Dry Cell Research Articles

BATERIAS DE CARROS ELÉTRICOS: MANUTENÇÕES E DESCARTES

The rapid growth in the adoption of electric vehicles brings to light challenges related to the maintenance and disposal of batteries, which are essential components for the operation of these vehicles. The central issue addressed is the sustainability of the battery life cycle, considering both the efficiency of their maintenance and the environmental impacts resulting from inadequate disposal. The context involves the transition to a greener economy and the demands for clean technologies, which makes it essential to discuss appropriate practices to extend the useful life of batteries and ensure their safe disposal. The main objective of this study is to analyze the maintenance practices of electric car batteries and disposal strategies, focusing on minimizing environmental impacts and optimizing the life cycle of components. The research seeks to identify effective methods to extend the useful life of batteries, in addition to evaluating existing recycling policies and processes. The methodology used includes a literature review of current battery maintenance and disposal practices, in addition to the analysis of case studies that exemplify different approaches and results in international contexts. The research also incorporates interviews with industry experts, aiming to obtain a comprehensive and updated view of best practices and challenges faced. This work contributes to the discussion on sustainability in the automotive sector and to the formulation of more efficient policies for the management of technological waste.

Decarbonizing Public Transportation: A Multi-Criteria Comparative Analysis of Battery Electric Buses and Fuel Cell Electric Buses

To combat global warming, many industrialized countries have announced plans to ban vehicles powered by fossil fuel in the near future. In alignment with this global initiative, many countries across the globe are committed to decarbonizing their public transportation sector, which significantly contributes to increased greenhouse gas emissions. A promising strategy to achieve this goal is the adoption of electric buses, specifically battery electric buses and fuel cell electric buses. Each technology offers distinct advantages and drawbacks, making the decision-making process complex. This research aims to answer two critical questions: What is the optimal choice for decarbonizing the bus transportation sector—electric battery buses or fuel cell electric buses? And what are the best energy carrier pathways for charging or refueling these buses? We propose a methodological framework based on multi-criteria decision-making to address these questions comprehensively. This framework utilizes the entropy weighting and the Technique for Order Preference by Similarity to the Ideal Solution (TOPSIS) methodologies to rank alternative bus technologies along with energy carrier pathways. The framework evaluates a range of criteria, including economic viability, energy demand, and environmental aspects. To illustrate the framework, we considered Qatar as a case study. Our results indicate that, with respect to economic viability and energy consumption, the operation of battery electric buses is favored over fuel cell electric buses, regardless of the energy pathway utilized during both the energy production and bus operation phases. However, from an environmental perspective, operating both bus alternatives using energy from green sources provides superior performance compared to when these buses are powered by natural gas sources.

Reengineering the Substrate Tunnel to Enhance the Catalytic Efficiency of Squalene Epoxidase.

Squalene epoxidase plays a pivotal role in the biosynthesis of ergosterol, its derivatives, and other triterpenoid compounds by catalyzing the transformation of squalene into 2,3-oxidosqualene. However, its low catalytic efficiency remains a primary bottleneck for the microbial synthesis of triterpenoids. In this study, the catalytic activity of the squalene epoxidase from Saccharomyces cerevisiae was significantly improved by reshaping its substrate tunnel, resulting in a marked increase in the yield of the final product, ergosterol. First, the amino acid in the catalytic pocket of squalene epoxidase was replaced with alanine (Ala), effectively reducing the steric hindrance, and thus, enhancing the affinity of the enzyme with its substrate. Then, the V249H/L343A mutant was obtained by redesigning the substrate tunnel of dominant mutant L343A, thus, increasing the titer of ergosterol. The study also elucidated the mechanism behind the increased catalytic activity of the V249H/L343A mutant through substrate tunnel parameter analysis and molecular dynamics simulations. Finally, a titer of 3345 mg/L of ergosterol was achieved by strains containing V249H/L343A in a 5 L bioreactor, with a specific yield of 84 mg/g dry cell weight (DCW), marking a 64% increase compared with the titer achieved by wild type strains. This study established a strong foundation for improving the synthetic efficiency of ergosterol and other triterpenoid compounds.

