journal article·2025-03-03Open access

A Comprehensive Model and Experimental Investigation of Venting Dynamics and Mass Loss in Lithium-Ion Batteries Under a Thermal Runaway

Ai Chen, Resul Sahin, Marco Ströbel, Thomas Kottke, Stefan Hecker, Alexander Fill

Batteries· Volume 11· Issue 3

Abstract

Thermal runaway (TR) has become a critical safety concern with the widespread use of lithium-ion batteries (LIBs) as an energy storage solution to meet the growing global energy demand. This issue has become a significant barrier to the expansion of LIB technologies. Addressing the urgent need for safer LIBs, this study developed a comprehensive model to simulate TR in cylindrical 18650 nickel cobalt manganese (NMC) LIBs. By incorporating experiments with LG®-INR18650-MJ1 cells, the model specifically aimed to accurately predict critical TR parameters, including temperature evolution, internal pressure changes, venting phases, and mass loss dynamics. The simulation closely correlated with experimental outcomes, particularly in replicating double venting mechanisms, gas generation, and the characteristics of mass loss observed during TR events. This study confirmed the feasibility of assuming proportional relationships between gas generation and the cell capacity and between the mass loss from solid particle ejection and the total mass loss, thereby simplifying the modeling of both gas generation and mass loss behaviors in LIBs under TR. Conclusively, the findings advanced the understanding of TR mechanisms in LIBs, providing a solid foundation for future research aimed at mitigating risks and promoting the safe integration of LIBs into sustainable energy solutions.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Advanced Battery Technologies Research · Advancements in Battery Materials · Radiation Effects in Electronics

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Institute for Photovoltaics, University of Stuttgart, Pfaffenwaldring 47, 70569 Stuttgart, Germany

MAP Battery Tests GmbH, Hauptstraße 117, 74599 Hengstfeld, Germany

Rolls-Royce Power Systems, Maybachplatz 1, 88045 Friedrichshafen, Germany

References (53)

