Search Results (2,431)

As the issue of energy scarcity becomes increasingly critical, the adoption of electric construction machinery emerges as a pivotal strategy to address the energy crisis. During the travel and operation of electric construction machinery, the machinery-specific battery packs are subjected to long-term mechanical shocks and random vibration loads, leading to resonance and structural damage failure. To address the multi-objective optimization design issues of machinery-specific battery packs for electric construction machinery under the action of random vibration and impact loads and to enhance the fatigue life and reduce the mass of the battery pack, this paper conducts optimization design research on a newly developed battery pack for an electric excavator. Firstly, a finite element model of the battery pack is established to conduct simulation analyses on its impact resistance characteristics and fatigue life. Secondly, through a comprehensive contribution analysis method, key components are identified, with the thickness dimensions of the battery pack parts selected as design parameters. Finally, using maximum stress under mechanical shock conditions and first-order constraint mode as constraint conditions, mass minimization and fatigue life maximization are set as optimization objectives. The Box–Behnken experimental design is employed alongside a Kriging approximation model; subsequently, the NSGA-II algorithm is utilized for multi-objective optimization. The optimization results show that, while meeting the basic static and dynamic performance requirements, the mass of the optimized battery pack outer frame is reduced by 56.8 kg, a decrease of 5.75%. Concurrently, the optimized battery pack’s fatigue life has increased by 1,234,800 cycles, which is an enhancement factor of 1.65 compared to pre-optimization levels. These findings provide significant reference points for optimizing structural performance and achieving lightweight designs in electric excavator battery packs. Full article

The clean energy transition is a paradigm shift from a carbon-intensive energy system to a renewable energy one. The new energy system requires large amounts of critical minerals, including lithium. However, the mining and extraction of these minerals introduces environmental challenges. Recycling critical minerals, a critical step for a circular economy, is a potential solution that could reduce the need for new mining, lowering the overall environmental impact. In this experimentally based work, we evaluate the lithium recycling labor- and cost-intensive preprocessing stage that is currently performed by large-scale recycling systems, reducing the efficiency and raising the costs of the downstream stages. We investigate multiple inexpensive and distributed alternatives to the preprocessing tasks that produce black mass (separation, grinding, and shredding techniques) in order to identify methods that improve the efficiency of the downstream recycling process. This work finds that shredding and grinding end-of-life batteries with equipment that can be purchased for under USD 1000 produces viable black mass for a fraction of the cost. Therefore, this work contributes toward the goal of a circular economy for battery energy storage by identifying the technical requirements and measuring the efficacy of redistributing the labor- and time-intensive preprocessing tasks to small-scale recyclers in order to enhance the efficiency of the downstream stages in the lithium-ion battery recycling reverse supply chain. Full article

Lithium-ion batteries (LIBs) are an indispensable power source for electric vehicles, portable electronics, and renewable energy storage systems due to their high energy density and long cycle life. However, the exponential growth in production and usage has necessitated highly effective recycling of end-of-life LIBs to recover valuable resources and minimize the environmental impact. Pyrometallurgical and hydrometallurgical processes are the most common recycling methods but pose considerable difficulties. The energy-intensive pyrometallurgical recycling process results in the loss of critical materials such as lithium and suffers from substantial emissions and high costs. Solvent extraction, a hydrometallurgical method, offers energy-efficient recovery for lithium, cobalt, and nickel but requires hazardous chemicals and careful waste management. Direct recycling is an alternative to traditional methods as it preserves the cathode active material (CAM) structure for quicker and cheaper regeneration. It also offers environmental advantages of lower energy intensity and chemical use. Hybrid pathways, combining hydrometallurgical and direct recycling methods, provide a cost-effective, scalable solution for LIB recycling, maximizing material recovery with minimal waste and environmental risk. The success of recycling methods depends on factors such as battery chemistry, the scalability of recovery processes, and the cost-effectiveness of waste material recovery. Though pyrometallurgical and hydrometallurgical processes have secured their position in LIB recycling, research is proceeding toward newer approaches, such as direct and hybrid methods. These alternatives are more efficient both environmentally and in terms of cost with a broader perspective into the future. In this review, we describe the current state of direct recycling as an alternative to traditional pyrometallurgical and hydrometallurgical methods for recuperating these critical materials, particularly lithium. We also highlight some significant advancements that make these objectives possible. As research progresses, direct recycling and its variations hold great potential to reshape the way LIBs are recycled, providing a sustainable pathway for battery material recovery and reuse. Full article