E-waste driven eco-friendly highly sensitive wearable capacitive sensors for physical activity monitoring and sign language recognition

Owing to the continual and rapid advancement in technology, there has been a significant surge in electronic waste (e-waste) in recent decades, resulting in a harmful impact on our environment. Due to the growing demand for battery-powered devices, non-rechargeable batteries are a significant source of e-waste. This study describes fabricating a paper-based graphite strain sensor that is eco-friendly, inexpensive, biodegradable, and sensitive to the applied strain. Readily accessible materials are employed to design and fabricate MIDC strain sensors. The Modified Interdigital Capacitor (MIDC) structure is formed on basic printing paper, and the conductive substance made with the ink of a gel pen and graphite from a drained dry cell is painted on the paper and used as electrode material. The suggested sensor has a high gauge factor value of 1998.578 and fast response and recovery time of 112 ms and 100 ms, respectively. The proposed prototype has also been utilized to inspect fitness exercises and physical activities on the human body, inspiring the potential for its integration into wearable systems for various applications. Reliable detection and differentiation of finger positions are achieved, highlighting the sensor's potential for more advanced sign language applications. It’s a good option to integrate the suggested strain sensor in wearable systems, such as telemedicine systems, electromechanical detection, healthcare, and physical activity monitoring of humans.

Conceptual model for extending electric vehicle battery lifetime

To maximise the resource efficiency of electric vehicle lithium-ion batteries (LIBs), their lifetimes can be extended through cascading second- and third-life applications. Using expert input, this study establishes a conceptual model for understanding these applications’ state of health (SOH) thresholds and user requirements. Using a qualitative methodology, including focus group discussions with multistakeholder experts and policy analysis of the European battery regulatory landscape, we propose extending LIB use. Our model outlines potential second- and third-life applications aiming to maximise battery value retention. The findings highlight gaps in current European Union regulations that inadequately support battery-repurposing strategies. The conceptual model with an SOH threshold and key performance indicators serves as a foundation for researchers and industries to explore cascading battery applications, foster long-term resource efficiency and contribute to the circular economy by extending LIB lifespans through repurposing initiatives.

Biosynthesis of plant-derived triterpenoid asiatic acid in Saccharomyces cerevisiae cell factories

Asiatic acid, a bioactive component of Centella asiatica (L.) Urban, exhibits plentiful valuable pharmacological properties. Herein, we engineered Saccharomyces cerevisiae to produce asiatic acid. Initially, asiatic acid was synthesized by expressing the Centella asiatica cytochrome P450 monooxygenases CYP714E19 and CYP716C11 in a Saccharomyces cerevisiae strain optimized for ursolic acid production. The engineered strain yielded 0.42 ± 0.01 mg/L and 0.067 ± 0.0013 mg/g dry cell weight (DCW) of asiatic acid. Subsequently, a suitable cytochrome P450 reductase was screened, and key enzymes were overexpressed to effectively convert ursolic acid to asiatic acid. Strengthening heme biosynthesis, promoting endoplasmic reticulum (ER) expansion, and enhancing the cofactor supply were implemented to improve P450 catalytic activity. Additionally, a PDZ-PDZlig-mediated protein self-assembly strategy was used to improve the efficiency of the CYP714E19 and CYP716C11 catalytic cascade. Finally, the highest production was achieved (30.09 ± 0.15 mg/L, 4.09 ± 0.01 mg/g DCW) in microbial cell factories. This work establishes a foundation for efficient production of asiatic acid.

On 3D Dispenser Printing of MnO2 Reinforced PVDF Matrix for Recycling of Dry Cell

On 3D Dispenser Printing of MnO2 Reinforced PVDF Matrix for Recycling of Dry Cell

Greening Your Drive: A Method of Effective Conversion from IC Engine Based Vehicle to EV

This research presents the most efficient method for turning vehicles with internal combustion engines (IC engines) into electric vehicles (EVs). With an emphasis on reducing the environmental footprint and optimizing energy efficiency, our strategy includes cutting-edge technology in electric powertrain parts, power electronics, and battery storage systems. This paper assesses performance indicators by thoroughly analyzing the integration of new electric drivetrain components and the retrofitting of old ones, including motor starting and energy usage. To produce energy-efficient EVs, we suggest a supercapacitor bank and an effective battery cooling system. The recommended approach, Safety concerns, environmental advantages, and economic viability are also covered. The suggested approach shows promise in terms of lower production of greenhouse gases, increased range, and cost-effectiveness. The results provide an efficient way of battery cooling system and efficient use of battery storage by integrating a supercapacitor bank. The outcomes support the worldwide trend towards environmentally sound methods of transportation by providing important insights that will accelerate the widespread use of sustainable EVs.

