Next Generation Batteries and EHS Challenges Kiran Joshi, Ph.D., CSP EHS Director Patent Agent
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 2
Consumer Electronics: Battery Capacity Not Keeping Up with Other Component Gains 2007: iphone 2012: iphone 5 2015: iphone 6S % change Processing speed 0.4 GHz 1.3 GHz 1.8 GHz 450% RAM 128 MB 1024 MB 2 GB 1400% Screen Resolution 150,000 pixels 730,000 pixels 1 M pixels 667% Battery Capacity 5.2 Wh 5.5 Wh 6.6 Wh 25% Seizing the Shifting Opportunity in the $41B Mobile Energy Storage Market, Lux Research, June 2013. http://www.apple.com/iphone-6s/specs/ ; https://www.ifixit.com/teardown/iphone+6s+teardown/ 3
Rated Range (miles) >200 mile range Automotive Battery Costs Force a Choice Between Vehicle Price and Range 300 250 98% of Vehicles Are Priced Less than $50K Mass Market 200 Tesla Model S3 150 Tesla Model S2 100 50 Toyota Rav4 BMW i3 Today s Vehicles 0 $100,000 $80,000 VW eup* $60,000 $40,000 Vehicle Price Ford Focus $20,000 Nissan Leaf $0 Innovation needed to enable high-range, affordable mass market electric vehicles *VW eup: NEDC range and UK MSRP before VAT and incentives. All others: EPA range and MSRP before tax credits in the US 4
Why Does Battery Safety Matter? Two forms of energy stored Reactants (Wh rating on the cell) Non participating components (e.g. organic electrolyte) Batteries contain the 3 legs of the fire triangle: an energy source, a fuel (e.g. electrolyte), and an oxygen source More potential energy in the electrolyte than usable energy stored between the battery s anode & cathode Push for higher energy density cells for cost, weight, and volume reasons can make safety challenges more difficult Need to develop inorganic ion conductors to minimize / eliminate flammable components in the cell Typical Wh/kg for lithium ion cells ranges between 100-250 5
Battery Fires According to Sony, contamination of Cu, Al, Fe and Ni particles during the manufacturing process may cause an internal short circuit. Tesla Car Fire http://batteryuniversity.com/learn/article/lithium_ion_safety_concerns A cell phone with a no-brand battery that vented with flame while charging in the back of a car. The heavily burned battery from Dreamliner JA829 after it suffered thermal runaway. 6
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 7
Dreamliner Li-Ion Battery Case Study 1/7/2013: At Boston Logan Airport; smoke from the auxiliary battery 1/14/2013: Japan; in-flight; passengers smelled smoke; precautionary landing; main battery involved 1/14/2014: At Narita Airport; redesigned battery with containment box Pictures from: NTSB.gov/new/press-releases 8
2013 Event NTSB.gov/new/press-releases 9
January 2013 NTSB Report NTSB investigation results: Internal short circuit leading to thermal runaway condition Propagating to remaining cells to battery thermal runaway Cell manufacturing defects and oversight of cell manufacturing processes Thermal management of lithium-ion batteries Insufficient guidance for manufacturers to use in determining and justifying key assumptions in safety assessments Insufficient guidance for FAA certification engineers to use during the type certification process to ensure compliance with applicable requirements Stale flight data and poor-quality audio recording of the 787 enhanced airborne flight recorder (EAFR) NTSB recommendations: 15 FAA on improving the guidance and training to industry 2 Boeing 1 to GS Yuasa Changes Made by Boeing www.ntsb.gov/news/press-releases/pages/pr20141201.aspx; full report available from: http://go.usa.gov/hjtj Boeing Battery Changes: Boeing/Graphic News 10
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 11
