Ongoing Research
Our discovery-driven research helps to understand the safety and performance of energy technologies to mitigate risks. Read more about our current projects below.
Paving the Way for Greener Hydrogen Generation with University of Houston
In an effort to realize the promise of green hydrogen technology, ESRI, and Dr. Xiaonan Shan at the University of Houston launched a collaborative research project to develop new materials and methods for producing hydrogen. The main objective of the project is to develop efficient and economically viable transition metal catalysts for the hydrogen and oxygen evolution reactions. The project also calls for understanding the safety associated with hydrogen generation at an R&D lab-scale.
Operando Spectroscopy Techniques for Solid-State Batteries with University of Houston
Solid-state batteries (SSBs) are claimed to improve safety and electrochemical performance compared to traditional liquid lithium-ion cells. ESRI’s SSB project pursues basic research to understand the fundamentals of this emerging technology. The present work aims to study the interfacial properties and lithium-ion migration through the interface using operando optical microscopic imaging and Raman spectroscopy techniques. This work is being carried out with Dr. Xiaonan Shan at the University of Houston.
New Lithium-ion Battery Materials with National University of Singapore
ESRI is partnering with Prof. Palani Balaya at the National University of Singapore to advance the safety science of novel materials used in lithium-ion cells. The research study focuses on developing new cathode materials, specifically manganese-doped lithium iron phosphate (LiMnFePO4), along with robust titanate-based anode materials. The study also includes optimizing electrode manufacturing and fabricating cylindrical 18650 cells. The research aims to provide insights into lithium-ion cells to enable fast-charging capability and high-power applications.
Selective Membranes for Magnesium-ion Conduction with University of Houston
The magnesium battery project, led by Prof. Yan Yao at the University of Houston, is dedicated to developing electrolyte and membrane materials to improve the conductivity of magnesium-ions while effectively preventing the passage of soluble organic substances. The results provide a strong foundation for refining the trade-off between selectivity and conductivity in magnesium-based membranes. The project ultimately evaluates the long-term stability of magnesium-organic cells equipped with different selective membranes, including alternative fluorine-free variations.
Hexagonal Boron Nitride incorporated PVDF Separators: A Path Toward Safer and More Stable Lithium-ion Batteries (ESRI internal study)
The project focuses on the fabrication of hexagonal boron nitride (h-BN) incorporated polyvinylidene fluoride (PVDF) separator by the electrospinning technique. Conventional lithium-ion batteries have limitations at high temperatures, and h-BN has excellent thermal conductivity. When incorporated into the PVDF matrix, h-BN can improve the thermal and mechanical stability of the separator by efficiently dissipating the heat generated during operation. The aim of fusing the thermally conductive h-BN with highly porous electrospun PVDF is to enhance the separator's wettability, ionic conductivity, and thermal stability, which can contribute to better electrochemical performance of lithium-ion batteries.
3D Printing of Anode-Free All-Solid-State Batteries with University of Houston
All-solid-state batteries represent a promising solution for next-generation energy storage. In addition, solid electrolytes allow for 3D geometry rather than the planar configuration used with liquid electrolytes. To realize this, 3D printing cell fabrication is being investigated. For this collaborative work with Dr. Zheng Fan at the University of Houston, the following tasks have been planned:
- Develop and synthesize printable slurries for each of the components of the battery.
- Develop a 3D printing platform with nozzle tips for direct writing of slurries.
- Investigate the interactions between electrodes and electrolytes during deposition and develop a "lab-on-a-nozzle" testing setup to identify key parameters for regulation quantitatively.
Library (for) Battery Research and Reference (Internal ESRI) LiBRaR(IE)
This LiBRaR(IE) project aims to establish a systematic database of development procedures for producing electrochemical cells. One of the barriers to battery research is that the fabrication procedure and testing methodology may drastically impact results, which makes replicating the research of other scientists difficult. By having a well-defined development procedure and testing best practices, objective improvements and crucial learnings can be more easily identified. This project will focus on the fabrication process of lithium-ion cells and a nuanced examination of the destructive physical analysis (DPA) procedure of commercial cells to investigate the impact of often unmentioned test parameters on observed results.
Novel Lithium Phosphate Salts as Flame-Retardant Additives for Enhanced Safety and Performance in Lithium-ion Batteries with Case Western Reserve University
Our collaborative project with Prof. John Protasiewicz at Case Western Reserve University aims to enhance battery safety by developing flame-retardant electrolytes. By incorporating innovative lithium phosphonate salts, we strive to significantly improve the safety and performance of lithium-ion and lithium-metal batteries. This research focuses on creating advanced solutions to mitigate fire risks and ensure safer and more reliable energy storage systems.
EVs4ALL (ARPA-E): Safety Evaluation of New Battery Chemistries at the Component and Low-Capacity Cell Levels (U.S. DoE)
In collaboration with Sandia National Laboratories, the University of Maryland, and Purdue University, research studies that include testing and modeling will be carried out to investigate the safety of material components and lab-scale very low-capacity cells with novel battery chemistries.