Sustainable Production of Shinorine from Agricultural Wastes Using Engineered Saccharomyces cerevisiae Expressing Novel d-Alanine-d-alanine Ligase from Pseudonocardia pini.

Shinorine, a compound known for its protective properties against UV radiation, is widely used in cosmetics and pharmaceuticals. Despite the construction of various recombinant Saccharomyces cerevisiae strains for shinorine production, achieving industrial-scale yields remains a challenge. In this study, genes encoding enzymes (DDGS, O-MT, and ATP-grasp enzyme) from Actinosynnema mirum were introduced into S. cerevisiae DXdT to enable the heterologous conversion of sedoheptulose 7-phosphate to mycosporine-glycine─the direct biosynthetic precursor of shinorine. Subsequently, a novel d-alanine-d-alanine ligase from Pseudonocardia pini was introduced to produce shinorine. The engineered strain (DXdT-MG-mi89-PP.ddl) produced 267.9 mg/L shinorine with a 48.6 mg/g dry cell weight (DCW) content in a medium supplemented with lignocellulosic hydrolysate derived from rice straw. Notably, the recombinant strain produced 1.7 g/L shinorine with a 79.1 mg/g DCW content from a corn steep liquor medium with a mixture of glucose and xylose. These results support the idea that sustainable shinorine production from agricultural wastes holds significant promise for industrial applications.

A cost-effectiveness comparison of renewable energy pathways for decarbonizing heavy-duty vehicles in China

Decarbonizing heavy-duty vehicles is becoming increasingly important, yet multiple renewable-based decarbonization pathways have not been compared systematically. To fill this gap, this study develops a techno-economic and environmental model that integrates the fuel cycle and vehicle cycle to assess these pathways for China. The model includes two energy storage technologies: batteries and hydrogen, three energy transmission options, and two vehicle types: fuel cell electric vehicles and battery electric vehicles. Five distinct low-carbon pathways are evaluated on a ton-kilometer basis, including cost, greenhouse gas emissions, and abatement cost relative to conventional diesel trucks. Results indicate that the most cost-effective battery electric vehicle pathway offers a 7 % lower ton-km cost than diesel trucks for a 49-ton gross vehicle weight. Battery electric vehicle charging combined with hydrogen for power generation is more cost-effective than direct use of hydrogen in fuel cell electric vehicles. All studied pathways can achieve over 80 % emission reduction compared to diesel trucks, with fuel cell electric vehicle pathways having the highest abatement costs of 103–117 USD/tonCO2. Analysis of the impact of gross vehicle weight and vehicle range indicates that battery electric vehicle pathways outperform fuel cell electric vehicle pathways across most dimensions. Costs of battery electric vehicle pathways do increase sharply for vehicle ranges beyond about 700 km, and fuel cell electric vehicles become more cost-effective relative to battery electric vehicles for ranges above approximately 1100 km, although all pathways are much more costly than diesel trucks at long ranges. The sensitivity analysis highlights the importance of powertrain efficiency and cost projections show that fuel cell electric heavy-duty vehicles can achieve cost-parity before 2030. These results highlight the desirability of promoting the adoption of heavier battery electric vehicles and providing more targeted subsidies for long-range fuel cell electric vehicles.

Regional vehicle energy consumption evaluation framework to quantify the benefits of vehicle electrification in plateau city: A case study of Xining, China

Vehicle electrification holds significant potential for driving both decarbonization and improved energy efficiency within the realm of road transportation. However, accurate quantification of energy consumption advantages offered by electric vehicles (EVs) has remained elusive, thus impeding their long-term development due to variations across cities and vehicle types. To address this challenge, we propose a novel regional vehicle energy consumption assessment framework that integrates a region-specific driving cycle (DC) database and advanced high-precision energy consumption models. The regional DC database is constructed using a Markov chain approach. The database is stochastic and diverse, while taking into account real driving features and regional geographic environments. Energy consumption models for internal combustion engine vehicle (ICEV), plug-in hybrid electric vehicle (PHEV) and battery electric vehicle (BEV) are constructed based on machine learning approach. These models have good generalization ability and prediction accuracy, with R2 of 0.86, 0.86 and 0.77 on the test set, respectively. According to the interpretability of the models, vehicle acceleration and vehicle specific power are considered to be the most important features affecting vehicle energy consumption. According to the evaluation results, compared to using ICEV, the promotion of PHEV and BEV in Xining, a plateau city, can reduce energy consumption by 27.83 % and 32.05 %, respectively. The framework not only unifies the scale of energy consumption evaluation among different vehicle types, but also its good generalization ability can be migrated and extended to the evaluation of vehicle energy consumption in various regions. The establishment of this framework will contribute to the promotion and popularization of electric vehicles, as well as the advancement of energy-saving initiatives in the transportation sector.

