Thermal management of lithium-ion batteries using fin-integrated nano-enhanced PCM under forced air convection: A CFD study

The increasing demand for high-energy-density lithium-ion batteries in electric vehicles (EVs) necessitates advanced thermal management solutions to ensure operational safety, efficiency, and longevity. This study presents the development and simulation of an improved battery thermal management system (BTMS) incorporating hybrid nano-enhanced phase change materials (HNPCM) and fin architectures. The addition of Al₂O₃ (1%) and graphene (3%) nanoparticles to paraffin significantly enhanced its thermal conductivity by 5.27 times, enabling superior heat dissipation despite a 7.2% reduction in latent heat capacity. Computational fluid dynamics simulations using the Newman, Tiedemann, Gu, and Kim model quantified heat generation rates reaching 763,999 W/m³ at a 10 C discharge rate. The fin/HNPCM configuration demonstrated a 12.54% reduction in maximum cell surface temperature compared to the baseline and a 9.62% improvement over fin-only setups. Furthermore, forced convection outperformed free convection, lowering temperatures by 5.5%. These results confirm that the hybrid BTMS effectively maintains safe operating temperatures, reduces thermal runaway risks, and extends battery lifespan. The findings offer a scalable solution for EV applications, with potential for further enhancements through optimized nanoparticle ratios, fin geometries, and system designs. • Thermal conductivity of HNPCM increased by 5.27× with 1% Al₂O₃ and 3% graphene. • Maximum heat generation reached 763,999 W/m³ at a 10 C discharge rate. • Fin/HNPCM configuration reduced peak surface temperature by 12.54% compared to baseline. • Forced convection improved cooling efficiency, lowering temperatures by an additional 5.5%.