Jiapei Zhao

In this study, a three-dimensional transient simulation model of a liquid cooling thermal management system with flow distributors and spiral channel cooling plates for pouch lithium-ion batteries has been developed. The cooling plates play the role of uniforming temperature distribution and reducing the maximum temperature within each battery, while the flow distributors have the function of reducing the temperature difference between batteries in the battery module. The accuracy of the thermophysical properties and heat generation rate of the battery was verified experimentally. The optimal structure and cooling strategy of the system was determined by single factor analysis as well as orthogonal test and matrix analysis methods. The optimal solution resulted in a maximum battery module temperature of 34.65 °C, a maximum temperature difference of 3.95 °C, and a channel pressure drop of 8.82 Pa. Using the world-harmonized light-duty vehicles test cycle (WLTC) conditions for a battery pack in an electric car, the performance of the optimal battery thermal management system (BTMS) design was tested, and the results indicate that the maximum temperature can be controlled below 25.51 °C and the maximum temperature difference below 0.21 °C, which well meet the requirements of BTMS designs.

To ensure optimum working conditions for lithium-ion batteries, a numerical study is carried out for three-dimensional temperature distribution of a battery liquid cooling system in this work. The effect of channel size and inlet boundary conditions are evaluated on the temperature field of the battery modules. Based on the thermal behavior of discharging battery obtained experimental measurements, two temperature control strategies are proposed and studied. The results show that the channel width of the cooling plates has a great influence on the maximum temperature in the battery module. It is also revealed that increasing inlet water flow rate can significantly improve the heat transfer capacity of the battery thermal management system, while the relationship between them is not proportional. Lowering the inlet temperature can reduce the maximum temperature predicted in the battery module significantly. However, this will also lead to additional energy consumed by the cooling system. It is also found that the Scheme 5 among various temperature control strategies can ensure the battery pack working in the best temperature range in different depths of discharge. Compared with the traditional one with a given flow rate, the parasitic energy consumption in Scheme 5 can be reduced by around 80%.

By integrating an Absorption Refrigerator (AR), a new hybrid system model is established to reuse the waste heat from a Molten Carbonate Direct Carbon Fuel Cell (MCDCFC) for additional cooling production. Various irreversible losses in each element of the system are numerically described. The operating current density span of the MCDCFC that allows the AR to work is derived. Under different operating conditions, the mathematical expressions for equivalently evaluating the hybrid system performance are derived. In comparison with the stand-alone MCDCFC, the maximum attainable power density of the proposed system and its corresponding efficiency are increased by 5.8% and 6.8%, respectively. The generic performance features and optimum operating regions of the proposed system are demonstrated. A number of sensitivity analyses are performed to study the dependences of the proposed system performance on some physical parameters and operating conditions such as operating temperature, operating current density, and pressure of the MCDCFC, cyclic working fluid internal irreversibility inside the AR, thermodynamic losses related parameters and the anode thickness of the MCDCFC. The obtained results may offer some new insights into the performance improvement of an MCDCFC through a reasonable heat management methodology.