BATTERY ENERGYBATTERY ENERGYANDAND

Advanced SuperGEL Battery Advanced SuperGEL Battery TechnologyTechnology

By Dr DJ BrownBy Dr DJ Brown

AGENDAAGENDA

Industrial Battery Overview Industrial Battery Overview Customer Technical RequirementsCustomer Technical Requirements Battery Energy’s SuperGel Battery Programme Battery Energy’s SuperGel Battery Programme - Background- Background - Purpose- Purpose ResultsResults - Float Performance- Float Performance - Cyclic Performance- Cyclic Performance - Resistance to abuse- Resistance to abuse Advantages of SuperGELAdvantages of SuperGEL Question and Answer Time Question and Answer Time

Industrial Battery Industrial Battery OverviewOverview

Lead Acid Batteries are under increasing threat from Lithium Lead Acid Batteries are under increasing threat from Lithium (ion) in a number of traditional areas such as standby and (ion) in a number of traditional areas such as standby and cyclic markets.cyclic markets.

Lead Acid batteries have been replaced in newer markets such as Lead Acid batteries have been replaced in newer markets such as PHEV’s and increasingly in electric bikes.PHEV’s and increasingly in electric bikes.

BATTERY ENERGY VIEW:BATTERY ENERGY VIEW:

Lead acid batteries will continue to dominate if:-Lead acid batteries will continue to dominate if:-a)a) Cost and not energy density is important, andCost and not energy density is important, andb)b) Customer technical and commercial requirements are met or Customer technical and commercial requirements are met or

exceeded.exceeded.

Customer Technical Customer Technical RequirementsRequirements

Good starting performanceGood starting performance Good float CapabilityGood float Capability Excellent cycling performanceExcellent cycling performance Good resistance to abuseGood resistance to abuse Fast charge capabilityFast charge capability PSOC (partial state of charge) PSOC (partial state of charge)

capabilitycapability Long life – especially in Long life – especially in

inclement conditionsinclement conditions Standard footprintStandard footprint

Rail MarketRail Market

Traditionally uses vented traction Traditionally uses vented traction batteries or some Ni-Cad for starting batteries or some Ni-Cad for starting and standby applications.and standby applications.

Newer requirements are for:-Newer requirements are for:-

Minimal maintenanceMinimal maintenance Passenger compartment securityPassenger compartment security Long life (>6-8 years)Long life (>6-8 years) Cycling at low states of chargeCycling at low states of charge

Traction/Utility MarketTraction/Utility Market

Newer requirements are for:-Newer requirements are for:- Fast charge capabilityFast charge capability PSOC capabilityPSOC capability Opportunity chargingOpportunity charging In Traction - Long life/low cost (3-4 In Traction - Long life/low cost (3-4

years) at double shiftyears) at double shift In utilities – Long life/low cost (>10 In utilities – Long life/low cost (>10

years service)years service)

Solar/Raps MarketSolar/Raps Market

PSOC capability (20 – 30% daily DOD)PSOC capability (20 – 30% daily DOD)

Good abuse resistance capabilityGood abuse resistance capability

System predictabilitySystem predictability

> than 10 years service life> than 10 years service life

ONLY ADVANCED SUPERGEL ONLY ADVANCED SUPERGEL BATTERIES CAN MEET ALL THESE BATTERIES CAN MEET ALL THESE

REQUIREMENTS.REQUIREMENTS.

Battery Energy Gel Battery Energy Gel Battery ProgrammeBattery Programme

Started 1992 with CSIRO*.Started 1992 with CSIRO*.

Worked with them and Worked with them and others through to mid 2000’s.others through to mid 2000’s.

Programme aim – to develop Programme aim – to develop sealed gel batteries at similar sealed gel batteries at similar cost to vented but with major cost to vented but with major performance advantages. performance advantages.

*Commonwealth Scientific & Industrial Research Organisiation

SuperGel TechnologySuperGel Technology

The basis for the Battery Energy SuperGel Technology is as The basis for the Battery Energy SuperGel Technology is as follows:-follows:-

In jar formation – provides lower cost, improved OH&S In jar formation – provides lower cost, improved OH&S and performance advantagesand performance advantages

Optimised paste mixing/curing processOptimised paste mixing/curing process

Thick plate technology (5.3mm positive and 3.9mm Thick plate technology (5.3mm positive and 3.9mm negative)negative)

High fumed Silica concentration (6%)High fumed Silica concentration (6%)

Optimised material selection process (VRLA lead, Optimised material selection process (VRLA lead, corrugated separators)corrugated separators)

GEL PRODUCTS INTRODUCED COMMERCIALLY 1996GEL PRODUCTS INTRODUCED COMMERCIALLY 1996

Gel Programme Gel Programme AchievementsAchievements

Battery Energy has developed a sealed SuperGel Battery Energy has developed a sealed SuperGel battery with high conversion of active material battery with high conversion of active material in formationin formation

The final products are characterised by:-The final products are characterised by:-

a)a) High degree of Ah efficiency (102 – 103%)High degree of Ah efficiency (102 – 103%)

b)b)Capable of PSOC operation over long periods of Capable of PSOC operation over long periods of charge/discharge cycles with minimal charge/discharge cycles with minimal overcharge. Starts out at 101%, probably 102% overcharge. Starts out at 101%, probably 102% at end of lifeat end of life

0

20

40

60

80

100

120

PSoC cycle no.

