NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

American Recovery & Reinvestment Act (ARRA)

NREL Battery Thermal and Life Test Facility

PI & Presenter: Matt Keyser

Energy Storage Task Lead: Ahmad Pesaran

Other Contributors: John Ireland, Dirk Long, Kandler Smith, 

Gi-Heon Kim, & Yoon Seok Jung

National Renewable Energy Laboratory

Golden, Colorado

Presented at the 2011 U.S. DOE Hydrogen 

Program and Vehicle Technologies Program 

Annual Merit Review & Peer Evaluation Meeting 

9-13 May 2011, Arlington, Virginia 

ARRAVT079 

This presentation does not contain any proprietary, confidential, or otherwise restricted information

NREL/PR-5400-50915
NATIONAL RENEWABLE ENERGY LABORATORY

Outline

2

• Overview

• Objectives 

• Relevance

• Approach

• Financial Summary

• Technical Accomplishments and Progress

– Equipment Purchased Under ARRA

– Laboratory Modifications for ARRA Equipment

• Looking Forward – Future Equipment Development

• Collaborations and Partnerships

• Summary and Conclusions
NATIONAL RENEWABLE ENERGY LABORATORY

Overview

• Project start date: April 2010

• Project end date: June 2012

• Percent complete: 70%

• Cost

• Energy storage performance

• Safety

• Calendar and cycle life

3

• Funding received in 

─ FY10: $2M - April

─ FY11: $0

Timeline

Budget

Barriers – Energy Storage

Partners

• AeroVironment

• Arbin

• Bitrode

• Cincinnati Sub Zero

• Netzsch

• Thermal Hazard Technologies

• ThermTest
NATIONAL RENEWABLE ENERGY LABORATORY

Objectives

4

• Acquire capital equipment to upgrade and enhance the battery 

thermal test facility at NREL with recovery act funds.

• Increase throughput of specialized testing, so that battery developers 

can more quickly obtain critical data in support of product design.

• Perform a greater number of unique tests to enhance understanding 

of cell thermal and lifetime performance and better guide designs for 

increasing performance and life. 

• Support DOE/FreedomCAR, USABC and the U.S. battery industry to 

meet the following goals for energy storage through improved 

thermal design:

– Reduce cost

– Improve safety 

– Improve performance

– Improve calendar and cycle life

• Validate thermal and life models to help U.S. industry accelerate 

product development.

• Increase the availability of equipment needed to evaluate and 

benchmark battery developers’ prototypes. 
NATIONAL RENEWABLE ENERGY LABORATORY

Milestones

5

Month-Year Milestone Status

June 2010 Progress Report on the Acquisition of Equipment and 

Facility Modifications – for ARRA funded Battery 

Thermal and Life Test Facility

Completed

December 2010 • Acquire Battery Cyclers

• Acquire and Install Environmental Chambers

• Acquire and Install Small Cell Calorimeter

• Power Point Progress Report

Completed

June 2011 • Complete Facility Modifications

• Install and Calibrate All Battery Cyclers

• Acquire, Install and Calibrate All Thermal 

Conductivity Meters

• Power Point Progress Report

On Track

December 2011 • Complete Install, Shake-Down, and Calibration of 

All Equipment

On Track

June 2012 • Final Report On Track
NATIONAL RENEWABLE ENERGY LABORATORY

Relevance

6

• The U.S. has dramatically increased investment in domestic 

battery production plants with Recovery Act funds – for example:

– Johnson Controls - $299 million 

– A123 Systems - $250 million

– Dow Kokam - $161 million

– CPI - $151 million

• Acquiring capital equipment to upgrade and enhance the battery 

thermal test facility at NREL will allow battery developers to 

improve the design of the cells produced at these plants. 

• It will also allow for an independent review of the performance of 

batteries from the new production plants.
NATIONAL RENEWABLE ENERGY LABORATORY

Equipment Acquisition/Installation

7

• Identify DOE/FreedomCAR, USABC, and domestic battery 

manufacturers’ requirements with regards to NREL’s test 

facilities.