Show source-provided references
1. A Review of Lithium Ion Battery Failure Mechanisms and Fire Prevention Strategies10.1016/j.pecs.2019.03.002 ↗
2. Safety Focused Modeling of Lithium-Ion Batteries: A Review10.1016/j.jpowsour.2015.11.100 ↗
3. Interaction of Cyclic Ageing at High-Rate and Low Temperatures and Safety in Lithium-Ion Batteries10.1016/j.jpowsour.2014.08.135 ↗
4. Tran, M.K., Mevawalla, A., Aziz, A., Panchal, S., Xie, Y., and Fowler, M. (2022). A Review of Lithium-Ion Battery Thermal Runaway Modeling and Diagnosis Approaches. Processes, 10.10.3390/pr10061192 ↗
5. Explosion Behavior Investigation and Safety Assessment of Large-Format Lithium-Ion Pouch Cells10.1016/j.jechem.2022.04.018 ↗
6. Wang, H., Xu, H., Zhang, Z., Wang, Q., Jin, C., Wu, C., Xu, C., Hao, J., Sun, L., and Du, Z. (2022). Fire and Explosion Characteristics of Vent Gas from Lithium-Ion Batteries after Thermal Runaway: A Comparative Study. eTransportation, 13.10.1016/j.etran.2022.100190 ↗
7. Kong, D., Wang, G., Ping, P., and Wen, J. (2022). A Coupled Conjugate Heat Transfer and CFD Model for the Thermal Runaway Evolution and Jet Fire of 18650 Lithium-Ion Battery under Thermal Abuse. eTransportation, 12.10.1016/j.etran.2022.100157 ↗
8. Richard, M.N., and Dahn, J.R. (1999). Accelerating Rate Calorimetry Study on the Thermal Stability of Lithium Intercalated Graphite in Electrolyte. I. Experimental. J. Electrochem. Soc., 146.10.1149/1.1391893 ↗
9. Richard, M.N., and Dahn, J.R. (1999). Accelerating Rate Calorimetry Study on the Thermal Stability of Lithium Intercalated Graphite in Electrolyte. II. Modeling the results and predicting differential scanning calorimeter curves. J. Electrochem. Soc., 146.10.1149/1.1391894 ↗
10. Chen, H., Buston, J.E.H., Gill, J., Howard, D., Williams, R.C.E., Read, E., Abaza, A., Cooper, B., and Wen, J.X. (2021). A Simplified Mathematical Model for Heating-Induced Thermal Runaway of Lithium-Ion Batteries. J. Electrochem. Soc., 168.10.1149/1945-7111/abd64c ↗
11. Coman, P.T., Darcy, E.C., and White, R.E. (2022). Simplified Thermal Runaway Model for Assisting the Design of a Novel Safe Li-Ion Battery Pack. J. Electrochem. Soc., 169.10.1149/1945-7111/ac62bd ↗
12. Hatchard, T.D., MacNeil, D.D., Basu, A., and Dahn, J.R. (2001). Thermal Model of Cylindrical and Prismatic Lithium-Ion Cells. J. Electrochem. Soc., 148.10.1149/1.1377592 ↗
13. A Three-Dimensional Thermal Abuse Model for Lithium-Ion Cells10.1016/j.jpowsour.2007.04.018 ↗
14. Kong, D., Wang, G., Ping, P., and Wen, J. (2021). Numerical Investigation of Thermal Runaway Behavior of Lithium-Ion Batteries with Different Battery Materials and Heating Conditions. Appl. Therm. Eng., 189.10.1016/j.applthermaleng.2021.116661 ↗
15. Theoretical and Experimental Analysis of the Lithium-Ion Battery Thermal Runaway Process Based on the Internal Combustion Engine Combustion Theory10.1016/j.enconman.2019.02.008 ↗
16. Characterization of Lithium-Ion Battery Thermal Abuse Behavior Using Experimental and Computational Analysis10.1149/2.0751510jes ↗
17. Zhang, Y., Mei, W., Qin, P., Duan, Q., and Wang, Q. (2021). Numerical Modeling on Thermal Runaway Triggered by Local Overheating for Lithium Iron Phosphate Battery. Appl. Therm. Eng., 192.10.1016/j.applthermaleng.2021.116928 ↗
18. Weber, N., Schuhmann, S., Tübke, J., and Nirschl, H. (2023). Chemical Thermal Runaway Modeling of Lithium-Ion Batteries for Prediction of Heat and Gas Generation. Energy Technol., 11.10.1002/ente.202300565 ↗
19. A Lumped Model of Venting during Thermal Runaway in a Cylindrical Lithium Cobalt Oxide Lithium-Ion Cell10.1016/j.jpowsour.2015.12.088 ↗
