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JME
Conservation through Kinetic Energy Harvesting
(The Need for Highly Reversible Energy Storage)
John R. MillerJME, Inc.
17210 Parkland Drive
Shaker Heights, OH 44120
University of KentuckyLexington, KY
June 4, 2009
JME
Contemporary History of Energy Conservation
• Dwelling heating fuel reduction—more insulation/designs
• Higher gas mileage in vehicles—smaller automobiles
• Hybrid vehicles developed—capture/store braking energy
• Energy capture, storage, and reuse in applications with
intermittent, reciprocating, or oscillating motion
JME
NASA Report TM-113176
Battery Problems Listed:• Inadequate life
• Limited current (discharge and charge)
• Inaccurate measurement of SOC
• Safety issues
First Large Capacitor
Hybrid Vehicle (1997)
• 20 F, 400 V system
• ~1.6 MJ stored energy
(440 Wh)
JME
NASA HYBRID GAS-ELECTRIC TRANSIT BUS46 s REPEATING POWER PROFILE
Po
wer
(kW
)
JME
CAPACITOR VOLTAGE DURING ONE CYCLE25 F capacitor, series resistance 0.04 ohm (RC=1 s)
Vo
lta
ge
(V
)
Accelerate Brake
NASA HYBRID GAS-ELECTRIC TRANSIT BUS Cont.
JME
Komatsu PC200-8 Hybrid Excavator
Source: Komatsu Web site
JME
Komatsu PC200-8 Hybrid Excavator
Source: Komatsu Web site
JME
Container Ship at Port
Up to 7,600 40-ft containers
Container mass up to 40 MT
Ship load up to 157,000 MT
Load can fill 35 100-car trains
JMERubber Tired Gantry Crane
JMEHybrid Rubber Tired Gantry Crane
7 MJ Capacitor--Efficient Regenerative Energy Capture
~40 % Fuel Saving / Significant Emission Reduction
Capacitor storage
Source: T. Furukawa, NCC
JME
Source: T. Furukawa, NCC
RESULTS
JME
Subway Train with Capacitor Storage
JME
GE HYBRID FREIGHT LOCOMOTIVE
4400 hp diesel-electric drive
2000 hp additional from batteries
~10% fuel savings typical
Source: Mike Vallance, GE
JME
• 20,000 road locomotives in North America
• 1500 billion ton-miles freight pa
• 40% total freight movement
• Highly efficient: 400 ton-miles/gal
• 4 billion gallons fuel pa
• 2.5% national fuel usage
• 320,000 gallons/loco/year
Significance of Railroad Modality
10% fuel usage reduction(per-loco values p.a. Hybrid Evolution Loco vs Tier 0)
32,000 gallons fuel
357 tons CO2 3.68 tons NOx 128 lb PM SOURCE: R. King, GE
JME
Applications Attractive for Energy Harvesting
• Cyclic operation with large energy swings
• High cycle rate
• Near continuous running
• Inefficiencies in the operation
JME
m/s
Energy of Motion
0
500
1000
1500
2000
0 5 10 15 20 25 30
Velocity (m/s)
Kin
eti
c E
ne
rgy
(k
J)
mph
: E = ½ MV2
Velocity
JME
Energy of Location
0
500
1000
1500
2000
0 5 10 15 20 25 30
Height (m)
Po
ten
tia
l E
ne
rgy
(k
J)
: E = MgH
JME70 kJ of Energy
2 MT vehicle moving 19 mph
2 MT mass lifted to 12 ft height
1 tsp sugar 4 g
1 D-cell alkali battery 140 g
22 kF / 2.5 V capacitor 4.6 kg
JME
Important Characteristics of a Storage System
used for Kinetic Energy Harvesting
• Response time less than characteristic times of
features in the power profile
• Efficient energy capture and storage
• High cycle life
• Long operational life
• Ability to effectively shed dissipated energy
• Low parasitic losses
JME
Electrochemical Capacitors have Features that
make them Attractive for Energy Harvesting
• High power density (response time ~1 second)
• Unlimited charge/discharge cycles
• Long operational life
• Maintenance free
• Generally environmentally friendly
• Safe
JME
electrochemical
Primary
ENERGY STORAGE COMPONENTS
Capacitor
Secondary
(rechargeable)
Battery
Lead
acidNiCd NMH
electrostatic
electrolytic
Li ion
JME
CAPACITOR TECHNOLOGY COMPARISON
1.0 MJ (277 Wh) Energy Delivery System
Capacitor Type Mass
(kg)
Volume
(m3)
Cost
(k$)
Response
time (s)
Electrostatic 200,000 140 700 10-9
Electrolytic 10,000 2.2 300 10-4
Electrochemical 30- 100 .02- 0.1 2 - 20 ~1
JME
ELECTROCHEMICAL CAPACITORS (ECs)
• Often called Supercapacitor or Ultracapacitor
• Invented by Standard Oil of Ohio in the 1960’s
• Product line introduced by NEC in 1978 (SOHIO license)
