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AQMD Plug-in Hybrid Vehicle Technical Forum: Li-Ion Technically Ready, Manufacturing a Big Barrier

12 July 2006

Aqmdphev1
The relative importance of the charge-sustaining mode and the charge-depleting mode in a PHEV. The chart shows the total consumption benefit as a function of the improvement in charge-sustaining mode consumption for HEVs and PHEVs with several electric range capabilities. Source: NREL

The California South Coast Air Quality Management District (AQMD) today held a Plug-in Hybrid Electric Vehicle (PHEV) Forum and Technical Roundtable focused on the technical issues related to advanced batteries and their effect on the development and commercialization of PHEVs.

The mission was to accelerate the deployments of PHEVs and the goal for the meeting was threefold: to discuss and assess capabilities of advanced batteries; to identify requirements and issues; and to initiate dialogue between different participants in the market and to establish their respective roles.

AQMD’s focus on PHEVs comes more from the emissions control frame of reference. The four-county South Coast district has the worst air quality in the country. Although the progress has been made over the past years in reducing emissions, emissions have plateaued, and at levels above required standards.

With the most immediate gains being made, AQMD is looking for longer term changes—such as that represented by PHEVs—to alleviate the air quality issues. In March, the AQMD board directed staff to expand PHEV activities. This technical meeting was a first step in that direction.

Participating in the panel discussion were:

  • Matt Miyasto, Technology Demonstrations Manager, AQMD
  • Mark Duvall, Manager Technology Development, EPRI
  • Tien Duong, Team leader Vehicle technologies, FreedomCAR (DOE)
  • Ahmad Pesaran, Principal Engineer, NREL (DOE)
  • Dan Doughty, Manager, Li-Ion Battery R&D, Sandia
  • Michael Andrew, Johnson-Controls-SAFT
  • Greg Hansen, Energy CS
  • Loic Gaillac, Southern California Edison

The general sense of the panel was that from an electrochemistry point of view, lithium-ion cells note only were poised to become the predominant PHEV system in the short- to medium-terms, but that they were basically ready to go.

There exist, however, a number of significant barriers to the commercialization of Li-ion PHEV battery systems, among them being cost, cycle life, and safety management. While the chemistry may be ready, in other words, the barriers are primarily on the manufacturing side.

The other significant issue that emerged during the discussion was the question of the system design target, specifically whether or not the PHEV needed a pure electric mode, or whether it could use a blended approach.

Plug-in hybrids use a grid-rechargeable energy storage system to provide capabilities beyond those of conventional charge-sustaining hybrid systems. A PHEV essentially has two battery operating modes: a charge-sustaining mode [recharging the battery during operation via regenerative braking, for example] and a charge-depleting mode [drawing down the charge from the grid]. The total consumption benefits of a PHEV are a combination of the charge-depleting and charge-sustaining modes.

Characteristics of a PHEV battery pack include:

  • Higher total energy capacity than those of HEVs;
  • The cell design has lower power density but higher energy density than HEVs;
  • The battery is deep discharged during driving to a lower minimum State of Charge than an HEV;
  • The battery is grid-recharged;
  • Total battery cost is higher than that of HEVs an represent a larger portion of the projected PHEV cost delta;
  • Battery energy is directly related to the per mile electrical energy consumption and the desired range;
  • Battery mass is greater but typically not to the extent that vehicle performance is significantly affected.

Tien Duong from the FreedomCAR project noted that the DOE has a draft goal of reducing the cost of PHEV batteries to $300 kWh by 2014. That would give a 10 kWh PHEV battery system a cost of about $3,000—about a quarter of the current cost. He also noted that the DOE is at work on a research roadmap for PHEVs, and that the draft roadmap should be ready by December.

Ahmad Pesaran from NREL pointed out that there is a broad spectrum of HEV-PHEV designs leading to different battery requirements. There are currently batteries that could meet the energy and power demands for PHEVs, he noted, but cost and the short cycle/calendar life are still major barriers.

While there are emission benefits with PHEVs, there are some differences between the emissions output of pure EV implementations and the blended EV range impacts that need to be understood. Specific points of discussion emerged around the current need for hybrids to fire up the engine to heat the catalytic converter at start-up. A PHEV with a robust EV mode would do so—but that in turn could confuse the existing testing regimens.

While NiMH systems have matured in power and energy, Li-ion systems support diverse chemistries and opportunities. Lithium-ion cells work basically on a shuttle mechanism, with the lithium ions moving back and for the between anode and cathode. Bsttery makers have an opportunity to change to the cathode and anode to improve characteristics such as recharge time or stability.

The lithium iron phosphate cathode chemistry used by Valence, for example, offers less potential watt output capacity than cobalt, but offers better safety characteristics. This is an exciting time for Li-ion, Pesaran noted, with new cathodes, new anodes and new electrolytes offering lower temperatures, better safety and lower cost.