• Identify equipment manufacturers.

• Acquire multiple quotes from vendors for each piece of 

equipment.

• Analyze quotes with regards to performance, cost, schedule,

and quality.

• Generate purchase request.

• Receive equipment in-house and install.

• Calibrate and verify performance meets manufacturer’s 

specifications.

Approach
NATIONAL RENEWABLE ENERGY LABORATORY

Facility Modifications

8

• Identify existing space and acquire new laboratory 

equipment.

• Perform an ES&H review on the new space to ensure a 

safe working environment.

• Identify necessary utility modifications—electrical, HVAC, 

chilled water, communication, and safety improvements.

• Complete RFPs for modifications and send out for bid.

• Evaluate bids and award contracts.

• Complete facility/utility modifications.

Approach
NATIONAL RENEWABLE ENERGY LABORATORY

NREL Battery Thermal and Life Test Facility 

9

The upgraded and enhanced facility will:

• Aid DOE, USABC, and domestic battery manufacturers in 

characterizing and evaluating new energy storage systems.

• Provide data for NREL’s empirical models for HEV, PHEV, and 

EV energy storage systems.

• Validate NREL’s life models, so engineers can quickly explore 

design trade-offs in battery usage, performance, life, and cost.

• Validate NREL’s multi-scale multi-dimensional (MSMD) 

electrochemical/thermal model, which predicts the spatial 

variations in cell performance, including non-uniformities of 

cycling, temperature, and heat generation. 

• Validate NREL’s thermal abuse models.

Approach
NATIONAL RENEWABLE ENERGY LABORATORY

Financials: Actual Cost vs. Planned Cost

10

$0

$200,000

$400,000

$600,000

$800,000

$1,000,000

$1,200,000

$1,400,000

$1,600,000

$1,800,000

$2,000,000

Jan-10

Feb-10

Mar-10

Apr-10

May-10

Jun-10

Jul-10

Aug-10

Sep-10

Oct-10

Nov-10

Dec-10

Jan-11

Feb-11

Mar-11

Apr-11

May-11

Jun-11

Jul-11

Aug-11

Sep-11

Oct-11

Nov-11

Dec-11

Cumulative Planned Cost Cumulative Actual Cost

Financials

Actual cost is on track with planned cost.
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Battery Testers – Almost 100 Channels

11

Cycler

Voltage 

Range 

(Volts)

Current 

Range 

(Amps)

Total 

Channels

5 Volt Bitrode Cycler 0-5 +/- 100 16

36 Volt Bitrode Cycler Chassis #1 0-36 +/- 300 4

36 Volt Bitrode Cycler Chassis #2 0-36 +/- 300 4

36 Volt Bitrode Cycler Chassis #3 0-36 +/- 300 4

100 Volt Bitrode Cycler Chassis #1 0-100 +/- 300 4

ABC-150 - Parallel All Channels 8-220 +/- 265 2

Arbin Battery Cyclers 0-5 +/- 2 64

Charge/discharge energy storage systems for thermal and life cycle testing.

Photo Credits:John Ireland/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Five Environmental Chambers

12

Test Parameter Value

Volume (ft3) 32.5

Internal Dimensions (inches) 38 x 38 x 38

Temperature Range (oC) -45 to +190

Live Load Capacity at –18oC (Watts) 3000

Number of Units 4

Test Parameter Value

Volume (ft3) 64

Internal Dimensions (inches) 48 x 48 x 48

Temperature Range (oC) -45 to +190

Live Load Capacity at –18oC (Watts) 3100

Number of Units 1

Accurately control ambient temperature for performance 

and life-cycling of cells.

Photo Credit: Dirk Long/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Glove Box for Destructive Physical Analysis 

MBraun

13

Unilab

1.95 m x 0.78 m x 0.900 m

Gas Purifier

O2 Sensor – Control to < 5 ppm

H2O Sensor – Control to < 5 ppm

Large Antechamber

Small Antechamber

Safely disassemble cells to understand their failure mechanisms.