• Originally used for computer memory backup
• Appreciation of other attractive features in 1990s– Extraordinary power performance compared with batteries (charge too)
– Very high cycle-life compared with batteries
– Long, maintenance-free operational life
– Safe, environmentally friendly technology
JMEDOUBLE LAYER CAPACITOR CONCEPT
• Discovered by Helmholtz
• C ~ 10 F/cm2
on electrode
• Charge stored physically (not chemically)
• Voltage limited by decomposition potential of
electrolyte
• Extremely large capacitances from high-
surface-area carbon electrodes
V-
V+ Qm
-Qm
+
electrodeelectrode
electrolyte +
+
+
+
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C+ C-Rel
R+rx
R-rx
1 1 1
C C Ct
CQ
V
m
CQ
V
m
EC CAPACITOR EQUIVALENT CIRCUIT
ELECTROLYTE
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+ - + -
JMEElectric Double Layer Model
d~1 nm
Capacitor
Area, A
+ Q
+
_Separation, d
Plate separation d ~1 nm
GIVES
C ≈ A/d ≈ 5 to 50 F/cm2
JME
Activated Carbon Electrode Material
Calgon Carbon
Corp. circa 1969
H. Fritz Stoeckli,
CARBON 28, (1990)
Area A~1500 m2/g for carbon
GIVES
C/M ~100 F/g
Area, A
+ Q
+
_Separation, d
Area, A
+ Q
+
_Separation, d
Area, A
+ Q
+
_Separation, d
Area, A
+ Q
+
_
Area, A
+ Q
+
_Separation, d
Capacitor
JME
Maxwell Technologies Electrode Manufacturing
JME
ESMA
Nippon
Chemi-Con
ECOND
ELITNESS
Power Systems
(Okamura)
LARGE EC PRODUCTS
LS Cable
Maxwell
Wima
Nichicon
Batscap
JME
70 kJ of Energy
2 MT vehicle moving 19 mph
2 MT mass lifted to 12 ft height
1 tsp sugar 4 g
1 D-cell alkali battery 140 g
22 kF / 2.5 V capacitor 4.6 kg
22 kF/2.5 V capacitor(physical charge storage)
One electrode 44 kF
Total capacitance 88 kF
assume DLC=10 F/cm2 = 0.1 F/m2
Total Electrode Surface Area
= 88,000/0.1 = 880,000 m2
= 940 m x 940 m
½ mile x ½ mile
• DISTRIBUTED STORAGE
• EXCEPTIONAL PURITY NEEDED
• 1-5 MJ TYPICAL SYSTEM SIZE
JMEEC -- BATTERY COMPARISON
PROPERTY BATTERY EC
Storage mechanism Chemical Physical
Power limitation Reaction kinetics,
mass transport
Separator ionic
conductivity
Energy limitation Electrode mass Electrode surface area
Output voltage Constant value Sloping value (SOC
known precisely)
Charge rate Limited by reaction
rates
Very high, same as
discharge rate
Cycle life limitations Physical stability,
chem. reversibility
Side reactions
Life limitation Thermodynamic
stability
Side reactions
JME
CHARGING TESTCaptured and Stored Regenerative Energy3000 F capacitor versus 12 Ah Li-ion batteryDependences captured and stored energy per Kg for 3000 F
Maxwell capacitor and battery on charging time.
1
10
100
1000
1 10 100 1000 10000
Charging time (s)
Sp
ec
ific
En
erg
y (
kJ
/kg
)
capacitor
battery
captured
stored
Dependences captured and stored energy per Kg for 3000 F
Maxwell capacitor and battery on charging time.
1
10
100
1000
1 10 100 1000 10000
Charging time (s)
Sp
ec
ific
En
erg
y (
kJ
/kg
)
capacitor
battery
captured
stored Equal
15 times
JME
CHARGING TESTRegenerative Energy Storage Efficiency3000 F capacitor versus 12 Ah Li-ion batteryDependences energy storage efficiency on charging
time for battery and 3000 F Maxwell capacitor
0
20
40
60
80
100
1 10 100 1000 10000
Time (s)
Eff
icie
ncy
(%
)
capacitor
battery
Dependences energy storage efficiency on charging
time for battery and 3000 F Maxwell capacitor
0
20
40
60
80
100
1 10 100 1000 10000
Time (s)
Eff
icie
ncy
(%
)
capacitor
battery
Charging time (s)
JMEOshkosh Truck Hybrid Refuse Vehicle
JMEKinetic Energy Harvesting
• ECs are attractive energy storage media that offer much
more than simply being a battery replacement
• Thoughtful design allows full exploitation of EC technology
to achieve significant energy conservation in a broad range
of important applications
• Fast and efficient charge
• Fast discharge
• High cycle life
• Long operational life
• Safe, maintenance-free operation
• High reliability
• Effective heat shedding in high-cycle-rate applications
