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Ultra-CapacitorsState Of The Art And Future Trends
May 2017
Jan-Hendrik Ernst –Application Engineering Manager
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Maxwell Technologies
Founded 1965; IPO – 1983 (NASDAQ: MXWL)
Corporate Headquarters: San Diego, California
370 employees worldwide
Design, Manufacturing: United States, Switzerland, China
2017 Acquisition of NESSCAP Energy
Overview
Target Markets
Business Highlights & Markets
A U T O T R U C KB U S W I N D G . E . S .R A I L
GridTransportation HV
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USA:
Maxwell Technologies, Inc.Global HQ & Technology Center
San Diego, CA
USA:Maxwell Technologies, Inc.
Electrode Manufacturing
Phoenix, AZ (Opened 2013)
SWITZERLANDMaxwell Technologies SA
Rossens
GERMANYMaxwell Technologies GmbH
Munich
CHINAContract Manufacturer
Shenzhen
CHINAMaxwell Technologies
Shanghai Trading Co., Ltd
CHINAContract Manufacturer
Tianjin
KOREAMaxwell Technologies Korea
Co., Ltd
TAIWANContract Manufacturer
Taichung
Electrode Manufacturing Sales, Engineering, Marketing Cell & Module Manufacturing
Maxwell Technologies – A Global Force
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• High Power, Fast Charge & Discharge (sub-seconds)
• Long lifetime >500,000 cycles
• Scalable from W to MW
• Wide operating temperature (- 40oC to 65oC)
• No chemical but electrostatic process
Ultra-Capacitor Properties
Ultracapacitors are high power, ultrafast response devices
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The basic material to make ultracapacitors is carbon from a
sustainable source: coconuts
Grind
Activation
Maxwell Electrode
• Coating• Rolling• Kneading• Pasting
Charred Carbon Activated Carbon
Dry and chip shells
Maxwell Ultracapacitors
• Insert• Impregnate• Seal
What is an Ultracapacitor (UCAP)?
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Ultra-Capacitor Technology
Ultra-Capacitors (a.k.a. Electrochemical Double Layer Capacitors, Supercapacitors)
Capacitance ≈ Surface Area
Separation Distance
An electronic charge accumulator having extreme
capacitor plate specific area and atomic scale charge
separation distance
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Comparing Ultra-Capacitors With Other Storage Types
0,01
0,1
1
10
100
1000
10 100 1000 10000
En
erg
y D
en
sit
y/[W
h/k
g]
Power Density/[W/kg]
MAXWELL Ultracapacitors
0.5 seconds
ConventionalCapacitor
.03 seconds
Lithium
Battery
1 hourLead Acid
Battery
Ni-Cad
Battery
10 hours
Ultra-Capacitors have high power density (charge/discharge rate), expressed as watts per kilogram.
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Maxwell Products
Cells (W)
Ultra High Capacity
• 1 – 3400 F capacitance range
• Cells available at
• 2.7 Volt
• 2.85 Volt
• 3 Volt
• Specific Power = 8500 W/kg,
• Specific Energy = 7.7Wh/kg
Modules (kW)
Easy Integration
• Application specific, from 12V to 160V
• Configurations to integrate into racks
and subsystems
• Integrated Monitoring and Balancing
Systems (kW-MW)
Multiple service Storage
• Multiple applications in a single
system
• Hybrid ultra capacitor-battery
energy storage systems
• Provided by Maxwell and its
integration partners
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Ultra-Capacitor Design Considerations
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•Voltage
•Power / Current / Energy
•Runtime
•Temperature
•Dutycycle
•Lifetime
•Balancing
•Monitring
Design of Ucap Systems
Type
Minimum Initial Capacitance 165 F 132 F
Number of unit in series 16 16
Number of stack in parallel 11 11
Quantity of unit for a system 176 176
Max Absolute system voltage 816 V 816 V
Rated Voltage 768 V 768 V
System Rated Capacitance 113.4 F 90.8 F
Usable Energy 6969.6 Wh 5575.7 Wh
Stored Energy 9293 Wh 7434 Wh
33454.080 kJ 26763.264 kJ
Peak Power 15965 kW 8014 kW
Device max ESR DC 9.16 mOhm 18.33 mOhm
System max ESR DC 9.24 mOhm 18.40 mOhm
BMOD0165 P048
EOLBOL
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Typical Ultra-Capacitor ApplicationsTransportation
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In over 30 thousand hybrid buses and 2.0M start / stop vehicles worldwide
AUTOMOTIVE BUS RAIL TRUCKING
Start / Stop
High Power e-Turbo
Active Suspension
Hybrid
Electric Bus
Engine Starting
Regeneration
Propulsion
Voltage Stabilization
Engine Starting
Over 10M ultracapacitor cells shipped into transportation applications
Auto & Transportation Applications
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Wayside Storage Project (Korea)
Content from WOOJIN Industrial Systems Co. Ltd.
