Periodic Reporting for period 1 - THOR (Innovative methodology for battery testing)
Reporting period: 2023-06-01 to 2024-11-30
Acceleration of growth of the battery sector is primordial in decarbonizing our economy as batteries play a vital role not only in making our mobility sustainable but also in increasing the uptake of renewable energies. Growth and particularly innovation in this sector are predominantly hindered by costly and time-consuming test protocols and methods that require large number of samples and sophisticated infrastructure. A battery concept generated in 2023 may at best reach the production stage in 2032 as performance, ageing and safety characteristics of the design must be assessed through a lengthy trial-and-error based physical testing. THOR project aims to shorten this timeframe, diminish the number of physical tests and nurture innovation in battery conception by developing a virtual tool - a Digital Twin that simulates battery behavior. The project targets mobility and stationary applications and focus on commonly used battery chemistries (representing 60% market share before 2030). Through an interdisciplinary approach involving experimentalists and modeling experts, 3 independent physics-based models for performance, lifetime and safety will be developed. The 3 models will then be combined and optimized using AI based approach to form a holistic digital twin of cell, module and pack. The digital twin will be accessible to the end-users through an efficient, user-friendly interface. THOR’s consortium covering the entire battery value chain will ensure that the project responds to the needs of battery industries (4 industrial partners including cell/ battery manufacturers and end-users) while enriching knowledge of the research community (3 research and technical organizations). In addition, the consortium aims to answer two requirements of the battery community: data harmonization and standardization of methodologies through the project. Ease-of-use, cost-effectiveness, rapidity and adaptability of the Digital Twin will be demonstrated by end-users. The project started 01/06/2023 and lasts 4 years. It gathers 9 European partners that are CEA, INERIS, VUB, FEAC, FLASH BATTERY, VARTA INNOVATION, ICONS, UNE and ENGIE-LABORELEC.
From M1 to M18, THOR project has launched activities on models development. Experimental tests matrices have been defined and started at cell level. Performances model has been calibrated and first simulation data are now available. Aging and safety tests campaigns have started and should last until end of 2025. Modules and packs designs have been defined. The prototyping activity is running. All the data collected on THOR’s samples will be harmonized and uploaded in a dedicated database which is now ready for implementation. Last but not least, a first dummy Graphical User Interface has been prepared on two different platforms to enable easy use of the battery digital twin developped in the project.
Results beyond the state of the art that are expected in THOR are :
- Reduction of costs related to equipment and infrastructures to enable the use of the Digital Twin by industries (industrial impact). The use of digital twin developed in THOR should reduce time, staff and materials required to develop and test a battery. This should enable a reduction of time by a factor 3 and a reduction of costs by a factor 2. The benefits on time and costs of the DT will be assessed with demonstration made by industrial partners in addition to the LCA conducted during the project. Time and cost for battery development and testing will be compared with and without use of DT.
- Improvement in understanding of the mechanisms occurring inside a battery system, discovery of new materials, generation of new materials knowledge and stimulation of the electrochemistry R&D efforts (scientific impact). The amalgamation of models in THOR will avoid sequential assessment of performance, aging and safety with time consuming iterations, difficult optimization and that will allow considering dependency between reaction mechanisms. With this approach, THOR will contribute to increase battery lifetime and safety by (i) providing a virtual tool enabling fast optimization of design, and (ii) contributing to a better understanding of phenomenon at stake. The THOR Digital Twin will enable direct visualization of performance, aging and safety instantaneously for a given battery design. Thanks to sensitivity studies and replicability studies conducted during the project, the development of models for a new chemistry will only require from 50% to 90% of the time and effort needed conventionally. The generation of new knowledge will be assessed compared to scientific literature.
- Increase in business opportunities in the battery industry due to cost reduction (economic impact). By accelerating time-to-market, THOR will allow European manufacturers to gain volumes, answering the market needs before foreign competitors. Through the reduction of development costs, THOR will also open the door for smaller companies (start-ups, SMEs) to participate in the research effort of the battery industry. This will stimulate the ecosystem and strengthen the European competitiveness in the sector. THOR will also contribute to accelerate circularity in the battery sector. The DT will provide a reliable prediction of battery performance, lifetime and safety and that will facilitate the development of the second-hand reuse of batteries, creating new business opportunities. Stakeholders mapping is on going.
