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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%

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$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

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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

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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

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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.

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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

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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

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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.

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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

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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)

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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

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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

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$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

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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

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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

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For Additional Information…

Dave HowellHybrid Electric Systems Program Manager

David.Howell@ee.doe.gov202-586-3148

QUESTIONS?