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Heat transfer optimization of winged-wavy rib cooling channels for LiFePO4 battery thermal management
(2026-10-01)
Kaewchoothong, Natthaporn
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Oo, Ye Min
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Gonsrang, Sarawut
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Sengchuai, Kiattisak
Effective thermal management is essential for maintaining the safety, durability, and performance of lithium-ion batteries. In this study, the heat transfer performance of a rib-enhanced cooling channel was experimentally investigated and subsequently applied to the thermal management of LiFePO<inf>4</inf> battery cells. A series of winged-wavy rib configurations with different inclination angles (30°, 45°, 60°, 75°, and 90°) was installed on the heated wall of a square cooling channel to examine their influence on flow structure, heat transfer enhancement, and pressure loss. Experiments were conducted under turbulent flow conditions with Reynolds numbers ranging from 10,000 to 30,000. The results show that introducing wing elements on the wavy ribs generates secondary flows and longitudinal vortices, thereby enhancing fluid mixing and disrupting the thermal boundary layer near the heated surface. Compared with the conventional wavy rib configuration, the normalized average Nusselt number increased by 16.1%, 21.7%, 24.2%, 23.3%, and 13.7% for rib inclination angles of 30°, 45°, 60°, 75°, and 90°, respectively. Although the rib structures increased the friction factor by approximately 53–64%, the 60° winged-wavy rib configuration exhibited the best thermo–hydraulic performance, with a thermal performance factor approximately 5.7% higher than that of the baseline case. Compared with previously reported rib-grooved and vortex-promoting passive enhancement configurations, the proposed winged–wavy rib combines periodic flow acceleration with longitudinal vortex generation, enabling effective near-wall mixing and thermal boundary-layer disruption for air-cooled battery thermal management applications. To evaluate practical applicability, the optimized rib configuration was implemented in a battery thermal management system for LiFePO<inf>4</inf> cells operating at charge–discharge rates of 0.4C–0.6C. The rib-assisted cooling channel reduced both the local and average surface temperatures and maintained the temperature difference among cells within approximately 1–2 °C, indicating improved temperature uniformity within the battery module. These results demonstrate that the proposed winged-wavy rib structure can enhance convective heat transfer and provide an effective passive cooling approach for lithium-ion battery thermal management systems.
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Optimization of chemical precipitation for valuable metal recovery from spent lithium nickel manganese cobalt oxide batteries
(2026-05-01)
Morawan, Nattaya
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Kruthun, Orathai
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Katers, John F.
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Attaphong, Chodchanok
This study investigated the optimized conditions for chemical precipitation to recover nickel manganese cobalt hydroxide (NiCoMn-OH) and lithium carbonate (Li<inf>2</inf>CO<inf>3</inf>) from spent lithium nickel manganese cobalt oxide (sLi-NMC) batteries. The research focused on establishing optimized conditions to maximize recovery efficiency and product purity. The process involved dismantling and incinerating the batteries to produce black powder, followed by acid leaching using H<inf>2</inf>SO<inf>4</inf> and H<inf>2</inf>O<inf>2</inf>, and a two-step precipitation to recover NiCoMn-OH and Li<inf>2</inf>CO<inf>3</inf>. Results indicated that the optimized incineration conditions for efficient black powder production were 600 °C for 30 min. During the leaching process, the optimized extraction of lithium, nickel, cobalt, and manganese was achieved using 1 M H<inf>2</inf>SO<inf>4</inf> with 2% H<inf>2</inf>O<inf>2</inf> at a liquid-to-solid ratio of 30:1 mL/g. In the first precipitation stage, the optimized conditions for co-precipitating the solid NiCoMn-OH using saturated NaOH were identified as pH 10, 25 °C, and a contact time of 90 min. The results showed that nickel, manganese, and cobalt were precipitated at 92.04%, 90.35%, and 86.78%, respectively (a purity of 98.67%). Finally, lithium was successfully recovered as Li<inf>2</inf>CO<inf>3</inf> using saturated Na<inf>2</inf>CO<inf>3</inf>, at pH 12, 100 °C, and a contact time of 120 min up to 96.51% (a purity of 98.98%). Ultimately, the optimized conditions obtained from this study can provide valuable data for waste management and serve as a comparative baseline for environmental impact assessment of conventional metal recovery, enabling direct comparisons with optimized alternative methods in future research.
