Optimal battery configuration for electrical vehicles in hot climates: A numerical comparative study of materials and cooling approaches

The battery plays a pivotal role in the electric vehicle (EV) sector, and the advancement of this industry hinges on enhancing the thermal performance and efficiency of batteries, especially in regions characterized by high-temperature extremes. The primary objective of this study is to propose a battery configuration capable of operating efficiently in hot regions. To achieve this goal, we have selected six battery materials, each possessing distinct physical characteristics, for an in depth investigation into their thermal behavior within a mini-channel Thermal Management System. Subsequently, we conducted a comparative analysis of various volumetric flow rates and flow directions to determine the optimal combination. Once the best configuration was identified, we conducted a case study using realistic ground-based meteorological data to evaluate the performance of the selected battery configuration under real conditions. The results of this study reveal that material which is characterized by the specific heat of 830J.kg-1.K-1, and a thermal conductivity of Kx = Ky = 34W.m-1.K-1 and Kz = 3.4W.m-1.K-1, exhibits the highest thermal performance. Taking into account the power required for the system, the most efficient volumetric flow rate is 0.05 L/min which requires a power of 3e-7W, with the same direction of fluid inlet and outlet in the minichannels. The selected material, volumetric flow rate, and flow direction in this study ensure that the maximum temperature of (Tmax) of the cell is maintained at 29.21 °C, with a temperature difference (Tdiff) of 1.56 °C. Regarding the case study, applying this optimal configuration under the climatic conditions of Benguerir, Morocco, results in a Tmax of 29.36 °C and a Tdiff of 1.58 °C, confirming the feasibility of the proposed battery configuration and its BTMS in high-temperature conditions.