Prepared for 7 x 24 Exchange

Transcription

1 Prepared for 7 x 24 Exchange

2 What do you know about EnerSys? World s largest Industrial battery company Headquartered in Reading, Pennsylvania USA Annual revenue in excess of $2.0 Billion; over 9000 Employees worldwide Manufactures and distributes industrial batteries in three markets Reserve Power Motive Power Aerospace & Defense Broadest product portfolio in industry Nationwide Service Group

3 Product Applications Reserve Power Telecom Wireline Extended Run time UPS Telecom - Wireless Wind & Solar Railroad Crossing Backup

4 Purpose of Batteries Once AC power is lost, batteries pick up the load until the generator starts or until power is regained Batteries provide power for both AC and DC equipment during outages Benefits of using batteries Immediate response (compared to generator) Do not require fuel source to be replenished Noiseless (no muffler) Only emissions are Oxygen & Hydrogen no Carbon or Nitrous emissions

5 Lead acid battery components Lead-acid battery consists of two dissimilar metals in acid solution Positive plate PbO 2 (black or dark chocolate brown when healthy) Negative plate Pb (light gray or gray) Acid H 2 SO 4 (clear water and sulfuric acid mixture) Separator (keeps positive and negative plates from touching) Jar/Cover (you have choices)

6 Lead acid battery construction

7 Typical Lead Acid Plate Primary failure of a lead acid battery is due to Grid Corrosion Grid Pasted Plate 8

8 Pros & Cons of VRLA Pros Low maintenance technology Long float life, specially pure lead Quick charge and discharge capability Charging and orientation flexibility Wide operating temperature (-65ºC to +80ºC) No memory effect State of charge easily measured (OCV) Low cost of ownership Cons Relatively low energy density (heavy) Cannot be stored in discharged state for too long Lower cycle life than NiCd cells Thermal runaway possible with excessive overcharge or improper thermal management More sensitive to high temperature than flooded lead acid cells

9 VRLA metallurgy Pure lead Grid metallurgy used when VRLA technology was introduced in the 1970s in a cylindrical format Lead calcium Introduced mainly to overcome manufacturing issues with pure lead Pure lead-tin Combines strengths of pure lead and lead calcium technologies while minimizing their weaknesses

10 Conventional Lead Calcium Battery Grids Use of a hardening alloy: Provides stiffness and strength for handling and manufacturing Grid is Cast Costs less to manufacture Accelerates grid corrosion Accelerates self-discharge Requires thicker plates for longevity 12

11 The Difference can be see in the Grain Structure Conventional Pb-Ca-Sn Book Mold Cast Grid Prone to growth and corrosion at grain boundaries Must be 3 to 4 times thicker than Pb-Sn or Pb grids for same life. High internal losses = short storage life Cold Rolled Pb Strip High purity lead (no hardening agents or tin) Cold rolling process produces finest grain structure. Highest resistance to anodic corrosion. High purity grids and electrolyte for long storage life 13

12 Lead Acid Battery Failure Mode Corrosion the oxidation of the battery grid Oxidation of the lead grid causes plate growth and eventually destroys the grid 14

13 Typical VRLA Batteries 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 EW/Thin Plate/10/02 15

14 TPPL Pure Lead Grid Pure Lead Crystalography 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 Pb-Ca grids EW/Thin Plate/10/02 16

15 High Purity Materials Virgin Lead Oxide Virgin Lead Medical Grade Acid EW/Thin Plate/10/02 17

16 High Purity Materials High purity materials are more expensive. but the advantages outweigh the extra cost!!! The advantages of high purity materials are: Low rate of self discharge = Long Shelf Life Low float charge current Low rate of grid corrosion = Long Service Life Low gassing rate Thinner positive grids = High Energy Density High Performance EW/Thin Plate/10/02 18

17 Cells are: Large Heavy TPPL Technology VRLA Grid Thickness Thick vs Thin Cells are: Smaller Lighter Grids are: Pb-Ca SBS Grids are: Prone to corrosion and growth Equivalent Float Life Products Resistant to corrosion and growth EW/Thin Plate/10/02 19

18 Pure Lead vs Lead Calcium Positive Grids Positive Grid Corrosion Battery service life is limited by the positive grid which slowly corrodes The rate and the nature of corrosion is effected by float/charging current, grid material and design Lead Calcium Tin (Pb-Ca-Sn) Pure Lead (Pb)

19 Life Battery 21

20 Another Major Difference for TPPL TPPL - Grid is Cold Rolled or Chill Cast and Punched Typical Lead Calcium Grid is Cast 2 V 2.5 AH D CELL SEALED-LEAD RECHARGEABLE BATTERY 22

21 TPPL Models Thin grid technology requires special manufacturing techniques A thin strip of lead is fed into a perforating machine, which punches out the holes that will contain the paste pellets Warrensburg, SBS J production EW/Thin Plate/10/02 23

22 TPPL Processing The perforated strip is fed through a pasting machine A thin layer of paper applied to each side of the pasted plate to retain the paste in the grid The strip is then cut into plates Because the grid is so soft the plates are easily damaged and must be handled carefully Warrensburg, SBS J production EW/Thin Plate/10/02 24

23 Why pure lead-tin VRLA? Feature Low internal resistance High purity system High compression Benefit Great high rate discharge capability (25C or more) Quick charge capability (100% capacity in 30 min.) Good discharge capability even at 20ºC Low self-discharge (2 yrs. shelf life at 25ºC) Longest float life among VRLA batteries (10+ years at 25ºC) Allows higher cyclability (1,300 JIS cycles) Higher resistance to vibration High temperature capability Small amount of tin High vent pressure Widest operating temperature range (-65ºC to +80ºC) Excellent overdischarge recovery capability Allows charging flexibility (CC, CV or combination) Accepts very aggressive charging Can be used in space (only VRLA acceptable to NASA)

