Advanced Lead Acid Battery Consortium Hybrid Electric Vehicles Challenge and Future for Advanced Lead-Acid Batteries Boris Monahov, ALABC, U.S.A.
Agenda 1. Why Hybrid Electric Vehicles (HEV)? 2. Sales trends and variety of HEVs 3. Requirements to the battery in HEVs 4. The ALABC and the lead-carbon batteries 5. The ALABC HEV demonstration program 6. Building the ALABC roadmap 2
Trends in car production (2010 to 2040) 1) Energy source transition from fossil to renewable 2) Turn from danger to nature to a planet improving tool Consumers dynamics, safety, fun acceptable price low additional costs long autonomy range immune to energy carrier price environmentally friendly Government safety for people and nature less fuel low CO 2 green loop: raw materials production use recycling Car producers ensure customer satisfaction keep green and safety value 3 sale more new vehicles Market growing demand for cars sustainable development
Trends in car production (2010 to 2040) Solution: replace ICE engine by machines powered from energy produced without changing the environment Propulsion Electric motor (good) gas turbine (expensive) compressed air (not mature) solar energy (expensive) wireless power transfer (not mature) Which battery? Lead-Acid NiMH Li-ion NiZn, Zn-air, post Li-ion El. energy storage - grid (not enough capacity) - batteries (not mature) - capacitors (expensive) - fuel cells (expensive) Trends? - ICE: stepping slowly down - ZEVs: rather slowly growing market 4 Transition 2010-2040: HYBRID ELECTRIC VEHICLES
Trends in low carbon car development 1. Use alternative fuels or mix with gasoline / diesel 2. Engine: enhanced cylinder filling, multi valves, new designs 3. Hybridize internal combustion engines with electric motors Optimize hybridization architecture Use better batteries for SLI and for energy storage 4. Optimize transmission and clutch: 5. Utilize the energy of the exhaust gases 6. Optimize the body reduced weight (aluminum (Ford), composite materials (BMW i8)) low rolling resistance tires, aerodynamics more efficient lubricants 5
Car Manufacturer s Values of HEV Batteries Battery features important for car manufacturers: 1. Safety PbA and NiMH: safe, Li-ion to improve (cell design, cell control, cooling) 2. Environment PbA are fully recycled, NiMH not yet, Li-ion need to develop recycling PbA have the smallest production CO 2 emissions footprint 3. Energy and power parameters Li-ion - light and strong, NiMH - long cycle life PbA - steadily improving 4. Last but not least: production costs $150 - $200 per kwh considered as a long term target for Li-Ion PbA remain about $100/kWh, NiMH and Li-ion are more expensive Li-ion expect cost reduction if produced in large series Lead-acid: not considered for full, plug-in and range extended hybrids. 6 The challenge for PbA: the battery choice for start-stops, micro, mild HEVs, keep strong market positions in next decades
Diversity of hybrid electric vehicles Vehicle Type Car example Regular Base Micro-1 Micro-2 Mild-1 Mild-2 Moderate Strong Parallel PHEV Extended Range PHEV most new EU cars Mazda Suzuki Coming soon GM Malibu Eco Hybrid Honda Civic Toyota Prius Ford Fusion Ford C-max Chevy Volt CO 2 Reduction, % 0 3-8 8-12 12-20 20-35 > 35 > 50 Sales forecast 2020 DECLINE DOMINANT RAPID RISE MODERATE RISE LIMITED RISE PARA- METERS El. Function SLI Start/Stop Regen Brake Launch assist Mild Power Assist Moderate Power Assist Limited Electric Drive Extended Electric Drive Largely Electric Drive El. Power, kw 2-4 2-4 2-4 5-12 10-15 12-20 25-60 40-100 70-130 Voltage, V 12 12 12-24 48 45-120 100-150 150-350 150-600 200 7
Various HEV types sales forecasts (Valeo) Stop-Start (+mild) sales will dominate: Europe - till 2025+, worldwide - longer Cummulative:xHEV + full + mild + St/St Source: 2013 Valeo Powertrain Forecast, D. Benchentrite, EEHE meeting, Bamberg, Germany, May 2014 8