All panel members agreed that one of the most pressing needs was larger demonstration PHEV fleets—on the order of several hundred vehicles in the aggregate.

I think what we heard today was that the best balance...is to put in a battery capable of only 20 kW rather than a full EV. Even in a vehicle like that (blended) you offer a lot of all-electric range. The evolution of the thing, if we have all electric range interspersed, or even just a Honda-type system where you are bleeding power into the system, will eventually evolve into more all-electric range, bigger and better all-electric range. If the automakers can get to the point where they can justify a 9 kWh battery or even 5 kWh on a car, then just as you saw with Toyota and Honda, you will see competition for providing more of that capability. And that will help all kinds of technologies.

—Greg Hansen

I think the technology is fanning out. I envision that in the future when you go buy a Ford Escape, you will have an option of Battery A, Battery B, Battery C with different cost-benefit ratios, etc. Customers will make the choices. I think it will diversify rather than narrow.

—Dan Doughty

Presentations and summary materials from the forum will be available on the AQMD website in several days.

Resources:

July 12, 2006 in Batteries, Hybrids, Plug-ins | Permalink | Comments (40) | TrackBack (1)

Comments

An engineer: We are right and wrong. Dont forget that a massive switch to¨PHEVs and EVs could reduce liquid fuel demand to less than 15% of current consumption.

Alternative fuels (all kinds) could support a drastically reduced demand.

More efficient lighter vehicles and a switch to electric heating and electric trains could further reduce the total liquid fuel demand level.

Posted by: Harvey D. | July 15, 2006 at 09:38 AM

(Dumb?) Question from a novice...
Does anyone know in terms of watts, how much electrical energy is required of the Prius to drive in EV mode?

I've been curious as most stories mention 1, 2 or 9 kWh electrical needs. I'm a computer guy not an engineer but do understand the concepts in terms of watts (as computer power supplies are rated in those terms) but not watt hours.

Thanks.

Posted by: Jack | July 15, 2006 at 07:58 PM


Kilowatt hours (KWh) are units of energy. Energy stored in a battery determines is how far the car can go. A car like the Prius gets about 3 miles/KWh. Thus a battery that stores 10KWh can provide power for about 30 miles of travel before the battery is drained.
Watts are units of power. Power is how fast energy gets used, and determines how fast the car can go (and how fast it can accelerate). A car like the Prius can creep along slowly on less than 10 KW; with 50 KW, it can travel moderate highway speed.
Energy and Power are often confused.

Posted by: Ken | July 16, 2006 at 12:08 AM

Although ethanol has about 75% the energy density of gasoline, it has an octane rating well above 100. The first thing we should do is to get rid of the low octane gas and immediately jump into higher compression ratio engines. Opposite to popular belief, gasoline engines are more efficient than diesel engines (as long as they have the same compression ratio). Having a system similar to the E85 SAAB that "samples" the fuel for octane rating is the easiest and cheapest way to "artificially" increase the compression ratio of a gas engine by injecting more air before the air-fuel mixture is compressed. This results in an net increase in thermal efficiency which translates in more power with the same fuel consumpition, or same power with less fuel consumption.

Posted by: freddy | July 16, 2006 at 06:27 PM

Although ethanol has about 75% the energy density of gasoline, it has an octane rating well above 100. The first thing we should do is to get rid of the low octane gas and immediately jump into higher compression ratio engines. Opposite to popular belief, gasoline engines are more efficient than diesel engines (as long as they have the same compression ratio). Having a system similar to the E85 SAAB that "samples" the fuel for octane rating is the easiest and cheapest way to "artificially" increase the compression ratio of a gas engine by injecting more air before the air-fuel mixture is compressed. This results in an net increase in thermal efficiency which translates in more power with the same fuel consumpition, or same power with less fuel consumption.

Posted by: freddy | July 16, 2006 at 11:48 PM

Does anyone know whether using photovoltaic cells could allow some battery capacity reduction? While the power contribution of such cells may be quite small, by having the car parked in the sun while at work or even during shorter periods could allow some recharging... or are such cells too expensive and heavy?

Posted by: alfredo | July 17, 2006 at 12:33 PM

alfredo, the LiX-75 that i linked to above actually employs solar panels for that purpose.
so does this homemade Solarvan
http://www.solarvan.co.uk/
the guy has his building costs listed on the page

Posted by: kert | July 18, 2006 at 04:10 AM

I'm going to take the whole issue a step further. Why can't we have EV mode cars in the Prius for example? I don't mean just for a few miles but like for 50-100 miles. An electric car can go up to 300 miles per charge.
And why can't PHEV and hybrids be equipped with optional solar panels on their top roof? Many cars park under the california sun. For most people they leave their cars outside in the sun for at least a few hours during work or classes. That's free electricity.
It's just too bad that the electric cars were destroyed by automobile industry(primary reason) because they were too good and would destroy their oil-vehicle market. If automobile industries were smarter they would have invested in the electric car because just like someone mentioned above they will have different quality batteries a,b,c, in the future and others features just like we do for oil-vehicles. We'd have quieter neighborhoods and more money to spend for christmas gifts.