24 Pure lead-tin vs. lead calcium VRLA Pure lead-tin Lead calcium Feature (Genesis XE) (Genesis NP) Calendar 25ºC 12+ yrs. for XE 3 to 6 yrs. Cycle life Temperature range -40ºC to 80ºC for XE with jacket -20ºC to 60ºC 25ºC Quick charge capability Float: VPC; no CL Cyclic: VPC; no CL 100% SOC in < 30 min. Float: VPC; no CL Cyclic: VPC; 0.25C CL Limited by current limit (CL) Shelf 25ºC Recharge every 24 months Recharge every 6 months -20ºC (% of 10-hr rate) 15 min. rate 1-hr. rate 15 min. rate 1-hr. rate

25 Higher Energy Density Automation of plate manufacture allows processing of thin Pb grid Result : 1mm Thin Bookmold casting requires inherent grid strength - thick with added hardeners Result: 2-4 mm Thick Means the difference between a 155AH lead calcium to a 170Ah Pure Lead Thin = Greater Surface Area = More Power 27

26 Recombination Efficiency Low float current and high efficiency recombination means there is virtually no gas emission under normal operating conditions FLOAT CURRENT & RECOMBINATION EFFICIENCY SBSC11 MONOBLOC 1 MONOBLOC 2 INITIAL WEIGHT (Kg) OCV CHARGE 2.27V/CELL : 168H Ah IN STABILISED FLOAT CURRENT (ma) WEIGHT AFTER CHARGE % RECOMBINATION EW/Thin Plate/10/02 28

27 SBS Technology SBSC11 GAS EVOLUTION TESTS AT ELEVATED TEMPERATURE TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED 40 C 2.45Vpc N/A LITRES/HOUR 50 C 2.45Vpc 610mA LITRES/HOUR 65 C 2.45Vpc 900mA LITRES/HOUR TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED 40 C Vpc 250mA LITRES/HOUR 50 C Vpc 450mA LITRES/HOUR 65 C Vpc 560mA 0.45 LITRES/HOUR TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED 40 C 2.27Vpc 40mA 0.00 LITRES/HOUR 50 C 2.27Vpc 80mA 0.00 LITRES/HOUR 65 C 2.27Vpc 270mA 0.00 LITRES/HOUR At 40C & 2.45Vpc data file corrupted so no float current value recorded At 20C & 2.27Vpc float current ranged betw een 10-20mA EW/Thin Plate/10/02 29

28 Long Service Life TPPL typical service life expectancy to 80% of rated capacity TEMPERATURE DEGREES CELSIUS MONTHS/YEAR 20C 25C 30C 35C 40C 45C 50C 55C EW/Thin Plate/10/02 30

29 Quick charging lead-tin VRLA Capacity returned 0.8C 10 Charge current, amps 1.6C C 10 60% 44 min. 20 min. 10 min. 80% 57 min. 28 min. 14 min. 100% 90 min. 50 min. 30 min. C 10 = amp-hour capacity at the 10-hour rate; 0.8C 10 = 80A for a 100Ah battery

30 Cycle life comparison

31 Thermal runaway comparison

32 3X Increased Shelf Life SBS Self Discharge Characteristics OPEN CIRCUIT VOLTAGE/STATE OF CHARGE DECAY AS A FUNCTION OF TEMPERATURE Open Circuit Voltage per Cell Approx % state of charge Up to 18 months of storage vs. 6 months for lead calcium C +30 C +25 C +20 C +10 C Stop installing dead batteries when deployments take longer than expected Months 35

33 XE Battery Features 12V pure lead-tin VRLA AGM battery UL94 V-0 flame retardant case and cover Rugged construction (optional metal jacket available, except for XE60 and XE95) -40ºC to 80ºC (-40 F to 176 F) with metal jacket Approved for shipping as non-hazardous, non-spillable

34 Batteries for Flywheels Advanced lead technology TPPL (XE) Battery cabinets sized for <20 second loads 480V strings 600kW for 30 Seconds More Power and Run Time

35 Flywheel TPPL Comparison Lower operating costs 250W float charge for flywheel 25W float charge for battery Flywheel Uses 1,971 KW Annually Flywheel Extra 1,944 lbs CO2 Annually Capital costs $30k for 750kW batteries $200k for 750kW flywheel 15% Cost (Initial) 30% Life (2X) 10 year life expectancy Solutions based approach

36 Where is pure lead-tin used? Anywhere a conventional lead calcium AGM is used plus where customer is looking for: Quick charge capability Longer float life than conventional AGM Longer cycle life than conventional AGM Wide operating temperature range Long shelf life High rate discharge capability in a smaller package High rate discharge & excellent cycle life in the same battery

37 Warrensburg, Missouri Facility 360,000 sq. ft. 33 acres 330+ employees ~30,000 Batts./day Automated Line First battery plant in the world to be certified as ISO 14001Environmental Management System ISO 9001 Certified Quality Management System Gold Pretreatment Award Missouri Water Environmental Association 1997 Industrial Water Quality Achievement Award FAA Certified Production Approval Holder (PAH/PMA) Approved Supplier to the Military 42

38 Recycling EnerSys provides a complete range of recycling support services. With logistics recovery you can contact us to arrange a drop off time, or to have us pick up your batteries. EnerSys follows fully compliant processing and batteries are only sent to lead smelters operating under Part B hazardous waste facility permits. EnerSys accepts all lead acid batteries. EnerSys exceeds state and federal requirements by giving you complete recycling documentation, including Recycling Certificates. Its good for business and good for the environment

39 Thank you!