Electrical vehicle (EV) batteries, particularly lithium-ion batteries, pose significant environmental challenges due to their hazardous components, the effects of initial building-material fabrication, and the difficulties of recycling and disposal. Policies and legislative strategies adopted by different governments to solve these issues are investigated in this manuscript, specifically based on circularity and resource use. Important steps are end-of-life management, safe disposal and transportation, avoidance of hazardous gas emissions, circularity, resource use, fire prevention, and expanded producer accountability. As of February 2024, New Jersey is the first and only state in the United States that has adopted a thorough legislative framework for EV battery management, therefore establishing a standard for other states. California passed major laws encouraging Zero-Emission Vehicle (ZEV) battery manufacture and recycling. Other states are likewise trying to show initiative by implementing and changing laws. Globally, the European Union is leading, while Canada, Australia, China, and others have created strong rules of regulation. This paper looks at and contrasts the environmental problems of lithium-ion electric vehicles with the legislative actions made by different nations and states to solve these problems. By means of a thorough examination of these policies, this paper seeks to present a whole picture of the current scene and the best techniques for lifetime management of EV batteries that can be embraced by different governments. In this manuscript, a comparison is made between two leading legislations, specifically that of the state of New Jersey and the European Union. To achieve the most beneficial outcome, it is the responsibility of stakeholders to promote rules; emphasize battery recycling, secure disposal, and extended producer accountability; promote innovation in sustainable battery technology; and try to build a pragmatic approach to battery management to mitigate environmental impacts based on a hybrid version of the legislations from the state of New Jersey and the European Union. Full article

Ternary lithium-ion batteries (LIBs) have the advantages of high energy density and high charging efficiency, and they are the preferred energy source for long-life new energy vehicles. However, when thermal runaway (TR) occurs in the ternary LIB, an open flame is easily produced. The burning phenomenon is intense, and the rapid of TR propagation is high; consequently, vehicle-level fire accidents are easily induced. These accidents have become the biggest obstacle restricting the batteries’ development. Therefore, this study investigates the TR behavior of ternary LIBs at the cell and module levels. The addition of an insulation layer alone, including ceramic nano fibers, glass fiber aerogel, and phase-change composite materials, cannot prevent TR propagation. To completely block the TR propagation, we developed a safety prevention strategy, combining the phase-change composite materials with a commercial liquid cooling plate. This approach provides a three-level TR protection mechanism that includes heat absorption, heat conduction, and heat insulation. The use of a 2 mm thick phase change composite material combined with a liquid cooling plate effectively prevents the TR propagation between60 Ah ternary LIBs with 100%SOCs.. The front surface temperature of the adjacent cell is maintained near 90 °C, with its maximum temperature consistently stays below 100 °C. This study successfully demonstrates the blockage of TR propagation and offers valuable insights for the thermal safety design of high-specific-energy LIBs; the aim is to improve the overall safety of battery packs in practical applications. Full article

Organic materials have emerged as promising candidates for cathode materials in lithium-ion batteries and supercapacitors, offering unique properties and advantages over traditional inorganic counterparts. This review investigates the use of organic compounds as cathode materials in energy storage devices, focusing on their application in lithium-ion batteries and supercapacitors. The review covers various types of organic materials, organosulfur compounds, organic free radical compounds, organic carbonyl compounds, conducting polymers, and imine compounds. The advantages, challenges, and ongoing developments in this area are examined and the potential of organic cathode materials to achieve higher energy density, improved cycling stability, and environmental sustainability is highlighted. The comprehensive analysis of organic cathode materials provides insights into their electrochemical performance, electrode reaction mechanisms, and design strategies such as molecular structure modification, hybridization with inorganic components, porous architectures, conductive additives, electrolyte optimization, binder selection, and electrode architecture to improve their efficiency and performance. In addition, future research in the field of organic cathode materials should focus on addressing current limitations such as low energy density, cycling stability, poor discharge capability, potential safety concerns and improving their performance. To do this, it will be necessary to improve structural stability, conductivity, cycle life, and capacity fading, explore new redox-active organic compounds, and pave the way for the next generation of high-performance energy storage devices. For organic cathode materials to be commercially viable, it is also essential to develop scalable and economical manufacturing processes. Full article

