extreme fast charging -...
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Extreme Fast Charging: Technical Gap Assessment
Christopher J. Michelbacher
International Battery Seminar
March 23, 2017
STI Number: INL/CON-17-41474
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• XFC Report Background
• Problem Statement and Introduction
• Battery, Vehicle, Economic, & Infrastructure Overview
• Grid Impacts
• Next Steps
Outline
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Objective• Leverage National Lab expertise integrated industry guidance and
findings to produce a strategic research document examining the technical gaps for extreme fast charging (XFC)
Charter• Multi-Lab collaboration project tasked by DOE to investigate the
technical challenges associated with XFC
National Laboratory points of contact• Christopher Michelbacher, INL (at DOE)• Ira Bloom, ANL• Eric Dufek, INL• Andrew Meintz, NREL• Tom Stephens, ANL
XFC Report Background
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Industry Participation• Auto Manufacturers
– BMW, Daimler, FCA, Ford, GM, Nissan, Porsche• EVSE Manufacturers & Network Operators
– ABB, AeroViornment, ChargePoint, Efacec USA, EVGO, GreenLots, Recargo/PlugShare
• Battery Manufacturers– Farasis, JCI
• Utility Suppliers– Black & Vaetch, BTC Power, EPRI, PG&E, Rock Mountain
Power, SMUD, SCE
XFC Report Background
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EV Refueling Experience• Charge time is a barrier to
broader technology adoption• Larger batteries take longer
to fully charge
The Problem
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Extreme Fast DC Charging• Supplements home and workplace charging• Facilitates longer distance all electric motoring • Mechanism to place EVs in near parity with ICEVs
Source: "DC Fast Charger Usage in the Pacific Northwest," Idaho National Laboratory, 2015.
GAS
The Solution
Target: XFC adds 150-190 miles of range in ~10 minutes or ~80% charge replacement for a 200-250 mile range BEV
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Introduction
350
• Consider the charging network as a whole. • Urban/Rural siting challenges (50 kW DCFC
installations)• Historically, DCFC primarily used to extend travel
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R&D & Cost• BatPac cost analysis
– Thinner active materials require more layers
• Drive up costs for inactive components
• Increase mass & volume– Impacts to energy density and specific
energy– Thermal management robustness
Battery Overview
R&D Increased Wh/kg
Thicker Electrodes
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Material Limitations• Current state-of-the-art material evaluation for XFC
– Lithium plating occurring during XFC? – How to mitigate its effects?
• Cell & electrode development and design– Anode, aspect ratio,
Battery Overview
6C
4C
2C
0.7C
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Pack Design• Thermal management
– Temperature gradient, heat transfer/rejection• Electrical safety
– Surface conductivity, insulators, stranded energy extraction
• Modeling– BMS, sensors & controls
Battery Overview
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Vehicle Findings• Vehicle/EVSE interoperability• High voltage impacts to vehicle level power
electronics– Volume, weight, cost, efficiency
• Thermal management– Design, volume, weight, cost
• Cybersecurity– Vehicle to EVSE communications security
• Safety– CCS connector evaluation for XFC suitability
Charging connector voltage and current range for new and existing vehicles
Vehicle Overview
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Economic Findings• How might XFC impact BEV adoption?
– Private, commercial, government, CAVs• XFC vehicle and infrastructure deployment analysis
– Operating & maintenance costs, station utilization, market penetration of XFC vehicles, technology costs
• Investigate influence of incentives and other policies as they relate to XFC capable BEV adoption– Station installation cost subsidies, vehicle OEM
role, government role, utility role• Cost models for XFC stations
– Leverage lessons learned from existing DCFC installations, station design, site location
Economic Overview
$0.00
$0.20
$0.40
$0.60
$0.80
$1.00
$1.20
$1.40
$1.60
$1.80
5 10 15 20 25 30 35 40 45 50
Tota
l Ele
ctric
ty C
ost (
$/kW
h)
Station Utilization (charges/day)
Impact of Utilization on XFC Electricity Breakeven Cost
EVSE Cost Amortization
Base Electricity Rate
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Infrastructure Findings• Compatibility & Standardization• Codes & Standards Unification• Ergonomics & Safety• Station Siting & Corridors• Integrated Communication & Controls• Human Factors & Consumer Usage• Managing Power & Energy Needs
– Energy charge ($/kWh) – Red = Green– Demand charge ($/kW) – Red = 3.5*
Green• Integrated Communication & Controls• Co-located Energy Storage or Generation
Time
Grid
Pow
er U
se, k
W
Infrastructure Overview
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Grid Impact of 350 kW Station
14
NREL-developed load profile data for DOE commercial reference buildings in Baltimore area. From OpenEI.org.
One day of data collected from a single fast charger in The EV Project. 92% charger efficiency assumed to determine AC load
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15
NREL-developed load profile data for DOE commercial reference buildings in Baltimore area. From OpenEI.org.
One day of data collected from a single fast charger in The EV Project, scaled to approximate 350 kW. 92% charger efficiency assumed to determine AC load.
Grid Impact of 350 kW Station
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This power is comparable to
NREL-developed load profile data for DOE commercial reference buildings in Baltimore area. From OpenEI.org.
Maximum possible power level
x 750
x 35
x 17
Grid Impact of 350 kW Station
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The Plan• Finalize technical gap assessment report• Develop a strategic R&D program plan• Coordinate research and deployment activities
with industry and other government agency stakeholders
• Continue to engage all stakeholders early and often as technology matures
Discussion Table
Auto OEMs
Utility Suppliers
EVSE Manufacturers
& Network Operators
Battery Manufacturers
Codes & Standards
Bodies
Policy Makers
Next Steps
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