So

C /

%

Regime 1 Regime 2

Regime 3

PSOC ExamplePSOC Example

Parameters:

- PSoC window - charge rate

- battery temperature - battery condition

- conditioning charge

Float PerformanceFloat PerformanceCharacterised by:-Characterised by:-- Very low float currants- Very low float currants- Good high rate performance- Good high rate performance- Typically 2-3 times longer life - Typically 2-3 times longer life on accelerated tests on accelerated tests compared to AGMcompared to AGM

Battery Energy Battery Energy SuperGELSuperGEL Float Currents Float Currents

Operating Operating

TemperatureTemperature

Degrees CDegrees C°°

Cell VoltagesCell Voltages

2.252.25 2.32.3 2.352.35 2.42.4

Per 100Ah in mAPer 100Ah in mA

2525 2525 110110 460460 15001500

3535 6060 210210 700700 20002000

4545 125125 520520 13001300 30503050

Cyclic Performance (1)Cyclic Performance (1)

Initial CSIRO test results 1200 cycles at 100% Initial CSIRO test results 1200 cycles at 100% DOD DOD – failure due to negative plate. Positive plate - – failure due to negative plate. Positive plate -

14% corrosion after 800 cycles.14% corrosion after 800 cycles.

High temperature tests (45 degrees) 555 (100% High temperature tests (45 degrees) 555 (100% DOD) cycles – no loss of capacity.DOD) cycles – no loss of capacity.

Cyclic Performance (2)Cyclic Performance (2)

PSOCPSOC

ETEC (US) 2001 – fast charge/PSOC 70% DOD (100% - 30%) - >1000 ETEC (US) 2001 – fast charge/PSOC 70% DOD (100% - 30%) - >1000 cycles. Battery Energy SuperGel is 2-3 times life of competitor gel cycles. Battery Energy SuperGel is 2-3 times life of competitor gel products.products.

ETEC Current testing – utility profile 80% - 30% SOC ~ 2000 cycles and ETEC Current testing – utility profile 80% - 30% SOC ~ 2000 cycles and still operating. AGM batteries 300 – 400 cycles under same profile.still operating. AGM batteries 300 – 400 cycles under same profile.

Solar – PERU ILZRO – RAPS daily ~ 35% DOD (80% - 45% SOC) in Solar – PERU ILZRO – RAPS daily ~ 35% DOD (80% - 45% SOC) in 240Vstrings. Still operating after 7 years (requirement 8 years).240Vstrings. Still operating after 7 years (requirement 8 years).

Abuse resistanceAbuse resistance

Overcharge – 2.6V for 8.5 Overcharge – 2.6V for 8.5 months ~ 3 times longer than AGM months ~ 3 times longer than AGM battery. battery.

Operating in the discharge state Operating in the discharge state - charge to 2.45V/discharge to - charge to 2.45V/discharge to 1.75V – battery walks down to 30% 1.75V – battery walks down to 30% SOC. 150 – 200 cycles (PSOC SOC. 150 – 200 cycles (PSOC without equalisation). Recovery without equalisation). Recovery process – 100% capacity X 2.process – 100% capacity X 2.

Water loss – much less than Water loss – much less than other batteries. (See next slide for other batteries. (See next slide for example)example)

No stratification observed.No stratification observed.

Water loss DataDuty 

Batterytype

Temp.

(°C)

RWLgev

(ml/Ah/cell/year)

WLcrit

(ml/Ah/cell)

Years to reach WLcrit (with WLcorr50)

Simulated 1-day RAPS service

  CSIRO (o) 25 0.02 3.5 85*

  CSIRO (o) 45 0.03 3.5 57*

  (m) 25 0.06 3.5 28*

  (m) 45 0.19 3.5 9

  (n) 25 0.10 2.4 6

  (n) 45 0.35 2.4 2

Field service

  (m) 0.07 3.5 24*

  (n) 0.07 2.4 9

ConclusionConclusion

Advanced SuperGel technology together with Advanced SuperGel technology together with advanced control techniques and further advanced control techniques and further battery optimisation will lead to a bright future battery optimisation will lead to a bright future for for industrial lead acid batteries.industrial lead acid batteries.

Independent of lithium battery technology Independent of lithium battery technology advancesadvances

BATTERY ENERGYBATTERY ENERGY

Australian Made Products, Australian Made Products, Designed for the harshest of Designed for the harshest of

Australian ConditionsAustralian Conditions

Australian owned company, Australian owned company, employing Australians.employing Australians.

QUESTION QUESTION TIME?TIME?