The team will study the safety characteristics of new battery materials provided by other partners in the same program. In addition, 100 mAh cells will be tested. The aim is to determine if the safety of a new cell chemistry can be established at the material and very low-capacity cell level in comparison to the baseline lithium-ion cell. The goal is to provide safety test protocols for a deterministic answer regarding the nature of future cell chemistries. The team will also conduct simulation and modeling studies in parallel to support the empirical studies.
Read more about ESRI’s U.S. Department of Energy’s (DOE) Advanced Research Projects Agency-Energy (ARPA-E) program sub-award.
Battery Energy Storage System: Safety Standards and Best Practices with Customized Energy Solutions
In partnership with Customized Energy Solutions (CES), ESRI will develop standards and best practices for battery energy storage systems (BESS) both in India and globally. The main goal of the project is to prepare a safety plan, guidebook, and step-by-step process for BESS. This guidebook will provide the overall guiding principles and the step-by-step process for authorities to plan and assess projects and for operators and companies to follow for safe operation.
Lithium-ion Internal Short Safety Study with Purdue University
The internal short hazard caused by internal defects during manufacturing or misuse in the field has been an ambiguous area for many years. Simulation of internal shorts leads to catastrophic thermal runaway; however, since the event of a catastrophic failure leaves little or no evidence due to the complete destruction of the battery, it is not easy to directly link an internal short cause to the catastrophic failure. In this collaborative project between ESRI and Purdue University, cells are exposed to different mild off-nominal conditions, and cycle-life testing within normal operating conditions is carried out afterward. The electrochemical and thermal behavior of the cells is closely monitored to determine if any abnormal features stand out. Destructive physical analyses are conducted on the cells to understand the internal changes caused by the off-nominal conditions that would create the internal shorts.
Fire and Smoke Characterization of Lithium-ion Cells with Modeling Studies with Case Western Reserve University
Thermal runaway of lithium-ion batteries is often accompanied by the release of toxic and flammable gases, particulates, smoke, and fire. This collaborative project between ESRI and Case Western Reserve University focuses on the experimental characterization of cell temperature, mass, and composition of the gases released during thermal runaway for cells at various states of charge (SOC). The experimental results will be used to develop a computational fluid dynamics (CFD) model capable of modeling battery fire dynamics. The intent is to develop a model that can provide a good understanding of the scale-up of the fires from cells to larger battery systems to reduce the number of thermal runaway experiments (which can significantly reduce cost and time).
Safety of Commercial 21700 Cells and Modules with NASA Johnson Space Center
ESRI is collaborating with the Energy Systems Test Area (ESTA) to study the safety of commercial 21700 cells and modules from different cell manufacturers. In this study, single cells and modules are subjected to off-nominal conditions such as external heating, overcharge, over-discharge, and external short to determine if safety features inside the cells provide protection. In addition to thermal hazards, gases generated from the cells will be analyzed to determine hazardous limits.
Large-Scale Lithium-ion Battery Fire Suppression Studies with Stress Engineering Services
The objective of this study, in collaboration with Stress Engineering Services, is to investigate the efficacy of water and aerosol suppressants in dealing with lithium-ion battery fires. Experiments are being designed to be representative of stationary grid energy storage applications, and tests will be conducted using single and multiple lithium-ion battery modules. Baseline and suppression tests will be performed to examine the efficacy of different suppressants in dealing with lithium-ion battery fires. Various measurements, including temperature, heat flux, gas, and particulate emissions characterization, will be conducted as a part of this experimental program. The results will inform the development of fire suppression strategies and also provide data sets for modeling large-scale lithium-ion battery fires and their suppression.
Characterization of the Performance and Safety of Commercial Sodium-ion Cells with Stress Engineering Services and ESRI Internal Study
Due to the abundance of sodium in nature, there is growing interest in using sodium-ion cells for various applications.
Internally, ESRI is working on understanding the performance of commercially available 18650 sodium-ion cells from different manufacturers. Cycle life tests under different C-rates while maintaining the cells at different temperatures are being studied.
ESRI is also collaborating with Stress Engineering Services to study the safety aspects of these commercially available cells. In this study, single cells and mini-modules are subjected to off-nominal conditions such as external heating, overcharge, over-discharge, and external short to understand outcomes. Results suggest that cell failure could result in thermal hazards and the release of emissions (gases and particulates). ESRI is also conducting studies to learn about the composition of such emissions.
Role of Oxygen on Ignition and Sustained Combustion in Thermal Runaway of Lithium-ion Cells with Purdue University
This collaborative effort between ESRI and Purdue University aims to enhance existing computational fluid dynamics (CFD) models and utilize specialized software tools to investigate critical factors affecting ignition time and flame behavior, with a particular focus on oxygen concentration. By integrating knowledge from established gas generation mechanisms, this research project aims to shed light on the complex dynamics of thermal runaway in lithium-ion batteries, especially how fuel composition, oxygen concentration, and initial temperature variations can influence ignition timing and subsequent thermal events.