2012 market forecast for 2020: micro hybrids The electric vehicle of the coming 10-15 years will be the micro hybrid with increased electric functionalities. Forecasts for 2020 2025: between 35 and 90 million micro hybrids Avicene 2020 OEM forecast: HEV: < 5 %; p-hev & EV: < 2 % Source: Chr. Pillot, Avicene Energy, France, 2013 Advanced Automotive Batteries Conference, Strasbourg, June 2013 Micro hybrid: > 50% Micro HEV Full HEV Battery Advanced lead-acid NiMH or Liion Battery cost, $ 300 3000 Fuel saving 5% 20% Sales in 2020 35,000,000 3,500,000 9
Car production rate and 48V micro HEVs The global production rate is growing steadily and is expected to continue: 3.6% a year worldwide 5.7% in developing and 1.2% in the developed countries Rapid growth is forecasted for 48V micro hybrids in the coming 10 years by LUX research. By 2025 48V micro hybrids are going to reach 10% of all micro hybrids Till 2030 this ratio will probably rapidly grow 10
Battery chemistry selection (no ALABC) PbA PbA, Li-Ion, PbA+ PbA, NiMH, Li-Ion NiMH, Li-Ion Li-Ion PbA issue in HEVs: negative plate sulfation 11
How is the battery operating in a 48 LC SH? 12
ALABC program: defeating PCL-3 effect, LC Added carbon 13
ALABC program: demonstrating LC batteries 100,000 miles 150,000 miles 12V and 48V LC Super Hybrids 48V LC Kia Optima turbo Diesel RAM 1500 HFE Natural Gas Hybrid Vehicle 14
Ultrabattery in a mild hybrid: our lessons 1. 150,000 miles on the road in Phoenix, Arizona 2. Battery shows almost no capacity loss 3. The battery serves as long as the vehicle! 15
The battery in the: a) car; b) micro HEV a Engine Alternator Regulator U(max) Starter 12V battery free will mystery Loads Ignition Lights Security Audio b Engine Start-Stop ISG 16 Microprocessor Computer Protocols U(max), U(min) boost charge BMS SOC, SOH mystery no standards 12V / 48V battery Dual chemistry Ultracapcior Loads Ignition Lights Security Infotainment HVAC Brakes Clutch Suspension E-motor
Ultrabattery in mild hybrid: our lessons 1. Cycle life of UB in mild hybrid as long as of NiMH 2. Fuel economy (charge acceptance) same and better than of NiMH 3. Energy throughput required: about 4,000 * Cn 4. 17 DCA Albena, June at 09, low 2014 temperature The ALABC is a Program subject of the International of Lead further Zinc Research Organization, improvement Inc.
Ultrabattery in mild hybrid: our lessons After 100,000 miles in a road test, 12 Ultra Battery modules: Voltage profiles all the same, no cell equalization needed! Benefits of Ultrabatteries: - no cell management electronics - no cooling at the cell level 18 LABAT 2011, Albena, Bulgaria, Copyright: June ALABC 7 10
The LC super Hybrid: a strong new concept System Metric Micro HEV LC Super Hybrid Mild Hybrid Full Hybrid Plug-in HEV Voltage 12V 12-48V OEM on-cost *estimate 150-700 750-1,500 24new concept - 130V 1,600 3,000 200-270V 300-400V 3,000 5,000 6,000 10,000 CO 2 Benefit % 4-7 % 15-30% 8-15% 15-30% 30%+ OEM Cost per 19 1% CO 2 Benefit 35-100 50-60 200-250 200-250 300-500
48 V How is the battery operating in a 48 LC SH? Pulse duration Charge / discharge pulse duration: 1 to 10 s Energy throughput in one NEDC cycle: 0.03 C n (one C n in 33 cycles) 1 hour a day 2,000 C n a year 12 V State of Charge 48 V 1,500*C n for 150,000 miles Battery life: 20,000 x C n Energy In and Out 20
Pb-A Batteries in SLI and in HRPSoC duty 21 Solution for HRPSoC: combine Faradaic capacity and EDL capacitance The energy throughput of the battery needs substantial increase
I recu / C n (A / Ah) Failure of lead-acid batteris in DCA tests DCA: Dynamic Charge Acceptance, (A (charge)/ah (C n )), 2012 Test B: Simulated Microhybrid Duty: Run-In EFB plus AGM poor flooded time / days ambient air 23 o C Charge acceptance of lead-acid batteries degrades rapidly in this simulation test (Dynamic) In 2012 enhanced lead-acid batteries already showed DCA improvements 0.6 A/Ah achieved today OEM: 2 A/Ah, 3 A/Ah E. Karden, F. Jöris, H. Budde-Meiwes, D.U. Sauer, Test Methods for Dynamic Charge Acceptance (DCA) of Microhybrid Starter Batteries, 13ELBC European Lead Battery Conference, Paris, France, September 2012 22
