Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation

Stefano Landini; Anindita Roy; Mohammad Ismail; Jack Panter; Gordhan Das Valasai

doi:10.11159/enfht25.138

Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation

Stefano Landini, Anindita Roy, Mohammad Ismail, Jack Panter, Gordhan Das Valasai

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

Abstract

This work investigates a new hybrid thermal management system (TMS) for light electric vehicle (LEV) battery packs that uses dielectric liquid immersion cooling and heat pipes to effectively control lithium-ion battery (LIB) thermal load. The proposed TMS exploits the heat pipes' excellent heat dissipation and dielectric fluids' uniform cooling. Different commercial dielectric oil chemistries
(Cargill DE-11772 and EF-3221, LK-STO50, and MIVOLT-DFK) are evaluated as heat transfer fluids (HTFs) and compared with air and deionised water as benchmark. A 3D steady-state CFD model is developed in Ansys 2024R1 to simulate the proposed TMS for a
4S4P (14.8V, 10 Ah) Lithium-Nickel Manganese Cobalt (NMC) battery pack. Under typical 2C discharge rate, the model preliminarily
examines the TMS thermal performance when simulating heat transfer with and without buoyancy effects. Buoyancy improves cooling
performance, especially for viscous fluids, lowering battery, HTF, and heat sink temperatures by 20%. With modest LIB heat generation
rates (up to 25 kW/m³), the TMS ensures effective cooling with minimum temperature increase. However, when reaching heat generation
rates up to 100 kW/m³, the battery temperature reaches 91.13°C, revealing the system's cooling capability limitations. The study examines
the effect of changing heat sink and insulation equivalent convective heat transfer coefficients. Increasing the heat sink coefficient from 10 to 100 W/m²K lowers the battery temperature from 138°C to 49°C, while increasing the insulation equivalent heat transfer coefficient from 1 to 50 W/m²K lowers battery temperature from 92°C to 46°C. This study shows that the hybrid TMS using heat pipes and immersion cooling may improve compact LEV safety, performance, and battery longevity under high-demand situations.

Original language	English
Title of host publication	Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025)
Editors	Lixin Cheng, Tassos G. Karayiannis, Sohel Murshed
Publisher	Avestia
ISBN (Print)	9781990800511
DOIs	https://doi.org/10.11159/enfht25.138
Publication status	Published - Apr 2025

Publication series

Name	Proceedings of the World Congress on Momentum, Heat and Mass Transfer
ISSN (Electronic)	2371-5316

Keywords

Lithium-Ion Batteries
Light Electric Vehicles
Thermal Management
Immersion Cooling
Dielectric Oils
Heat Pipes
Passive Cooling

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.11159/enfht25.138Licence: Unspecified

Cite this

Landini, S., Roy, A., Ismail, M., Panter, J., & Valasai, G. D. (2025). Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation. In L. Cheng, T. G. Karayiannis, & S. Murshed (Eds.), Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025) Article ENFHT 138 (Proceedings of the World Congress on Momentum, Heat and Mass Transfer). Avestia. https://doi.org/10.11159/enfht25.138

Landini, Stefano ; Roy, Anindita ; Ismail, Mohammad et al. / Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation. Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025). editor / Lixin Cheng ; Tassos G. Karayiannis ; Sohel Murshed. Avestia, 2025. (Proceedings of the World Congress on Momentum, Heat and Mass Transfer).

