ZEBRA Battery Flat Plate Cell Design

by Cord-H. Dustmann, Battery Consult AG, Switzerland

BATTERY

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BATTERY

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2© BATTERY CONSULT

▪ Sun shines everywhere for everybody, free of charge

▪ Energy storage makes sun available 24/7

▪ Keep the coal in the soil and the oil in the hole

Source: http://research.asrc.albany.edu/people/faculty/perez/

World Energy Recources

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www.zumbach.com

BATTERY

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We store solar energy in salt

ZEolith Battery Research Africa, initially

Zero Emission Battery Research Activity for ZEV by AABG

Durathon by General Electric => Chaowei, China

SoNick by Fiamm, Italy

Salt Battery by Battery Consult

Names for the ZEBRA Technology

4

+-

b’’-Al2O3

Na+

Charge:

e-

BidirectionalInverter

Ni

NiCl2

NaCl

NaCl

2Cl-

2Na+

NaAlCl4 + Additive

Na

2e-

250°C

2 NaCl + Ni ↔ NiCl2 + 2 NaNi: -1480 Wh/kg - -690 Wh/kg = -790 Wh/kg, OCV=2,58V

Fe: -1501 Wh/kg - -782 Wh/kg = -719 Wh/kg, OCV=2,35V

Tubular cell

© BATTERY CONSULT

• Materials • Processes• Safety• Recycling• Performance- Energy- Power- Temperature

e-

ZEBRA Chemistry was invented 1986

by Johan Coetzer in CSIR

BATTERY

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ZEBRA Cells developed

BATTERY

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BATTERY

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www.zumbach.com

NA/NI-CL2 BATTERY CELLS

1© BATTERY CONSULT | Technology Presentation 2017

ZEBRA

38 AhMES-DEA, anno 2000

Fiamm since 2009

GE, 2013-2015

Chaowei start 2018

STC

50 AhBattery Consult

for ITAIPU, 2016

Flat Plate

Cell 25 AhBattery Consult 2017

Tubular cell (right) and Flat Plate Cell (left) BATTERY

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BATTERY

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110 mm

20 mm

Melt reservoir

Pos. Electrode

α- ring

β"- disk

Neg. ElectrodeBipolar plate

tube

BATTERY

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Zelldichtung TCB = Thermo Compression Bond

The TCB Seal limits the cell diameter to the tubular shape

Glass Compression Seal to overcome the diameter constrain of TCBBATTERY

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BATTERY

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The subassembly

Compressive

Stress

(green)

Parts for Subassembly

Subassembly cut view Calculated stresses (FEM)

α-ring

Glass

Liquid salt (200°C) vacuum impregnation lab equipment for cathode BATTERY

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Lab Press for lab tablet pressing

Specific resistance and capacity for impregnated (ZEBRA) cathode & tablet

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Raw Material Cost for a FPC StackBATTERY

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Ni 39,8%

Ceramic 4,5%

Steel 42,3%

Al 1,8%

Salts 9,3%Others 2,3%

Ni: LME 18.10.2018: 13 $/kg + 35% Ni price is very volatile

Total1 kWh per stackMaterial cost per stack 56 CHFAutomated production costs 30% of raw material cost gives 77 CHF

Result 77 CHF/kWh

Production using PV electricity in SA?

12PV Home Battery Sytem

Eo = 7 kWh OCV = 325V

m = 70kg V = 70l

BATTERY

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BATTERY

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PV Inverter & Battery Integrated (Prototype testing status)

2 * 3 kW MPPTDC/AC Grid Inverter

3 kW, 1 Ø

DC/DC Battery Inverter 3 kW

THE SB-7 SALTBATTERY – THE FIRST PRODUCT

13

Battery Consult AG in Meiringen, Switzerland

Multidisciplinary Team with 9 persons:

Physicists

Chemist

Mechanical Engineers

Electric Engineers

Administration AC

DC

BMS

Energy meter

The Battery Consult Battery storage with

integrated BMS (Battery Management System = Solar Inverter & Battery

Controller)

DC

7 kWhOCV=325V

Sale to grid @

(4 Rp/kWh)

PV Installation 28

kWp

Peak consumption

Buy from grid

@ (11

Rp/kWh)

SaltBattery

12kWh / 5kW

© BATTERY CONSULT

Test setup @ Battery Consult

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www.zumbach.com

We store solar energy in Salt

PITCH DECK

……

……

We store Solar energy in Salt

BATTERY

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BATTERY

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