Battery Cell Terminology Anode: A negative electrode that donates electrons during cell discharge Battery: An electrochemical cell in which stored chemical energy is converted into electrical energy Cathode: A positive electrode that accepts electrons during cell discharge Energy Density: Energy per unit volume (Wh/L) Power Density: Power per unit volume (W/L) Specific Energy: Energy per unit weight (Wh/kg) Specific Power: Power per unit weight (W/kg) Lithium Ion Battery: Rechargeable battery in which lithium ions are stored in both cathode and anode Lithium Metal Battery: A battery utilizing lithium metal or lithium alloy as the anode Li Ion Battery Picture Taken From: http://www1.eere.energy.gov/vehiclesandfuels/pdfs/pir/vtp_goals-strategies-accomp.pdf 12
Conventional Li ion summary (simplified) Cross-section of electrodes - Al foil - Cathode (e.g. LiCoO 2 ) - Separator - Anode (e.g. graphite: LiC 6 ) - Cu foil Thickness of layer ~30-100 um Inactive Materials: Binders (polymers for adhesion & cohesion) Separator & electrolyte Conductive additives Packaging (can, tabs, terminals, etc.) http://www.exponent.com/batteries/ 13
Examples of a Cell Material Cathode Materials LiCoO 2 LiNi x Co y Al z O 2 (NCA) LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC) LiFePO 4 (LFP) Anode Materials Graphite based Silicon based Li Electrolytes Organic carbonates + Lithium hexafluorophosphate Separators Porous Polymer Picture taken from: J.M.Tarascon, M.Armand, Nature 414 (2001) 359-367. 14
Battery Cell Construction Most modern battery cells are composed of multiple metal foils (with active materials) placed in metal cans or pouches. There are several different types of enclosures and assembly methods. Cylindrical cell Alkaline Li-ion cylindrical wound Wound prismatic Stacked prismatic Coin cell Source:LINDEN S HANDBOOK OF BATTERIES; Tarascon 2001 doi:10.1038/35104644 15
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 16
EHS Challenges at Each Stage Research and Development Manufacturing Shipping Integration Into Product and In the Field Remember that the end goal is to create a Sustainable product and future: -How do we keep the environment, workers, and consumers safe? End of Life 17
Research and Development Challenges - EHS Can be a Light Lab Occupancy Chemical Load Chemical, Fire, Ergonomics, Electrical, Mechanical Hazards Young scientists, fast paced environment Some Examples of Chemical Hazards: Variety of chemicals and formulations Characterization of new formulations Flammable, pyrophoric Water Sensitive Metals (Na, Mg, Li) and nano powders which can catch fire Phosphides, Sulfides, Nitrides (Sulfides which can generate toxic gases) Chemicals heated at high temperatures while pressed under high pressure Shipping of new chemical formulations for testing purposes Work Environment Buildings Glove boxes Dry rooms Reactors (High Pressure and Temperature) Machine Shop Electrical Test Systems Ergonomics, Electrical and Mechanical Hazards These are generic photos (not QunatumScape photos). 18
Safe Use of Lithium or Laminated Lithium Flammable solid, highly reactive Incompatible with water, acids, bases, oxidizing agents 2Li(s) + 2H 2 O 2LiOH(aq) + H 2 (g) (220 KJ/mol generated) Use it only under argon or in the dry room; Keep the containers closed when not in use Store sealed lithium in the flammable cabinet in the dry room when not in use Segregate waste and submerge in mineral oil Use LithX for small lithium fire Remember to empty the GB waste bin efore exposing the contents to air. Only trained employees can use the yellow fire extinguisher. QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 19
Safe Use of Sulfide Compounds Examples: Lithium Sulfide, Phosphorus Pentasulfide, Arsenic Sulfide, Sulfide slurries Flammable, toxic, corrosive, irritants Contact with water releases Hydrogen Sulfide gas flammable and toxic Handle Sulfide powders inside the glove box under inert atmosphere If using in a dry room, handle only in a hood P2S5 can not be handled in the Dry Room. Use only in a Glove Box Package the sulfide waste in zip lock bags and store under exhausted conditions Reactively purge the glove box if opening it to the atmosphere for maintenance H 2 S sensors Warning at 1 ppm (orange light); alarm at 2.5 ppm (red light and audible) PEL for H 2 S is 10 ppm (can smell at 5 ppb) QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 20
