The decarbonisation of the transport sector is an imperative step in our efforts to drastically reduce greenhouse gas emissions. In this context, electric vehicles (EVs) powered by lithium-ion batteries have emerged as one of the most promising options. However, in order to make the transition from internal combustion engine vehicles towards EVs economically and environmentally beneficial, it is crucial to reduce battery life cycle costs and carbon footprint. To do so, a key strategy is to increase the battery lifetime as an increased use phase can reduce the pressure on raw materials and counterbalance the cost and environmental impacts incurred during battery manufacturing. Battery lifetime is impacted by several factors such as depth of discharge and cycling rates [1]. Furthermore, temperature-induced stress can lead to accelerated capacity fade. Elevated temperatures can lead to capacity fade caused by chemical side reactions such as solid-electrolyte interface growth or electrolyte decomposition; too low temperatures can result in lithium plating. Therefore, efficient thermal management systems (TMS) are crucial as they ensure an optimal cell operating temperature during usage and thus slow down adverse temperature effects and battery degradation. In this study, the impact of the TMS on battery lifetime and in turn on life cycle cost and carbon footprint is evaluated [2]. To this end, the battery lifetime for various TMS including air cooling, surface cooling, tab cooling and immersion cooling is simulated. The cycle lifetime is then further implemented in carbon footprint and life cycle cost models to calculate economic and environmental impacts during the manufacturing and use phase. Indeed, it is demonstrated that by switching the battery TMS from air cooling to liquid cooling, the battery life cycle cost and carbon footprint can be reduced by 27 % and 25 %, respectively. Moreover, an optimised cell design is proposed, which increases the achievable heat extraction rate through the tabs enabling a more efficient tab cooling system. Tab cooling has the advantage towards surface cooling that cell temperature gradients, which accelerate battery degradation, are reduced thus leading to a prolonged battery cycle life [3]. Implementing tab cooling, the carbon footprint and life cycle cost can be reduced by 35 % and 40 %, respectively, compared with conventional cell designs combined with air cooling systems. This study reveals that engineering solutions such as battery management systems are a swift and impactful tool to significantly increase the economic and environmental benefits of EVs.[1] Birkl, C.R., Roberts, M.R., NcTurk, E., Bruce, P.G., Howey, D.A. J. Power Sources 341 (2017), pp. 373-386. [2] Lander, L., Kallitsis, E., Hales, A., Edge, J.S., Korre, A., G. Offer, G. Appl. Energy 289 (2021), p. 116737. [3] Hunt, I.A., Zhao, Y., Patel, Y., Offer, G. J. Electrochem. Soc. 163 (2016); pp. A1846–52.
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