Electric vehicle (EV) batteries play a crucial role in sustainable transportation, with reliability being pivotal to their performance, longevity, and environmental impact. This study explores battery reliability from micro (individual user), meso (industry), and macro (societal) perspectives, emphasizing interconnected factors and challenges across the lifecycle. A novel lifecycle framework is proposed, introducing the concept of “Zero-Life” reliability to expand traditional evaluation methods. By integrating the reliability ecosystem with a dynamic system approach, this research offers comprehensive insights into the optimization of EV battery systems. Furthermore, an expansive Social–Industrial Large Knowledge Model (S-ILKM) is presented, bridging micro- and macro-level insights to enhance reliability across lifecycle stages. The findings provide a systematic pathway to advance EV battery reliability, aligning with global sustainability objectives and fostering innovation in sustainable mobility. Full article

Silicon-based anodes suffer from the loss of physical integrity due to large volume changes during alloying and de-alloying processes with electrolytes. By integrating electrochemically inert, physically strong, ductile nickel layers with a multi-layered thin-film silicon anode, the long-life cycling of the Si/Ni/Si/Ni anode was demonstrated. A capacity retention of 82% after 200 cycles was measured, surpassing the performance of conventional silicon thin-film anodes. This is attributed to the effective suppression of internal local stress induced by nonuniform volume expansion by the nickel layers. These findings offer a promising pathway towards the practical implementation of high-capacity silicon-based anodes in advanced lithium-ion batteries. Full article

A frequently large variation in load conditions is of great impact on the service life of fuel cells during the operation of fuel cell vehicles and further increases the maintenance cost of the system. This study proposed a method of power demand prediction of the proton exchange membrane fuel cell (PEMFC) on vehicles in the actual traffic environment. The hybrid power system topology of fuel cells and power battery on commercial vehicles is selected to build a fuel cell model, and the accuracy of the fuel cell model is verified. An improved multiple grey prediction method is then proposed to predict the power demand during the sampling period of the fuel cell while considering a dynamic time window in the prediction period. Comparisons were made between this proposed model and the other two prediction models as a single-step prediction and multi-step prediction. Data of CHTC-HT and field testing working conditions were used to evaluate these three prediction models in fuel cell power demand. Results showed that the multiple grey method showed a better prediction performance than the other models, indicated by the lowest error value of 16.944% under the CHTC-HT condition, the lowest error value of 2.169% under stable conditions with less variable load and 1.930% under dynamic conditions with frequent load changes in field testing. This study of the demand power prediction can be devoted to pre-tuning the fuel cell system to avoid performance degradation caused by unanticipated power fluctuation. Full article

This paper investigates the design of a digital product passport (DPP) model based on the asset administration shell (AAS) framework to support the circular economy while ensuring cross-industry applicability. In a circular economy, resources are continuously reused, fostering more sustainable manufacturing. The European Commission’s initiatives target this issue, with the DPP playing a critical role in sharing product sustainability information, such as product composition and repairability, throughout its lifecycle. However, a widely applicable DPP approach has yet to be established. This study consolidates existing standards, and scientific literature to develop a data model that aligns with circular economy principles. Using the AAS framework initially developed by the Plattform Industrie 4.0, we mapped the data requirements to submodel templates and addressed gaps in the data needed for real-life implementation. The results demonstrate that the proposed DPP data model is specific enough for practical use cases, such as the upcoming EU battery passport, while remaining flexible enough for application across various industries. The AAS framework’s adaptability and comprehensive data exchange capabilities make it a suitable foundation for developing DPPs that support the transition to a circular economy. Full article

Battery Energy Storage Systems (BESSs) are critical in modernizing energy systems, addressing key challenges associated with the variability in renewable energy sources, and enhancing grid stability and resilience. This review explores the diverse applications of BESSs across different scales, from micro-scale appliance-level uses to large-scale utility and grid services, highlighting their adaptability and transformative potential. This study also includes advanced applications such as mobile energy storage, second-life battery utilization, and innovative models like Energy Storage as a Service (ESaaS) and energy storage sharing. Additionally, it discusses the integration of machine learning (ML) and large language models (LLMs), including advanced reinforcement learning (RL) algorithms, to optimize BESS operations and ensure safety through dynamic and data-driven decision-making. By examining current technologies, modeling methods, and future trends, this review provides a comprehensive overview of BESSs as a cornerstone technology for sustainable and efficient energy management, leading to a resilient energy future. Full article

As part of the energy transition, near-Zero-Energy-Buildings use electric systems that reduce emissions and consumption. Nevertheless, the increased use of such systems comes with the E-waste challenge. Circular Economy concepts try to make more efficient use of these materials, but sustainable evaluations mainly focus on energy and emissions. The developed automated text analysis tool quantifies the appearance of circularity concepts in open-access literature about different stages of production, use, and end-of-life for heat pumps, Lithium-Ion batteries, photovoltaic modules, and inverters. The energy focus is corroborated in different amounts depending on the component and stage, and when circularity concepts appear, they are centred on waste and recycling. Numerical variables to model environmental impact available in open-access literature are limited, generalised, or present in a wide range. Access to product environmental specifications should be encouraged to ensure that energy transition is sustainable in all its dimensions. Full article

