Bay Area Safety Symposium - Next Generation Batteries and EHS … · 2017-03-13 · Resolution...

Next Generation Batteries and EHS Challenges

Kiran Joshi, Ph.D., CSP

EHS Director

Patent Agent

Agenda

• Why we need better batteries

– Market

– Boeing 787 Case Study

• Battery 101

• Safety

– Environmental, Health, and Safety

– Product

– Shipping

• Relevant Regulations

• Q&A

23/13/2017 QUANTUMSCAPE PROPRIETARY

Consumer Electronics: Battery Capacity Not Keeping Up with Other Component Gains

3“Seizing the Shifting Opportunity in the $41B Mobile Energy Storage Market,” Lux Research, June 2013. http://www.apple.com/iphone-6s/specs/ ; https://www.ifixit.com/Teardown/iPhone+6s+Teardown/

Battery Capacity

25%

Processing speed

RAM

Screen Resolution

2007: iPhone

0.4 GHz

2012: iPhone 5

1.3 GHz

128 MB 1024 MB

150,000 pixels 730,000 pixels

5.2 Wh 5.5 Wh

% change

450%

1400%

667%

2015: iPhone 6S

1.8 GHz

2 GB

1 M pixels

6.6 Wh


http://www.apple.com/iphone-6s/specs/

https://www.ifixit.com/Teardown/iPhone+6s+Teardown/

0

50

100

150

200

250

300

$0$20,000$40,000$60,000$80,000$100,000

Rat

ed

Ran

ge (

mile

s)

Vehicle Price

BMW i3

Mass Market

Tesla Model S3

Tesla Model S2

Toyota Rav4

Ford FocusNissan Leaf

Today’s Vehicles

98% of Vehicles Are Priced Less than $50K

>20

0 m

ile r

ange

Automotive Battery Costs Force a Choice Between Vehicle Price and Range

Innovation needed to enable high-range, affordable mass market electric vehicles

4

VW eUp*

*VW eUp: NEDC range and UK MSRP before VAT and incentives. All others: EPA range and MSRP before tax credits in the US3/13/2017 QUANTUMSCAPE PROPRIETARY

Why Does Battery Safety Matter?

• Two forms of energy stored

– Reactants (Wh rating on the cell)

– Non participating components (e.g. organic electrolyte)

• Batteries contain the 3 legs of the fire triangle: an energy source, a fuel (e.g. electrolyte), and an oxygen source

• More potential energy in the electrolyte than usable energy stored between the battery’s anode & cathode

• Push for higher energy density cells for cost, weight, and volume reasons can make safety challenges more difficult

– Need to develop inorganic ion conductors to minimize / eliminate flammable components in the cell

• Typical Wh/kg for lithium ion cells ranges between 100-250


Battery Fires

6

According to Sony, contamination of Cu, Al, Fe and Ni particles during the manufacturing process may cause an internal short circuit.

http://batteryuniversity.com/learn/article/lithium_ion_safety_concerns

A cell phone with a no-brand battery that vented with flame while charging in the back of a car.

Tesla Car Fire

The heavily burned battery from Dreamliner JA829 after it suffered thermal runaway.


http://batteryuniversity.com/learn/article/lithium_ion_safety_concerns

Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


Dreamliner Li-Ion Battery Case Study

8

• 1/7/2013: At Boston Logan Airport; smoke from the auxiliary battery

• 1/14/2013: Japan; in-flight; passengers smelled smoke; precautionary landing; main battery involved

• 1/14/2014: At Narita Airport; redesigned battery with containment box

Pictures from: NTSB.gov/new/press-releases 3/13/2017 QUANTUMSCAPE PROPRIETARY

2013 Event

9NTSB.gov/new/press-releases


January 2013 – NTSB Report

• NTSB investigation results:

– Internal short circuit leading to thermal runaway condition

• Propagating to remaining cells to battery thermal runaway

– Cell manufacturing defects and oversight of cell manufacturing processes

– Thermal management of lithium-ion batteries

– Insufficient guidance for manufacturers to use in determining and justifying key assumptions in safety assessments

– Insufficient guidance for FAA certification engineers to use during the type certification process to ensure compliance with applicable requirements

– Stale flight data and poor-quality audio recording of the 787 enhanced airborne flight recorder (EAFR)

• NTSB recommendations:

– 15 FAA on improving the guidance and training to industry

– 2 Boeing

– 1 to GS Yuasa

• Changes Made by Boeing

10www.ntsb.gov/news/press-releases/Pages/PR20141201.aspx; full report available from: http://go.usa.gov/HJtJBoeing Battery Changes: Boeing/Graphic News


http://www.ntsb.gov/news/press-releases/Pages/PR20141201.aspx

http://go.usa.gov/HJtJ

Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


Battery Cell Terminology

• Anode: A negative electrode that donates electrons during cell discharge

• Battery: An electrochemical cell in which stored chemical energy is converted into electrical energy

• Cathode: A positive electrode that accepts electrons during cell discharge

• Energy Density: Energy per unit volume (Wh/L)

• Power Density: Power per unit volume (W/L)

• Specific Energy: Energy per unit weight (Wh/kg)

• Specific Power: Power per unit weight (W/kg)

• Lithium Ion Battery: Rechargeable battery in which lithium ions are stored in both cathode and anode

• Lithium Metal Battery: A battery utilizing lithium metal or lithium alloy as the anode

12Li Ion Battery Picture Taken From: http://www1.eere.energy.gov/vehiclesandfuels/pdfs/pir/vtp_goals-strategies-accomp.pdf


Conventional Li ion summary (simplified)

http://www.exponent.com/batteries/

- Cu foil

- Al foil

- Anode (e.g. graphite: LiC6 )

- Cathode (e.g. LiCoO2)

Cross-section of electrodes

Inactive Materials:Binders (polymers for adhesion & cohesion)Separator & electrolyteConductive additivesPackaging (can, tabs, terminals, etc.)

Thickness of layer ~30-100 um

- Separator

13

Examples of a Cell Material

• Cathode Materials

– LiCoO2

– LiNixCoyAlzO2 (NCA)

– LiNi1/3Mn1/3Co1/3O2 (NMC)

– LiFePO4 (LFP)

• Anode Materials

– Graphite based

– Silicon based

– Li

• Electrolytes

– Organic carbonates +

Lithium hexafluorophosphate

• Separators

– Porous Polymer

14Picture taken from: J.M.Tarascon, M.Armand, Nature 414 (2001) 359-367.



Battery Cell Construction

Alkaline Li-ion cylindrical wound

Source:LINDEN’S HANDBOOK OF BATTERIES; Tarascon 2001 doi:10.1038/35104644

Stacked prismatic

Wound prismatic

Coin cell

Cylindrical cell

Most modern battery cells are composed of multiple metal foils (with active materials) placed in metal cans or pouches. There are several different types of enclosures and assembly methods.

15

Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


EHS Challenges at Each Stage

Research and Development Manufacturing Shipping

17

Integration Into Product and In the Field

End of LifeRemember that the end goal is to create a Sustainable product and future:

-How do we keep the environment, workers, and consumers safe?


Research and Development Challenges - EHS• Can be a Light Lab Occupancy – Chemical Load

– Chemical, Fire, Ergonomics, Electrical, Mechanical Hazards– Young scientists, fast paced environment

• Some Examples of Chemical Hazards:– Variety of chemicals and formulations

• Characterization of new formulations – Flammable, pyrophoric – Water Sensitive– Metals (Na, Mg, Li) and nano powders which can catch fire – Phosphides, Sulfides, Nitrides (Sulfides which can generate toxic gases)– Chemicals heated at high temperatures while pressed under high pressure– Shipping of new chemical formulations for testing purposes

• Work Environment – Buildings– Glove boxes– Dry rooms– Reactors (High Pressure and Temperature)– Machine Shop– Electrical Test Systems

• Ergonomics, Electrical and Mechanical Hazards

18These are generic photos (not QunatumScape photos).


Safe Use of Lithium or Laminated Lithium

• Flammable solid, highly reactive

• Incompatible with water, acids, bases, oxidizing agents

2Li(s) + 2H2O → 2LiOH(aq) + H2(g) (220 KJ/mol generated)

• Use it only under argon or in the dry room;

– Keep the containers closed when not in use

– Store sealed lithium in the flammable cabinet in the dry room when not in use

• Segregate waste and submerge in mineral oil

• Use LithX for small lithium fire

QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 19

Remember to empty the GB waste binefore exposing the contents to air.

Only trained employees can use the yellow fire extinguisher.

Safe Use of Sulfide Compounds

• Examples: Lithium Sulfide, Phosphorus Pentasulfide, Arsenic Sulfide, Sulfide slurries– Flammable, toxic, corrosive, irritants

• Contact with water releases Hydrogen Sulfide gas – flammable and toxic

• Handle Sulfide powders inside the glove box under inert atmosphere– If using in a dry room, handle only in a hood– P2S5 can not be handled in the Dry Room.

