FLOODED (VLA ), SEALED (VRLA), GEL, AGM TYPE, FLAT … · Dr. Wieland Rusch Keith Vassallo Gary Hart Research & Development General Manager Entrepreneur BAE Batterien GmbH BAE Corporate

E N E R G Y F R O M B A T T E R I E S

BATTCON 2006

FLOODED (VLA ), SEALED (VRLA), GEL, AGM TYPE, FLAT PLATE, TUBULAR PLATE:

THE WHEN, WHERE, AND WHY. HOW DOES THE END USER DECIDE ON THE BEST

SOLUTION?

Dr. Wieland Rusch Keith Vassallo Gary Hart

Research & Development General Manager Entrepreneur

BAE Batterien GmbH BAE Corporate G.K. Hart POWER Inc.

Berlin, Germany North America Ontario, Canada


GLOBAL MARKET – GLOBAL BATTERIES ?

-AGM vertical

VLA tubularGEL

VLA flatAGM horizontal

300 to 3000Ah

12V AGM block

12V AGM block

12V AGM block

25 to 200Ah

Far EastEuropeNorth America


TYPE COMPARISON

OGiVOGiOPzVOPzS

VRLAVLAVRLAVLA

FLATTUBULAR

PERFORMANCE AND ENDURANCE

GELAGM


POSITIVE PLANTÈ PLATE

• High power output• Long operational life• Low cycle stability (ca. 200 cycles)• High cost battery, old-fashioned

• Gravity cast grid with enlarged surface by lamellas

• Active mass (PbO2) is produced by corrosion


POSITIVE TUBULAR PLATE

• Highest operational life

• Highest endurance of cycles

• 8mm thickness of the electrode restricts the high power performance

• Gauntlets: radial pressure, no horizontal bars

• Circular rods, pressure cast,Lead-selenium (OPzS), Lead-calcium (OPzV)

• High porosity by read-lead filling


POSITIVE ROUND - GRID FLAT PLATE

• High power output• Good cycle endurance • Long operational life

• Circular rods like in tubular plates; but 50% more plates

• Lead-selenium alloy, fine grains, low corrosion


COMPARISON

VLA TUBULAR PLATE VERSUS VLA FLAT PLATE


PERFORMANCE COMPARISON

0,23 mOhm0,125 mOhmInner resistance

12 pos. plates, 8,0mm


Plates, thickness

L x W x H = 215 x 277 x 710 mmSize

88 kg, 193,8 lb102 kg, 224,7 lbWeight

1340Ah1350AhC10, 25°C, 1,80V

12 OPzS 120018 OGi 1440Type

TUBULARFLAT


DISCHARGE POWER: FLAT VS TUBULAR

0

500

1000

1500

2000

2500

3000

3500

4000

10 min 100 min 1000 min

Dis

ch

arg

e p

ow

er

W / c

ell

12 OPzS 1200 18 OGi 1440

Flat: 66% more power / volume


POWER PER COST: FLAT VS TUBULAR

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

150%

10 min 100 min 1000 minCell p

ow

er

per

co

st

rela

ted

to

OP

zS

12 OPzS 1200 18 OGi 1440

TUBULAR: 20% more W / $


ACCELERATED LIFE TIME TEST

QUALIFICATION FOR NUCLEAR POWER PLANTS:

IEEE 535-1986: 20 days at 145F (62,8°C) equals 1 year


ACCELERATED LIFE TIME TEST: SAMPLES

3 cells 1520Ah3 cells 2000Ah6 cells 2000Ahsamples



1,24g/ml 2,23V1,24g/ml 2,25V1,24g/ml 2,23Vdensity float V

flattubular - GELtubulartype

OGi

ventedOPzV

valve-regulatedOPzS

vented




1,24g/ml 2,23V1,24g/ml 2,25V1,24g/ml 2,23Vdensity float V

flattubular - GELtubulartype

OGi

ventedOPzV

valve-regulatedOPzS

vented


SEISMIC TEST IN THREE DIMENSIONS

5 times seismic test à 30s,

1 times air plane crash test à 30s


AIRPLANE CRASH TEST


TUBULAR PLATE CELLS: 550 days at 145F

0

20

40

60

80

100

120

140

160

0 50 100 150 200 250 300 350 400 450 500 550 600

float at 62,8°C with 2,23V / days

3h

- c

ap

ac

ity

at

20

°C / %

16OPzS 2000 7OPzS 490 4OPzS 200

Seismic test

IEEE 535-1986:27,5 years at 77F


FLOAT CURRENTS OF TUBULAR AND FLAT

0

50

100

0 5 10 15 20 25 30

OPERATIONAL LIFE AT 25°C

FL

OA

T C

UR

RE

NT

AT

2,2

3V

IN

m

A/1

00A

h

OPzS 2000

OPzS 490

OPzS 200

OGi 1520

OGi 800

OGi 480TUBULAR PLATE VLALEAD SELENIUM

FLAT PLATE VLALEAD SELENIUM

E N E R G Y F R O M B A T T E R I E Swrus 30082005

PLATES AFTER 550 DAYS AT 145F

Positive plate 94.6% PbO2

Negative plate 2.8% PbSO4


Growth of OPzS poles at life‘s end


• Labyrinth in the lead pole

• Primer onto the labyrinth

• ABS injection-moulding like a panzer

• Sliding pole: during growth a clean uncorroded pole shaft is moving upwards and maintains the 100% seal of the rubber ring.

• Washers in polarity colors

• Service ring for impedance measurements, IP25 protected

• Copper inserts for OGi, brass inserts for OPzS and OPzV.

