12V Start-Stop and 48V Mild Hybrid LMO-LTO Batteries
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1 12V Start-Stop and 48V Mild Hybrid LMO-LTO Batteries Veselin Manev Ph.D., Kevin Dahlberg Ph.D., Susmitha Gopu, Steve Cochran 35 th International Battery Seminar & Exhibit Ft. Lauderdale, Florida, March 28, 2018
2 XALT - Building on Eighteen Years of Proven Experience 1990 s Development 2000 s 2010 s of large format cells in Korea Manufacturing brought to United States Re-emerging with new products, capabilities, and strategic partnerships Kokam Companies, Ltd. Began producing large format lithium polymer batteries Townsend Capital purchases controlling interest in $305 M in grants Kokam Co., Ltd ($161M DOE and $144 MEGA grants) Townsend acquires Dow Chemical s interest Dow Kokam LLC renamed XALT Energy, LLC R&D 100 Finalist for new LTO chemistry Townsend XALT begins invests in production of new XALT receives ALD Coating NMC ceramic GB/T Certification Technology separator cell for LTO cell PBES partnership for marine market Launching Gen II cell Kokam technology brought to US Official formation of Dow Kokam LLC 50/50 JV between Dow Chemical and Townsend Ventures Commercial production of large format cells at Midland Battery Park XALT & ONRL partnership XALT is exclusive supplier of Li-on batteries for Formula E XALT Technology Park opens in Pontiac 2Ah R&D line Established in Midland XALT Delivers 1 st commercial XPAND subpacks and BMS Commences XALT cell and pack sales 2
3 World-Class Manufacturing Capabilities Superior Quality Control Extensive raw material acceptance testing Highly Sophisticated Manufacturing Process Coating and Drying Electrode Punching Cell Assembly Stacking Extensive process automation with Advanced robotic stacking and vision systems for enhanced quality control, reliability and consistency No human handling of electrodes All manufacturing in clean/dry rooms Electrolyte Filling Formation Grading and Packaging Full product traceability Quality checks throughout the operation Complete separation of anode and cathode lines to eliminate risk of cross contamination XALT utilizes a proven manufacturing process with state-of-the-art automated equipment to efficiently produce superior and consistent cells that can be relied upon. 3
4 XALT Energy, LLC: from Cells to Systems XALT design and manufacture: Large format, long-life NMC and LTO Li-ion cells 263 mm x 266 mm and 225 mm x 225 mm Compact, Safe, Reliable Battery Packs XMP and XMOD State-of-the-art Battery Management Systems System peripherals, including service tools 4
5 XALT Battery Products Applications HK Electric Bus - 70kWh LTO 40 Ft Grid Energy Storage Container 2.4MWh NMC Prinsesse Benedikte Hybrid Ferry 2.7MWh NMC New Flyer Electric Bus - 200kWh NMC Community Energy Storage 250kWh NMC Ampere All-Electric Ferry 1.4MWh NMC Gillig Electric Bus - 100kWh NMC Formula e 53 Ah HE NMC Etta Ferd Supply Vessel - 260kWh NMC
6 6
7 XALT s NMC/Graphite Gen I vs Gen II Cells Same Cell Format Gen I NMC/Graphite 40 Ah High Power Gen II NMC/Graphite 65 Ah Ultra High Energy Both cells have the same format and are available as cells or modules XMP71P (40 HP) and XMOD114E (65 UHE) 7
8 XALT Start-Stop started from its NCM-LTO battery expertise For LMO-LTO start-stop battery development, XALT successfully utilized its extensive expertise in stabilization of electrode interfaces created during development of the 60Ah NCM-LTO cell. The basic parameters of the 60 Ah HP NCM-LTO cell is shown on the right and its unique and unmatched cycle life performance is illustrated on the next two slides. 8
9 60 HP NMC-LTO cell cycling performance The graphs in this slide show the 25oC cycle life production validation test of the current baseline cell. The test is performing at 100% DOD, 2C/2C charge & discharge rate. As displayed, after 18,000 of 100% DOD cycles at 25oC there is 1% capacity fade and no significant change in the cell s impedance. 9
10 60 HP NMC-LTO cell cycling performance The group of graphs in this slide shows the 55oC cycle life validation test of a new cell production process. The test is performing at 55oC, 100% DOD, and 2C/2C charge & discharge rate. As displayed, after 5,000 cycles at 55oC the cells display about 1% capacity fade and no significant change in the cell s impedance. 10
11 XALT LMO-LTO Cell Design & Performance Strategy As shown below the increase in specific surface areas of electrode materials greatly decreases the cell s impedance at -30oC and respectively increases its cold cranking power. In order to assure good cold cranking performance the XALT start-stop battery strategy includes increase in BET of electrode materials and respectively stabilizing their interface by use of a combination of interface protective layers. Effect of surface area of LMO on EIS at different temperatures (a) 25 C, (b) 0 C, (c) -30 C 11
