BATTCON 2006 FLOODED (VLA ), SEALED (VRLA), GEL, AGM TYPE, FLAT PLATE, TUBULAR PLATE: THE WHEN, WHERE, AND WHY. HOW DOES THE END USER DECIDE ON THE BEST SOLUTION? Dr. Wieland Rusch Keith Vassallo Gary Hart Research & Development General Manager Entrepreneur BAE Batterien GmbH BAE Corporate G.K. Hart POWER Inc. Berlin, Germany North America Ontario, Canada
GLOBAL MARKET GLOBAL BATTERIES? North America Europe Far East 25 to 200Ah 12V AGM block 12V AGM block 12V AGM block 300 to 3000Ah VLA flat AGM horizontal VLA tubular GEL - AGM vertical
TYPE COMPARISON PERFORMANCE AND ENDURANCE TUBULAR FLAT VLA VRLA VLA VRLA OPzS OPzV OGi OGiV AGM GEL
POSITIVE PLANTÈ PLATE Gravity cast grid with enlarged surface by lamellas Active mass (PbO2) is produced by corrosion High power output Long operational life Low cycle stability (ca. 200 cycles) High cost battery, old-fashioned
POSITIVE TUBULAR PLATE Gauntlets: radial pressure, no horizontal bars Circular rods, pressure cast, Lead-selenium (OPzS), Lead-calcium (OPzV) High porosity by read-lead filling Highest operational life Highest endurance of cycles 8mm thickness of the electrode restricts the high power performance
POSITIVE ROUND - GRID FLAT PLATE Circular rods like in tubular plates; but 50% more plates Lead-selenium alloy, fine grains, low corrosion High power output Good cycle endurance Long operational life
COMPARISON VLA TUBULAR PLATE VERSUS VLA FLAT PLATE
PERFORMANCE COMPARISON FLAT TUBULAR Type C10, 25 C, 1,80V Weight Size Plates, thickness Inner resistance 18 OGi 1440 1350Ah 102 kg, 224,7 lb L x W x H = 215 x 277 x 710 mm 18 pos. plates, 4,8mm 0,125 mohm 12 OPzS 1200 1340Ah 88 kg, 193,8 lb 12 pos. plates, 8,0mm 0,23 mohm
DISCHARGE POWER: FLAT VS TUBULAR 4000 Flat: 66% more power / volume Discharge power W / cell 3500 3000 2500 2000 1500 1000 500 0 10 min 100 min 1000 min 12 OPzS 1200 18 OGi 1440
POWER PER COST: FLAT VS TUBULAR Cell power per cost related to OPzS 150% 140% 130% 120% 110% 100% 90% 80% 70% 60% 50% TUBULAR: 20% more W / $ 10 min 100 min 1000 min 12 OPzS 1200 18 OGi 1440
ACCELERATED LIFE TIME TEST QUALIFICATION FOR NUCLEAR POWER PLANTS: IEEE 535-1986: 20 days at 145F (62,8 C) equals 1 year
ACCELERATED LIFE TIME TEST: SAMPLES OPzS OPzV OGi vented valve-regulated vented type tubular tubular - GEL flat density float V 1,24g/ml 2,23V 1,24g/ml 2,25V 1,24g/ml 2,23V samples 6 cells 200Ah 3 cells 200Ah 3 cells 480Ah samples 6 cells 490Ah 3 cells 490Ah 3 cells 800Ah samples 6 cells 2000Ah 3 cells 2000Ah 3 cells 1520Ah
SEISMIC TEST IN THREE DIMENSIONS 5 times seismic test à 30s, 1 times air plane crash test à 30s
AIRPLANE CRASH TEST
3h - capacity at 20 C / % 160 140 120 100 80 60 40 20 0 TUBULAR PLATE CELLS: 550 days at 145F Seismic test 0 50 100 150 200 250 300 350 400 450 500 550 600 float at 62,8 C with 2,23V / days 16OPzS 2000 7OPzS 490 4OPzS 200 IEEE 535-1986: 27,5 years at 77F
FLOAT CURRENTS OF TUBULAR AND FLAT 100 FLOAT CURRENT AT 2,23V IN ma/100ah 50 0 FLAT PLATE VLA LEAD SELENIUM TUBULAR PLATE VLA LEAD SELENIUM 0 5 10 15 20 25 30 OPzS 2000 OPzS 490 OPzS 200 OGi 1520 OGi 800 OGi 480 OPERATIONAL LIFE AT 25 C
PLATES AFTER 550 DAYS AT 145F Negative plate Positive plate wrus 30082005 2.8% PbSO 4 94.6% PbO 2
Growth of OPzS poles at life s end wrus 30082005
Cross section of the terminal Labyrinth in the lead pole Primer onto the labyrinth ABS injection-moulding like a panzer 16 mm Sliding pole: during growth a clean uncorroded pole shaft is moving upwards and maintains the 100% seal of the rubber ring. Washers in polarity colors Service ring for impedance measurements, IP25 protected Copper inserts for OGi, brass inserts for OPzS and OPzV. wrus 071004