- Motivate younger generation to study electrochemistry and take part in battery R&D effort, enhance R&D of electrical vehicles (societal impact). The THOR solution will help making the transport sector cleaner and more sustainable. The project will provide a tool to innovate more eco-friendly design, increasing the engagement of citizens to participate in the transition of the energy sector into a cleaner and more sustainable one. Increase in reliability (accuracy of models, better understanding of mechanisms) and in safety will foster a better acceptability by citizens and businesses and motivate scientists to engage in battery R&D effort. The first reporting period focused on creating a community interested in THOR topics and activities. The social media community count 356 followers while the website reached 4,300 pageviews, mostly from Italy, France, Belgium, USA, The Netherlands, Germany and Greece
- Acceptance of virtual tests as part of the certification process (regulatory impact). THOR will develop an accurate and reliable digital twin, which can be a tool for performing virtual test. Some partners are involved in standardization committees and can help making the standards evolve, allowing digital testing as a part of the certification process. This would accelerate the certification process. Number of new standards projects will be assessed at the end of the project.
- Reduction of costs related to equipment and infrastructures to enable the use of the Digital Twin by industries (industrial impact). The use of digital twin developed in THOR should reduce time, staff and materials required to develop and test a battery. This should enable a reduction of time by a factor 3 and a reduction of costs by a factor 2. The benefits on time and costs of the DT will be assessed with demonstration made by industrial partners in addition to the LCA conducted during the project. Time and cost for battery development and testing will be compared with and without use of DT.
- Improvement in understanding of the mechanisms occurring inside a battery system, discovery of new materials, generation of new materials knowledge and stimulation of the electrochemistry R&D efforts (scientific impact). The amalgamation of models in THOR will avoid sequential assessment of performance, aging and safety with time consuming iterations, difficult optimization and that will allow considering dependency between reaction mechanisms. With this approach, THOR will contribute to increase battery lifetime and safety by (i) providing a virtual tool enabling fast optimization of design, and (ii) contributing to a better understanding of phenomenon at stake. The THOR Digital Twin will enable direct visualization of performance, aging and safety instantaneously for a given battery design. Thanks to sensitivity studies and replicability studies conducted during the project, the development of models for a new chemistry will only require from 50% to 90% of the time and effort needed conventionally. The generation of new knowledge will be assessed compared to scientific literature.
- Increase in business opportunities in the battery industry due to cost reduction (economic impact). By accelerating time-to-market, THOR will allow European manufacturers to gain volumes, answering the market needs before foreign competitors. Through the reduction of development costs, THOR will also open the door for smaller companies (start-ups, SMEs) to participate in the research effort of the battery industry. This will stimulate the ecosystem and strengthen the European competitiveness in the sector. THOR will also contribute to accelerate circularity in the battery sector. The DT will provide a reliable prediction of battery performance, lifetime and safety and that will facilitate the development of the second-hand reuse of batteries, creating new business opportunities. Stakeholders mapping is on going.
- Motivate younger generation to study electrochemistry and take part in battery R&D effort, enhance R&D of electrical vehicles (societal impact). The THOR solution will help making the transport sector cleaner and more sustainable. The project will provide a tool to innovate more eco-friendly design, increasing the engagement of citizens to participate in the transition of the energy sector into a cleaner and more sustainable one. Increase in reliability (accuracy of models, better understanding of mechanisms) and in safety will foster a better acceptability by citizens and businesses and motivate scientists to engage in battery R&D effort. The first reporting period focused on creating a community interested in THOR topics and activities. The social media community count 356 followers while the website reached 4,300 pageviews, mostly from Italy, France, Belgium, USA, The Netherlands, Germany and Greece
- Acceptance of virtual tests as part of the certification process (regulatory impact). THOR will develop an accurate and reliable digital twin, which can be a tool for performing virtual test. Some partners are involved in standardization committees and can help making the standards evolve, allowing digital testing as a part of the certification process. This would accelerate the certification process. Number of new standards projects will be assessed at the end of the project.