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BATTERY ENERGY AND Advanced SuperGEL Battery Technology By Dr DJ Brown
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AGENDA Industrial Battery Overview Customer Technical Requirements Battery Energy’s SuperGel Battery Programme - Background - Purpose Results - Float Performance - Cyclic Performance - Resistance to abuse Advantages of SuperGEL Question and Answer Time
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Industrial Battery Overview Lead Acid Batteries are under increasing threat from Lithium (ion) in a number of traditional areas such as standby and cyclic markets. Lead Acid batteries have been replaced in newer markets such as PHEV’s and increasingly in electric bikes. BATTERY ENERGY VIEW: Lead acid batteries will continue to dominate if:- a)Cost and not energy density is important, and b)Customer technical and commercial requirements are met or exceeded.
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Customer Technical Requirements Good starting performance Good float Capability Excellent cycling performance Good resistance to abuse Fast charge capability PSOC (partial state of charge) capability Long life – especially in inclement conditions Standard footprint
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Rail Market Traditionally uses vented traction batteries or some Ni-Cad for starting and standby applications. Newer requirements are for:- Minimal maintenance Passenger compartment security Long life (>6-8 years) Cycling at low states of charge
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Traction/Utility Market Newer requirements are for:- Fast charge capability PSOC capability Opportunity charging In Traction - Long life/low cost (3-4 years) at double shift In utilities – Long life/low cost (>10 years service)
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Solar/Raps Market PSOC capability (20 – 30% daily DOD) Good abuse resistance capability System predictability > than 10 years service life ONLY ADVANCED SUPERGEL BATTERIES CAN MEET ALL THESE REQUIREMENTS.
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Battery Energy Gel Battery Programme Battery Energy Gel Battery Programme Started 1992 with CSIRO*. Worked with them and others through to mid 2000’s. Programme aim – to develop sealed gel batteries at similar cost to vented but with major performance advantages. *Commonwealth Scientific & Industrial Research Organisiation
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SuperGel Technology The basis for the Battery Energy SuperGel Technology is as follows:- In jar formation – provides lower cost, improved OH&S and performance advantages Optimised paste mixing/curing process Thick plate technology (5.3mm positive and 3.9mm negative) High fumed Silica concentration (6%) Optimised material selection process (VRLA lead, corrugated separators) GEL PRODUCTS INTRODUCED COMMERCIALLY 1996
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Gel Programme Achievements Battery Energy has developed a sealed SuperGel battery with high conversion of active material in formation The final products are characterised by:- a)High degree of Ah efficiency (102 – 103%) b)Capable of PSOC operation over long periods of charge/discharge cycles with minimal overcharge. Starts out at 101%, probably 102% at end of life
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0 20 40 60 80 100 120 PSoC cycle no. SoC / % Regime 1 Regime 2 Regime 3 PSOC Example Parameters: - PSoC window- charge rate - battery temperature- battery condition - conditioning charge
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Float Performance Characterised by:- - Very low float currants - Good high rate performance - Typically 2-3 times longer life on accelerated tests compared to AGM
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Battery Energy SuperGEL Float Currents OperatingTemperature Degrees C° Cell Voltages 2.252.32.352.4 Per 100Ah in mA 25251104601500 35602107002000 4512552013003050
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Cyclic Performance (1) Initial CSIRO test results 1200 cycles at 100% DOD – failure due to negative plate. Positive plate - 14% corrosion after 800 cycles. High temperature tests (45 degrees) 555 (100% DOD) cycles – no loss of capacity.
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Cyclic Performance (2) PSOC ETEC (US) 2001 – fast charge/PSOC 70% DOD (100% - 30%) - >1000 cycles. Battery Energy SuperGel is 2-3 times life of competitor gel products. ETEC Current testing – utility profile 80% - 30% SOC ~ 2000 cycles and still operating. AGM batteries 300 – 400 cycles under same profile. Solar – PERU ILZRO – RAPS daily ~ 35% DOD (80% - 45% SOC) in 240Vstrings. Still operating after 7 years (requirement 8 years).
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Abuse resistance Overcharge – 2.6V for 8.5 months ~ 3 times longer than AGM battery. Operating in the discharge state - charge to 2.45V/discharge to 1.75V – battery walks down to 30% SOC. 150 – 200 cycles (PSOC without equalisation). Recovery process – 100% capacity X 2. Water loss – much less than other batteries. (See next slide for example) No stratification observed.
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Water loss Data Duty Battery type Tem p. (°C) RWL gev (ml/Ah/cell/year) WL crit (ml/Ah/cell) Years to reach WL crit (with WL corr50 ) Simulated 1-day RAPS service CSIRO (o)250.023.585* CSIRO (o)450.033.557* (m)250.063.528* (m)450.193.59 (n)250.102.46 (n)450.352.42 Field service (m) 0.073.524* (n) 0.072.49
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Conclusion Advanced SuperGel technology together with advanced control techniques and further battery optimisation will lead to a bright future for industrial lead acid batteries. Independent of lithium battery technology advances
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BATTERY ENERGY Australian Made Products, Designed for the harshest of Australian Conditions Australian owned company, employing Australians. QUESTION TIME?
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