Safe Handling of Powders Handle all powders under an exhausted enclosure in the Dry Room (if not air or water sensitive) or in the Glove Box Take precautions to change gloves inside the Glove Box Wipe the equipment before bringing it out from the Dry Room or the Glove Box Fluoride powders can generate HF when come in contact with water Use of PPE Respirators (P100 or Multi-Cartridge) Button the lab coat to avoid getting any powder on your clothes Change gloves frequently Get the coat laundered once a week or more often if needed Milling or Spray Drying of Powders High surface area, large amount of energy storage Powder ignition just by touching/tapping or exposing to air Housekeeping around equipment Photo Buchi Spray Dryer QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 21
Battery Manufacturing Facility Design and Construction of the Facility B-Occupancy may not be sufficient. May need high hazard occupancy buildings based on the chemical load Air emission controls, other regulations Design, Purchase and Installation of the Equipment Coaters, Mixers, Dryers, Rollers, Laminators, Cutters Location of supply chain Manufacturing Sourcing of chemicals - Li Automation Challenges Work Fast Expectations Engineering may still be worked on. Battery Testing Equipment and Lab Location and construction of the lab where fire/explosion testing can be done Process to handle vented and exploded cells Fire and Electrical Safety where testing is being done Personnel safety involved with inspection and testing How to handle corroded cells Remove jewelry Insulated tools Photos: http://www.eurotecusa.com/id19.html; http://www.arbin.com/ 22
Battery Storage Facility Depending on the Battery, may need to use a separate high hazard occupancy storage room: 2-4 h fire wall Built in fire-fighting system Explosion proof lighting Separate air conditioning Gas sensors (H 2, H 2 S, Cl 2 and others based on the hazards) Restricted access 23
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 24
Product Safety Standards and Testing Protocols Underwriters Laboratories (UL) UL 1642 Lithium batteries UL 2054 Household and Commercial batteries UL 2580: Batteries for use in Electric Vehicles Institute of Electrical and Electronic Engineers (IEEE) IEEE 6125: Rechargeable Batteries for Mobile Computing Devices IEEE 1725: Rechargeable Batteries for Cell Phones Society of Automotive Engineers J2464: Electrical and Hybrid Electric Vehicle Rechargeable Energy Storage System, Safety and Abuse Testing J2929: Electric and Hybrid Vehicle Propulsion Battery System Safety Standards Lithium Based Rechargeable Cells International Electrotechnical Commission (IEC) IEC 62281: Safety of Primary and Secondary Lithium Cells/Batteries during Transportation United Nations (UN) Recommendation on the Transport of dangerous Goods, Manual of Tests and Criteria, Part III, Section 38.3 Battery Safety organization (BATSO) BATSO 01: Manual for Evaluation of Energy Systems for Light Electric Vehicles 25
SAE Recommended Practice for Safety Testing: SAE J2464 Most comprehensive recommended industry test practices Does not specify HSL (hazard safety levels) Focus is on tests and their conditions 3/13/2017 Source: SAE J2464 Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing 26 QUANTUMSCAPE PROPRIETARY
UN 38.3: Required for Shipping Designation Test Name (Cell Count) Purpose 38.3.4.1 T.1: Altitude Simulation (10 cells, T1-T5 seq) Simulates air transport under low pressure conditions 38.3.4.2 T.2: Thermal Test Assesses cell and battery seal integrity and internal electrical connections The test is conducted using rapid and extreme temperature changes 38.3.4.3 T.3: Vibration Simulates vibration during transport 38.3.4.4 T.4: Shock Simulates possible impacts during transport 38.3.4.5 T.5: External Short Circuit Simulates an external short circuit 38.3.4.6 T.6: Impact (10 cells) 38.3.4.7** T.7: Overcharge** (0 cells) 38.3.4.8 T.8: Forced Discharge (20 cells) Simulates an impact (i.e. 9.1kg mass from 61 cm height) Evaluates the ability of a rechargeable battery to withstand an overcharge condition** Evaluates the ability of a rechargeable cell to withstand a forced discharge condition 3/13/2017 Source: Recommendations on the Transport of Dangerous Goods: Manual of Tests & Criteria, Fifth Revised Edition 27 **Test not applicable to cells when used with a battery system that provides this protection QUANTUMSCAPE PROPRIETARY
