Flex & Evolion Lithium-Ion batteries for UPS, Switchgear and Telecom America Inc. Industrial Standby Division 2016
Agenda 1. Li-Ion Technology 2. Intensum Flex System 3. Evolion 4. Li-Ion into Standby Already in the Field. 2
1 LITHIUM-ION TECHNOLOGY 3
Li-Ion Basics - History The future of batteries Lithium-ion 1991: Sony introduced the first Li-ion cell (18650 format) 1992: introduced its commercially available Li-ion cell 1976: Exxon researcher Whittingham described lithium-ion concept in Science publication entitled Electrical Energy Storage and Intercalation Chemistry Large format cells in 2004. 1792 1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990 4
Li-Ion Chemistries Positive (cathode) LiCoO2 (LCO) LiNiCoAlO2 (NCA) 4,40 4,20 125 Ah/kg 145 Ah/kg 195 Ah/kg LiNiMnCoO2 (NMC) 4,00 LiMn2O4 (LMO) LiFePO4 (LFP) VOLTAGE (V) 3,80 3,60 162 Ah/kg Negative (anode) 3,40 LiNiO2 LiCoO2 Graphite 3,20 LiMn2O4 LiFePO4 Emerging anodes Lithium titanate 3,00 0,00 50,00 100,00 150,00 CAPACITY (Ah/kg) 200,00 250,00 Silicon-based 5
Major Lithium Ion Chemistries Tradeoffs among the four principal lithium ion battery technologies Source: Battcon Paper J.McDowall The furthered colored shape extends along a given axis, the better the performance along that dimension 6
Li Ion Cell Construction Prismatic Cylindrical 7
LIB Safety - A System design Approach Four critical pillars of safety Materials and Process Control Particle contamination of incoming materials Particle and humidity control Process validation/ control Choice of Chemistry Cathode Based on the application and battery usage Anode Others Cell Design Current interruption Venting Thermal Mgmt System Design Electronics Software Mechanical Architecture 8
Li-Ion Flexibility 100 000 10 000 Ultra-high power (VLU) Very-high power Li-ion (VLV) Main energy storage options 100C Super capacitor High Power Li-ion (VLP) 10C 1000 Medium Power Li-ion (VLM) Power [W/kg] 100 Standard Lead-Acid Ni-Cd AgO-Zn High energy Li-ion (VLE) C 10 Ni-MH C/10 1 0 20 40 60 80 100 Energy [Wh/kg] 120 140 Ragone diagram 9 160 180 200 C/100
Lithium-ion vs Traditional Chemistries 10-40 40-60 4000 Lead has derating from +35 C and below -10 C Better energy dentisty: lower footprint compared to lead High cycling life and calendar life 2 0 a f
2 INTENSIUM FLEX PRODUCT RANGE For Industrial UPS, Switchgear 11
Flex The Li-ion flexibility for your Mission Critical Flex is a complete lithium-ion battery system from Cells, to Electronic Management, through system design, hardware/software and cabinets. This integrates those 3 main building blocs: Li-ion module (Synerion range) 48V: 48P, 48M, 48E 24V: 24P, 24M, 24E Cells only + electronic (cell balancing, sensors,.;) Module selection based on discharge profile BMM (Battery Management Module) 300A continuous Electronics: management of the string, communication,.. MBMM (Master Battery Management Module) Electronic inside: management of the parallelism, communication,.. 13
Synerion architecture SMU board: conducts information (V,A,T ) to BMM Lithium ion cylindrical cells: technology 14
BMM 300A Ensures communication and operation in the designed voltage, current and temperature ranges Operating voltage 190V to 960V 300A (400A peak 10 sec) Pre-charge, self power and HMI as standard Manual disconnect (2 poles) on front face 3U height 15
MBMM Characteristics Manages the parallelism and communications when system configuration involves more than 1 string Manual disconnect on front face 16
Flex, example: 120V, SYN24E or M, 360Ah / ~43.2kWh Components MBMM Racks and cabinets Charger DC Panel Containers 17