Extraction of carbon and preparation of activated carbon from waste dry cell battery

The goal of this research was to synthesize activated carbon (AC) from discarded batteries, and the crystallographic characterization of the final product (AC), intermediate product, and raw sources were explored. The formation of activated carbon was confirmed by utilizing an X-ray diffractometer (XRD) that revealed the structure of activated carbon was hexagonal. The crystallite size of activated carbon was computed by applying several model equations (Linear straight-line method of Scherrer's equation, Monshi-Scherrer method, Sahadat-Scherrer method, Size-Strain plot method, Halder-Wagner method, Williamson-Hall method), and the range of calculated crystallite size was 5–28 nm. The weight loss occurred in the two stages those was explored by a thermogravimetric analyzer (TGA). Fourier Transform Infrared Spectrophotometer (FTIR) confirmed that there was no significant change in the peak position between intermediate product and activated carbon except for the intensity and peak separation difference. Field Emission Electron Microscope (FE-SEM) revealed several types of shapes of the waste source, intermediate product, and main product (AC).

Exploring discharged dry cell as an electrocatalyst for oxygen evolution reaction

Abstract Transition metal compounds with a high affinity for oxygen in dry cell configurations, such as MnO2, Mn3O4, and ZnxMn3O4−x, exhibit exceptional electrocatalytic properties in the oxygen evolution reaction (OER). However, the disposal of these dry cell materials, unlike that of rechargeable batteries, poses environmental hazards. In this study, we focused on optimizing these manganese oxides for energy-related applications, specifically OER. To achieve this goal, we investigated the electrocatalytic behaviour of both used and fresh dry cells in OER. Our results show that the used dry cell material achieved a current density of 10 mA·cm−2 at an overpotential of 525 mV, whereas the fresh dry cell required an overpotential 100 mV higher to reach the same current density. We further characterized the nature of these fresh and used materials using various techniques, including x-ray diffraction (XRD), scanning electron microscopy (SEM), thermogravimetric analysis (TGA), Raman spectroscopy, Fourier-transform infrared spectroscopy (FT-IR), and contact angle measurements. The enhanced activity of the used dry cell can be attributed to the formation of highly active Mn3O4 from MnO2 and graphene oxide under discharging conditions.

Process development and environmental impact assessment of sustainable poly(3-hydroxybutyrate) separation and purification via Paraburkholderia sacchari cell lysis using crude enzymes

Downstream separation and purification of poly(3-hydroxybutyrate) has been developed via combined crude enzyme bacterial cell lysis followed by solvent extraction and circular utilisation of bacterial lysate as nutrient supplement for PHB production. Enzymatic lysis of Paraburkholderia sacchari cells was initially evaluated using crude enzymes produced via solid state fermentation of Aspergillus oryzae. The optimum protease activity (156 U per g cell dry weight) resulted in 66.9% lysis of residual cell weight. PHB purification with 1,3-dioxolane, dimethyl carbonate, anisole, ammonium laurate and chloroform were evaluated at different processing parameters (extraction duration, temperature) using wet and dry bacterial cells as well as enzymatically lysed wet bacterial cells. The highest recovery yield (94.5%) and purity (98.1%) were obtained with 1,3-dioxolane at 80°C and 6h processing time using enzymatically disrupted bacterial cells. The bacterial cell lysate was used as nutrient supplement for circular PHB production in fed-batch P. sacchari bioreactor cultures leading to the production of 78.7 gPHB/L, 56.9% (w/w) PHB content and 2.3g/(Lꞏh) productivity. Low global warming potential (1.3 CO2-eq/kgPHB) and abiotic depletion fossil (14.4 MJ/kgPHB) were estimated for PHB purification via enzymatic cell lysis and PHB extraction with 1,3-dioxolane demonstrating the development of a sustainable and circular process for PHB production.