Increasing sophistication in battery test equipment to approximate use conditions Test equipment exists to simulate temperature, humidity, altitude, and vibration simultaneously to better approximate life and safety in actual customer use cases 3/13/2017 Source: http://thermotron.com/ QUANTUMSCAPE PROPRIETARY 28
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 29
Lithium Battery Transportation In Brief Lithium Ion Batteries UN Numbers and Description UN3480, Lithium ion battery UN3481, Lithium ion battery packed with equipment UN3481, Lithium ion battery contained in an equipment Packaging Class 9, Miscellaneous Dangerous Goods Can be exempted from Section II IATA depending on the amount of lithium (Check amounts and Wh restrictions) Follow Packing instructions (R)965-967 PG II Requirements for weight limits, package drop tests from 1.2m, and approved outer packaging Identify, package, mark and label per IATA; must be signed by trained shipping employee Lithium Metal Batteries UN Numbers and Description UN3090, Lithium metal battery UN3091, Lithium metal battery packed with equipment UN3091, Lithium metal battery contained in an equipment Packaging Class 9, Miscellaneous Dangerous Goods Can be exempted from Section II IATA depending on the amount of lithium (Check amounts and Wh restrictions) Follow Packing instructions (R)968-970 PGII Requirements for weight limits, package drop tests from 1.2m, and approved outer packaging Identify, package, mark and label per IATA; must be signed by trained shipping employee 3/13/2017 Earl.Whitley@dot.gov for changes to Lithium Battery shipment regulations. QUANTUMSCAPE Another good source PROPRIETARY is: Battery Transportation Safety Workshop, San Diego, 2015. 30
Lithium Batteries Transportation Markings to Know LABELING CARGO AIRCRAFT ONLY + HAZARDOUS MATERIAL SHIPPING PAPER - Shipper / Receiver - Number of Types of Package - UN 3090 - Cargo Aircraft Only (If Air) - Page Number - Volume / Weight - Emergency Response Information + Telephone Number - Certification + Signature (Most Common Violation) Technology exists for containers that allow the gases to be released through a filter but does not allow the flame to get through: WWW.Gelkoh.de; http://pyrophobic.com/ 31
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 32
Regulatory References All Local, State and Federal Laws still apply (EPA, OSHA, UFC, UBC, DOT, IATA, etc.) US, EU, China and Japan can have different safety and battery regulations. ROHS, WEEE in EU and any other local regulations in these countries still apply. Some Battery Safety Standards: IEC 62133 Lithium Cells and Batteries for portable applications IEEE 1625 Lithium ion battery system for mobile computing devices IEEE 1725 Lithium ion battery systems for cellular phone application ISO DIS 12495-3 Lithium ion batteries for EV application SAE 2464, 2929 Battery pack safety committees UL 1642 Lithium cells UL 2054 Household and commercial batteries for potable applications UL 2575 Lithium ion batteries for portable tools and appliances UN Manual of Tests and Criteria, Part III, 38.3 FedEx, UPS websites contain information on lithium battery shipping (DOT/IATA) 33
Some Sources for Additional Learning Conferences: Knowledge Foundation TIAX National Transportation Safety Board US Department of Energy Energy Efficiency and Renewable Energy National Labs UL Private Consulting Firms Information can be provided upon request. 34
Lithium and 7-Up! 3/13/2017 QUANTUMSCAPE PROPRIETARY 35
Agenda Why we need better batteries Market Boeing 787 Case Study Battery 101 Safety Environmental, Health, and Safety Product Shipping Relevant Regulations Q&A 36