The Future of (Electrochemical) Energy Storage

The Future of (Electrochemical) Energy Storage Venkat Srinivasan Staff Scientist Lawrence Berkeley National Lab

1. There is still a need for a better battery 2. Batteries evolve slowly… at 6% increase in energy density a year 3. We need to discover new materials and manufacturing them at scale 4. Need to connect research and manufacturing to accelerate innovation

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Quick introduction

Joint Center for EnergyBatteries Materials Research Storage Research (JCESR) CalCharge

(BMR) Program (Battery “Hub”)

Public-privateNext-generation Revolutionary new partnershipmaterials for storage concepts focussed on storagebatteries

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The history of battery research and manufacturing Battery Research Battery Manufacturing

But times are changing 3

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Disruption has already occurred in the consumer electronics industry

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' ,4.~ BERKELEY LAB ~-..... -..--., Its happening in electric cars

Instead of this… We have…

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And it will happen on the grid

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S. orage ndus . ry Cele rates Big Win In Cal·fornia

o h"ng rath r igni can j t hap ·nd : outh arfo n· MliU.:~ ( larg t grid-conn d tor a Sate . Th fi ·m gre er than h th utility califomia P blic U · iti mandat .

==0.1- 0 ag n h of h Un

capabirty. requir d to under he

Th companie cho n to provid torage ar as follo

• le En r · Holdin , Inc. 25.6

• dvanced icrogrid Solution 50.0

• St m 85.oMW

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0"

50"

100"

150"

200"

250"

300"

350"

400"

1970" 1975" 1980" 1985" 1990" 1995" 2000" 2005" 2010"

Energy'Den

sity'(W

h/kg)'

Moore’s law for batteries

Lead acidNickel Metal Hydride

Li-ion:5% per year

Li-ion commercialized

Battery pack

Target

2-5x improvement in energy density needed to achieve range parity with gasoline cars

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-

0"

100"

200"

300"

400"

500"

600"

700"

800"2002"

2003"

2004"

2005"

2006"

2007"

2008"

2009"

2010"

2011"

2012"

2013"

Cost%($

/kWh)%

EV Battery packs

EV Target

Batteries at $100-$125/kWh will be the tipping point.

Grid Target

...and cost remains very high

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Gigafactory

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BERKELEY LAB ~-.-y-~-.y

Flow Batteries

1

2

4

6

10

2

4

6

100

2

4

6

1000 S

peci

fic E

nerg

y (W

h/kg

)

100

101

102

103

104

Specific Power (W/kg)

-

36 s0.1 h1 h

100 h

-

-

-

Fuel Cells

36 s0.1 h1 h

100 h

-

Acceleration

Rang

e

EV goal

3.6 s36 s0.1 h1 h

10 h

100 h

Source: Product data sheets

PHEV goalEV – Electric Vehicle PHEV– Plug-in Hybrid- Electric Vehicle

IC Engine=2500 Wh/kg

Status of batteries for vehicle applications

Capacitors

Lead-acidNi-MH

Li-ion

But its not just about energy and power density

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But its more than just energy and cost

10

0!

20!

40!

60!

80!

100!

Energy Density (500 Wh/l)

Specific Energy (235 Wh/kg)

Calendar life (15 years)

Cycle life (1000 cycles)

Selling price (125 $/kWh)

Fast charge to 80% DOD (15 mins)

Temperature range (-40 to 65 C)

Li-ion in electric vehicles

Batteries are a compromise between these various requirements

Where is the cost in a Li-ion battery?

Material-38%

Cell manufacturing-46%

Pack-16%

Need to focus on materials and on manufacturing

SeparatorElectrolyte

Cathode

Electrode Preparation-24%

Assembly-36%

Formation-22%

Winding-18%

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1 '?'

3

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Battery 101- How do we make a better battery?

