2. Overview of Range

Transcription

1 Advanced Battery Solutions For Demanding Applications

2 Contents 1. Brand History 2. Overview of Range 3. Features & Benefits 4. Applications 5. Manufacturing Locations 6. Typical Manufacturing Process 7. What Makes PowerSafe SBS Different? 8. Typical Construction 9. Standard SBS Types 10. EON Technology SBS Types 11. EON Technology 12. EON Technology for Hybrid Power System Applications 13. Optional Advanced Accessories 14. Installation Examples 15. Customer/User Reference List 16. Competitive Analysis 17. Summary

3 1. Brand History

4 Year 2000

5 2. Overview of Range

6 Top Terminal Types (7 360Ah) - 12 volts: SBS 8, 15, 30, HB30, 40 and 60-6 volts: SBS 110 and volts: SBS 300 and 390 J Types (12 64Ah) -12 volts, JIS footprint: SBS J13, J16, J30, J40 and J70 Front Access B Types Front Access B Types (31 38Ah) - 12 volts: SBS B8/B8F, B10/B10F Front & Top Access EON Technology Types (62 410Ah) -12 volts: SBS B14/B14F, C11/C11F, 100/100F, 170F & 190F -2 volts: SBS 410

7 3. Features & Benefits

8 Thin plate, pure lead, VRLA, AGM technology High grade acid & superior quality materials UL94 V-0 flame retardant ABS container and lid (Noryl for J types) 15 year design life at 20 C (Eurobat Long Life classification) Compact footprint Maximum volumetric energy density Ideal for a wide range of applications Can be installed in any orientation except inverted Wide operating temperature range: -40 C to +50 C Up to two year shelf life Unique manufacturing process Compliant with IEC /22 & Telcordia SR-4228

9 4. Applications

10 Telecommunications UPS Utilities Oil & Gas Industry Emergency Lighting Renewable Energy...

11 5. Manufacturing Locations

12 Warrensburg, Missouri, USA Newport, South Wales, UK ISO 9001 & ISO certified factories

13 Types manufactured both in Newport and Warrensburg SBS 30, HB30, 40, 60, J13, J40, J70, C11/C11F Types manufactured in Newport exclusively SBS 8, 15, 110, 130, 300, 390, 410, B8/B8F, B10/B10F, B14/B14F, 100/100F, 170F, 190F Types manufactured in Warrensburg exclusively SBS J16, J30, 145/145F

14 6. Typical Manufacturing Process

15 Pure Lead Ingots Produce Oxides Lead Strip Manufacturing Perforation Make Active Material Clean, Dry & Storage Pasting Electrode Prep. Cut Strip into Plates Plate Curing Assembly Leak Detection Plastic Component Assembly Terminal Assembly Section Assembly Fill & Form Acid Fill Cooling Form & Charge Final Test Packaging Dispatch

16 Lead Strip Manufacturing PowerSafe SBS thin plate technology requires special manufacturing techniques

17 Perforation Thin strips of lead are fed into perforating machines which punch out holes

18 Pasting Perforated lead strips are fed through pasting machines A layer of paper is applied to each side of the pasted plate to retain the paste in the grid

19 Plate Stacking Plates are stacked automatically by robots

20 Curing Process Stacks of plates are loaded onto racks and placed into ovens to dry

21 Plate Group Assembly Robots stack positive and negative plates into plate groups

22 Section Assembly Plate groups are loaded into a compression jig

23 Cast-on-Strap Jigs are loaded onto cast-on-strap machines, inverted and dipped into lead to cast group bars and flags

24 Testing Once plate groups have been boxed in, short circuit testing takes place

25 Through-the-Wall Weld Flags are welded either in parallel or series depending upon the product

26 Lid Sealing & Leak Detection Boxes and lids are hermetically sealed by machines and are pressuretested for leak detection

27 Terminal Assembly Nuts are fitted to terminals Resin is applied to form a secondary seal Discs are added to indicate polarities (note that this occurs just before the end of line testing)

28 Acid Filling Batteries are filled with high grade electrolyte by machines

29 Formation Batteries are connected and charged

30 End of Line Testing A high current is passed though every bloc or cell to check for quality and integrity check purposes

31 7. What Makes PowerSafe SBS Different

32 A) Pure Lead Technology

33 Typical VRLA AGM Battery Grids Positive grid alloy is Pb-Ca-Sn Corrosion at the grain boundaries leads to: Grid corrosion Grid growth Reduction in current carrying capacity Loss of contact between grid and active material

34 PowerSafe SBS Pure Lead Grids Pure lead crystallography The very fine grain structure makes the grid far more resistant to corrosion Pure lead grids with the same design life can be much thinner than lead calcium grids