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Enhanced adaptive Hamiltonian control strategy for battery-ultracapacitor hybrid systems in electric vehicle applications
(2025-12-01)
Mungporn, Pongsiri
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Khomfoi, Surin
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Namin, Anon
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Thongpron, Jutturit
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Yodwong, Burin
This paper presents an enhanced Hamiltonian control law integrated with differential flatness theory, designed for hybrid vehicle systems utilizing batteries and ultracapacitors (UCs). Compared to conventional methods, the proposed approach improves transient stability, enables dynamic power sharing, and reduces battery stress under rapid load variations, making it particularly effective for commercial electric vehicle (EV) applications. These vehicles operate under dynamic load conditions such as frequent acceleration, breaking, and regenerative events, which demand high-performance power management. The primary objective of the proposed control law is to manage power flow and optimize energy utilization in such hybrid systems. By combining Hamiltonian control with differential flatness techniques, the strategy dynamically regulates energy distribution between the battery and the UC. This is particularly relevant in DC microgrid applications, including vehicle systems, where constant power load (CPL) challenges frequently arise. To evaluate the effectiveness of the proposed strategy, an experimental test bench was developed using a Li-ion battery module (LFeLi-48,100 TB, 48 V, 100 Ah) and a UC module (188.88 F, 51.3 V). Experimental results confirm the superior performance of the proposed control law throughout various load–drive cycles.
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Seawater submersion for cylindrical lithium-ion batteries thermal runaway prevention
(2024-10-10)
Meelapchotipong, Pongkorn
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Charoenphonphanich, Chinda
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Masomtob, Manop
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Kunanusont, Nattanai
Lithium-ion batteries (LIBs) are currently used in various electric vehicles, including electric boats. To assess the risk of fire due to thermal runaway of the LIB during the operation of ferries, seawater can be used as a cooling fluid for the LIB to prevent thermal runaway as it is abundant. However, the seawater could corrode the electrodes of the battery, which would lead to toxic wastewater. Prevention of thermal runaway of lithium-ion batteries by submersion in seawater needs to be investigated to clarify the corrosion that could lead to toxic wastewater. In this study, fully charged, pristine 18650 NMC Li-ion cells were submerged in synthetic seawater (SSW) to investigate the corrosion effect compared to deionized (DI) water. The results showed that SSW induced rapid voltage discharge, leading to corrosion on the electrodes and toxic effluents, while DI water maintained the stability of the cells and did not cause any corrosion effect. In addition, the prevention of thermal runaway was investigated by exposing fully charged LIB to extreme overheating conditions. The liquid submersion system was activated by rapid voltage drop monitoring to evaluate its effectiveness in preventing thermal runaway (TR). The investigation of TR prevention by SSW submersion showed that the TR process can be effectively prevented. In addition, no corrosion effect was observed during submersion in SSW as the battery voltage was not applied. This study shows that seawater can be used to prevent TR in LIB and does not cause environmental problems comparable to water.
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Modeling Li-ion Battery Using Measurement Data
(2023-01-01)
Yutthanava, Tanapon
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Khomfoi, Surin
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Phophongviwat, Teeraphon
A precise battery model is essential for battery management system to predict state of charge and cell balancing. The aims of this paper are improved Lithium-ion battery model and study behavior of Lithium-ion battery. In this paper a second-order equivalent circuit of battery lithium-ion is developed to use for Lithium-ion Nickel based battery. The model is developed and validated with experiment result in MATLAB/SIMULINK/SIMSCAPE, As the comparison, The developed model is capable to predict current-voltage performance accurately in battery management system.
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A Comparative Study on the Parameter Identification of an Equivalent Circuit Model for an Li-ion Battery Based on Different Discharge Tests
(2022-03-01)
Poopanya, Piyawong
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Sivalertporn, Kanchana
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Phophongviwat, Teeraphon
An effective model of battery performance is important for battery management systems to control the state of battery and cell balancing. The second-order equivalent circuit model of a lithium-ion battery is studied in the present paper. The identification methods that include the multiple linear regression (MLR), exponential curve fitting (ECF) and Simulink design optimization tool (SDOT), were used to determine the model parameters. The aim of this paper is to compare the validity of the three proposed algorithms, which vary in complexity. The open circuit voltage was measured based on the pulse discharge test. The voltage response was collected for every 10% SOC in the interval between 0–100% SOC. The battery voltages calculated from the estimated parameters under the constant current discharge test and dynamic discharge tests for electric vehicles (ISO and WLTP) were compared to the experimental data. The mean absolute error and root mean square error were calculated to analyze the accuracy of the three proposed estimators. Overall, SDOT provides the best fit with high accuracy, but requires a heavy computation burden. The accuracy of the three methods under the constant current discharge test is high compared to other experiments, due to the nonlinear behavior at a low SOC. For the ISO and WLTP dynamic tests, the errors of MLR are close to that of SDOT, but have less computing time. Therefore, MLR is probably more suitable for EV use than SDOT.

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