C10 TUBULAR VLA (OPzS) CYCLE TEST 120 100 80 60 40 20 0 6 OPzV 420 Ah IEC 896-1 OPzS 420 Ah Discharge 3h with 84Ah (app. 75% DOD C4) Discharge 3h with 84A (app. 75% DOD C4) Recharge 21h with 2,40V, initially 84A Recharge 21h with 2,40V, initially 84A 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 Dec 1994 Cycles Jun 1999
ENDURANCE COMPARISON On float with 2,23V at 62,8 C IEEE 535-1986 Float current increase in 20 years Cycles IEC 60 896-1 75% DOD C4 Flat plate OGi 425 days 21,3 years at 25 C 33 years at 20 C Factor 2 1200 Tubular plate OPzS 550 days 27,5 years at 25 C 42,7 years at 20 C Factor 3 1700
COMPARISON VRLA VERSUS VLA
ADVANTAGES VRLA VERSUS VLA GAS EVOLUTION ONLY 10%, VENTILATION REQUIREMENT ONLY 20% (EN 50 272-2) LESS PROVISION AGAINST ACID LEAKAGE NO HANDLING WITH ACID AND WATER NO IMPURITY PROBLEMS WITH REFILLING WATER NO SHORT CIRCUITS DUE TO ACCUMULATED MUD
DISADVANTAGES VRLA VERSUS VLA OXYGEN INGRESS DISCHARGES THE NEGATIVE PLATE OXYGEN RECOMBINATION REDUCES NEGATIVE POLARISATION: IN UNFAVOURABLE DESIGNS DISCHARGE OF NEGATIVE DURING FLOAT! MAX. TEMPERATURE 45 C INSTEAD of 55 C LESS INSPECTION METHODS LESS AWARENESS OF HEALTH
PERFORMANCE COMPARISON VRLA TUBULAR GEL VLA TUBULAR Type C10, 25 C, 1,80V Weight Size Plates, thickness Inner resistance 6 OPzV 300 326 Ah 23,3 kg, 51,3 lb L x W x H = 380/3 x 205 x 380 mm 6 pos. plates, 8,4mm 1,8 mohm 6 OPzS 300 317 Ah 23kg, 50,7lb 6 pos. plates, 8,0mm 1,6mOhm
POWER PER COST VRLA VERSUS VLA Cell power per $, OPzV set to 100% 130% 120% 110% 100% 90% 80% 70% TUBULAR GEL: HERE THE SAME W / $ 10 min 100 min 1000 min 6 OPzV 300 6 OPzS 300
TUBULAR GEL: 450 DAYS AT 145F 3h capacity at 20 C / % 180 160 140 120 100 80 60 40 20 0 IEEE 535-1986 22,5 years at 77F Seismic test 0 50 100 150 200 250 300 350 400 450 500 float at 62,8 with 2,25V / days 16OPzV 2000 7OPzV 490 4OPzV 200
C10 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 TUBULAR GEL (OPzV) CYCLE TEST IEC 60 896-2 OPzV 420 Ah cycle: discharge with 84 A during180 min (nearly 60% C 10 ) recharge characteristic: IU charging voltage: 2,4V charging time: 21 h initial charging current: 84A Discharge 3h with 84A (app. 75% DOD C4) Recharge 21h with 2,40V, initially 84A 0 200 400 600 800 1000 1200 1400 1600 1800 16.6.1999 Cycles 8.6.2005
ENDURANCE COMPARISON VRLA VS VLA On float with 2,23V at 62,8 C IEEE 535-1986 Float current increase in 20 years Cycles IEC 60 896, 75% DOD C4 VRLA tubular GEL OPzV 450 days 22,5 years at 25 C 35 years at 20 C Factor 1 > 1700 VLA tubular OPzS 550 days 27,5 years at 25 C 42,7 years at 20 C Factor 2 > 1700
COMPARISON VRLA: GEL VERSUS AGM Lifetime Low costs Stable capacity High power density Thermal run-aw ay AGM GEL Low resistance Endurance of cycles Deep discharges possible Tubular plates possible
GEL - AGM thermal-runaway-simulation T max = 50 C after 28 h total current increases to 5A 6V 68Ah GEL T max = 80 C after 4,5 h total current increases to 40A 6V 68Ah AGM cited from: D. Berndt, E. Meißner, W. Rusch, Aging effects..., Proceedings 15.INTELEC, Paris, 1993
CONCLUSION For applications with high safety level, like utilities, bank data centers, telecom central stations etc. VLA is preferred. Flat plate batteries < 60 min < tubular plate batteries UPS: bridging time < 60 min, life < 10 years, low cost: life > 10 years, high safety: AGM is preferred GEL flat plate is preferred. TELECOM: bridging time > 60 min, life 20 years TUBULAR GEL is preferred. SOLAR: high cycle life TUBULAR GEL is preferred.