Prepared for 7 x 24 Exchange 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 Product Applications Reserve Power Telecom – Wireline Telecom - Wireless Extended Run time Wind & Solar UPS Railroad Crossing Backup 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 Lead acid battery components • Lead-acid battery consists of two dissimilar metals in acid solution – Positive plate – PbO2 (black or dark chocolate brown when healthy) – Negative plate – Pb (light gray or gray) – Acid – H2SO4 (clear – water and sulfuric acid mixture) – Separator (keeps positive and negative plates from touching) – Jar/Cover (you have choices) Lead acid battery construction Typical Lead Acid Plate Primary failure of a lead acid battery is due to Grid Corrosion Grid 8 Pasted Plate Pros & Cons of VRLA Pros Cons Low maintenance technology Relatively low energy density (heavy) Long float life, specially pure lead Cannot be stored in discharged state for too long Quick charge and discharge capability Lower cycle life than NiCd cells Charging and orientation flexibility Thermal runaway possible with excessive overcharge or improper thermal management Wide operating temperature (-65ºC to +80ºC) More sensitive to high temperature than flooded lead acid cells No “memory” effect State of charge easily measured (OCV) Low cost of ownership 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 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 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 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 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 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 High Purity Materials Virgin Lead Oxide Virgin Lead Medical Grade Acid EW/Thin Plate/10/02 17 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 TPPL Technology VRLA Grid Thickness Thick vs Thin Cells are: Cells are: • Large • Smaller • Heavy • Lighter Grids are: Pb-Ca SBS • Prone to corrosion and growth Grids are: • Resistant to corrosion and growth Equivalent Float Life Products EW/Thin Plate/10/02 19 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) Life Battery 21 Another Major Difference for TPPL Typical Lead Calcium – Grid is Cast TPPL - Grid is Cold Rolled or Chill Cast and Punched 2 V 2.5 AH D CELL SEALED-LEAD RECHARGEABLE BATTERY 22 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 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 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 • Widest operating temperature range (-65ºC to +80ºC) capability Small amount of tin High vent pressure • 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) Pure lead-tin vs. lead calcium VRLA Feature Pure lead-tin (Genesis XE) Lead calcium (Genesis NP) Calendar life @ 25ºC 12+ yrs. for XE 3 to 6 yrs. 1300 625 -40ºC to 80ºC for XE with jacket -20ºC to 60ºC Cycle life Temperature range Charging @ 25ºC Quick charge capability Shelf life @ 25ºC Capacity @ -20ºC (% of 10-hr rate) Float: 2.25-2.30 VPC; no CL Cyclic: 2.40-2.50 VPC; no CL Float: 2.25-2.30 VPC; no CL Cyclic: 2.40-2.50 VPC; 0.25C CL 100% SOC in < 30 min. Limited by current limit (CL) Recharge every 24 months Recharge every 6 months 42% @ 15 min. rate 70% @ 1-hr. rate 4% @ 15 min. rate 38% @ 1-hr. rate Higher Energy Density Bookmold casting requires inherent grid strength - thick with added hardeners Automation of plate manufacture allows processing of thin Pb° grid Result: 2 - 4 mm Thick Result : 1mm Thin Means the difference between a 155AH lead calcium to a 170Ah Pure Lead Thin = Greater Surface Area = More Power 27 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 INITIAL WEIGHT (Kg) OCV CHARGE 2.27V/CELL : 168H Ah IN STABILISED FLOAT CURRENT (mA) WEIGHT AFTER CHARGE % RECOMBINATION MONOBLOC 1 MONOBLOC 2 26.532 26.44 13.123 13.108 3.6 20 26.529 99.6 3.53 20 26.438 99.7 EW/Thin Plate/10/02 28 SBS Technology SBSC11 GAS EVOLUTION TESTS AT ELEVATED TEMPERATURE TEMPERATURE FLOAT VOLTAGE (V) FLOAT I 40 C 2.45Vpc N/A 50 C 2.45Vpc 610mA 65 C 2.45Vpc 900mA GAS EVOLVED 0.580 LITRES/HOUR 0.880 LITRES/HOUR 2.020 LITRES/HOUR TEMPERATURE FLOAT VOLTAGE (V) FLOAT I 40 C 2.375 Vpc 250mA 50 C 2.375 Vpc 450mA 65 C 2.375 Vpc 560mA GAS EVOLVED 0.111 LITRES/HOUR 0.190 LITRES/HOUR 0.45 LITRES/HOUR TEMPERATURE FLOAT VOLTAGE (V) FLOAT I 40 C 2.27Vpc 40mA 50 C 2.27Vpc 80mA 65 C 2.27Vpc 270mA GAS EVOLVED 0.00 LITRES/HOUR 0.00 LITRES/HOUR 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 Long Service Life TPPL typical service life expectancy to 80% of rated capacity MONTHS/YEAR 1 2 3 4 5 6 7 8 9 10 11 12 TEMPERATURE DEGREES CELSIUS 20C 25C 30C 35C 40C 15 14.6 14.2 13.8 13.4 15 14.2 13.4 12.6 11.9 15 13.8 12.6 11.6 10.6 15 13.4 11.9 10.6 9.5 15 13 11.3 9.7 8.4 15 12.6 10.6 8.9 7.5 15 12.3 10 8.2 6.7 15 11.9 9.5 7.5 6 15 11.6 8.9 6.9 5.3 15 11.3 8.4 6.3 4.7 15 10.9 8 5.8 4.2 15 10.6 7.5 5.3 3.8 45C 13 11.3 9.7 8.4 7.3 6.3 5.5 4.7 4.1 3.6 3.1 2.7 50C 12.6 10.6 8.9 7.5 6.3 5.3 4.5 3.8 3.2 2.7 2.2 1.9 55C 12.3 10 8.2 6.7 5.5 4.5 3.7 3 2.5 2 1.6 1.3 EW/Thin Plate/10/02 30 Quick charging lead-tin VRLA Capacity returned Charge current, amps 0.8C10 1.6C10 3.1C10 60% 44 min. 20 min. 10 min. 80% 57 min. 28 min. 14 min. 100% 90 min. 50 min. 30 min. C10 = amp-hour capacity at the 10-hour rate; 0.8C10 = 80A for a 100Ah battery Cycle life comparison Thermal runaway comparison 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 2.17 100 2.16 96 2.15 91 2.14 87 2.13 83 2.12 79 2.11 74 +40°C +25°C +30°C +20°C +10°C 2.10 70 0 6 12 18 24 30 36 Months 35 42 48 Approx % state of charge Up to 18 months of storage vs. 6 months for lead calcium. Stop installing dead batteries when deployments take longer than expected 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 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 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 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 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 1995-1997 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 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” Thank you !