@inproceedings{8f2c9890a2e94bccb466a9732946abae,

title = "Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation",

abstract = "This work investigates a new hybrid thermal management system (TMS) for light electric vehicle (LEV) battery packs that uses dielectric liquid immersion cooling and heat pipes to effectively control lithium-ion battery (LIB) thermal load. The proposed TMS exploits the heat pipes' excellent heat dissipation and dielectric fluids' uniform cooling. Different commercial dielectric oil chemistries(Cargill DE-11772 and EF-3221, LK-STO50, and MIVOLT-DFK) are evaluated as heat transfer fluids (HTFs) and compared with air and deionised water as benchmark. A 3D steady-state CFD model is developed in Ansys 2024R1 to simulate the proposed TMS for a4S4P (14.8V, 10 Ah) Lithium-Nickel Manganese Cobalt (NMC) battery pack. Under typical 2C discharge rate, the model preliminarilyexamines the TMS thermal performance when simulating heat transfer with and without buoyancy effects. Buoyancy improves coolingperformance, especially for viscous fluids, lowering battery, HTF, and heat sink temperatures by 20%. With modest LIB heat generationrates (up to 25 kW/m³), the TMS ensures effective cooling with minimum temperature increase. However, when reaching heat generationrates up to 100 kW/m³, the battery temperature reaches 91.13°C, revealing the system's cooling capability limitations. The study examinesthe effect of changing heat sink and insulation equivalent convective heat transfer coefficients. Increasing the heat sink coefficient from 10 to 100 W/m²K lowers the battery temperature from 138°C to 49°C, while increasing the insulation equivalent heat transfer coefficient from 1 to 50 W/m²K lowers battery temperature from 92°C to 46°C. This study shows that the hybrid TMS using heat pipes and immersion cooling may improve compact LEV safety, performance, and battery longevity under high-demand situations. ",

keywords = "Lithium-Ion Batteries, Light Electric Vehicles, Thermal Management, Immersion Cooling, Dielectric Oils, Heat Pipes, Passive Cooling",

author = "Stefano Landini and Anindita Roy and Mohammad Ismail and Jack Panter and Valasai, {Gordhan Das}",

year = "2025",

month = apr,

doi = "10.11159/enfht25.138",

language = "English",

isbn = "9781990800511",

series = "Proceedings of the World Congress on Momentum, Heat and Mass Transfer",

publisher = "Avestia",

editor = "Lixin Cheng and Karayiannis, {Tassos G.} and Sohel Murshed",

booktitle = "Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025)",

}

Landini, S, Roy, A, Ismail, M, Panter, J & Valasai, GD 2025, Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation. in L Cheng, TG Karayiannis & S Murshed (eds), Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025)., ENFHT 138, Proceedings of the World Congress on Momentum, Heat and Mass Transfer, Avestia. https://doi.org/10.11159/enfht25.138

Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation. / Landini, Stefano; Roy, Anindita; Ismail, Mohammad et al.
Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025). ed. / Lixin Cheng; Tassos G. Karayiannis; Sohel Murshed. Avestia, 2025. ENFHT 138 (Proceedings of the World Congress on Momentum, Heat and Mass Transfer).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

TY - GEN

T1 - Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation

AU - Landini, Stefano

AU - Roy, Anindita

AU - Ismail, Mohammad

AU - Panter, Jack

AU - Valasai, Gordhan Das

PY - 2025/4

Y1 - 2025/4

N2 - This work investigates a new hybrid thermal management system (TMS) for light electric vehicle (LEV) battery packs that uses dielectric liquid immersion cooling and heat pipes to effectively control lithium-ion battery (LIB) thermal load. The proposed TMS exploits the heat pipes' excellent heat dissipation and dielectric fluids' uniform cooling. Different commercial dielectric oil chemistries(Cargill DE-11772 and EF-3221, LK-STO50, and MIVOLT-DFK) are evaluated as heat transfer fluids (HTFs) and compared with air and deionised water as benchmark. A 3D steady-state CFD model is developed in Ansys 2024R1 to simulate the proposed TMS for a4S4P (14.8V, 10 Ah) Lithium-Nickel Manganese Cobalt (NMC) battery pack. Under typical 2C discharge rate, the model preliminarilyexamines the TMS thermal performance when simulating heat transfer with and without buoyancy effects. Buoyancy improves coolingperformance, especially for viscous fluids, lowering battery, HTF, and heat sink temperatures by 20%. With modest LIB heat generationrates (up to 25 kW/m³), the TMS ensures effective cooling with minimum temperature increase. However, when reaching heat generationrates up to 100 kW/m³, the battery temperature reaches 91.13°C, revealing the system's cooling capability limitations. The study examinesthe effect of changing heat sink and insulation equivalent convective heat transfer coefficients. Increasing the heat sink coefficient from 10 to 100 W/m²K lowers the battery temperature from 138°C to 49°C, while increasing the insulation equivalent heat transfer coefficient from 1 to 50 W/m²K lowers battery temperature from 92°C to 46°C. This study shows that the hybrid TMS using heat pipes and immersion cooling may improve compact LEV safety, performance, and battery longevity under high-demand situations.