Environmental performance of a multi-energy liquid air energy storage (LAES) system in cogeneration asset – A life cycle assessment-based comparison with lithium ion (Li-ion) battery

Increase in energy demand is shaping both developed and developing countries globally. As a result, the endeavour to reduce carbon emissions also encompasses electrical energy storage systems to ensure environmentally friendly power production and distribution. Currently, the scientific community is actively exploring and developing new storage technologies for this purpose. The focus of this work is to compare the eco-friendliness of a relatively novel technology such as liquid air energy storage (LAES) with an established storage solution such as Li-Ion battery (Li-ion). The comparison is carried out through Life Cycle Assessment (LCA) methodology which aims to assess the environmental impacts from each life stage, according to different impact categories. In particular, the study refers to the unitary storage and the delivery of electricity as well as cooling energy, considering all the inefficiencies and limits of each technology. The results show that in the full electric case study Li-ion battery environmentally outperform LAES due to (1) the higher round trip efficiency and (2) the significantly high environmental impact of the diathermic oil utilized by LAES, accounting for 92 % of the manufacture and disposal phase. Conversely, the cogeneration case study highlights that the “flexibility” and “dualism” of LAES, capable to efficiently deliver both electricity and cooling, offset the impact related to the higher electricity consumption during the use phase. Notably in energy mix frameworks with high share of primary energy source from fossil fuels, cogenerative LAES demonstrates superior environmental performance compared to Li-ion battery (i.e. 1302 kgCO2eq/MWhe vs 1140 kgCO2eq/MWhe for Singapore energy mix), attributable to its reduced electricity consumption.

Bidirectional circulating preheating method harnessing engine and battery waste heat reuse in hybrid electric vehicles

In hybrid electric vehicles (HEVs), both the engine and power batteries experience reduced performance at low temperatures, necessitating the consumption of significant energy for preheating. The bidirectional preheating system method, which for the first time applies waste thermal energy to preheat both the engine and power battery in HEVs, utilizes the engine’s residual thermal energy to preheat the power battery and the thermal energy from the power battery to preheat the engine. To implement this method, a numerical model of the engine radiator and power battery waste heat is first established, and the temperature rise characteristics and temperature distribution of the waste heat system are simulated and analyzed. This analysis reveals the heat transfer law of the engine radiator and power battery waste heat. An automatic bidirectional thermal control device based on waste heat reuse is designed. The device utilizes a multi-stage series thermal energy transfer system with phase change materials (PCM) as the medium. A low-temperature experiment is conducted to assess the integration of heating and cooling between the engine and power battery. The results indicate that this method effectively utilizes the engine’s waste heat for both heating and cooling purposes. Specifically, a heat exchanger is used to preheat the power battery using the engine’s cooling residual heat, maintaining the internal battery temperature at 30 °C. Simultaneously, the residual heat from the power battery’s cooling system is circulated back to the engine body, preheating the engine coolant to 42 °C. Compared with existing HEVs, it can save more than 90% of the preheating energy consumption of the engine and power battery. This method can reduce power battery and engine warm-up time by more than 50%, while reducing emissions by more than 40% during engine cold start. This approach effectively addresses the challenge of low-temperature preheating for both power batteries and engines by utilizing cooling residual heat bidirectionally, thereby maximizing energy utilization efficiency in HEV systems and optimizing both battery and engine performance.

Mycelial mass, microbial lipids and γ-linolenic acid (GLA) by Cunninghamella elegans cultivated on agro-industrial residues

In the current study, the Zygomycetes fungus Cunninghamella elegans NRRL Y-1392 was evaluated for its ability to grow in extracts derived from dried and ground agricultural residues, such as mushroom stalks and roots from hydroponically cultivated lettuces and produce poly-unsaturated fatty acids (PUFA) and γ-linolenic acid (GLA) rich lipids. Initially, the compositions of stalks and lettuce roots were analysed, and the fungus was batch-flask cultivated on six different commercial semi-defined substrates containing different sugars detected in stalks and roots to evaluate its catabolic ability. C. elegans was capable to assimilate all sugars, but at a lower rate in the case of arabinose. Subsequently, C. elegans was cultivated on tailor-made semi-defined commercial substrates, resembling hydrolysates containing carbohydrates found in mushroom stalks, under both nitrogen-excess and nitrogen-limited conditions, and resembling that of hydrolysates of roots, under nitrogen-excess conditions. Based on the results, under nitrogen-excess conditions, in the case of media resembling stalks hydrolysates, higher production values for biomass, PUFAs, and GLA were observed (20.3 g/L, 1906 mg/L, 668 mg/L), accompanied by high productivity values due to short cultivation periods, while under nitrogen limitation, high lipid accumulation (lipid in dry cell weight =48%, w/w) was presented, and lipids rich in oleic acid were produced. Finally, the fungus was cultivated on a medium derived from hot water-extraction applied to mushroom stalks, enriched with organic nitrogen sources. The fungus was successfully grown on the sugar-rich water-extract derived from mushroom stalks, resulting in dry biomass of 14.5 g/L, lipids of 1.8 g/L, with 15% (w/w) of GLA in cellular lipids.

