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<p>Efficient thermal management is essential for ensuring the safety, performance, and lifespan of lithium-ion battery packs employed in electric vehicles (EVs). Among various battery thermal management approaches, immersion cooling has emerged as a promising solution owing to its superior heat dissipation capability and temperature uniformity. In the present work, a Computational Fluid Dynamics (CFD)-based comparative investigation was conducted to evaluate the thermal performance of three cooling fluids, namely water–glycol, Castrol DC 20, and 3&#xa0;M Novec 7000, under immersion cooling conditions for cylindrical lithium-ion battery modules. Three-dimensional simulations were performed using ANSYS Fluent to analyze temperature distribution, heat transfer characteristics, and cooling effectiveness under identical operating conditions. The simulation results demonstrated that immersion cooling significantly enhanced battery thermal regulation compared to the no-cooling condition. The maximum battery cell temperature decreased from 330.24&#xa0;K in the absence of cooling to 326.04, 321.00 and 312.60&#xa0;K using water–glycol, Castrol DC 20, and 3&#xa0;M Novec 7000, respectively. Similarly, battery pack temperature was reduced from 330.24 to 316.74, 310.80 and 304.32&#xa0;K for the respective cooling fluids. Among the investigated coolants, 3&#xa0;M Novec 7000 exhibited the highest Reynolds number (348,165) and convective heat transfer coefficient (1711 W m<sup>-2</sup> K<sup>-1</sup>), resulting in superior heat removal capability despite its relatively lower thermal conductivity. The findings indicate that fluid hydrodynamics and convective heat transfer characteristics play a more significant role in immersion cooling performance than thermal conductivity alone. The study provides a comprehensive comparative assessment of commercially available dielectric fluids and establishes 3&#xa0;M Novec 7000 as the most effective coolant for immersion-cooled EV battery thermal management systems. The outcomes offer valuable design insights for the development of advanced battery cooling technologies for next-generation electric vehicles.</p>

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Computational fluid dynamics (CFD) based comparative assessment of dielectric fluids for immersion cooling in batteries of electric vehicles

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月3日

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  • Harsh Salakiya,
  • Roshan Raman,
  • Hakan Caliskan,
  • Praveen Barmavatu,
  • Zafar Said,
  • Utku Kale,
  • Artūras Kilikevičius

摘要

Efficient thermal management is essential for ensuring the safety, performance, and lifespan of lithium-ion battery packs employed in electric vehicles (EVs). Among various battery thermal management approaches, immersion cooling has emerged as a promising solution owing to its superior heat dissipation capability and temperature uniformity. In the present work, a Computational Fluid Dynamics (CFD)-based comparative investigation was conducted to evaluate the thermal performance of three cooling fluids, namely water–glycol, Castrol DC 20, and 3 M Novec 7000, under immersion cooling conditions for cylindrical lithium-ion battery modules. Three-dimensional simulations were performed using ANSYS Fluent to analyze temperature distribution, heat transfer characteristics, and cooling effectiveness under identical operating conditions. The simulation results demonstrated that immersion cooling significantly enhanced battery thermal regulation compared to the no-cooling condition. The maximum battery cell temperature decreased from 330.24 K in the absence of cooling to 326.04, 321.00 and 312.60 K using water–glycol, Castrol DC 20, and 3 M Novec 7000, respectively. Similarly, battery pack temperature was reduced from 330.24 to 316.74, 310.80 and 304.32 K for the respective cooling fluids. Among the investigated coolants, 3 M Novec 7000 exhibited the highest Reynolds number (348,165) and convective heat transfer coefficient (1711 W m-2 K-1), resulting in superior heat removal capability despite its relatively lower thermal conductivity. The findings indicate that fluid hydrodynamics and convective heat transfer characteristics play a more significant role in immersion cooling performance than thermal conductivity alone. The study provides a comprehensive comparative assessment of commercially available dielectric fluids and establishes 3 M Novec 7000 as the most effective coolant for immersion-cooled EV battery thermal management systems. The outcomes offer valuable design insights for the development of advanced battery cooling technologies for next-generation electric vehicles.