• Use only in a Glove Box

• Package the sulfide waste in zip lock bags and store under exhausted conditions

• Reactively purge the glove box if opening it to the atmosphere for maintenance

• H2S sensors– Warning at 1 ppm (orange light); alarm at 2.5 ppm (red light and audible)

• PEL for H2S is 10 ppm (can smell at 5 ppb)

QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 20

Safe Handling of Powders

• Handle all powders under an exhausted enclosure in the Dry Room (if not air or water sensitive)

or in the Glove Box

• Take precautions to change gloves inside the Glove Box

• Wipe the equipment before bringing it out from the Dry Room or the Glove Box

• Fluoride powders can generate HF when come in contact with water

• Use of PPE

– Respirators (P100 or Multi-Cartridge)

– Button the lab coat to avoid getting any powder

on your clothes

– Change gloves frequently

– Get the coat laundered once a week or more

often if needed

• Milling or Spray Drying of Powders

– High surface area, large amount of energy storage

• Powder ignition just by touching/tapping or exposing to air

– Housekeeping around equipment

QUANTUMSCAPE PROPRIETARY & CONFIDENTIAL 21Photo – Buchi Spray Dryer

Battery Manufacturing Facility

• Design and Construction of the Facility– B-Occupancy may not be sufficient.– May need high hazard occupancy buildings based on the chemical load– Air emission controls, other regulations

• Design, Purchase and Installation of the Equipment– Coaters, Mixers, Dryers, Rollers, Laminators, Cutters– Location of supply chain

• Manufacturing– Sourcing of chemicals - Li– Automation Challenges– Work Fast Expectations

• Engineering may still be worked on.

• Battery Testing Equipment and Lab– Location and construction of the lab where fire/explosion

testing can be done• Process to handle vented and exploded cells

– Fire and Electrical Safety where testing is being done– Personnel safety involved with inspection and testing

• How to handle corroded cells• Remove jewelry• Insulated tools

22Photos: http://www.eurotecusa.com/id19.html; http://www.arbin.com/


http://www.eurotecusa.com/id19.html

Battery Storage Facility

• Depending on the Battery, may need to use a separate high hazard occupancy storage room:

– 2-4 h fire wall

– Built in fire-fighting system

– Explosion proof lighting

– Separate air conditioning

– Gas sensors (H2, H2S, Cl2 and others based on the hazards)

– Restricted access


Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


Product Safety Standards and Testing Protocols

• Underwriters Laboratories (UL)

– UL 1642 – Lithium batteries

– UL 2054 – Household and Commercial batteries

– UL 2580: Batteries for use in Electric Vehicles

• Institute of Electrical and Electronic Engineers (IEEE)

– IEEE 6125: Rechargeable Batteries for Mobile Computing Devices

– IEEE 1725: Rechargeable Batteries for Cell Phones

• Society of Automotive Engineers

– J2464: Electrical and Hybrid Electric Vehicle Rechargeable Energy Storage System, Safety and Abuse Testing

– J2929: Electric and Hybrid Vehicle Propulsion Battery System Safety Standards – Lithium Based Rechargeable Cells

• International Electrotechnical Commission (IEC)

– IEC 62281: Safety of Primary and Secondary Lithium Cells/Batteries during Transportation

• United Nations (UN)

– Recommendation on the Transport of dangerous Goods, Manual of Tests and Criteria, Part III, Section 38.3

• Battery Safety organization (BATSO)

– BATSO 01: Manual for Evaluation of Energy Systems for Light Electric Vehicles

3/13/2017 QUANTUMSCAPE PROPRIETARY 25

QUANTUMSCAPE PROPRIETARY

SAE Recommended Practice for Safety Testing: SAE J2464

Source: SAE J2464 Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing

• Most comprehensive recommended industry test practices

• Does not specify HSL (hazard safety levels)

• Focus is on tests and their conditions

3/13/2017 26

QUANTUMSCAPE PROPRIETARY

UN 38.3: Required for Shipping

Source: Recommendations on the Transport of Dangerous Goods: Manual of Tests & Criteria, Fifth Revised Edition**Test not applicable to cells when used with a battery system that provides this protection