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Sepa

rato

r

Cathode

Curre

nt C

ollec

tor

Anode

Curre

nt C

ollec

tor

e−e−

e−

Electrolyte

Electrolyte: • Liquid organic solvents • Polymers • Gels

Cathode: • Layered oxides • Spinel-based compositions • Olivine-based compositions

Anode: • Carbon-based • Alloys and intermetallics • Oxides

Cost can be lowered by: lower cost materials, higher energy materials/cells (lower $/kWh), and/or cheaper manufacturing

Electrolyte: • Sulfuric acid • Potassium hydroxide • Potassium hydroxide

Cathode: • Lead oxide • Nickel Hydroxide • Nickel Hydroxide

Anode: • Lead sulfate • Cadmium • Metal Hydride

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Summary• Li-ion batteries will get cheaper as the Gigafactory ramps up.

• But, to reach a tipping point, a further 2-3x reduction in cost is needed.

• Complicated due to the many different metrics over which batteries have to be optimized.

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We need innovations to ensure we hit the tipping point. Some of these innovations will be in materials.

But we also need innovations in manufacturing.

Electrolyte oxidation

Finding new materials: The principle

5

4

3

2

1

0

Pot

entia

l vs

Li/L

i+

1.00.80.60.40.20.0Stoichiometric coefficient, x in LixC6

1.0 0.8 0.6 0.4 0.2 0.0

Stoichiometric coefficient, y in LiyCoO2

Lithium concentration, x in LixC6

Pot

entia

l vs.

Li/L

i+ , V

Lithium concentration, y in LiyCoO2

Li+ + C6 + e - LiC6

LiCoO2 Li+ + CoO2 + e-

Discharged Charged

280 mAh/g

372 mAh/g

Lithium plating

Electrolyte reduction

Energy=Capacity (mAh/g) x Voltage

140 mAh/g

Electrode breathing (Stress/Cracking)

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Finding new materials: Focus areas

Enable high voltage cathodes (>4.3 V)

Silicon and tin anodes: 3-10x capacity vs.

graphite

Sulfur cathodes: 1675 mAh/g vs. 140-180 mAh/g

Lithium metal anode: 10x capacity vs. graphite at

lower potential

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Magnesium/Calcium-ion batteries: 2-3x capacity of lithium

Each approach promises to increase energy/decrease cost

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Lithium concentration, y in LiyCo02

0.8 0.6 0.4 0.2 0.0

5 Electrolyte oxidation

> + .....J 4 =:::: .....J

(I)

> 3 ro

:.::; C: (1) 2 -0 c..

1 •-----1➔--_--_-_----~;~ -~ -~~-~ -~~--~ --~;~~- ---------------. ~--

o -~'.=:e:========::=Ji~~m 0.0 0.6 0.8

Lithium concentration, x in LixC6 Lithium plating

From materials to a battery

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Mixing Coating Drying Calen- dering

Slitting Tabbing Winding

Electrode Winding

or Stacking

Can filling

Can tabbing

Cell connecting

Module filling

BMS adaption

Battery assembly

NMP PVdF Carbon TM-oxide

NMP

Cell filling

Cell forming

Cell sorting

Cell evaluating

Separator

Electrolyte

Cell sealing

NMP capture

Eliminating process steps and new processing methods can lead to lower cost batteries

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There are now numerous attempts to innovate in the labEn

ergy

Den

sity

incre

ase

or C

ost d

ecre

ase

TimeToday

But when will these reach the market?

Al-ion systems

Non-aqueous flow molecules

Li-metal based systems

High capacity conversion cathodes (S, air)

Low temperature Na-S

Mg-ion systems

New cell design Aqueous sodium-ion

systems

Silicon anodes

Modified aqueous flow molecules

High voltage, high capacity cathodes Non aqueous

sodium-ion

Advanced lead acid

Green: Grid Blue: Vehicle

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The Challenge of Translation from Lab to Market

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1975 1990

Sony Li-ion battery

1995 2000 20121983

Manganese

1980

Cobalt

Some Li-ion research

Li-ion research intensifies

IronMIT prof. starts A123 Systems

GM does not pick A123

A123 Chapter 11

1. Lab-to-market is slow! 2. Scale up and manufacturing is a challenge 3. Need close connection between R&D and manufacturing to accelerate innovation 4. Need to consider market demand