35 Corrosion of Grid Structures Actual X-Section Of Positive Grids Pure Lead (Pb) Lead Tin Calcium (Pb-Sn-Ca) Pure Lead grids mean less grid corrosion = longer service life

36 B) Thin Plate Technology

37 Positive Grid Thickness for Equivalent Float Life Products Thick versus Thin Pb-Ca SBS Cells are large and heavy Grids are prone to corrosion and growth Typical grid thickness ratio: Pb-Ca = 1 SBS = 0.6 Cells are smaller and lighter Grids are resistant to corrosion and growth Equivalent Float Life Products

38 Advantages of Thin Plate Pure Lead Technology More efficient use of active material Increased grid conductivity Efficient recharge High discharge performance

39 Higher energy density (smaller and lighter) Battery Cabinet Battery Cabinet Typical Pb-Ca PowerSafe SBS On average PowerSafe SBS occupies between 10-25% less space than Pb-Ca products

40 C) High Purity Materials

41 Virgin Lead Oxide Virgin Lead High Grade Acid

42 Advantages of the Use of High Purity Materials Low rate of self discharge = Long shelf life Low float charge current Low rate of grid corrosion = Long float life Low gassing rate

43 8. Typical Construction

44 Tough flame retardant box & lid Thick-wall V-0 rated ABS plastic, highly resistant to shock and vibration Manifold With integral flame arrestor and fitted as standard for remote venting High integrity terminal Patented dual seal terminal design for long life and leak resistance Self-regulating pressure relief valve Low pressure non-return valve prevents ingress of atmospheric oxygen Easy clip terminal insulating cover Fitted as standard for added safety. Provides spacing for voltage readings, connectors and optional remote venting High performance pure lead positive plates Grids designed to resist corrosion and prolong active life Separators Superior quality microporous glass mat separator with high absorption and stability Integral handles For ease of handling during transport and installation SBS 100

45 9. Standard SBS Types

46 Standard Types General Specifications

47 Standard Types Outline Drawings

48 10. EON Technology SBS Types

49 EON Technology Types General Specifications

50 11. EON Technology

51 What is EON Technology Major technological evolution of the proven SBS Thin Plate Pure Lead (TPPL) technology, specifically designed for harsh environments and cyclic applications Electro-chemical optimisation to significantly enhance cyclic performance under float charge conditions Cyclic performance further enhanced under fast charge conditions

52 Why EON Technology Evolving market features Rapid economic & technological expansion into developing world regions Tougher environmental conditions (extreme temperatures, remote conditions, etc.) Less power reliability Increase of environmental awareness (carbon footprint, pollution, noise), in particular by telecom operators Impact on battery needs More cyclic capability Better deep discharge capability Faster recharge capability

53 EON Technology s Benefits SBS EON Float Cycle Endurance (75% D.O.D C3) to BS6290/4 (1997) % Nominal Capacity % increase in cycles relative to year 2000 designs (400 v 300) 20 % Nominal Capacity End of Life Number of Cycles

54 EON Technology s Benefits Float Cycle Test to IEC (DCH 40%C10, CHA 2.29Vpc, 22h) End of Discharge Voltage (V) Number of Cycles

55 EON Technology s Benefits SBS EON Deep Discharge (100% C10) Float Cycle Life Hours Approximately 40% increase relative to yr 2000 designs Number of Cycles

56 Cycle Life SBS EON Cycle Life as a Function of Depth of Discharge (C10 rate, Charge Float Voltage) Number of Cycles % Depth of Discharge

57 EON Technology s Advances (Float Cycling) Circa 33% increase in float cycle capability when compared to existing designs (BS6290 part 4) Circa 650 float cycles to the IEC specification introduced in 2005 (40% depth of discharge C10) Circa 40% increase in deep discharge float cyclic capability

58 EON Technology Goes Further Further research into fast charging revealed that substantial additional gains could be achieved by: 1) Increased charge voltages & 2) Increased charge currents Benefits: 1) Reduction in recharge time 2) Further increases in cyclic capabilities

59 Recharge Characteristics Recharge Time to Full State of Charge as a Function of Charge Volts & Depth of Discharge as a Function of Charge Volts. & Depth of Discharge % DEPTH OF DISCHARGE (C10) Vpc 2.29Vpc TIME TO 100% STATE OF CHARGE (HRS)

60 TIME (HRS) Recharge Characteristics Time to Full State of Charge as a Function of Current Limit & Depth of Discharge (Recharge 2.40Vpc) C10A C10A 6 0.3C10A 4 0.5C10A 2 1.0C10A 0 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% DEPTH OF DISCHARGE

61 Cycling Characteristics SBS EON 60% Depth of Discharge C10 Cycle Test (Recharge at 2.40Vpc, 0.13C10 Amps to 1.03 Charge Factor) End of Discharge Volts Cycles