Photo Credits: Matt Keyser/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Small Cell Calorimeter

Thermal Hazard Technology

Isothermal Battery Colorimeter

Model IBC-001 

(Standard)

IBC-002

(High Sensitivity)

Temp Range -20 to 80 -20 to 80

Dynamic Range 100uW to 

10W

10uW to 2 Watts

Chamber Size 34.5mm ID x 

61.5mm High

34.5mm ID x 

61.5mm High

Battery Testing? Yes Yes

Cycler

Capability

0-4A Chrg/1-10A 

disch/1mA res

0-1A Chrg/1-1A 

disch/1uA res

14

Understanding the entropic changes with a cell and how this affects life.

Photo Credits: John Ireland/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Thin Film Thermal Conductivity Meter

Netzsch

LFA 447

Temp Range RT to 300

Number of Samples 4

Sample Size 25.4mm

Sample Types Solid, Liquid, Powder, 

Laminated

Test Atmosphere Pressure, Air, Inert, Oxidizing, 

Reducing, Static, Dynamic

Thermal Diffusivity 0.01 to 1000mm2

/s

Thermal Conductivity 0.1 to 2000W/mK

Accuracy 3%

Repeatability 2%

15

Developing a test procedure for accurately measuring the thermal conductivity of 

battery materials – thin films.

Photo Credits: John Ireland/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Acquired Bulk Thermal Conductivity Meter

ThermTest

TPS 500

Temperature Range -100oC to 200oC

Number of Samples 1

Sample Size (φ) 13mm to unlimited

Sample Thickness 3mm to unlimited

Sample Types Solid, Liquid, Powder, 

Paste

Test Atmosphere Air

Thermal Diffusivity 0.02 to 40mm2

/s

Thermal 

Conductivity 0.03 to 100W/mK

Accuracy <5%

Repeatability 2%

16

Developing a test procedure for accurately measuring the thermal conductivity of 

battery materials – bulk materials.

Photo Credits: John Ireland/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Before After

Thermal Test Facility (TTF) Laboratory Space Modifications

17

Photo Credits: Dirk Long/NREL

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY 18

TTF Laboratory Layout - Schematic 

Cabinets Cabinets

Baths

ABC-150

Cal 6V/72V Bitrodes Arbin

AC/

AC

Environmental 

Chamber

Large Cal

IR Station ABC-150 

Comp

Cabinet Door Workbench

Environmental

Chamber

Workbench

Environmental 

Chamber

Environmental 

Chamber

Environmental 

Chamber

ABC-150

Bitrode

Bitrode

Bitrode

Bitrode

Bitrode

Workbench Workbench

Hazardous 

Chemical 

Storage

Computer 

Station

Environmental 

Chambers

Cabinets

Thermal

Management

Loop

ARRA-Funded Lab Space Existing Battery Lab
NATIONAL RENEWABLE ENERGY LABORATORY 19

16/216 Laboratory Layout with ARRA Equipment Workbench DSC/ARC Glove Box Fume Hood

ARC 

Comp

ARC

DSC

Entry way

DPA Glove Box

36 Volt Bitrode

Coin Cell 

Calorimeter

Arbin

Bulk 

Thermal

Conductivity

Door

Gas 

Cylinders

Thin Film

Thermal

Conductivity Workbench
NATIONAL RENEWABLE ENERGY LABORATORY

NREL is Designing/Fabricating a Custom Cell Calorimeter

• NREL already has two calorimeters (module and pack), why 

the need for another calorimeter?

– Existing USABC activities require NREL’s calorimeters 100% of the 

time. With the addition of U.S.-sponsored cell production facilities, the 

number of cells received for testing at NREL will only increase.

• Why build a cell calorimeter?

– While NREL has two calorimeters that can test cells, the time constant 

between tests is large due to the thermal mass of the calorimeters. 

NREL’s present calorimeters were designed for modules and packs. 

