lithium-ion Polymer Battery Cell
Lithium-rich Cathode: Nickel-Manganese-Cobalt
Lithium-rich Cathode: Nickel-Manganese-Cobalt
Lithium-ion Battery Technology for Plug-in Electric Vehicles
EERE VTO supported the development of the core cell technology that is currently used in the Chevrolet Volt PEV battery and the Ford Focus EV battery.
The cell, which contains a graphitic anode and a mixture of Nickel-Manganese-Cobalt and Manganese spinel oxides, was developed in collaboration with LG Chem Michigan from early 2004 through 2012.
The Nickel-Manganese-Cobalt cathode in the LG Chem cell was developed at Argonne National Laboratory with support from EERE VTO from 2002-2010.
Ford Focus EV
4
ARRA-Battery Manufacturing Supply Chain
MATERIALS BASF Toda Novolyte (BASF) Honeywell Chemetall Foote EnerG2 Pyrotek FutureFuel Celgard ENTEK/JCI H&T Waterbury
CELL/PACK A123 JCI SAFT EnerDel CPI-LG DOW-Kokam GM
Adv. Lead-Acid Exide East Penn
eere.energy.gov
GM Battery Pack AssistRockwood hydroxide production
Domestic battery manufacturing plants are
supplying batteries to several hybrid and electric vehicles
including Chevy Volt EREV Opel Ampera EREV Cadillac ELR, Chevy Spark EV BMW Active Hybrid 7 HEV Land Rover Mercedes S Class S 400 Mercedes E Class HEV, Odyne PHEV heavy duty
vehicles. XLHybrids (which provides fleet
vehicles to FedEx, Chevy, and GMC)
Stationary Systems
5
2013 sales set a record, 2014 sales fell a bit shorter
– 592,000 EDV Sales in 2013 (All-Time High), 554,000 in 2014
97,000 PEV Sales in 2013, 115,000 in 2014
Over 3.8 million EDVs on the road Jan.1, 2015
– 2011: 14% Li-ion– 2012: 25% Li-ion– 2013: 40% Li-ion– 2014: 42% Li-ion
Advances in battery technology and manufacturing remain critical for the market success of all HEVs & PEVs.
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
Li-ion PHV/EVLi-ion HEVNiMH HEV Light-duty TrucksNiMH HEV Cars
U.S. Electric Drive Vehicle Sales, by Technology(1999-2014)
Year
EDV
Sale
sVTO’s R&D Led to SignificantElectric Drive Vehicle Sales Growth
6
2.65 GWhs of Lithium-ion Batteries were installed in Electric Drive vehicles sold in the USA in 2014.
0.000
0.500
1.000
1.500
2.000
2.500
3.000
3.500
Installed Electric Drive Vehicle Battery Capacity(GWh installed in vehicles)
Year
Inst
alle
d ED
V B
atte
ry C
apac
ity (G
Wh)
Li-ion HEV
Li-ion PHV/EV
NiMH HEV LD Trucks
NiMH HEV Cars
2010: 3% Li-ion 2011: 58% Li-ion 2012: 67% Li-ion 2013: 82% Li-ion 2014: 86% Li-ion
Annual Increases in Lithium-ion Batteries Installed Capacity in LDVs
7
Clean Energy Manufacturing InitiativeHow can EERE’s actions and investments promote US clean energy manufacturing that is competitive in the global market?
Raw Mat’ls & Processed Mat’ls Electrodes & Cells Battery pack
Current Vehicle LIB Value Chain Value Share25-40% 30-45% 20-35%
1) Excess worldwide manufacturing capacity exists across the supply chain As U.S. demand grows and stabilizes, packs will likely be assembled domestically, and
materials production, electrode production, and cell assembly may occur regionally.
2) Cost to manufacture lithium-ion batteries in the US does not prohibit market success Multiple technologies likely to be competitive for different vehicle architectures i.e. EV,
PHEV, HEV, micro-hybrid.
3) Market has not settled on a technology “winner”. Opportunity exists to disrupt the market through the development and commercialization
of more advanced lithium ion battery materials technologies that are not being manufactured today.
8
Vehicle Weight Reduction
Electric Drive System Cost Reduction
Battery ImprovementsAnd Cost Reduction
The Department of EnergyEV Everywhere Grand Challenge
Technology Push (R&D): targets focus on reducing PEV costs– Advanced batteries, – electric drive systems, – Lighter weight structures, – enabling technologies such as
advanced climate control. Charging Infrastructure (Enablers):
Critical issues include codes and standards, siting, grid integration, permitting, and signage.
Market Pull (Consumer Acceptance): Consumer education and exposure to PEVs, innovative PEV ownership incentives, and leadership by example among public and private fleets.
Enable the U.S. to be the first in the world to produce plug-in electric vehicles that are as affordable as today’s gasoline-powered vehicles within the next 10 years.
