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We develop three novel enhanced mixed integer-linear representations of the power limit of the battery and its efficiency as a function of the charge and discharge power and the state of charge of the battery, which can be directly implemented in large-scale power systems models and solved with commercial optimization solvers. Using these battery representations, we conduct a techno-economic analysis of the performance of a 10 MWh lithium-ion battery system testing the effect of a 5-min vs. a 60-min price signal on profits using real time prices from a selected node in the MISO electricity market. Results show that models of lithium-ion batteries where the power limits and efficiency are held constant overestimate profits by 10% compared to those obtained from an enhanced representation that more closely matches the real behavior of the battery. When the battery system is exposed to a 5-min price signal, the energy arbitrage profitability improves by 60% compared to that from hourly price exposure. These results indicate that a more accurate representation of li-ion batteries as well as the market rules that govern the frequency of electricity prices can play a major role on the estimation of the value of battery technologies for power grid applications.

The price of the cathode active materials in lithium ion batteries is a key cost driver and thus significantly impacts consumer adoption of devices that utilize large energy storage contents (e.g. electric vehicles). A process model has been developed and used to study the production process of a common lithium-ion cathode material, lithiated nickel manganese cobalt oxide, using the co-precipitation method. The process was simulated for a plant producing 6500 kg day −1 . The results indicate that the process will consume approximately 4 kWh kg NMC −1 of energy, 15 L kg NMC −1 of process water, and cost $23 to produce a kg of Li-NMC333. The calculations were extended to compare the production cost using two co-precipitation reactions (with Na 2 CO 3 and NaOH), and similar cathode active materials such as lithium manganese oxide and lithium nickel cobalt aluminum oxide. A combination of cost saving opportunities show the possibility to reduce the cost of the cathode material by 19%.

Successful deployment of electric vehicles requires maturity of the manufacturing process to reduce the cost of the lithium ion battery (LIB) pack. Drying the coated cathode layer and subsequent recovery of the solvent for recycle is a vital step in the lithium ion battery manufacturing plant and offers significant potential for cost reduction. A spreadsheet model of the drying and recovery of the solvent, is used to study the energy demand of this step and its contribution towards the cost of the battery pack. The base case scenario indicates that the drying and recovery process imposes an energy demand of ∼10 kWh per kg of the solvent n-methyl pyrrolidone (NMP), and is almost 45 times the heat needed to vaporize the NMP. For a plant producing 100 K battery packs per year for 10 kWh plug-in hybrid vehicles (PHEV), the energy demand is ∼5900 kW and the process contributes $107 or 3.4% to the cost of the battery pack. The cost of drying and recovery is equivalent to $1.12 per kg of NMP recovered, saving $2.08 per kg in replacement purchase.

Low-cost energy storage systems are required to support extensive deployment of intermittent renewable energy on the electricity grid. Redox flow batteries have potential advantages to meet the stringent cost target for grid applications as compared to more traditional batteries based on an enclosed architecture. However, the manufacturing process and therefore potential high-volume production price of redox flow batteries is largely unquantified. We present a comprehensive assessment of a prospective production process for aqueous all vanadium flow battery and nonaqueous lithium polysulfide flow battery. The estimated investment and variable costs are translated to fixed expenses, profit, and warranty as a function of production volume. When compared to lithium-ion batteries, redox flow batteries are estimated to exhibit lower costs of manufacture, here calculated as the unit price less materials costs, owing to their simpler reactor (cell) design, lower required area, and thus simpler manufacturing process. Redox flow batteries are also projected to achieve the majority of manufacturing scale benefits at lower production volumes as compared to lithium-ion. However, this advantage is offset due to the dramatically lower present production volume of flow batteries compared to competitive technologies such as lithium-ion.

The flexible plant postulated in this study would produce four types of batteries for electric-drive vehicles – a hybrid (HEV), 10-mile range and 40-mile range plug-in hybrids (PHEV), and a 150-mile range battery-electric (EV). The annual production rate of the plant is 235,000 battery packs (HEV: 100,000; PHEV10: 60,000; PHEV40: 45,000; EV: 30,000). The cost savings per battery pack calculated with the Argonne BatPaC model for this flex plant vs. dedicated plants range from 9% for the EV battery packs to 21% for the HEV packs including the battery management systems (BMS). The investment cost savings are even larger, ranging from 21% for EVs to 43% for HEVs. The costs of the 1.0-kWh HEV batteries are projected to approach $714 per unit and that of the EV batteries to approach $188 per kWh with the most favorable cell chemistries. The best single indicator of the cost of producing lithium-manganate spinel/graphite batteries in a flex plant is the total cell area of the battery. For the four batteries studied, the price range is $20–24 per m2 of cell area, averaging $21 per m2 for the entire flex plant.

In valuing new active materials chemistries for advanced batteries, the theoretical specific energy is commonly used to motivate research and development. A packaging factor is then used to relate the theoretical specific energy to the pack-level specific energy. As this factor is typically assumed constant, higher theoretical specific energies are judged to result in higher pack-level specific energies. To test this implicit assumption, we calculated the fraction of the theoretical specific energy achieved on the pack level for hypothetical cell chemistries with various open-circuit voltages and theoretical specific energies using a peer-review bottom-up battery design model. The pack-level specific energy shows significant dependence on the open-circuit voltage and electrochemical impedance due to changes in the quantity of inactive materials required. At low-valued average open-circuit voltages, systems with dramatically different theoretical specific energies may result in battery packs similar in mass and volume. The fraction of the theoretical specific energy achieved on the pack level is higher for the lower theoretical specific energy systems mainly because the active materials mass dominates the pack mass. Finally, low-valued area-specific impedance is shown to be critical for chemistries of high theoretical specific energy and low open-circuit voltage to achieve higher pack-level specific energies.

Battery design is a critical aspect of material and system development that leads to the commercialization of effective electrochemical energy storage systems. Successful modeling of battery designs relies upon accurate calculation of the area specific impedance (ASI). A simplified calculation of the ASI is presented that accounts for physical limitations without performing computationally expensive calculations. The limiting currents for transport within the electrolyte and within the intercalation materials are implemented into a linear form of the Butler–Volmer equation to calculate the interfacial impedance. Lithium-ion batteries are then designed to examine the effect of power to energy ratio on battery dimensions. A large ASI is shown to be detrimental to battery design regardless if the increase in impedance results from mass transport limitations or a reduction in electrochemical active area due to small electrode loadings. The smaller electrochemical active area does not increase the voltage losses of a battery when a constant C-rate is maintained. However, the higher ASI values from low electrode loadings require a larger separator and current collector area resulting in a greater battery volume and weight to achieve similar energy and power requirements when compared to a system with a lower ASI.