Recycling spent battery components into highly efficient hydrogen and oxygen evolution electro-nano-catalysts

Inspired by the 'waste-to-resource' strategic theme for environmental recovery, here we present the recycling of spent dry cells and spent Lithium-ion batteries aiming to achieve the preparation of cheap and efficient electrocatalysts for Proton Exchange membrane electrolyzers instead of the precious-based electrocatalysts. Graphite doped with manganese (IV) oxide nanoparticles, graphite doped with manganese (IV) oxide and aluminum oxide nanoparticles, lithium cobalt oxide doped with copper oxide nanoparticles, and lithium cobalt oxide doped with copper oxide and zinc oxide nanoparticles synthesis procedures are done via hydrothermal method at a pressure of 4.5 Mpa at 180 ○C. Electrochemical characterization is done to determine overpotential, tafel slope, and electrocatalytic stability via a three-electrode system. The optimum results are observed by the graphite doped with manganese (IV) oxide nanoparticles, which show -55.06 mV and -41.33 mV/dec as overpotential and tafel slope at -10 mA/cm2 for hydrogen evolution reaction with surface area of 40.87 m2/g and 21.05 nm as crystal size and Graphite doped with manganese oxide and aluminum oxide nanoparticles, which show 321.58 mV and 174.14 mV/dec as overpotential and Tafel slope for oxygen evolution reaction at 10 mA/cm2 with surface area of 7.64 m2/g and 44.43 nm as crystal size.

An operational discontinuous Galerkin shallow water model for coastal flood assessment

Hydrodynamic modeling for coastal flooding risk assessment is a highly relevant topic. Many operational tools available for this purpose use numerical techniques and implementation paradigms that reach their limits when confronted with modern requirements in terms of resolution and performances. In this work, we present a novel operational tool for coastal hazards predictions, currently employed by the BRGM agency (the French Geological Survey) to carry out its flooding hazard exposure studies and coastal risk prevention plans on International and French territories. The model, called UHAINA (wave in the Basque language), is based on an arbitrary high-order discontinuous Galerkin discretization of the nonlinear shallow water equations with SSP Runge–Kutta time stepping on unstructured triangular grids. It is built upon the finite element library AeroSol, which provides a modern C++ software architecture and high scalability, making it suitable for HPC applications. The paper provides a detailed development of the mathematical and numerical framework of the model, focusing on two key-ingredients : (i) a pragmatic P0 treatment of the solution in partially dry cells which garantees efficiently well-balancedness, positivity and mass conservation at any polynomial order; (ii) an artificial viscosity method based on the physical dissipation of the system of equations providing nonlinear stability for non-smooth solutions. A set of numerical validations on accademic benchmarks is performed to highlight the efficiency of these approaches. Finally, UHAINA is applied on a real operational case of study, demonstrating very satisfactory results.

On the Volume Expansion of Lithium Ion Battery Electrodes (I) after Wetting, and (II) Selection of the Right Amount of Electrolyte

The electrolyte is necessary for transport of lithium ions between the negative and positive electrode within the battery cell. The lower the amount of electrolyte, the higher the energy density and specific energy. Hence, it is important to understand which cell parameters are relevant to determine the right amount of electrolyte. Here, three different cell designs in 1 to 5 Ah pouch cells where investigated for cell impedance after filling, cell capacity after formation, C-rate performance, and capacity retention for up to 3,000 full cycles. Wetting the cell with electrolyte, the cell pore volume changed between 25%–35% due to changes of 6%–16% in the thickness of the anode and cathode. Although electrolyte volumes >0.85 times the wet cell pore volume showed minimal resistance before formation, only electrolyte volumes of 1.08 times the wet cell pore volume were sufficient for a successful formation process. For long-term cycling, a minimum electrolyte volume of 1.19 times the wet cell pore volume was required to improve long-term cycling performance. Future experiments will investigate the correlation of capacity fade with electrolyte consumption for different electrolytes.