2022 Battery Technology$125/kWh250 Wh/kg400 Wh/l
2,000 W/kg
9
DOE Hybrid & Electric Vehicle Systems Program Structure, Budget, and Information Resources
Vehicle SystemBattery R&DElectric Drive
FY 2015 ($144.1M)
Electric Drive Power Electronic Drive Motors ($21M)
Vehicle System Vehicle Testing Modeling & Simulation Component Efficiency
Improvements Grid Integration Codes & Standards
($40.4M)
Battery R&D Materials R&D Battery Development Advanced Processing
($82.7M)
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Cell Design & Optimization Electrochemical Couples Power & Capacity Life Improvement
Industry/Lab 0.5 - 1.0 Ah cells
Cell Targets350 Wh/kg750 Wh/l
1,000 “C/3” cycles
VTO Battery R&D ActivitiesFY2015 Budget: $82M
Battery Development EDV Cell/Module Des. Performance Increase Cost Reduction
USABC, Testing, CAE 5 - 40+ Ah cells
Pack Targets: $125/kWh250 Wh/kg : 400 Wh/l
2,000 W/kg
Battery Materials R&D Capacity Improvement Failure Mitigation
Laboratory/University 10-100 mAh cells
Anodes (600+ mAh/g)Cathodes (300+ mAh/g)Electrolytes (5 volt)
11
DOE/USABC reduced the cost of PEV batteries by 70% and doubled their
energy density during the past 5 years
Current cost of advanced PHEV battery technology estimates average $289/kWh, useable
Batteries ranged from PHEV 40 packs (~14 kWh).– These battery development
projects focus on advance cathodes, processing improvements, cell design and pack optimization.
– Standard electrolyte & graphite anode were used.
Results based on prototype cells & modules meeting DOE/USABC performance targets.
Detailed USABC battery cost model used to estimate the cost of PEV battery packs assuming that 100,000 batteries are manufactured annually.
Progress and ResultsCost Reduction
PHEV Battery Cost ($/kWh)
2007 2008 2009 2010 2011 2012 20142013
1,000
800
600
400
200
0
1,200
Year
12
Projected Cost for a 100kWh Battery Pack
These are the best case projections: all chemistry problems solved, performance is not limiting, favorable system engineering assumptions, high volume manufacturing
Courtesy: JCESR Energy Storage Hub
Extensive cost modeling has been conducted on advanced battery chemistries using the ANL BatPaCmodel.
Significant cost reductions are possible using more advanced lithium ion materials (see figure)
– Lithium-ion: Silicon anode coupled with a high capacity cathode presents moderate risk pathway to less than 125/kWhuse
– Lithium metal is a higher risk pathway to below $100/kWhuse
USABC EV45kWhuse
Future Battery R&DAdvanced Battery Chemistries
13
$132
Target: 50% reduction
No Change
$212
Objective: by 2020, reduce critical material and manufacturing costs by 50%.
Focus on the energy, water, environmental, and labor costs which, depending on component, can range from ~20% –60% of the materials cost.
Reduce energy intensity for producing materials.
Focus on $/kWh reduction
Battery Manufacturing Costs
Low-cost Production of Disruptive Battery Materials
14
Electrode Production ~47%
Mixing, Coating & DryingPressing & Slitting
Formation &Sorting
~33%
Cell Assembly & Electrolyte Filling
~20%
The cell production line comprises a number of discrete unit operations –process steps in fabricating the cell from its component materials. Breakthroughs Needed
NMP solvent substitute
Dry processing Fast curing binders High-speed deposition UV, Microwave, or IR
flash lamp drying Ultrahigh packing
density In situ separator
coatings
Currently a 3-6 week process that assures performance, life, & safety of a cell
Breakthroughs Needed Form SEI layer during material mixing or electrode processing High speed In-Situ NDI techniques to detect flaws & internal shorts
Electrode manufacturing and cell fabrication are 30-45% of battery cost.
Electrode Production and Cell Assembly
15
Johnson Controls demonstrated novel cathode slurry processing techniques that
– reduced N-Methylpyrrolidone (NMP) solvent use by 32%– increased coated electrode density by 31%.
Miltec developed stable, first-of-its-kind, UV curable binders for Li-ion cathodes and demonstrated novel cathode slurry processing techniques.
– Reduced NMP solvent use by 100%. – Achieved cathode thickness and porosity similar to
conventional electrodes (~60 mm and ~25%).– Retained 50% capacity after 2,000 1C/1C cycles
DOE/USABC contracts with Celgard and Entek reduced Li ion separator cost from $3/m2 to ~$1.20/m2.
Nanosys developed a silicon-graphite anode material (SiNANOde™) that demonstrated 850mAh/g of reversible capacity and ~500 cycles
Recent Accomplishments
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Resources VTO Annual Merit Review Report
http://www1.eere.energy.gov/vehiclesandfuels/resources/vt_merit_review_13.html
R&D Annual Progress Reports http://energy.gov/eere/vehicles/vehicle-technologies-office-annual-progress-reports
R&D Roadmaps http://www1.eere.energy.gov/library/pir_publicationsnew.aspx/page/8#Plans
R&D Highlights (USCAR)http://www.uscar.org/commands/files_download.php?files_id=371
VTO Battery R&D Information Resources
17
For Additional Information…
Dave HowellHybrid Electric Systems Program Manager
QUESTIONS?