Cross section of the terminal

16 mm


TUBULAR VLA (OPzS) CYCLE TEST

6 OPzV 420 Ah

Discharge 3h with 84Ah (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A

C10

Dec 1994 Cycles Jun 1999

0

20

40

60

80

100

120

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

Dezember 1994 Juni 1999

IEC 896-1 OPzS 420 AhDischarge 3h with 84A (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A


ENDURANCE COMPARISON

17001200Cycles IEC 60 896-1

75% DOD C4

Factor 3Factor 2Float current

increase in 20 years

42,7 years at 20°C33 years at 20°C

27,5 years at 25°C21,3 years at 25°CIEEE 535-1986

550 days425 daysOn float with 2,23V at

62,8°C

Tubular plate OPzSFlat plate OGi


COMPARISON VRLA VERSUS VLA


ADVANTAGES VRLA VERSUS VLA

• GAS EVOLUTION ONLY 10%, VENTILATION REQUIREMENT ONLY 20% (EN 50 272-2)

• LESS PROVISION AGAINST ACID LEAKAGE

• NO HANDLING WITH ACID AND WATER

• NO IMPURITY PROBLEMS WITH REFILLING WATER

• NO SHORT CIRCUITS DUE TO ACCUMULATED MUD


DISADVANTAGES VRLA VERSUS VLA

• OXYGEN INGRESS DISCHARGES THE NEGATIVE PLATE

• OXYGEN RECOMBINATION REDUCES NEGATIVE POLARISATION: IN UNFAVOURABLE DESIGNS DISCHARGE OF NEGATIVE DURING FLOAT!

• MAX. TEMPERATURE 45°C INSTEAD of 55°C

• LESS INSPECTION METHODS – LESS AWARENESS OF HEALTH


PERFORMANCE COMPARISON

1,6mOhm1,8 mOhmInner resistance

6 pos. plates,8,0mm


Plates, thickness

L x W x H = 380/3 x 205 x 380 mmSize

23kg, 50,7lb23,3 kg, 51,3 lbWeight

317 Ah326 AhC10, 25°C, 1,80V

6 OPzS 3006 OPzV 300Type

VLA TUBULARVRLA TUBULAR

GEL


POWER PER COST VRLA VERSUS VLA

70%

80%

90%

100%

110%

120%

130%

10 min 100 min 1000 min

Cell

po

wer

per

$,

OP

zV

set

to 1

00%

6 OPzV 300 6 OPzS 300

TUBULAR GEL: HERE THE SAME W / $


TUBULAR GEL: 450 DAYS AT 145F

0

20

40

60

80

100

120

140

160

180

0 50 100 150 200 250 300 350 400 450 500

float at 62,8° with 2,25V / days

3h

ca

pa

cit

y a

t 2

0°C

/ %

16OPzV 2000 7OPzV 490 4OPzV 200

Seismic test

IEEE 535-1986

22,5 years at 77F

0

20

40

60

80

100

120

140

160

180

0 50 100 150 200 250 300 350 400 450 500

float at 62,8° with 2,25V / days

3h

ca

pa

cit

y a

t 2

0°C

/ %

16OPzV 2000 7OPzV 490 4OPzV 200

Seismic test

IEEE 535-1986

22,5 years at 77F


TUBULAR GEL (OPzV) CYCLE TEST

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

0 200 400 600 800 1000 1200 1400 1600 1800

cycle: discharge with 84 A during180 min (nearly 60% C10)recharge characteristic: IUcharging voltage: 2,4Vcharging time: 21 hinitial charging current: 84A

IEC 60 896-2 OPzV 420 Ah

Discharge 3h with 84A (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A

C10

16.6.1999 Cycles 8.6.2005


ENDURANCE COMPARISON VRLA VS VLA

Factor 2Factor 1Float current

increase in 20 years

> 1700> 1700Cycles IEC 60 896,

75% DOD C4

42,7 years at 20°C35 years at 20°C

27,5 years at 25°C22,5 years at 25°CIEEE 535-1986

550 days450 daysOn float with 2,23V

at 62,8°C

VLA tubular OPzSVRLA tubular GEL

OPzV


COMPARISON VRLA: GEL VERSUS AGM

Lifetime

Stable capacity

Thermal run-away

Endurance of cycles

Tubular plates possibleDeep discharges possible

Low resistance

High power density

Low costs

AGM

GEL


GEL - AGM thermal-runaway-simulation

• Tmax = 50°C after 28 h

• total current increases to 5A

• 6V 68Ah GEL

• Tmax = 80°C after 4,5 h

• total current increases to 40A

• 6V 68Ah AGMcited from: D. Berndt, E. Meißner, W. Rusch, Aging effects...., Proceedings 15.INTELEC, Paris, 1993


CONCLUSION

• For applications with high safety level, like utilities, bank data centers, telecom central stations etc. VLA is preferred.Flat plate batteries < 60 min < tubular plate batteries

• UPS: bridging time < 60 min, life < 10 years, low cost: AGM is preferredlife > 10 years, high safety: GEL flat plate is preferred.

• TELECOM: bridging time > 60 min, life 20 yearsTUBULAR GEL is preferred.

• SOLAR: high cycle lifeTUBULAR GEL is preferred.

Documents

FLOODED (VLA ), SEALED (VRLA), GEL, AGM TYPE, FLAT … · Dr. Wieland Rusch Keith Vassallo Gary Hart Research & Development General Manager Entrepreneur BAE Batterien GmbH BAE Corporate