AB - This work investigates a new hybrid thermal management system (TMS) for light electric vehicle (LEV) battery packs that uses dielectric liquid immersion cooling and heat pipes to effectively control lithium-ion battery (LIB) thermal load. The proposed TMS exploits the heat pipes' excellent heat dissipation and dielectric fluids' uniform cooling. Different commercial dielectric oil chemistries(Cargill DE-11772 and EF-3221, LK-STO50, and MIVOLT-DFK) are evaluated as heat transfer fluids (HTFs) and compared with air and deionised water as benchmark. A 3D steady-state CFD model is developed in Ansys 2024R1 to simulate the proposed TMS for a4S4P (14.8V, 10 Ah) Lithium-Nickel Manganese Cobalt (NMC) battery pack. Under typical 2C discharge rate, the model preliminarilyexamines the TMS thermal performance when simulating heat transfer with and without buoyancy effects. Buoyancy improves coolingperformance, especially for viscous fluids, lowering battery, HTF, and heat sink temperatures by 20%. With modest LIB heat generationrates (up to 25 kW/m³), the TMS ensures effective cooling with minimum temperature increase. However, when reaching heat generationrates up to 100 kW/m³, the battery temperature reaches 91.13°C, revealing the system's cooling capability limitations. The study examinesthe effect of changing heat sink and insulation equivalent convective heat transfer coefficients. Increasing the heat sink coefficient from 10 to 100 W/m²K lowers the battery temperature from 138°C to 49°C, while increasing the insulation equivalent heat transfer coefficient from 1 to 50 W/m²K lowers battery temperature from 92°C to 46°C. This study shows that the hybrid TMS using heat pipes and immersion cooling may improve compact LEV safety, performance, and battery longevity under high-demand situations.

KW - Lithium-Ion Batteries

KW - Light Electric Vehicles

KW - Thermal Management

KW - Immersion Cooling

KW - Dielectric Oils

KW - Heat Pipes

KW - Passive Cooling

UR - https://avestia.com/MHMT2025_Proceedings/

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U2 - 10.11159/enfht25.138

DO - 10.11159/enfht25.138

M3 - Conference contribution

SN - 9781990800511

T3 - Proceedings of the World Congress on Momentum, Heat and Mass Transfer

BT - Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025)

A2 - Cheng, Lixin

A2 - Karayiannis, Tassos G.

A2 - Murshed, Sohel

PB - Avestia

ER -

Landini S, Roy A, Ismail M, Panter J, Valasai GD. Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation. In Cheng L, Karayiannis TG, Murshed S, editors, Proceedings of the 10th World Congress on Momentum, Heat and Mass Transfer (MHMT 2025). Avestia. 2025. ENFHT 138. (Proceedings of the World Congress on Momentum, Heat and Mass Transfer). doi: 10.11159/enfht25.138

Strategies for Hybrid Immersion Cooling Of Light Electric Vehicle Battery Packs: A Numerical Investigation

Abstract

Publication series

Keywords

UN SDGs

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Numerical investigation of hybrid immersion cooling strategies for battery packs in light electric vehicles

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