– In order to increase throughput, NREL approached DOE about the 

design of a cell calorimeter with minimal thermal mass—reducing the 

time between tests and increasing the number of test points per day.

• Why design a custom cell calorimeter?

– After extensive research, NREL was unable to find a calorimeter 

company that would build the unit for HEV, PHEV, and EV cells.

– Most calorimeters on the market have minimal current ratings 

(less than 10 amps). 

– The cell calorimeter must be rated at several hundred amps for energy 

storage systems in advanced vehicle applications.

20

Technical Accomplishments

Early Design Questions
NATIONAL RENEWABLE ENERGY LABORATORY

NREL Plans to Build Its Custom Cell Calorimeter by Scaling Down 

NREL’s Existing Large Calorimeter 

• NREL designed a large calorimeter 

able to handle modules, sub-modules 

and packs and accurate enough to test 

individual cells.

– How can the large calorimeter design 

be scaled to test individual cells?

• In order to simplify the large 

calorimeter design, it was necessary to 

understand several design aspects as 

they relate to cell calorimeter design.

– Bus bars are required due to the high 

currents seen by HEV, PHEV, and 

EV cells, but where should they be 

located in a cell calorimeter? 

– How can the number of heat flux 

gauges (HFGs) be minimized? 

21

Normal heat 

flux

Temperature

Max ΔT: 4.4 K

3.5%

2.0%

1.0%

0.6%

Small amount of heat is 

flowing out from the side.

Technical Accomplishments
NATIONAL RENEWABLE ENERGY LABORATORY

Future Work

22

• Finish electrical and chilled water modifications to the 

existing laboratories.

• Shake-down and calibrate all instrumentation received 

under the ARRA task.

• Complete fabrication of custom cell isothermal 

calorimeter.

• The battery thermal management test loop could not be 

designed until facility services (water, power, etc.) 

installations were designed/in place. NREL has collected 

enough information on these services, and design is 

underway. NREL anticipates that the purchase of the 

test loop will also meet the scheduled milestone date.

Future Work 
NATIONAL RENEWABLE ENERGY LABORATORY

Summary

23

• NREL is on track to meet the original spending dates/milestones.

• NREL anticipates costing 80% of the $2M by May—one year after 

receiving funding—and 95% of the funds by September 30th.

• The two items that are not yet purchased are ones that are not offthe-shelf, but require design by NREL researchers/engineers:

– The custom cell isothermal calorimeter design has been complex, but is complete. 

The instrument is currently being built and is on schedule.

– The battery thermal management test loop is on schedule.

• We purchased 7 battery testers (~100 channels), a small cell 

isothermal calorimeter, two thermal conductivity meters, 5 

environmental chambers, and a glove box.

• Secured laboratory space for new equipment.

• Updated electrical and chilled water supply to new laboratory space.

Summary
NATIONAL RENEWABLE ENERGY LABORATORY

Collaborations and Partnerships

24

• Acquired equipment from the following manufacturers:

– AeroVironment

– Arbin

– Bitrode

– Cincinnati Sub Zero

– Netzsch

– Thermal Hazard Technologies

– ThermTest
NATIONAL RENEWABLE ENERGY LABORATORY 25

Technical Back-Up Slides
NATIONAL RENEWABLE ENERGY LABORATORY

Financials: ARRA Battery Upgrade Financial Summary

26

Description Purpose Estimated Cost Cost to Date Estimated Total Cost

Module Battery Cycler

Thermal and life cycle testing 

of cells $490,977 $ 486,850.00 $ 486,850.00

Pack Battery Cycler

Thermal and life cycle testing 

of cells $159,553 $ 158,360.00 $ 158,360.00

Cell Battery Cycler

Thermal and life cycle testing 

of cells $54,548 $ 51,360.00 $ 51,360.00

Custom Cell Calorimeter

Evaluates heat generation and 

efficiency of cells $201,933 $ 30,000.00 $ 201,933.00

Small Cell Calorimeter

Evaluates heat generation and 

efficiency of cells $105,057 $ 49,950.00 $ 49,950.00

Module Environmental Chamber - 

32 ft3

Controls temperature of cells 

under test $115,390 $ 113,420.00 $ 113,420.00

Pack Environmental Chamber - 64 

ft3

Controls temperature of cells 

under test $46,156 $ 41,195.00 $ 41,195.00

Thermal Conductivity - Bulk 

Materials

Measure thermal conductivity 

of materials $57,695 $ 20,000.00 $ 20,000.00

Xenon Flash Thermal Conductivity 

Instrument - Thin Films

Measure thermal conductivity 

thin films $70,808 $ 79,173.00 $ 79,173.00

Thermal management in the loop 

testing apparatus

thermal management in the 

loop testing apparatus $125,880 $ 9,800.00 $ 125,800.00

Battery Internal Evaulation

Disassemble batteries to 

understand failure 

mechanisms in cells. $62,940 $ 38,520.00 $ 62,940.00

Additional Equipment - Due to 

Cost Underrun - Isothermal Baths, 

Dilatometer, Scales, etc...

Controls temperature of cells 

under test $ - $ 75,000.00

Miscellaneous - Connectors, 

Materials, etc. - $26,225 $ 21,500.00 $ 26,225.00

Laboratory Modifications $150,000 151,000.00 $ $ 176,450.00

Labor $332,839 158,460.00 $ $331,344

Total $2,000,000 1,409,588 $2,000,000

* Potential Purchases POs Completed

Evaluating 

Technologies On-Going Long Term
NATIONAL RENEWABLE ENERGY LABORATORY

Financials: Planned Purchase Date vs. Actual Purchase Date

27

May-10

Aug-10

Nov-10

Feb-11

Jun-11

Sep-11

Dec-11

Original Plan - SOW Schedule Funds Actually Received - April 15, 2010 Actual Equipment Acquisition Date
NATIONAL RENEWABLE ENERGY LABORATORY 28

TTF Laboratory Layout – ARRA Infrastructure Modifications

E17, 18 Cabinets

Baths

ABC-150

Cal 6V/72V Bitrodes Arbin

AC/

AC

E7, F2

F7

IR Station ABC-150 

Comp

Cabinet Door Workbench

E6, F1

Workbench

E8, F3

E9, F4

E10, F5

E19

E1

E5

E2

E3

E4

E15, E16, L6 E13, E14, A2, L7

Hazardous 

Chemical 

Storage

L1-5

Environmental 

Chambers

Cabinets

E11, E12, F6, A1

Exhaust Fan

E20,E21

E22,E23
NATIONAL RENEWABLE ENERGY LABORATORY

TTF Electrical Circuits and Chilled Water

29

Circuit Voltage Current Phase Comments

E1 480 210 3 No De-rating - Equipment Maximum Power Draw

E2 480 115 3 No De-rating - Equipment Maximum Power Draw

E3 480 115 3 No De-rating - Equipment Maximum Power Draw

E4 480 115 3 No De-rating - Equipment Maximum Power Draw

E5 480 38 3 No De-rating - Equipment Maximum Power Draw

E6 480 25 3 Circuit Rating

E7 208 40 3 Circuit Rating

E8 208 40 3 Circuit Rating

E9 208 40 3 Circuit Rating

E10 208 40 3 Circuit Rating

E11 120 20 1 Circuit Rating

E12 208 30 1 Circuit Rating

E13 120 20 1 Circuit Rating

E14 208 30 1 Circuit Rating

E15 120 20 1 Circuit Rating

E16 208 30 1 Circuit Rating

E17 120 20 1 Circuit Rating

E18 208 30 1 Circuit Rating

E19 480 150 kVA 3 Transformer Rating

E20 120 20 1 Circuit Rating

E21 120 20 1 Circuit Rating

E22 120 20 1 Circuit Rating

E23 120 20 1 Circuit Rating

Circuit Flow (GPM)

F1 6.5

F2 3.9

F3 3.9

F4 3.9

F5 3.9

F6 10

F7 15

Total 47.1

Previous slide

shows locations