Linda Gaines

ANALYSIS OF TECHNOLOGY OPTIONS TO REDUCE THE FUEL CONSUMPTION OF IDLING TRUCKS

Long-haul trucks idling overnight consume more than 838 million gallons (20 million barrels) of fuel annually. Idling also emits pollutants. Truck drivers idle their engines primarily to (1) heat or cool the cab and/or sleeper, (2) keep the fuel warm in winter, and (3) keep the engine warm in the winter so that the engine is easier to start. Alternatives to overnight idling could save much of this fuel, reduce emissions, and cut operating costs. Several fuel-efficient alternatives to idling are available to provide heating and cooling: (1) direct-fired heater for cab/sleeper heating, with or without storage cooling; (2) auxiliary power units; and (3) truck stop electrification. Many of these technologies have drawbacks that limit market acceptance. Options that supply electricity are economically viable for trucks that are idled for 1,000--3,000 or more hours a year, while heater units could be used across the board. Payback times for fleets, which would receive quantity discounts on the prices, would be somewhat shorter.

Impact of Recycling on Cradle-to-Gate Energy Consumption and Greenhouse Gas Emissions of Automotive Lithium-Ion Batteries

This paper addresses the environmental burdens (energy consumption and air emissions, including greenhouse gases, GHGs) of the material production, assembly, and recycling of automotive lithium-ion batteries in hybrid electric, plug-in hybrid electric, and battery electric vehicles (BEV) that use LiMn(2)O(4) cathode material. In this analysis, we calculated the energy consumed and air emissions generated when recovering LiMn(2)O(4), aluminum, and copper in three recycling processes (hydrometallurgical, intermediate physical, and direct physical recycling) and examined the effect(s) of closed-loop recycling on environmental impacts of battery production. We aimed to develop a U.S.-specific analysis of lithium-ion battery production and in particular sought to resolve literature discrepancies concerning energy consumed during battery assembly. Our analysis takes a process-level (versus a top-down) approach. For a battery used in a BEV, we estimated cradle-to-gate energy and GHG emissions of 75 MJ/kg battery and 5.1 kg CO(2)e/kg battery, respectively. Battery assembly consumes only 6% of this total energy. These results are significantly less than reported in studies that take a top-down approach. We further estimate that direct physical recycling of LiMn(2)O(4), aluminum, and copper in a closed-loop scenario can reduce energy consumption during material production by up to 48%.

The significance of Li-ion batteries in electric vehicle life-cycle energy and emissions and recycling's role in its reduction

Three key questions have driven recent discussions of the energy and environmental impacts of automotive lithium-ion batteries. We address each of them, beginning with whether the energy intensity of producing all materials used in batteries or that of battery assembly is greater. Notably, battery assembly energy intensity depends on assembly facility throughput because energy consumption of equipment, especially the dry room, is mainly throughput-independent. Low-throughput facilities therefore will have higher energy intensities than near-capacity facilities. In our analysis, adopting an assembly energy intensity reflective of a low-throughput plant caused the assembly stage to dominate cradle-to-gate battery energy and environmental impact results. Results generated with an at-capacity assembly plant energy intensity, however, indicated cathode material production and aluminium use as a structural material were the drivers. Estimates of cradle-to-gate battery energy and environmental impacts must therefore be interpreted in light of assumptions made about assembly facility throughput. The second key question is whether battery recycling is worthwhile if battery assembly dominates battery cradle-to-gate impacts. In this case, even if recycled cathode materials are less energy and emissions intensive than virgin cathode materials, little energy and environmental benefit is obtained from their use because the energy consumed in assembly is so high. We reviewed the local impacts of metals recovery for cathode materials and concluded that avoiding or reducing these impacts, including SOx emissions and water contamination, is a key motivator of battery recycling regardless of the energy intensity of assembly. Finally, we address whether electric vehicles (EV) offer improved energy and environmental performance compared to internal combustion-engine vehicles (ICV). This analysis illustrated that, even if a battery assembly energy reflective of a low-throughput facility is adopted, EVs consume less petroleum and emit fewer greenhouse gases (GHG) than an ICV on a life-cycle basis. The only scenario in which an EV emitted more GHGs than an ICV was when it used solely coal-derived electricity as a fuel source. SOx emissions, however, were up to four times greater for EVs than ICVs. These emissions could be reduced through battery recycling.

LIFE-CYCLE ENERGY SAVINGS POTENTIAL FROM ALUMINUM-INTENSIVE VEHICLES.

The life-cycle energy and fuel-use impacts of US-produced aluminum-intensive passenger cars and passenger trucks are assessed. The energy analysis includes vehicle fuel consumption, material production energy, and recycling energy. A model that stimulates market dynamics was used to project aluminum-intensive vehicle market shares and national energy savings potential for the period between 2005 and 2030. We conclude that there is a net energy savings with the use of aluminum-intensive vehicles. Manufacturing costs must be reduced to achieve significant market penetration of aluminum-intensive vehicles. The petroleum energy saved from improved fuel efficiency offsets the additional energy needed to manufacture aluminum compared to steel. The energy needed to make aluminum can be reduced further if wrought aluminum is recycled back to wrought aluminum. We find that oil use is displaced by additional use of natural gas and nonfossil energy, but use of coal is lower. Many of the results are not necessarily applicable to vehicles built outside of the United States, but others could be used with caution.