20. Thermal-Runaway Experiments on Consumer Li-ion Batteries with Metal-Oxide and Olivin-Type Cathodes10.1039/C3RA45748F ↗
21. Zou, K., He, K., and Lu, S. (2022). Venting Composition and Rate of Large-Format LiNi0.8Co0.1Mn0.1O2 Pouch Power Battery during Thermal Runaway. Int. J. Heat Mass Transf., 195.10.1016/j.ijheatmasstransfer.2022.123133 ↗
22. Wang, G., Kong, D., Ping, P., Wen, J., He, X., Zhao, H., He, X., Peng, R., Zhang, Y., and Dai, X. (2023). Revealing Particle Venting of Lithium-Ion Batteries during Thermal Runaway: A Multi-Scale Model toward Multiphase Process. eTransportation, 16.10.1016/j.etran.2023.100237 ↗
23. Mao, B., Zhao, C., Chen, H., Wang, Q., and Sun, J. (2021). Experimental and Modeling Analysis of Jet Flow and Fire Dynamics of 18650-Type Lithium-Ion Battery. Appl. Energy, 281.10.1016/j.apenergy.2020.116054 ↗
24. Modeling of Thermal Runaway Propagation in a Pouch Cell Stack10.1007/s10694-020-00970-6 ↗
25. Model-Based Thermal Runaway Prediction of Lithium-Ion Batteries from Kinetics Analysis of Cell Components10.1016/j.apenergy.2018.06.126 ↗
26. Kriston, A., Podias, A., Adanouj, I., and Pfrang, A. (2020). Analysis of the effect of thermal runaway initiation conditions on the severity of thermal runaway—numerical simulation and machine learning study. J. Electrochem. Soc., 167.10.1149/1945-7111/ab9b0b ↗
27. Mei, W., Liu, Z., Wang, C., Wu, C., Liu, Y., Liu, P., Xia, X., Xue, X., Han, X., and Sun, J. (2023). Operando monitoring of thermal runaway in commercial lithium-ion cells via advanced lab-on-fiber technologies. Nat. Commun., 14.10.1038/s41467-023-40995-3 ↗
28. Pegel, H., Schaeffler, S., Jossen, A., and Sauer, D.U. (2023). Extensive experimental thermal runaway and thermal propagation characterization of large-format tabless cylindrical lithium-ion cells with aluminum housing and laser welded endcaps. J. Electrochem. Soc., 170.10.1149/1945-7111/ad0cd3 ↗
29. Kennedy, R.W., Marr, K.C., and Ezekoye, O.A. (2021). Gas Release Rates and Properties from Lithium Cobalt Oxide Lithium Ion Battery Arrays. J. Power Sources, 487.10.1016/j.jpowsour.2020.229388 ↗
30. Kim, J., Mallarapu, A., Finegan, D.P., and Santhanagopalan, S. (2021). Modeling Cell Venting and Gas-Phase Reactions in 18650 Lithium Ion Batteries during Thermal Runaway. J. Power Sources, 489.10.1016/j.jpowsour.2021.229496 ↗
31. Ostanek, J.K., Li, W., Mukherjee, P.P., Crompton, K., and Hacker, C. (2020). Simulating Onset and Evolution of Thermal Runaway in Li-ion Cells Using a Coupled Thermal and Venting Model. Appl. Energy, 268.10.1016/j.apenergy.2020.114972 ↗
32. Li, W., León Quiroga, V., Crompton, K.R., and Ostanek, J.K. (2021). High Resolution 3-D Simulations of Venting in 18650 Lithium-Ion Cells. Front. Energy Res., 9.10.3389/fenrg.2021.788239 ↗
33. Fedoryshyna, Y., Schaeffler, S., Soellner, J., Gillich, E.I., and Jossen, A. (2024). Quantification of venting behavior of cylindrical lithium-ion and sodium-ion batteries during thermal runaway. J. Power Sources, 615.10.1016/j.jpowsour.2024.235064 ↗
34. Gillich, E.I., Steinhardt, M., Fedoryshyna, Y., and Jossen, A. (2024). Mechanical Measurement Approach to Characterize Venting Behavior during Thermal Runaway of 18650 Format Lithium-Ion Batteries. Batteries, 10.10.3390/batteries10040142 ↗
35. Willstrand, O., Pushp, M., Andersson, P., and Brandell, D. (2023). Impact of different Li-ion cell test conditions on thermal runaway characteristics and gas release measurements. J. Energy Storage, 68.10.1016/j.est.2023.107785 ↗