62 Cycling Characteristics SBS EON 80% Depth of Discharge C10 Cycle Test (Recharge at 2.40Vpc, 0.13C10 Amps to 1.03 Charge Factor) End of Discharge Volts Cycle Number

63 Cycle Life SBS EON Cycle Life as a Function of Depth of Discharge (C10 rate, Charge 2.40Vpc) Number of Cycles % Depth Of Discharge

64 How is EON Technology Possible EON technology s achievements result from combination of: Electro-chemical advancements, High-rate charge algorithm research, Latest robotic manufacturing processes Continuous process improvements Thin Plate Pure Lead ( TPPL ) technology All SBS EON Technology types retain SBS traditional features and benefits such as: High energy density 15 year design life 2 year shelf life Wide operating temperature range, etc SBS EON Technology models can often be used as a fit-for-fit direct replacement into existing systems

65 12. EON Technology For Hybrid Power System Applications

66 What is a Hybrid Power System For example, a remote location GSM base-station relying 100% on diesel generator power > The Middle-East and African continent regions are heavily populated with such systems > Estimate of 40,000 base stations in Africa, each using on average 20,000 litres of diesel fuel per year > Networks expanding at 120,000 base stations per year in Africa > Rising costs of fuel and maintenance, combined with increased carbon footprint and noise awareness, make generator power less and less attractive for operators

67 Application Overview & Battery Impacts Isn t t the solution obvious and simple? > GSM base stations already have back-up batteries so why not turn off the generators during the night and use the batteries to support the base station? Doesn t t this solution sound perfect? > With over-sized batteries and under-sized loads, standby batteries can supply the real load for 6-8 hours, sometimes longer > Less noise, pollution, fuel consumption and maintenance So, where is the catch? > Over the last decade there have been substantial advances in lead-acid battery design, primarily longer life with more power and reduced space demand > However, these batteries were never designed with heavy daily cyclic, hybrid power applications as described above in mind > A typical standby backup battery would deliver fewer than 400 cycles when over 50% capacity is used during each cycle > On a daily basis, even with the most sophisticated control systems, 400 cycles would only equal 13 months battery life Not enough!

68 Application Overview & Battery Impacts Conclusions > Financial economics and remote location logistics demand a battery life of at least 3 years 3 years means >1100 cycles at a depth of discharge of 50% or more Less than 50% generally means too large a battery and too high costs For the battery, a hybrid power application is similar to a fork-lift truck application, except the battery does not move i.e. a daily cycle, with a quick recharge and minimal time for battery rest between recharge and the next discharge 1100 cycles means different battery technologies > As a global leader in both Motive and Reserve Power batteries, Hawker has the application knowledge and product technology to meet these hybrid marked demands PowerSafe SBS EON Technology is one of the solutions proposed by Hawker

69 SBS EON Batteries in Hybrid Systems Conversion to hybrid system means that the generator is used to supply the existing base-station load and also to recharge a bank of PowerSafe SBS EON batteries A control system then turns off the generator and the batteries discharge to support the load The generator is restarted by the control system at a predetermined depth of battery discharge The control system is responsible for accurate recharge of the battery, ready for the next cycle

70 What are the Benefits Reduced running costs less running time = less fuel Improved system reliability battery backup allows recovery time if generator fails or fails to start Reduced maintenance generator maintenance intervals extended Increased generator reliability generators do not like to run at low loading, many sites today have oversized generators (battery recharge increases generator load) Reduced logistics costs less fuel and less maintenance = fewer routine site visits Redeployment of redundant equipment many existing sites have two generators for redundant backup, batteries replace one generator

71 What are the Economics Based on studies and trial sites, it is projected that the total equipment and installation investment can be recovered within 24 months, using a system designed to discharge 10 hours per day, and recharge for 14 hours, and sized to give 3 years of service life Clearly, the savings grow quickly from there on, as battery replacement represents only maximum 50% of the initial cost

72 Battery Considerations in Hybrid Systems Key factors which should influence battery technology selection are: 1. Available space (existing or new accommodation) 2. Available recharge power 3. Battery environment How do these factors matter?