12 XALT LMO-LTO Cell Design & Performance Strategy During discharge the LTO material loses three Li. During the first two Li there is no change in electronic conductivity. During the extraction of the last Li the LTO changes its electronic conductivity by 11 orders of magnitude from a good electronic conductor to an insulator. So the XALT start-stop strategy includes the use of a high energy cell design rather than a high power one, to get a 75 Wh/kg LMO-LTO cell, and to decrease the energy fade in the end of the life to about 10% in order to avoid the operation in last 30% SOC. 12
13 XALT s LMO-LTO Start-Stop Battery under development The basic parameters and performance of XALT s 12 V start stop battery under development are outlined in the table below. Based on the 1 Ah lab cells data the pack will consist of 5 of 48 Ah cell with 75Wh/kg specific energy, which will deliver 600 Wh pack energy. The total cells weight will be 8 kg and the pack weigh is expected to be 10 kg. 12 V Start Stop Pack Configuration Nominal votage 12 V Cells & Pack capacity 48 Ah Cells number 5 Pack Energy 600 Wh Cells weight 8 kg Cells Sp energy 75 Wh/kg Max voltage 14.5 V Min voltage 10.5 V Max power 16 kw Expected pack weight 10 kg 13
14 2C/2C & 100% DOD Cycle 30oC for Start/Stop LMO-LTO Cells Single layer LMO-LTO lab cells performed about 4,000 cycles at 100% DOD and 30oC with 97% capacity retention (blue curves), suggesting more then 20,000 of 100% DOD cycles at 30oC. The current 1 Ah LTO-LMO cells (red curve) so far are performing much better - no change in capacity the first 1000 cycles and impedance leveling off after 10% increase 14
15 2C/2C & 100% DOD Cycle 30oC, 45oC and 55oC 1 Ah LMO-LTO Cells In addition to the good 30oC cycling performance the current baseline 1 Ah LMO-LTO cells display also good elevated temperature performance. As illustrated below the 1 Ah LMO-LTO cells are keeping 96% of their capacity after more than 1100 cycles at 55oC. The Models predict at least 5,000 cycles at 55oC with 80% capacity retention. 15
16 Cold Crank Data from 1Ah LMO-LTO Cells Scaled Up to 8 kg Cells Pack 1Ah lab cell performance scaled up to 8 kg cells in 10 kg start-stop 12 V battery pack Cold Crank procedure: 3 cycles of: 0.5 sec pulse power of 6kW 4 sec pulse power of 4kW 10sec rest 100% SOC 50% SOC 16
17 48 V & 16 kw Mild Hybrid vs. Gen 2 48 V & 24 kw Battery Configuration We used the same cell design as reported in previous slides for start-stop application, and scaled up the 1 Ah lab cell performance to 48 V & 16 kw and 48V & 24 kw batteries packs. The 16 kw power is considered to be in the highest range of mild hybrid applications, while the 24 kw power is in the lower range of full hybrid batteries. The calculated parameters and performance of both packs are listed below: 48 V & 16 kw Mild Hybrid Pack Configuration Nominal votage 48 V Cell capacity 12 Ah Cells number 18 Max power (operational) 16 kw Max power at 70% SOC 23 kw Energy 540 Wh Cells weight 7.2 kg Max voltage 52 V Min voltage 36 V Cells Sp energy 75 Wh/kg Expected pack weight 9 kg Gen 2 48V & 24 kw Pack Configuration Nominal votage 48 V Cell capacity 18 Ah Cells number 18 Max power (operational) 24 kw Max power at 70% SOC 33 kw Energy 810 Wh Cells weight 10.8kg Max voltage 52 V Min voltage 36 V Cells Sp energy 75 Wh/kg Expected pack weight 14 kg 17
18 48 V & 16 kw Mild Hybrid HPPC results from 1Ah LMO-LTO cells scaled up to 7.2 kg cells weight in a 48 V mild hybrid battery pack suggests 10 sec charge & discharge pulse power much higher than 16 kw in the 40%-95% SOC operating window. The graph on the right shows the current during the max 16 kw power as a function of state of charge. As displayed the expected max 10 sec pulse current is in the range of 400 A which is acceptable. 18
19 Gen 2 48 V & 24 kw Pack Configuration HPPC results from 1Ah LMO-LTO cells scaled up to 10.8 kg cells weight in a 48 V full hybrid battery pack suggests charge & discharge power higher than 24 kw in the 40%-95% SOC operating window. The expected current at the max 24 kw & 10 sec pulse power shown on the right graph suggests max current exceeding 600 A and this may create an issue that needs to be addressed. 19
20 Summary: As displayed XALT production NCM-LTO cells show unmatched cycle life performance at both room (18,000 cycles with 1% capacity fade) and elevated temperature (5,000 at 55oC with 1% capacity fade) The LMO-LTO cells, which are currently under development for start-stop battery application, also show very good cycle life data suggest at least 20,000 of 100% DOD cycles at 30oC and 5,000 cycles at 55oC with 80% capacity retention. The HPPC test of the LMO-LTO cells with the same design as the current 1 Ah lab cells for the start-stop program shows that LMO-LTO chemistry can support 16 kw 48 V mild hybrid battery with about 0.5 kwh energy and 9 kg weight. The HPPC data also show that the LMO-LTO chemistry can support 24 kw 48 V hybrid battery with 0.8 kw energy and kg weight. As the HPPC power data are obtained from cells with relatively high specific energy for LMO- LTO chemistry cells it is imperative that we can trade energy for power by decreasing electrode thickness and increase the 48 V battery power for a lower available energy. 20
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