C&D Carbon Battery Introduction C&D C b B tt I t d ti - - PowerPoint PPT Presentation

C&D C b B tt I t d ti C&D Carbon Battery Introduction Nov, 2014

1

C&D Technologies Property

C&D Carbon Technology C&D Carbon Technology

2

C&D Technologies Property

Traditional Stationary Battery Applications

Float Service Cycle Service 0C

UPS UPS

>20 Power 1C Energy and Energy and P 1

T l T l

rgy Infrastructure Infrastructure

Telecomm Telecomm

Energy and Energy and Infrastructure Infrastructure (Renewables) (Renewables) Ener C/20

3

(Renewables) (Renewables) <

C&D Technologies Property

Emerging Trends ‐ Application Breakdown

Float Service Cycle Service 0C >20 Power 1C Energy and Energy and Infrastructure Infrastructure

UPS UPS

P 1

Telecomm Telecomm

Renewable, Renewable, Grid Scale Grid Scale Storage Storage rgy Energy and Energy and Ener Infrastructure Infrastructure C/20

4

<

C&D Technologies Property

Consequences for Battery Technology

• Many emerging trends for energy storage have opposing technology

y g g gy g pp g gy requirements for the batteries

• High cycle life vs. High power

Hi h t t ti Hi h l lif

• High temperature operation vs. High cycle life
• Changing application requirements can impact other battery requirements
• Ultra‐ high discharge rates impact cycle life as DOD changes from shallow to

Ultra high discharge rates impact cycle life as DOD changes from shallow to moderate.

• New applications require clear understanding of the limiting components
• Partial State of Charge (PSOC) operation leads to negative sulfation
• The increase in impedance over life of the system affects Ultra‐high discharge

rates

5

C&D Technologies Property

C&D Battery Design Strategy

• Batteries designed to Customer Application

– Close customer contact to identify attributes of the application – Design each product line to optimize performance to the unique attributes of the applications – All trends to greater application specific designs – Smaller space = more customer revenue generating equipment!

6

C&D Technologies Property

Challenges to Current Technology

Cycle Life is the Key

• Battery used for regulation will be cycled every 15 minutes or 35,000 cycles/year at 3‐10% DOD
• Spinning reserve and peak shifting requires up to 365 cycles/year at 50‐80% DOD
• To be viable at least 5 years life is required with 10 years being requested

y y PSOC Operation

• To be viable at least 5 years life is required with 10 years being requested
• The battery needs to accept opportunity charging

with high efficiency

• Charging at float voltage for limited time results in

PSOC Operation

g g g Partial State of Charge (PSOC) operation.

• The repeated operation of VRLA cells at a PSOC

leads to “irreversible” capacity loss.

7

C&D Technologies Property

Mechanism of Negative Plate Sulfation

• Discharge

g Pb + HSO4‐ 2e + Pb2+ + SO4

2‐ + H+ Deposition Dissolution

PbSO4

• Charge

PbSO4 Pb2+ + SO4

2‐ + 2e + H+ Dissolution

Pb + H SO4

‐

Deposition

8

C&D Technologies Property

Negative Sulphation

9

C&D Technologies Property

Research Strategy

• Lead sulfate formation is inevitable under PSOC operation
• Reduction of lead sulfate can only take place where it comes into

contact with an electronic conductor ‐ High surface area required for effective contact with lead sulfate crystals ‐ High conductivity required for electron transfer High conductivity required for electron transfer

• We have to improve lead sulfate charge acceptance by increasing

conductivity of the NAM (Negative Active Material) conductivity of the NAM (Negative Active Material).

10

C&D Technologies Property

C&D Solution

• Integrated Carbon/Lead Negative electrode and High Performance Positive

Electrode

• The C&D solution is engineered for high cycling PSoC operation. Utilizing

an integrated Carbon negative and an advanced positive plate design and active material formulation.

11

C&D Technologies Property

C&D Carbon Battery

What Is C&D Carbon Battery?

