A. Air Cooling
Method: Pass ambient air through the battery rack using fans or vents.
Advantages: Low cost, maintenance-friendly, easy.
Disadvantages: Not effective at high temperatures; potential for creating hot spots.
Well-designed battery energy storage systems (BESS) are growing rapidly worldwide. For efficient and safe operation, thermal management is necessary. Proper temperature management can maintain the efficiency of the battery, prevent degradation, and reduce the likelihood of fire. In this blog, we will talk about key cooling technologies, best practices in modeling, and practical design steps and end with how Huijue Group's solutions can improve your BESS project.
1. Influence of Temperature on BESS Performance
- Lowered efficiency: Increased temperature reduces charging/discharging efficiency.
- Accelerated aging: Temperature increases will accelerate degradation and shorten life.
- Safety risks: Excessive overheating causes thermal runaway, a dangerous chain reaction.
Key point: Maintaining proper temperature control instantly prolongs the battery life, performance, and safety of the battery energy storage system.
2. BESS Cooling Methods
B. Liquid Cooling
Method: Liquid coolant moves through channels or pipes around the battery.
Advantages: Extremely precise and even temperature control, optimally suited to high-density systems.
Disadvantages: Higher expense and complexity, potential leak points.
C. Hybrid Cooling
Method: Combines air and liquid systems—e.g., liquid cooling core modules and cabinet fans.
Advantages: Binds cost and efficiency together.
Disadvantages: Requires system coordination.
3. Modeling Thermal Behavior in BESS
Before you actually make a physical model, you ought to use computer modeling in order to understand the heat flow within a battery energy storage system (BESS).
Thermal Modeling Steps
- Estimate heat sources: Compute the heat generated by battery cells and conductive components (e.g., busbars).
- Choose a cooling model:
- Detailed modeling: Model every cell and conductor—extremely accurate, but complex.
- Simplified modeling: Simplify heat output of every module to estimate—simple and fast.
- Simulate the interaction of solid components with fluids (air or liquid).
- Output helps analyze temperature distribution and focus areas.
For instance, in the liquid-cooled BESS simulation, the temperature differential between modules was approximately 13°C, and the maximum differential could be 28°C. In the air-cooled rack, the back cells were warmer, leading us to enhance the airflow grille design.
4. Prepare for Thermal Runaway Conditions
Thermal runaway—if an overheated battery ignites surrounding cells—is a critical safety risk.
Modeling approaches are:
- Simulate overheating as a result of internal battery faults.
- Observe heat transfer in the battery pack.
- Identify hot spots and design protective devices, such as thermal barriers or rapid shutdown systems.
Simulation testing can support engineers to enhance safety before real-world deployment.
5. Best Practices in Thermal Management Design
This is a concise checklist to guide BESS thermal system design:
- Choose the best cooling mechanism: air, liquid, or hybrid cooling.
- Model heat sources and flow paths correctly.
- Utilize CFD software and heat transfer modeling.
- Optimize cabinet layout: fans, vents, coolant channels.
- Identify hot spot detection and minimization.
- Test for worst-case scenarios: e.g. thermal runaway.
- Design for ease of maintenance: easy filter access, drain valves, sensors.
- Monitor at all times: utilize thermal sensors and real-time controls.
- Design for redundancy: redundant fans, multiple loops, thermal cutouts.
6. Case Studies: Air vs. Liquid Cooling Models
Liquid-cooled BESS: Simulated 14,000s at 1C, showing even temperatures across modules and peak at 28°C.
Air-cooled BESS: Identified hotspots at the rear due to uneven airflow—highlighting the need for improved internal ventilation or layout adjustments.
These examples highlight how simulation can guide better system design and prevent failures.
Power Your BESS with Huijue Group’s Advanced Solutions
Build or enhance battery energy storage systems, choose Huijue Group, and enjoy better safety, smart control, and long-term design.
Huijue Hot Backup BESS Products
- Wall mounted battery module: Compact in size, best suited for clean and ventilated indoor applications.
- Outdoor cabinet storage system: Tough and durable, can withstand harsh weather, suits combined cooling solutions.
- Intelligent EMS and control unit: Real-time temperature monitoring, automatic cooling system regulation, alarm setup to prevent thermal issues.
With Huijue, you will obtain advanced modules, intelligent management systems, and professional services to ensure the safe, efficient, and stable operation of your battery energy storage system.