LC Batteries with Enhanced DCA Shin Kobe Improvement in DCA: performance closer to target DCA problem in regular lead-acid batteries Improvement 50% and more Advanced LC batteries able to resolve the problem soon T. Okoshi, Shin Kobe El. Machinery, Japan, 2013 Advanced Automotive Batteries Conference, Strasbourg, June 2013 The major issue of Pb-A batteries - shorter life due to low DCA - gets rapidly improved by inexpensive technology steps Source: 23 David Albena, Weinberg, June 09, Wiley 2014 Rein LLP, What s The ALABC New is in a Program the lead of Battery the International Policy World, Lead presentation Zinc Research Organization, at the 124 BCI Inc. convention, Scottsdale, April Copyright: 30, AZ, ALABC 2012
Vehicle Type Battery for micro/mild HEVs? LC batteries Micro-1 Micro-2 Mild-1 Mild-2 Moderate Strong Parallel PHEV Extended Range PHEV CO 2 Reduction, % 0 3-8 8-12 12-20 20-35 > 35 > 50 ALABC LCSH, % 12-20 12-30 Costs, $ / % CO 2 base 65-80 Sales forecast Regular DECLINE El. Function SLI Start/Stop Regen Brake Launch assist Mild Power Assist Hybrid 45-130 265-330 400-660 DOMINANT RAPID RISE MODERATE RISE LIMITED RISE Moderate Power Assist Limited Electric Drive Extended Electric Drive Largely Electric Drive El. Power, kw 2-4 2-4 2-4 5-12 10-15 12-20 25-60 40-100 70-130 Voltage, V 12 12 12-24 48 45-120 100-150 150-350 150-600 200 Lead-acid Ni MH Li - ion Battery combination Lead Carbon Meeting 2020 CO 2 targets: - inexpensive SUSTAINABLE batteries < 60V - in the best selling car design and price range - for mass transition, in short time 24
ALABC roadmap for the next 20 years Total energy throughput and DCA are key parameters Advanced LAB have sufficient cycle life and energy throughput (Honda Civic) Next target: a full hybrid (like Toyota Prius), and why not a low-end plug-in DCA is already about 0.6 A/A, will soon reach 1 A/Ah. We need rapidly more A/Ah for getting durable, reliable and light enough batteries 25
ALABC roadmap for the next 20 years Overview of required TET, DCA and cycle life (in years) Blue scale service life, red scale DCA, black scale TET 1. ALABs have lower parameters than Li-ion ones 2. To make them compatible we need to enhance technical performance but keep the benefits: - low material and production costs 26 - complete The ALABC is recycling a Program of the International Lead Zinc Research Organization, Inc.
Cost benefit of PbA vs. Li-Ion batteries Keeping cost low: a critical condition for the success of LAB 1. LAB: 75-150 $/kwh depending on design 2. Li-ion: more expensive, depending on design. Their costs are expected to decrease if in production. 3. About 2030 Li-ion might costs low as lead-acid Advanced LABs need rapid enhancement. New designs can cost more. To keep costs low, ALAB can afford only limited extra costs. LAB have some extra cost space but only temporary and under conditions: 1. Case A. Slow increase in cost. Critical year 2025. 2. Case B. Rapid increase in cost. Critical year 2020. 3. Expensive new technology rises costs. Due to massive sales cost drop rapidly again. No critical year. Remark: Only Li-ion sown here, no NiMH, no NiZn. 27 Sources: a) Chr. Pillot, AABC, Atlanta, February The ALABC 2014; is b) a Program ALABC data of the bank. International Lead Zinc Research Organization, Inc.
Conclusions 1. Micro and mild hybrids to dominate the market at least till 2020-2025 2. The new generation of advanced (Lead-Carbon) batteries has been tested in micro and mild hybrid electric vehicles. Battery performance: energy and cycle life sufficient (better mileage, 150,000+ road miles) 3. LC batteries can be further enhanced by 3D plate design; by negative and positive active mass improvement (adding carbon and other additives, enhanced local electrolyte supply) 4. The LC batteries for micro/mild hybrids are as good as other advanced chemistries and have long enough cycle life at HRPSoC cycling. They have also lower cost, higher safety, are produced from domestic materials, and are totally recycled 5. The combination of LC batteries and optimized micro hybrid electric vehicles offers an affordable market alternative and can change the HEV market in the coming two decades. 28
Thank you very much for your kind attention! Dr. Boris Monahov ILZRO - ALABC E-mail: bmonahov@ilzro.org Web: www.alabc.org 29