Simulations and Modeling of Fire Suppression for Large-Scale Lithium-ion Battery Storage with University of Texas at Arlington
Prevention and suppression of fires resulting from thermal runaway in large-scale battery systems is one of the most significant challenges concerning lithium-ion battery safety. Although several candidate techniques are available to extinguish fires in these scenarios, their effectiveness still needs to be determined, and the method of suppressant release needs to be optimized. Since experimental measurements for large-scale systems can be costly and complicated, developing robust and reliable simulation models is crucial. This collaboration between ESRI and the University of Texas at Arlington aims to construct thermal simulation tools to enhance our understanding of the module-to-module propagation of fires resulting from thermal runaway and the effect of various fire-suppression techniques in large-scale battery systems. Results from these models will be compared with data collected from ongoing experimental measurements at ESRI to understand and enhance the robustness of the model.
Modeling the Effect of Over-Discharge on Cycling of Lithium-ion Batteries with University of Texas at Austin
Over-discharge of the battery is a safety concern and can lead to performance degradation and high temperature in the cell. This collaborative program between ESRI and the University of Texas at Austin focuses on a modeling approach that helps identify the underlying mechanism for high temperature in the cell and the effects of long-term aging of cells. The loss of capacity predicted by this model aligns with experimental data for different over-discharge protocols. Copper dissolution from the anode and the coupling of subsequent breakdown and reformation of the solid-electrolyte interphase (SEI) layer cause non-linear capacity decay during over-discharge cycles.
Coupled Electric, Thermal, and Electrochemical Model of a Battery Module (ESRI internal study)
A battery module comprises several lithium-ion cells connected in series and parallel configurations to obtain the desired voltage, current, and power specifications. The overall response of a module can be affected by the electrical topology, the thermal topology, and cell-to-cell variations. A coupled electric, thermal, and electrochemical model is being developed to simulate the charge-discharge of a battery module. This physics-based model uses a simplified electrochemical-thermal model at the cell scale. At the module scale, the modeling framework accounts for the interactions between cells due to electric and thermal connectivity.
Deciphering Lithium-ion Battery Safety: In-depth Analysis of Lithium Plating and Interphase Dynamics with University of Chicago
Potential safety risks in batteries become particularly pronounced under harsh conditions such as cold weather, rapid charging, or improper use like overcharging. It has been found that the safety and longevity of lithium-ion batteries are directly linked to the solid-electrolyte interphase (SEI) because it acts as a passivation layer that regulates lithium ions' movement during charging and discharging cycles. This collaborative effort between ESRI and the University of Chicago aims to perform an in-depth analysis of lithium plating and SEI components.
For this work, the following tasks are planned:
- Develop the SEI components quantification setup.
- Investigate the lithium plating behavior and SEI evolution at different charge rates and temperatures.
- Investigate the degradation mechanism with different overcharge conditions.
- Formulate new liquified electrolyte for silicon-based anodes.
Transition to Detonation Limits in Blended Hydrogen-Natural Gas Mixtures with University of Ottawa
At present, about a third of North America’s energy needs are met by natural gas. It is believed that greenhouse gas emissions can be reduced significantly by adopting hydrogen as an energy carrier or by blending hydrogen with natural gas. This collaborative project between ESRI and the University of Ottawa aims to investigate the detonation limits of the hydrogen-natural gas mixtures at different ratios. This project includes experiments of gas mixtures at lower pressures (~10kPa) to determine detonation limits and the development of numerical combustion models. Results from this program will inform safety considerations for the transportation of hydrogen-natural gas mixtures.
Center for Advances in Resilient Energy Storage (CARES) with Purdue University
Established in early 2024 as a collaborative effort between ESRI and Purdue University, the Center for Advances in Resilient Energy Storage (CARES) at Purdue University aims to enhance the safety, degradation, and performance of energy storage systems through comprehensive multi-scale experiments, analytics, and modeling. The center's current research focuses on the safety of next-generation batteries, including solid-state batteries, metallic anodes with liquid electrolytes, and sodium-ion batteries. As a part of the CARES program, multiple long-term focus areas are pivotal for advancing sustainable energy solutions.
Study on the Effects of Over-Discharge on Imbalanced Battery Modules with Purdue University
This collaborative project between ESRI and Purdue University aims to study the effects of over-discharge of a single bank due to an imbalance in battery modules. For this study, tests are being performed at the cell level and, subsequently, at the module level. The performance of the battery modules will be studied closely during the subsequent charge/discharge cycling to determine if any abnormal behavior occurs. Results from this program will help examine the potential occurrence of an internal short circuit. Such knowledge is critical for various applications ranging from electric vehicles to energy storage systems.