Flex, example: 480V, SYN48P, capable of ~500kW for 5 min 17
Flex vs High Power VRLA 375kW / 3 VRLA SafT Delta Related Benefits Minutes Flex kwh installed 280 130 53.57% Energy savings : less energy consumptions in floating mode and charge Footprint (sq Ft) 21 10 52.38% Improve TCO : lower real estate cost, other equipement can be installed Weight (lbs) 10000 2000 80.00% Improve TCO : lower infrastruture cost, easy and quicker to maitain Calendar 5 to 7 20 2.5 to 3 Improve TCO : less replacement over 20 years Life 25degC times less Eficiency 83 to 87% 96 to 99% Energy savings & Improve TCO : less energy consumptions in floating mode and charge, les power/energy installed Optimal Operating temperature range 20 to 30 DegC 15 to 45DegC HVAC consumptions savings & Improve TCO : extend the operating temperature of the battery room and save HVAC consumptions and related costs Recharging time 5 to 7hrs 1.5hr 3 to 5 times better Improve System availability Communication To be added Included Improve Predictive Maintenance and System availability :SOC, SOH, Alarms and custonized battery information alaready avaialble Electrochemistry L/A Li Ion Improve System availability : No sudden death Improve Environemental footprint : CO2 reduction (~40%) Improve TCO : less maintenance 19
Flex vs High Power VRLA here below a analyze we did for a Customer within a particular case which describe Maintenance Task and compare VLA and Li-ion 20
Uninterruptible Power Supplies (UPS) Industrial Lithium-ion Benefits >8x lighter installed weight compared to lead-acid >4x smaller Installed footprint: compared to VRLA >95% roundtrip efficiency >5x faster recharge than lead-acid types >3000 cycles to 80% Depth-of-Discharge (DoD) >17 years life duration at room temperature Modular system integrating cells, balancing and supervision Integrated supervision (state-of-charge/health, alarms, etc.) Significantly lower environment impact than lead-acid Optimised performance for different (HP/MP/E) 21 Flex for UPS
s support and commitment to reach the Li-ion battery for UPS breakthrough Warranty : 10 years full on the battery (Modules, Chemistry) / 5 years full on the overall system. Integration Guidelines : overview of how to integrate the Flex lithium ion battery system in a standby application. General Safety Recommendations - Flex (Lithium ion) Batteries for UPS Applications in Indoor Environments The purpose of this document is to inform our customers about particular safety recommendations in order to properly install and operate our lithium ion batteries. 22 Flex for UPS
s support and commitment to reach the Li-ion battery for UPS breakthrough NFPA Safety Recommendations for Li-ion Battery Systems : : This document contains safety recommendations for the use of lithium ion chemistries, following the guidelines of the National Fire Protection Association (NFPA). UL-listed Lithium-Ion Batteries for UPS Applications : is pleased to announce this update for our lithium-ion battery systems for the UPS market related to UL qualification. Li-ion Recycling Policy : s position and commitment regarding Li-ion battery recycle 23 Flex for UPS
3 Evolion 24
EVOLION : main features overview 10.24 inch. 8.50 inch. 15.90 inch. VL80E cell (Li-ion, NCA) 77 Ah (C8), 3.9 kwh 48V 4,857 Wh/ft3 66lb 59 Wh/lb Paralleling Only BMS built in (BMST) RS485/MODBUS communication Standard accessory kit :power & communication wires, fuse Produced in Jacksonville, FL, since 2013 25 25 proprietary information Confidential
Certification & conformance status 26 26
Massive Paralleling configuration : from 1 to 80 Modules 83.9 inch. 16.15 inch. 27 27 20.5 inch.