Designation Test Name (Cell Count) Purpose

38.3.4.1 T.1: Altitude Simulation (10 cells, T1-T5 seq)

• Simulates air transport under low pressure conditions

38.3.4.2 T.2: Thermal Test • Assesses cell and battery seal integrity and internal electrical connections

• The test is conducted using rapid and extreme temperature changes

38.3.4.3 T.3: Vibration • Simulates vibration during transport

38.3.4.4 T.4: Shock • Simulates possible impacts during transport

38.3.4.5 T.5: External Short Circuit • Simulates an external short circuit

38.3.4.6 T.6: Impact (10 cells)

• Simulates an impact (i.e. 9.1kg mass from 61 cm height)

38.3.4.7** T.7: Overcharge**(0 cells)

• Evaluates the ability of a rechargeable battery to withstand an overcharge condition**

38.3.4.8 T.8: Forced Discharge (20 cells)

• Evaluates the ability of a rechargeable cell to withstand a forced discharge condition

3/13/2017 27

Test equipment exists to simulate temperature, humidity, altitude, and vibration simultaneously to better approximate life and safety in actual customer use cases

28Source: http://thermotron.com/

Increasing sophistication in battery test equipment to approximate use conditions


Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


Lithium Battery Transportation – In Brief

30

• Lithium Ion Batteries– UN Numbers and Description

• UN3480, Lithium ion battery• UN3481, Lithium ion battery packed with

equipment• UN3481, Lithium ion battery contained in an

equipment

– Packaging• Class 9, Miscellaneous Dangerous Goods• Can be exempted from Section II IATA depending

on the amount of lithium (Check amounts and Wh restrictions)

– Follow Packing instructions (R)965-967• PG II

– Requirements for weight limits, package drop tests from 1.2m, and approved outer packaging

– Identify, package, mark and label per IATA; must be signed by trained shipping employee

• Lithium Metal Batteries– UN Numbers and Description

• UN3090, Lithium metal battery• UN3091, Lithium metal battery packed with

equipment• UN3091, Lithium metal battery contained in an

equipment

– Packaging• Class 9, Miscellaneous Dangerous Goods• Can be exempted from Section II IATA depending

on the amount of lithium (Check amounts and Wh restrictions)

– Follow Packing instructions (R)968-970• PGII

– Requirements for weight limits, package drop tests from 1.2m, and approved outer packaging

– Identify, package, mark and label per IATA; must be signed by trained shipping employee

[email protected] for changes to Lithium Battery shipment regulations. Another good source is: Battery Transportation Safety Workshop, San Diego, 2015. 3/13/2017 QUANTUMSCAPE PROPRIETARY

mailto:[email protected]

Lithium Batteries Transportation – Markings to Know

31

HAZARDOUS MATERIAL

SHIPPING PAPER

- Shipper / Receiver

- Number of Types of Package

- UN 3090

- Cargo Aircraft Only (If Air)

- Page Number

- Volume / Weight

- Emergency Response Information

+ Telephone Number

- Certification + Signature (Most

Common Violation)

+CARGO

AIRCRAFT

ONLY

LABELING

Technology exists for containers that allow the gases to be released through a filter but does not allow the flame to get through: WWW.Gelkoh.de; http://pyrophobic.com/


http://www.gelkoh.de/

Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


Regulatory References

• All Local, State and Federal Laws still apply (EPA, OSHA, UFC, UBC, DOT, IATA, etc.)

• US, EU, China and Japan can have different safety and battery regulations.

– ROHS, WEEE in EU and any other local regulations in these countries still apply.

• Some Battery Safety Standards:

– IEC 62133 – Lithium Cells and Batteries for portable applications

– IEEE 1625 – Lithium ion battery system for mobile computing devices

– IEEE 1725 – Lithium ion battery systems for cellular phone application

– ISO DIS 12495-3 – Lithium ion batteries for EV application

– SAE 2464, 2929 – Battery pack safety committees

– UL 1642 – Lithium cells

– UL 2054 – Household and commercial batteries for potable applications

– UL 2575 – Lithium ion batteries for portable tools and appliances

– UN Manual of Tests and Criteria, Part III, 38.3

• FedEx, UPS websites contain information on lithium battery shipping (DOT/IATA)


Some Sources for Additional Learning

• Conferences:– Knowledge Foundation– TIAX

• National Transportation Safety Board

• US Department of Energy – Energy Efficiency and Renewable Energy

• National Labs

• UL

• Private Consulting Firms– Information can be provided upon request.


Lithium and 7-Up!

QUANTUMSCAPE PROPRIETARY 353/13/2017

Agenda


– Market


• Battery 101

• Safety


– Product

– Shipping


• Q&A


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Bay Area Safety Symposium - Next Generation Batteries and EHS … · 2017-03-13 · Resolution...

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