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• Emergency Power for Local Door Controller
• No scheduled maintenance allowed
• Stringent environmental requirements (temperature, vibration, shock)
• Aviation Safety Standards
Advantages by using Maxwell Ultracapacitors
Low weight
Long Life
High reliability
No maintenance
Airbus A380 – Emergency Back up Power
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Hybrid Bus
MAN Lion’s City Hybrid
• In service in Munich, Paris, Barcelona, Milano, Vienna…
• Breaking / accelerating fully electrically
• Brake energy recuperation
• Up to 30% reduced fuel consumption
• Silent approach and departure at bus stop
• Zero emission in the bus stop area
• 6 x HTM Modules:
• Voltage range: 400-700VDC
• Nominal current: 150A (max. 500A)
• Usable Energy content: 400-600Wh
• Electrical power: 200 kW
Bus
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Typical Ultra-Capacitor ApplicationsGRID
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Boost power and fail
safe back-up power
Wind farm retrofit –
battery replacement
Voltage / Frequency
Stabilization
Solar & Wind Firming
Peak Shaving
UPS: bridging / back-
up
Power Stabilization
Brake energy
recovery
Voltage and Power
stabilization
Green Infrastructure Markets
GRID / MICROGRID
ENERGY STORAGEINDUSTRIAL WAYSIDE RAIL
In over 54,000 wind turbines worldwide
Improving the reliability of the grid in the kW to MW scale
Over 8M ultracapacitor cells shipped into green infrastructure applications
WIND PITCH
CONTROL
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1. Resource Adequacy and Firm Capacity
2. Frequency Regulation
3. Energy Firming
4. Energy Shifting and Arbitrage
5. Renewables and Distributed Energy Resource Smoothing
Short and long duration applications may be stacked in a single energy storage system to maximize value
Primary Drivers for Utility Energy Storage
SHORT DURATION LONG DURATION
Power Quality & Reliability
Frequency Response/Regulation
Grid Voltage Stability
Renewables Time Shifting
Load Shifting
Spinning Reserves
Forecast HedgingGrid Operational Support
Requires frequent discharge
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Project Highlights: SDG&E
• SDG&E Borrego Springs Microgrid (Generators and Batteries)
• Ultra-capacitors rapidly respond to PV intermittency
microgrid stabilization
• Maxwell Ultracapacitor System Solution
• SDG&E completing site preparation (trenching, etc.)
• System commissioning Q2 2017
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• UCAPS smooth intermittent renewable energy generation in cycles - milliseconds timeframe
• Light cloud cover can cause large swings in output power
• Rated size: 250 kW for 3 min at end of life
• System design life: 20 years
Renewable Energy Smoothing
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Wind Farm Energy Stabilization – NE ChinaMAXWELL CONFIDENTIAL
• Wind Intermittency Smoothing
• Largest generation-side energy storage plant in China
• Facility already had Li-ion and flow batteries operating, added
Ultracapacitors for Faster Response
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Requirement Ultracapacitors Batteries Combination
Rapid Energy Capture <1 second 2-5 seconds < 1 second
Rapid Power Delivery <1 second 2-5 seconds < 1 second
Extended Temperature Range Excellent Poor Good
Product Life 8-15 years 2-6 years 4-10 years
Run Time (Energy) Seconds to Minutes Minutes to hours Seconds to hours
Batteries – Ultra-Capacitor Hybrid Systems:
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Typical Ultra-Capacitor ApplicationsIndustrial
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Industrial
Hybrid Harbor Crane
Straddle Carriers & Cranes
• Diesel-electric
• Lift load leveling / lowering
• 150 kW peak power
• Rapid energy storage through energy recapture
• Down-sizing of on-board engine
• Reduction of emissions and noise
• Clean harbor mandates met
• Peak power through ultra-capacitors
• Improved energy efficiency
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Public Transportation / Cabins
• Olympic games 2012 in London; spanning over the
Thames River between Greenwich and the Royal Docks
• 6 – 8 Mbit WLAN connection enabling HDTV broadcasting
• Two 48V modules used as energy storage
• Quick recharge at every station
• Also in service in Singapore (hot condition), Koblenz and
Lenzerheide (cold condition)
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General: Lower Cost; More Energy; Longer Life
GRID Scale Applications:•Monitoring Security•Scalability
Transportation Applications:•Higher Operation Temperature•Customization
Industrial Applications:•Standardization•Integration
Ultra-Capacitor Outlook
Requirements For The Future