Posted by: John M. | July 19, 2006 at 12:04 AM

Highly efficient small diesel engines can get better over all efficiency than gasoline engines and diesel does not cost as much to refine from crude oil. Such engines used in a constant speed mode to charge a battery in a car can have very low emissions. The overall efficiency is better than that of hydrogen produced from any source. Diesel or dimethylether can be made from coal for fuel for such diesel engines. Slightly modified diesel engines can burn corn oil directly, and recent reports state that this is more energy efficient than ethanol from corn. There is a very small diesel generator being built in a suitcase like package for a hybrid military vehicle. Replace your engine by pulling it out with a handle and inserting a new one. If you need more performance plug in two generators or more into your car.

Relatively cheap batteries have been available for a long time for full electric cars. These are called Zebra batteries and are made by MES-DEA who is producing a limited number of cars for Switzerland. These batteries use one fifth the amount of nickel that NiMH batteries use for the same energy and have a longer deep cycle life.

An electric car without at least a small gasoline or diesel generator built into it, is both an engineering and public relations mistake. Even if the small generator is never used it only weighs 20 pounds or less, and five gallons of fuel would take the car 200 miles at slow speeds and only weigh 30 pounds.

Posted by: henry gibson | July 20, 2006 at 04:11 PM

Most people don't drive hundreds of miles every day but they need a car that can do so ocasionally. Given that most families have two cars these days I think a pure could be sold as an ideal "second car". Having access to a gas car for long trips considerably reduces the percieved "problem" with electric cars. Of course it's no good if it looks like the car Noddy drives.

Posted by: Colin Watters | July 24, 2006 at 12:25 PM

Hello- is there anybody out there??
issue is large format ability and guess what? Valence has it nailed down. yes expensive but still cost effective...

Posted by: geoff | July 24, 2006 at 09:21 PM

Strictly novice... but I have a couple of questions
about batteries. Is it true that big oil bought the battery companies ie: lithium ion companies?
Why do L.I. batteries cost 50k to 100k? This is exactly why electric cars can't hit the street...to much $ for the batteries.
Do all e.v. have to be so ugly? I have seen some beautiful prototypes but nothing that doesn't have a delivery date of 2007. Wouldn't the perfect match be the L.I. battery and the exotic kit car....no rules?

Posted by: jim | August 01, 2006 at 06:42 PM

Dear Jim,

About your post on August 1 re: litiium Ion batteries and that the possibility that big oil owns some if not all of these companies.
Well, as you can see from the response generated since that time.....nobody gives a damn. No one has answered you and nobody knows anything, including me.
It is for the above reason that I would delete this web site from all memory in your computer because it is totally worthless with useless members who can't come up with any hope of an intelligent answer.

Horace Mann

Posted by: horace mann | August 06, 2006 at 03:11 PM

Lion batteries don't cost 50k, more like 20k for very large capacity ones (like tesla's 50kWh 250mi ev range), 12k-10k (installed conversion kit)for the phev ones (180lbs 9kWh 60-50 mile ev range) expected to go down to 5k w/ mass production. Battery probably less than 10k for 9kWh now. Its even less for the prius if its only a 9 mile range. I may be mistaken because using the small batteries 9kWh only costs around 3k. About bought patents, I know GM bought up advanced nimh patents for the ev1 project then sold it to Texaco, and Chevron merged, so now it owns the patents. Chevron specifically forbids licensing of the patents for plug-ins or ev use, they only allow it in hybrids.

Posted by: Jake | November 04, 2006 at 02:10 AM

my 66 volkswagen beetle got 50 miles to the gallon 50 years before this hybrid crap!!! And the beetle was standard internal combustion engine!!! What gives!?!?!?! Hybrids utilize way to much bullshite to gain fuel economy!! why doesn't anyone make a 50 mile to the gallon combustion!!! its a conspiracy !!!

66 beetle cost about $700 dollars
back in the day, new hybrids are about $40,000 come on!!!

Posted by: anonymous | December 28, 2006 at 10:59 AM

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» Li-Ion Technically Ready from After Gutenberg
The charge-depleting mode is when charge is restored if the battery is connected to a plugged-in charger, in the case of electric vehicles, or when the generator set restores charge, in the case of serial hybrids. ... [Read More]

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