Advanced cooling techniques of tubular lithium-ion batteries and thermal, exergy, economic (3E) analysis: Lifecycle cost analysis of foam-enhanced PCM systems

Liquid-based cooling systems have garnered considerable attention due to their ability to handle high discharge rates from batteries. Yet, their thermodynamic and financial consequences are not well studied. This paper addresses the gap by developing a detailed 3E (exergy, energy, and economic) analysis of a thermal control system for tubular lithium-ion batteries with a 5C rate of discharge. Three nanochannel-cooled battery combinations, consisting of aluminum (Al), phase change material (PCM), and a lather-enhanced PCM composite, were considered utilizing a novel nanofluid, which is water infused with 0.4% Al2O3, 0.3% MXene, and 0.3% multi-walled carbon nanotubes (MWCNTs). The lather-PCM system recorded the lowest peak temperature (312.17K) and the lowest mass flow rate (0.1875 g/s), whereas the Al-based system was best at the maximum flow rate (1 g/s). The PCM-only setup had the highest peak temperatures and the most significant temperature difference between cells. The Al block had the highest thermal efficiency (76.03) and exergy efficiency (37.9) at low flow rates. The lather-PCM system was not as efficient overall, but it exhibited superior thermal uniformity and reduced exergy destruction. Although the PCM-only unit was the least expensive ($42.33), it was unable to sustain safe operating temperatures. However, the Al system was more expensive because more pumping was necessary, but it also had superior performance. Nevertheless, the PCM system grounded on lather can offer a more affordable long-term solution because it has balanced performance and consumes less energy. Copper lather was found to be the best thermal regulator, exergy, and system performance among the tested lather materials compared to Al and nickel.