73 Battery Considerations in Hybrid Systems 1. Available space If a PowerSafe SBS EON Technology bloc can be directly fitted in place of existing batteries, then an SBS EON solution should be much cheaper than OPzV technology where new accommodation (cabinet or rack) will be required Let s also remember that SBS EON offers up to 20% more energy in the same space/volume as some standard telco batteries This makes PowerSafe SBS EON the preferred offering for hybrid retrofit applications

74 Battery Considerations in Hybrid Systems 2. Available recharge power For reliable cyclic performance, a minimum of 10% C10 in Amps (10 amps /100Ah of battery) is needed as battery recharge power. Let s not forget that the generator also has to supply the load during battery recharge The higher the available recharge power, the more attractive the fast recharge of SBS EON becomes However, this works in two ways: Fast recharge = high savings, e.g. up to 75% fuel saving Fast recharge = short cycle time = shorter total battery life It is necessary to achieve a balance by multiple calculations

75 Battery Considerations in Hybrid Systems 3. Battery environment During recharge, especially if large recharge power is available, batteries will be generating heat. Rectifiers, running at full power, will also generate more heat Even with charge voltage compensation for temperature, high temperatures have a reducing effect on battery cycle life We recommend that the control system is designed to stop the high voltage charging (switch to float charging) if battery temperature exceeds certain levels

76 Battery Considerations in Hybrid Systems 3. Battery environment The battery temperature must be monitored and controlled The maximum surface temperature of battery must not be higher than +55 C A sensor must be fitted on battery case side Recommended Sensor Location

77 Successes & Opportunities Hawker has been working closely with several hybrid system solution partners for projects covering North Africa and the Middle-East Partners include power integrators, Telco OEM s, consultants and system integrators Several orders already taken for production systems with EON Technology batteries

78 Successes & Opportunities Hawker is involved in several trial systems working in different regions of the world. For example, systems have been working in Africa for more than 2 years now Kidong: ( 87A ) Batt/Gen Duty Cyle % Shimba Hills: ( 81A ) Batt/Gen Duty Cyle % 100% 100% 90% 90% 80% 80% 70% 70% 60% 50% 40% Batt % Gen % 60% 50% 40% Batt % Gen % 30% 30% 20% 20% 10% 10% 0% % Kaani: ( 72/60 A ) Batt/Gen Duty Cyle % Tulia: ( 69A ) Batt/Gen Duty Cyle % 100% 100% 90% 90% 80% 80% 70% 70% 60% 50% 40% Batt % Gen % 60% 50% 40% Batt % Gen % 30% 30% 20% 20% 10% 10% 0% %

79 Complex Hybrid The Next Step The hybrid concept described so far in this presentation can be referred to as simple hybrid, i.e. just a generator, a battery and a controller The more ambitious and far-sighted players in this field are looking to a future of increasingly green power sites. These would use a combination of batteries, solar panels, wind turbine and sometimes back-up generator Compared to the simple hybrid concept, these complex systems are much harder to control and manage and put much higher strain and demands on the batteries Hawker is actively engaged in trial systems to expand our knowledge and look for further battery development needs

80 13. Optional Advanced Accessories

81 A) Remote Venting

82 Ideal for sealed cabinets and where little or no room ventilation is available Gas can be vented outside the battery enclosure Vents are connected together with a flexible tube that can take any gas outside the battery compartment

83 B) SBS Aqua

84 Designed specifically for underground telecom applications Ideal for sites at risk of flooding Available in 4 sizes SBS 15, 30, 40 & 60 Safe, hermetically sealed terminals Waterproof connections Vent adaptor design for remote gas venting In-line fuse protection available

85 C) Metal Jackets

86 Prevents battery container wall distortion in high temperature applications Allows the battery to operate in temperatures up to +80 C Available on selected types: SBS J13, J16, J30, J40 and J70

87 14. Installation Examples

88 Telecom / Cabinet Installations

89 Telecom / Cabinet Installations / Remote Venting

90 Solar / Motorway Application in France PowerSafe SBS batteries store energy from the solar panel Energy is released during periods without sunshine and during the night

91 15. Customer/User Reference List

92 Alcatel (France) Aramco (Saudi Arabia) AT&T (USA) Battery Technologies (RSA) Bell Atlantic (USA) Bouygues Telecom (France) British Telecom Chloride Power Protection (UK) Eaton (Finland) Eltek Emerson Erskine Systems (UK) France Telecom Motorola Nokia Nortel Orange (France) Power One Shanghai Bell (China) Southerwestern Bell (USA) Telefonica (Spain) Etc.

93 16. Competitive Analysis

94 PowerSafe SBS: in a class of its own Closest competition only use lead-tin-calcium in similar size box With EON Technology, SBS technical supremacy extends further

95 17. PowerSafe SBS - Summary

96 Unrivalled VRLA AGM technology Unique manufacturing process Top and front terminal, high integrity designs for maximum flexibility High volumetric and gravimetric energy density Long design life Superior shelf life Superior recovery from abusive over-discharge Harsh environment endurance Wide operational temperature range Can be installed in any orientation except inverted High grade materials UL94 V-0 rated flame retardant plastic Successfully used in both high performance and low rate, long life float applications High cycling endurance (selected models) Low maintenance Low cost of ownership

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