2009

Manganese commercialized

Power tools

Chevy Volt

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The history of battery research and manufacturing

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Battery Research Battery Manufacturing

When R&D and manufacturing are disconnected, innovation is slow

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Collaboration as an accelerator

The battery equivalent

50 nm

Revolutionary new materials and storage concepts

Process and manufacturing R&D

Markets for batteries (Vehicles, grid, vehicle-to-grid, second life)

Innovation will occur by connecting R&D, manufacturing, and markets

Silicon valley Secret history of Silicon Valley, Steve Blank

co-locating 20

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Critical Mass and Global Impact

•California has one the largest and most dynamic concentrations of the energy storage sector in the world

•With an outsized impact on industry and market development globally

• More than 120 energy storage companies are located in California

• But no “center of gravity”

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Program Areas

Technology Acceleration Pre-Commercialization Support

Professional Development Ecosystem Facilitation

Accelerating from innovation to installation

• Companies conduct propriety research inside Berkeley Lab

• Advanced Manufacturing Roadmap

• First MSE in Batteries with SJSU • IBEW-NECA Energy Storage

Standard and Certification Development

The history of battery research and manufacturing

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Battery Research Battery Manufacturing

When R&D and manufacturing are disconnected, innovation is slow

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The problem: A lesson from the PV industry• Building the same technology that is already in Asia not compelling

24How do we solve this challenge?

ANALYSIS

hi : DOI: 10.1039/ 3 0701b

View Article Online V,low .:Journal

Assessing the drive s of regio al trends in so a photovoltaic ma facturing

Al an C. Goodrich, Doug las M. Pow 11, b ~ d . Jam s,a Micha I Woodhous a

nd Tonio Buonassisi

Th , ho ovol ic (PV) in ry h grown ra idly s ourc of n r y and onomic ivi y. Sine 2008,

h a • ge ma nu fact er-sal pric o PV modul s as d d in d yo a actor o o coincidin wi a

signi icant increase in t he scale o manufacturi ng in China. Using a ho om-up model for wafer-based

·neon PV, min oth hi oric I nd fu ri fa o -loca ion d ci ions f om h p r of a

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1 the role of innovative technology in altering regional competinve advantage. We find that the historical

price advantage of a China-based factory re lative to a U.S. based factory islnot driven by country-specificl advanta es but instead b scale and su I -chain develo ment. Loo ing forward, we calculate that

pric adv n ag of Chi n -ba d actory n la iv o U.S. s d f a ory is no driven by cou ntry- p cifk

advan ages bu in ead by seal and sup ly chain dev lopmen Loo in orward, we caku la e ha

t echnology innovat ions ay resu lt in e ectively equiva len m'nimum sustainable manufacturing p ·ces

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One approach- Rebuilt the supply chain and the scale

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Cost of the factory: $4-5B

But is this the only way?

ed 2020 G·ga ac ory Produc io Exceeds 20 3 Globa rod ction

-.i40 - - - - ------ -- --- ---- ------- -- ---

Gob I c II upply 35 t aln10 t --- -- -------- ------- ·- - , --

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20 10 2011 2012 2013 20 I~ 20 15 2016 2017 2018 20 19 2020

Battery pack cost/kWh reduced )30% by Gen Ill volume ramp in 2017

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An alternate approach

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Would this “advanced” battery be amenable to manufacturing in the US?

Supply chain Process stepsMixing Die casting

Drying …..

PackagingTabbing Packaging

Formation …..

Aluminium Copper

polymer separator Electrodes

…..

