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<p>Effective battery thermal management system (BTMS) is critical for lithium-ion battery (LIB) safety and performance in electric vehicles. This study presents a CFD-driven optimisation framework for an immersion cooling BTMS using sustainable palm biodiesel as coolant. The Multi-scale Multi-Domain (NTGK) framework is conducted to effectively capture the complex interactions among various physicochemical processes. The Electrochemical-thermal Model (ECM) is applied using the Newman, Tiedeman, Gu, and Kim (NTGK) model. A conjugate heat transfer model for a 3S2P pouch cell module (20 Ah LiFePO₄) is developed and validated against experimental data (&lt; 2% error). The CFD model of a battery module is developed to train an ultra-fast metamodel for battery geometry optimisation. Two key parameters are optimised, namely: battery gap spacing (3–10 mm) and inlet/outlet width (5–15 mm), via Optimal Latin Hypercube Sampling, Support Vector Regression, and GDE3 algorithm. Palm biodiesel is used as a dielectric coolant in the proposed system to preserve LIB temperature within 20–40 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(^\circ{\rm C} \)</EquationSource> </InlineEquation>, preventing thermal runaway and ensuring a lightweight BTMS design. Compared to a conventional 3M-Novec, the palm biodiesel achieved system lightweight by 43%. The findings can establish biofuel immersion cooling as an eco-friendly BTMS solution, achieving Pareto-optimal figures: T<sub>max</sub> &lt; 29.9°C, Δ<i>T</i> &lt; 5°C, and Δ<i>P</i> &lt; 145.275 Pa (at 5C and 0.05 m/s).</p>

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Framework for rapid design and optimisation of immersive battery cooling system

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年11月12日

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  • Ali Almshahy,
  • Z. Khatir,
  • K. J. Kubiak,
  • M. Al Qubeissi

摘要

Effective battery thermal management system (BTMS) is critical for lithium-ion battery (LIB) safety and performance in electric vehicles. This study presents a CFD-driven optimisation framework for an immersion cooling BTMS using sustainable palm biodiesel as coolant. The Multi-scale Multi-Domain (NTGK) framework is conducted to effectively capture the complex interactions among various physicochemical processes. The Electrochemical-thermal Model (ECM) is applied using the Newman, Tiedeman, Gu, and Kim (NTGK) model. A conjugate heat transfer model for a 3S2P pouch cell module (20 Ah LiFePO₄) is developed and validated against experimental data (< 2% error). The CFD model of a battery module is developed to train an ultra-fast metamodel for battery geometry optimisation. Two key parameters are optimised, namely: battery gap spacing (3–10 mm) and inlet/outlet width (5–15 mm), via Optimal Latin Hypercube Sampling, Support Vector Regression, and GDE3 algorithm. Palm biodiesel is used as a dielectric coolant in the proposed system to preserve LIB temperature within 20–40 \(^\circ{\rm C} \) , preventing thermal runaway and ensuring a lightweight BTMS design. Compared to a conventional 3M-Novec, the palm biodiesel achieved system lightweight by 43%. The findings can establish biofuel immersion cooling as an eco-friendly BTMS solution, achieving Pareto-optimal figures: Tmax < 29.9°C, ΔT < 5°C, and ΔP < 145.275 Pa (at 5C and 0.05 m/s).