Efficient Immersion Cooling of Lithium-Ion Batteries: A CFD and MOGA-Based Optimization Study

A thermal management system is crucial to ensure temperature uniformity in electric vehicle battery packs. Maintaining the battery system’s temperature within a safe range is critical to prolonging the service life of lithium-ion cells. This study investigates the efficiency of direct liquid immersion cooling systems for lithium-ion battery units in electric vehicles. In this work, Computational Fluid Dynamics (CFD) simulations were employed to analyze the thermal behavior of a 23-cell battery module cooled by immersion, coded by commercial software ANSYS Fluent 2025 R1. For the optimization calculations, an in -hose code was developed in in Python and implemented. The module was optimized by adjusting various design and operating parameters. Immersion cooling, achieved by submerging the battery in a cooling fluid, offers markedly higher heat transfer performance than conventional cooling techniques. The optimal temperature distribution and heat dissipation were achieved by modifying the cell length and diameter, followed by adjustments to the width, length, and height of the battery case, and finally, the coolant inlet velocity. The outcomes of this study are expected to provide valuable guidance for researchers and engineers in both academia and industry, contributing to the development of more powerful, reliable, and long-lasting electric vehicles.