4 SAFT LI-ION INTO STANDBY 29
Critical Power center for Southern Company/Crim, Utility Company 120 VDC Market Segment : Industrial/Utility backup for substation equipments Application requirements Critical Power Center 2hrs backup time @ 55A + 30s @150A 120VDC 160Ah to 820Ah, from 20kWh to 100kWh 20 years life time Systems in the field : 30 since 2013. large deployment on going 30 Lithium-ion L&L
Critical Power center for Southern Company/Crim, Utility Company 120 VDC Li-Ion benefits expected and Market trends NERC and FERC Regulations to log and track critical systems information (Batteries) Large deployment expected within Utility Company Li-Ion offer Iflex batteries in a system kit from 2 to 10 strings in parallel of 5 Modules 24M in series 120VDC from 20kWh to 100kWh Why Strong capabilities in US, customize and active support Active is IEEE, UL comitee 31 Lithium-ion L&L
Primax/Broselco, Primax/Manitoba Hydro, FDA Lab, 120VDC Switchgears Market segment: Industrial backup for electrical equipement Application requirements > Switchgear ex. 8hrs backup time @ 5A + 1min @60A 120 VDC Li-Ion benefits expected > Foot print savings, > TCO approach, > Low maintenance > 20 years lifetime Systems in the field : 5 since 2015 32 Lithium-ion L&L
FDA Lab & Primax/Broselco - Switchgears 120VDC Li-Ion offer IFlex batteries in a system or in kit from 2 to 10 strings in parallel of 5 Modules 24M or 24E in series 120VDC from 10kWh to 100kWh Current business market and Trends 5 systems in the field with Honeywell, Primax, Jacobs Eng. More systems expected mainly driven by Utilties and Industrial companies Why Flexible and customized LIB solutions, local and active support 33 Lithium-ion L&L
Backup for PV Systems CAT, HCI Energy Market segment: Off grid PV backup Application requirements > Mining or Supervision Utilizes 48Volt bus, Evolion batteries - 560Ah battery, for UPS load. 10kW for 8hrs with APC Schneider or CAT PV inverter Li-Ion benefits expected > TCO approach (20years ife, No Maintenance), Footprint and weight savings, Systems in the field : 1 + 10 to 20 additional systems quoted Li-Ion offer > From 1 to 50 Evolions in parallel as a system kit or turnkey system in racks, incl recommandation for electrical architecture (safety perspective) > Current business market and Trends > PV system growth required backup Why > Strong capabilities in US, customize and active support > Large experience : More than 50,000 Evolions in the filed since 2012 34 Lithium-ion L&L
FCB : UPS Data Center 50kW/15min backup time Market segment: UPS Data Center Application requirements Replace VRLA batteries, with existing Eaton s UPS 432 VDC nominal 50kW, 15min backup time UPS Data Center located at FCB headquarter Li-Ion benefits expected Maintenance cost reduction, weight savings, TCO approach, introduce innovation and improve environmental image. Systems in the field : 1 Li-Ion offer 1 strings of 9 modules Syn48MFe in series market and Trends Since this system is approved, opportunity to scale to large FCB Data Centers Recurrent business expected : from 10 to 50 systems/year Why Strong capabilities in US, Customize turnkey system and active support Li-ion power performances 35 Lithium-ion L&L
Filmwerk : UPS Trailer 160kW/5min backup time Market segment: Large UPS/Modular or containerized UPS for Data Center Application requirements Replace VRLA batteries, with existing Eaton s UPS9390 480 VDC nominal 1600kW, 5min backup time UPS located into a trailer Li-Ion benefits expected Maintenance cost reduction, weight savings, TCO approach, introduce innovation and improve environmental image. Systems in the field : 1 Work in progress +4 expected in 2016 Li-Ion offer 2 strings of 10 modules Syn48PFe in series market and Trends Interesitng trend of Modular/containerized UPS for industrial or Data Center Recurrent business expected : from 2 to 10 systems/year Why Strong capabilities in US, Good Industrial Image, Li-Ion power performances Customize turnkey system and active support 36 Lithium-ion L&L
AVL ECO-H Peak shaving for O&G Driling Market segment : O&G Drilling Application requirements > Fuel saving > High cycling & power application, Hybrid Power Management system battery allows immediate on demand power and the levelling of power usage peaks for rigs, Li-Ion benefits expected > High power efficiency at discharge and charge level to reduce fuel consumption, fuel emissions and operating expenses > TCO approach Systems in the field : 1 + 2 under discussion 37 Lithium-ion L&L
Li-ion end-to-end capability Technology More than 15 years experience Criteria : Performance, Safety and Service Life Manufacturing Process control is key for life and reliability Cell manufacturing and System assembly 4 production sites (France and U.S.) System Capability System Design, development, qualification Mechanical, Electrical, Qualification and Testing Pre-project & project management 38