Disrupted Disrupted

Sepa

rato

r

Cathode

Curre

nt C

ollec

tor

Anode

Curre

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ollec

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e−e− Electrolyte

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_I _I_I _I _I _I_I _I

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$0.279'

$0.234'$0.221' $0.219'

$0.354'

$0.272'

$0.232' $0.223'

0.000'

0.050'

0.100'

0.150'

0.200'

0.250'

0.300'

0.350'

0.400'

Asia00.14'GWh/year'

Asia0'0.3'GWh/year'

Asia01'GWh/year'

Asia035'GWh/year'

San'Jose0'0.14'GWh/

year'

San'Jose0'0.3'GWh/

year'

San'Jose0'1'GWh/year'

San'Jose0'35'GWh/year'

Cost%Breakdown%.%$/Whr%%Thin%Laptop%Ba7ery%

Other'

Facility'

Labor'

DepreciaEon'

COC0Indirect'

COC0Direct'

High volume automated manufacturing case

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• Cost in CA is 4.7% higher than Asia (1.8% for Gigafactory case) • The advantage of colocation, ease of continued innovation, IP protection, economic and

political climate, and the enhanced performance of the device, would offset the higher cost

Key: Innovation not imitation

$60 M $90M $250 $6-7B

■

■

■

■

■

■

]~~------------'

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Ener

gy D

ensit

y or

Cos

t fra

ctio

n

Today

Al-ion systems





Mg-ion systems

New cell design

Aqueous sodium-ion systemsSilicon

anodes


High voltage, high capacity cathodes

Non aqueous sodium-ion

Advanced lead acid

Time

Manufacturing competitiveness map

( ___ __..)

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r

r " \.. - "' I

\... .,

r " \.. ~

~

\.. ~

Ener

gy D

ensit

y or

Cos

t fra

ctio

n

Today

Al-ion systems





Mg-ion systems

New cell design


anodes



Non aqueous sodium-ion

Advanced lead acid

Disruption of existing manufacturing

Manufacturing competitiveness map

( ___ __..)

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\.. ~ .,

r

r " \.. - "' I

\... .,

r " \.. ~

~

\.. ~

Manufacturing competitiveness mapEn

ergy

Den

sity

or C

ost f

ract

ion

Disruption of existing manufacturingToday


New cell design




Al-ion systems


Mg-ion systems


anodes


Non aqueous sodium-ionAdvanced lead

acid

Low Medium Highl I -:

- - 1 r : 1 .a ( ( J

__.) ( J

( J r

r ., r \,.

\.. ~ r " \.. ~

, "

r "I

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\.. ~ .... ....

Manufacturing competitiveness mapTe

chno

logy

rea

dine

ss le

vel

Supply chain/process disruption

Low

High

Low

High

Today


New cell design




Al-ion systems


Mg-ion systems

Aqueous sodium-ion systems

Silicon anodes

High voltage, high capacity cathodes Non aqueous

sodium-ion

Advanced lead acid

Target

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Focus should be on moving technologies to the top right.

Need to establish close connection between research and manufacturing to accelerate innovation.

r

)

Can we create the Sematech for batteries? Goal: How do we move to the top right?

More meetings are planned with companies across the supply chain (from materials to modules)

Cut down process steps Modernize battery manufacturing Develop new designs

Develop process modelsNeed access to a pilot lineDevelop process metrology

1. Move away from slot die casting 2. “Fix” formation and use energy lost 3. Need to decrease process steps 4. Need reliable dry process

1. Bring “lean manufacturing” and six sigma principles to bear

2. Need modular manufacturing method

3. Use space 3D, rather than 2D

1. Need sensing inside battery, go beyond voltage

2. Need high power cells that also achieve high energy and high safety

3. Need to develop designs that reduce losses at pack scale

1. Need accurate process flow models and cost estimates 2. Need believable accelerated tests 3. Need battery designs on a computer

1.Improve yield by ensuring adequate feedback loops 2. Need inline diagnostics 3. Ensure control over every process step

1. Access to analytical and testing equipment

2.Need standardization of materials and processes

Summary• Markets for storage are opening up and will grow

• Batteries will get cheaper (thanks to Tesla)

• But to reach mass market, we will need further innovations

• These innovations will involve new materials and new manufacturing processes.

• There are many attempts to achieve these innovations; but translation from lab to market takes a decade

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We need to focus on scaling and manufacturing to accelerate innovation

The Future of (Electrochemical) Energy Storage

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