Better Efficiency with
Electrolyte Circulation
Intersolar 2014
Ralf Hachmeyer
HOPPECKE Batterien GmbH & Co. KG
Bontkirchener Straße 1
D-59929 Brilon-Hoppecke
www.hoppecke.com
Motive Power
Systems
Reserve Power Special Power
Systems
Systems
Service
Electrolyte Circulation System
Usage of vented lead acid batteries (VLA) in off-grid systems
Burkina Faso
AC system
Battery: OPzS solar.power
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Electrolyte Circulation System
Usage of vented lead acid batteries (VLA) in off-grid systems
Tahiti
Rural electrification; AC system
Battery used: OPzS solar.power
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Electrolyte Circulation System
Usage of vented lead acid batteries (VLA) in off-grid systems
Namibia
Rural electrification; AC system; Battery: OPzS solar.power
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Electrolyte Circulation System
Causes and Consequences of acid stratification
Acid stratification in lead acid batteries means that acid density is higher at the bottom of the
battery cell and lower at the upper region of the battery cell.
Causes1):
Sulfuric acid arising on the electrodes during battery charging is heavier than diluted sulfuric
acid and is therefore sinking to the bottom of the battery cell.
Consequences of acid stratification1):
Battery cell will be preferably charged in upper cell region and discharged at bottom region.
State of charge (SoC) is lower at the bottom compared to the upper area of the plates.
Higher cycling in bottom region of a battery cell. Thus increasing cycle dependent aging.
Higher acid densities at bottom of cell -> lead sulfate increases in bottom region of plates.
Lower acid densities in upper region -> creation of dendrites and increasing corrosion.
1) Andreas
Jossen, BaSyTec GmbH: „Säureschichtung in Bleibatterien“, März 2005
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Electrolyte Circulation System
Causes and Consequences of acid stratification
Consequences of acid stratification – Premature aging:
In the lower cell region:
Concentrated sulfuric acid attacks lead harder. The lead of negative electrode in particular the
active mass is converted to lead-sulfate. This lead-sulfate falls out (-> capacity loss).
In the upper cell region:
Lead is not stable in diluted acid – it dissolves.
Furthermore:
Lower energy efficiency of the battery
Degraded charge acceptance
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Electrolyte Circulation System
Causes and Consequences of acid stratification
Observations for typical battery operation in PV – systems1):
Cycling operation with 30% depth of discharge (DoD) leads to a significant acid stratification
already after the first cycle.
Acid stratification between the electrode plates is significantly higher after charging phase
compared to acid stratification after discharge phase.
1) Andreas
Jossen, BaSyTec GmbH: „Säureschichtung in Bleibatterien“, März 2005
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Overview Components
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Overview Components
Air outlet with
back pressure
valve
Current Sensor
Air intake with filter
Fuses
Air tube
Power Supply Cable
Battery connection
cable (to loads resp.
charger)
Air tube
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Benefits
Your benefits with the HOPPECKE Electrolyte
Circulation System:
Economic Recharge – cost reduction through increased
charging efficiency, significant reduced recharge time
Environmental-friendly – reduced runtime of additional
(Diesel) generators and cost savings
Extended battery service life – no acid stratification
Minimum maintenance costs – maintenance free pump
system (automatically controlled)
Reduced battery service costs – reduced water loss for
longer refill intervals
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Applications
Typical Applications:
Solar-/Off-grid applications
Power supply for remote off-grid applications and isolated
power networks, drinking water supply systems, healthcare
facilities
Telecommunications
Mobile phone stations, BTS stations, Off-grid/on-grid
solutions
Traffic Systems
Signaling systems, Lighting
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Benefits
Increase of efficiency and cost savings:
Typically up to 120% of discharged energy need to be recharged in order to reach the initial
state of charge (vented lead acid battery types). This charging factor includes the elimination of
acid stratification.
Application of the HOPPECKE electrolyte circulation system reduces the required charging
factor significantly. Increase of efficiency is up to 15% compared to charging without
electrolyte circulation system.
Therefore less time and energy is required to recharge the battery and to achieve a
homogeneous electrolyte distribution.
The electrolyte circulation system reduces also service costs because of reduced water loss
compared to conventional charging.
Moreover the HOPPECKE electrolyte circulation system increases service life of the battery
and provides environmental and economical benefits for the entire battery system.
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Reference
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Reference
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Electrolyte Circulation System
HOPPECKE Electrolyte Circulation System – Reference
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Electrolyte Circulation System
HOPPECKE – Company Information
Independent family enterprise since 1927
2013
2013
2012
2012
2008
2007
2006
2001
2000
1999
1997
1994
1976
1973
1927
Introduction of sun.systemizer – storage for
self-consumption of PV energy
Introduction of grid.systemizer – off-grid energy container solutions
Founding of HOPPECKE India and HOPPECKE Switzerland
Opening of the new HOPPECKE Technology-Center
in Zwickau, Germany
Founding of HOPPECKE Advanced Battery Technology GmbH
Founding of the HOPPECKE Service GmbH & Co. KG
Opening of HOPPECKE production plant in Wuhan, China
Founding of HOPPECKE Technologies GmbH & Co. KG
"Vlies-Technologie" awarded prize for innovation
Opening of distribution company and battery assembly
in Shanghai, China
Founding of HOPPECKE Batterie Systeme GmbH
All plants awarded quality certificates in accordance with
DIN ISO 9001
Construction of Brilon lead recycling smelter
Introduction of employee participation
Company founded by Carl Zoellner
Dr. Marc Zoellner
Managing Director since 2003
Claus Zoellner
Since 2003 Chairman
of the Advisory Board,
Managing Director 1967 until 2003
Ernst Zoellner
Managing Direcotor until 1967
Carl Zoellner
Founder of the company,
Managing Director until 1943
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Electrolyte Circulation System
HOPPECKE – Company Information
MOTIVE POWER SYSTEMS
Development, production and worldwide sales of
motive power energy systems
RESERVE POWER SYSTEMS
Development, production and worldwide sales of
stationary power systems
SPECIAL POWER SYSTEMS
Development, Production and worldwide sales of
FNC ® -, Li-Ion und NiMH- based battery storage systems
SERVICE
Worldwide energy service and maintenance
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Electrolyte Circulation System
HOPPECKE – Company Information
HOPPECKE Worldwide
HOPPECKE Subsidiary
HOPPECKE Representative
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Thank you…
Thank you for your
attention.
See you at the HOPPECKE
booth B1.410
www.hoppecke.com
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