36. Shi, C., Wang, H., Shen, H., Wang, J., Li, C., Li, Y., Xu, W., and Li, M. (2024). Thermal Runaway Characteristics and Gas Analysis of LiNi0.9Co0.05Mn0.05O2 Batteries. Batteries, 10.10.3390/batteries10030084 ↗
37. Thermal Runaway of Commercial 18650 Li-ion Batteries with LFP and NCA Cathodes – Impact of State of Charge and Overcharge10.1039/C5RA05897J ↗
38. Shen, H., Wang, H., Li, M., Li, C., Zhang, Y., Li, Y., Yang, X., Feng, X., and Ouyang, M. (2023). Thermal Runaway Characteristics and Gas Composition Analysis of Lithium-Ion Batteries with Different LFP and NCM Cathode Materials under Inert Atmosphere. Electronics, 12.10.3390/electronics12071603 ↗
39. Refined Study on Lithium Ion Battery Combustion in Open Space and a Combustion Chamber10.1016/j.psep.2020.03.037 ↗
40. Kriston, A., Adanouj, I., Ruiz, V., and Pfrang, A. (2019). Quantification and Simulation of Thermal Decomposition Reactions of Li-ion Battery Materials by Simultaneous Thermal Analysis Coupled with Gas Analysis. J. Power Sources, 435.10.1016/j.jpowsour.2019.226774 ↗
41. Test of Reaction Kinetics Using Both Differential Scanning and Accelerating Rate Calorimetries As Applied to the Reaction of LixCoO2 Non-Aqueous Electrolyte10.1021/jp001187j ↗
42. The Studies on Structural and Thermal Properties of Delithiated LixNi1/3Co1/3Mn1/3O2 (010.1016/j.ssi.2006.03.055 ↗
43. Li, W., Crompton, K., Hacker, C., and Ostanek, J.K. (2020). Comparison of current interrupt device and vent design for 18650 format lithium-ion battery caps. J. Energy Storage, 32.10.1016/j.est.2020.101890 ↗
44. Comprehensive gas analysis on large scale automotive lithium-ion cells in thermal runaway10.1016/j.jpowsour.2018.07.051 ↗
45. Isobaric Vapor-Liquid Equilibria of Binary Mixtures Containing the Carbonate Group -OCOO-10.1021/je049859c ↗
46. Predicting Outflow from High Pressure Vessels10.1205/095758201531095 ↗
47. Finegan, D.P., Scheel, M., Robinson, J.B., Tjaden, B., Hunt, I., Mason, T.J., Millichamp, J., Di Michiel, M., Offer, G.J., and Hinds, G. (2015). In-operando high-speed tomography of lithium-ion batteries during thermal runaway. Nat. Commun., 6.10.1038/ncomms7924 ↗
48. Kirchev, A., Guillet, N., Brun-Buission, D., and Gau, V. (2022). Li-Ion Cell Safety Monitoring Using Mechanical Parameters: Part I. Normal Battery Operation. J. Electrochem. Soc., 169.10.1149/1945-7111/ac48c8 ↗
49. Fill, A., Kopp, M., Hemmerling, J., Baazouzi, S., Tendera, L., and Birke, K.P. (2023, January 19–21). Three-Dimensional Model of a Cylindrical Lithium-Ion Cell—Influence of Cell Design on State Imbalances and Fast-Charging Capability. Proceedings of the 2023 IEEE 32nd International Symposium on Industrial Electronics (ISIE), Helsinki, Finland.10.1109/ISIE51358.2023.10227929 ↗
50. Heenan, T.M.M., Jnawali, A., Kok, M.D.R., Tranter, T.G., Tan, C., Dimitrijevic, A., Jervis, R., Brett, D.J.L., and Shearing, P.R. (2020). An Advanced Microstructural and Electrochemical Datasheet on 18650 Li-Ion Batteries with Nickel-Rich NMC811 Cathodes and Graphite-Silicon Anodes. J. Electrochem. Soc., 167.10.1149/1945-7111/abc4c1 ↗
51. Amount of Free Liquid Electrolyte in Commercial Large Format Prismatic Li-Ion Battery Cells10.1149/2.1151904jes ↗
52. Wang, Q., Sun, J., Yao, X., and Chen, C. (2006). Thermal Behavior of Lithiated Graphite with Electrolyte in Lithium-Ion Batteries. J. Electrochem. Soc., 153.10.1149/1.2139955 ↗
53. Steinhardt, M., Gillich, E.I., Rheinfeld, A., Kraft, L., Spielbauer, M., Bohlen, O., and Jossen, A. (2021). Low-Effort Determination of Heat Capacity and Thermal Conductivity for Cylindrical 18650 and 21700 Lithium-Ion Cells. J. Energy Storage, 42.10.1016/j.est.2021.103065 ↗