To promote sustainability and reduce the ecological footprint of recycling processes, this study develops an analytical tool for fast and accurate identification of components in photovoltaic panels (PVs) and Li-Ion battery waste, optimizing material recovery and minimizing resource wastage. The laser-induced breakdown spectroscopy (LIBS) technique was selected and employed to identify fluoropolymers in photovoltaic back sheets and to determine the thickness of layers containing fluorine. LIBS was also used for Li-Ion batteries to reveal the elemental composition of anode, cathode, and separator materials. The analysis not only revealed all the elements contained in the electrodes but also, in the case of cathode materials, allowed distinguishing a single-component cathode (cathode A containing LiCoO₂) from multi-component materials (cathode B containing a mixture of LiMn₂O₄ and LiNi_0.5Mn_1.5O₄). The results of LIBS analysis were verified using SEM-EDS analysis and XRD examination. Additionally, an indirect method for identifying fluoropolymers (polytetrafluoroethylene (PTFE) or poly(vinylidene fluoride) (PVDF)) employed to prepare dispersions of cathode materials was proposed according to the differences in wettability of both polymers. By enabling efficient material identification and separation, this study advances sustainable recycling practices, supporting circular economy goals in the renewable energy sector. Full article

Achieving high energy densities in lithium-ion batteries requires advancements in electrode materials and design. This study investigated the incorporation of multi-walled carbon nanotubes (MWCNTs) with high commercial viability as conductive additives into two types of high-nickel cathode materials, LiNi_0.8Co_0.1Mn_0.1O₂ and LiNi_0.92Co_0.07Mn_0.01O₂. To ensure a uniform distribution within the electrodes, MWCNTs were uniformly dispersed in the solvent using ultrasonication, the most effective and straightforward dispersion method. This enhancement improved both electronic and ionic conductivity, facilitating the formation of an efficient electron transfer network. Unlike the cells using only carbon black, the electrodes with MWCNTs exhibited lower internal resistances, facilitating higher lithium-ion diffusion. The cells with MWCNTs exhibited a capacity retention of 89.5% over their cycle life, and the cells with 2 wt% MWCNTs exhibited a superior rate capability at a high current density of 1 C. This study highlights that incorporating well-dispersed MWCNTs effectively enhances the electrochemical performance of ultrahigh-loading cathodes in lithium-ion batteries (LIBs), providing valuable insights into electrode design. Full article

It is necessary to maintain safe, efficient, and compatible energy storage systems to meet the high demand for electric vehicles (EVs). Lithium manganese nickel cobalt (NMC) and lithium ferro phosphate (LFP) batteries are the most commonly used lithium batteries in EVs. It is imperative to note that batteries are classified according to their electrochemical performance. A number of factors play a crucial role in determining how efficiently batteries can be used. These factors include the cell temperature, energy density, self-discharge, current limits, aging, and performance measurements. This paper offers a proposed electrothermal model for comparison between LFP and NMC batteries. This model demonstrates the different behaviors according to their application in EVs. This is carried out through studies of state of charge (SoC), state of health (SoH), thermal runaway, self-discharge, and remaining useful life (RUL) in EVs. According to numerical analysis, this paper examines how these different types of batteries behave in EVs to assist in the selection of the most suitable battery taking into account the operating temperature and discharge current using a helpful thermoelectric model reflecting battery safety and life span effectively. Using MATLAB Simulink, the data selected in the electrothermal model are combined from a number of references that are incorporated into lookup tables that affect the change in values in the electrothermal model. The cells are implemented in an EV system using a current test to examine the measured current that goes in and comes out of the battery cells during charging and discharging processes taking into account motoring and regenerative braking for a specified drive cycle time and a number of discharging cycles. It was found that LFP batteries have better stability for open circuit voltages of 3.34 volts over a wide range of conducted temperatures. NMC batteries, on the other hand, exhibit some open circuit voltage variation of 0.053 volts over the temperature range used. Furthermore, the self-discharging current of LFP batteries was about 12 times lower than that of NMC batteries. Compared to LFP batteries, NMC batteries have a higher energy density per unit of mass of 150%, which reflects their greater discharge range. As a result of temperature effects, it has been revealed that LFP batteries are about two times more stable during discharging than NMC batteries, particularly at higher temperatures, such as 45 degrees. Full article