Estimation of Fuel Use by Idling Commercial Trucks

This paper uses the recently published 2002 Vehicle Inventory and Use survey to determine the number of commercial trucks in the categories that are most likely to idle for periods of more than 0.5 h at a time. On the basis of estimated numbers of hours for both overnight idling by sleepers and long-duration idling by all size classes during their workdays, the total fuel use by idling trucks is estimated to be more than 2 billion gallons per year. Workday idling is determined to be a potentially much larger energy user than overnight idling, but data are required before any definitive conclusions can be reached. Existing technologies can reduce overnight idling, but development may be needed to reduce workday idling.

Material and energy flows in the materials production, assembly, and end-of-life stages of the automotive lithium-ion battery life cycle

This document contains material and energy flows for lithium-ion batteries with an active cathode material of lithium manganese oxide (LiMn{sub 2}O{sub 4}). These data are incorporated into Argonne National Laboratorys Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET) model, replacing previous data for lithium-ion batteries that are based on a nickel/cobalt/manganese (Ni/Co/Mn) cathode chemistry. To identify and determine the mass of lithium-ion battery components, we modeled batteries with LiMn{sub 2}O{sub 4} as the cathode material using Argonnes Battery Performance and Cost (BatPaC) model for hybrid electric vehicles, plug-in hybrid electric vehicles, and electric vehicles. As input for GREET, we developed new or updated data for the cathode material and the following materials that are included in its supply chain: soda ash, lime, petroleum-derived ethanol, lithium brine, and lithium carbonate. Also as input to GREET, we calculated new emission factors for equipment (kilns, dryers, and calciners) that were not previously included in the model and developed new material and energy flows for the battery electrolyte, binder, and binder solvent. Finally, we revised the data included in GREET for graphite (the anode active material), battery electronics, and battery assembly. For the first time, we incorporated energy and material flows for battery recycling into GREET, considering four battery recycling processes: pyrometallurgical, hydrometallurgical, intermediate physical, and direct physical. Opportunities for future research include considering alternative battery chemistries and battery packaging. As battery assembly and recycling technologies develop, staying up to date with them will be critical to understanding the energy, materials, and emissions burdens associated with batteries.

Energy and Environmental Impacts of Electric Vehicle Battery Production and Recycling

Electric vehicle batteries use energy and generate environmental residuals when they are produced and recycled. This study estimates, for 4 selected battery types (advanced lead-acid, sodium-sulfur, nickel-cadmium, and nickel-metal hydride), the impacts of production and recycling of the materials used in electric vehicle batteries. These impacts are compared, with special attention to the locations of the emissions. It is found that the choice among batteries for electric vehicles involves tradeoffs among impacts. For example, although the nickel-cadmium and nickel-metal hydride batteries are similar, energy requirements for production of the cadmium electrodes may be higher than those for the metal hydride electrodes, but the latter may be more difficult to recycle.

Life-Cycle Analysis of Production and Recycling of Lithium Ion Batteries

This paper discusses what is known about the life-cycle burdens of lithium ion batteries. Constituent-material production and the subsequent manufacturing of batteries are emphasized. Of particular interest is estimation of the impact of battery material recycling on battery manufacturing. Because some materials come from comparatively less plentiful resources, the recycling of lithium ion batteries and the potential impact on battery-production life-cycle burdens are discussed. This effort represents the early stage of lithium ion battery life-cycle analysis, in which processes are characterized preparatory to detailed data acquisition. Notwithstanding the lack of data on production of battery materials, it is estimated that the energy use and greenhouse gas emissions associated with battery manufacturing make up only a small percentage of a plug-in hybrid vehicles total life-cycle energy use. Further, the recycling of battery materials potentially can significantly reduce the material production energy.

Operation of an Aluminum-Intensive Vehicle: Report on a Six-Year Project

In 1994, Ford produced a small demonstration fleet of Mercury Sables with aluminum bodies. Argonne National Laboratory obtained one of these vehicles on a lease so that Laboratory staff could observe the wear characteristics of the body under normal operating conditions. The vehicle was placed in the transportation pool, parked outdoors, and used by staff members for both local and longer trips. The vehicle performed normally, except for having particularly good acceleration because of its light weight and highpower SHO engine. No significant problems were encountered that related to the Al body or engine. No special driving protocols were observed, but a log was kept of trip lengths and fuel purchases. Fuel economy was observed to be improved, compared with that of a similar conventional steel-bodied vehicle that was available for one year of the lease period. The vehicle was tested on a chassis dynamometer to obtain emissions and fuel economy over the federal test cycle. The impacts of further mass reduction were also simulated. At the end of the lease, the body was in excellent condition, which we documented with a set of detailed photographs before the vehicle was returned to Ford. There were minor imperfections in the painted surface, probably resulting from the omission of an E-coat during the painting process. We also examined three similar conventional vehicles for comparison; these exhibited varying degrees of rust.

Lifecycle Analysis for Automobiles: Uses and Limitations

There has been a recent trend toward the use of lifecycle analysis (LCA) as a decision-making tool for the automotive industry. However, the different practitioners` methods and assumptions vary widely, as do the interpretations put on the results. The lack of uniformity has been addressed by such groups as the Society of Environmental Toxicology and Chemistry (SETAC) and the International Organization for Standardization (ISO), but standardization of methodology assures neither meaningful results nor appropriate use of the results. This paper examines the types of analysis that are possible for automobiles, explains possible pitfalls to be avoided, and suggests ways that LCA can be used as part of a rational decision-making procedure. The key to performing a useful analysis is identification of the factors that will actually be used in making the decision. It makes no sense to analyze system energy use in detail if direct financial cost is to be the decision criterion. Criteria may depend on who is making the decision (consumer, producer, regulator). LCA can be used to track system performance for a variety of criteria, including emissions, energy use, and monetary costs, and these can have spatial and temporal distributions. Because optimization of one parameter is likely to worsen another, identification of trade-offs is an important function of LCA.