• A C&D Carbon Battery uses a unique Positive Electrode design for cycling

and a Pb/Carbon Negative Electrode. / g

• The technology addresses both electrodes yielding a high cycling battery
• The technology addresses both electrodes yielding a high cycling battery

capable of Partial State of Charge (PSoC) operation.

12

C&D Technologies Property

Key Problems We Face and C&D Solution

Negative Electrode Negative Electrode

− Problem: Active material suffers sulphation;

− Solution: CARBON TECHNOLOGY. Positive Electrode

− Problem: Positive grid corrosion;

− Solution: Unique Positive Design for Cyclic.

13

C&D Technologies Property

Carbon types & generalized properties

14

C&D Technologies Property

C&D Carbon Battery Performance C&D Carbon Battery Performance Improvement

15

C&D Technologies Property

C&D Carbon Battery Models

Specifications:

• SHC12‐40
• SHC12‐65
• SHC12‐100

SHC12 110

• SHC12‐110
• SHC 12‐100FT
• SHC 12‐150FT
• SHC 12‐200FT

S C 00

• SHC 2‐300
• SHC 2‐400
• SHC 2‐600

16

C&D Technologies Property

C&D Carbon Technology Improvement

• A. Improved Temperature Performance.
• B. Improved Charge Acceptance.
• C. Greatly slow down the sulfation speed in PSoC application. Improved

PSoC Cycling Performance.

• D. Significantly improved Cycle Performance.

17

C&D Technologies Property

C&D Carbon Battery: Low Temperature Characteristics

• Lead‐acid batteries are severely affected by low temperatures.

‐ Due to an increase in internal resistance caused by a “slowing down”

• f the battery’s chemical reaction and ion diffusion rates.

– A rule of thumb, reaction rates are cut in half for each 10°C drop in temperature.

• This is directly related to the amount of electrode surface area covered

with active material that is available for conversion.

18

C&D Technologies Property

C&D Carbon Battery: Low Temperature Characteristics

• C&D Carbon battery has outstanding discharge performance at low

ambient temperatures relative to commercial flooded lead‐acid and ambient temperatures relative to commercial flooded lead acid and conventional valve‐regulated lead‐acid (VRLA) batteries ‐ The extremely high available surface area of Carbon material.

C b B tt C ti l L d A id Carbon Battery vs. Conventional Lead Acid C/10 Capacity vs. Temperature

95 105 65 75 85

Capacity (%)

Carbon STD

45 55 65

• 20
• 15
• 10
• 5

5 10 15 20 25

19

20 15 10 5 5 10 15 20 25

Temperature (C)

C&D Technologies Property

C&D Carbon Battery: Low Temperature Characteristics

• As Figure shown above, at ‐20deg C, a conventional lead acid battery will
• nly yield 50% of its rated capacity. C&D Carbon battery can yield 66%
• f its rated capacity in this same temperature. This means the C&D

Carbon battery will provide nearly more than 16% more Ah capacity y p y p y than the same sized conventional lead acid product at ‐20deg C.

• Benefit for users on the battery sizing

Benefit for users on the battery sizing ‐ sized smaller at the same amps output, smaller space ‐ more powerful, less number of batteries, less accessories cost l l if i i bl i l l d id ‐ last longer if its size were comparable to a conventional lead‐acid battery.

20

C&D Technologies Property

C&D Carbon Battery: High Temperature Characteristic

• The optimum operating temperature for a lead‐acid battery is 25 ℃

‐ As a rule of thumb, every 8 ℃ to 10 ℃ rise in temperature will increase grid corrosion by a factor of two and result in premature failure for the g y p battery.

• Lead grids corrode in the acidic electrolyte with the presence of lead

Lead grids corrode in the acidic electrolyte with the presence of lead dioxide (positive‐plate active material). High ambient and operating temperatures accelerate this process.

21

C&D Technologies Property

C&D Carbon Battery: High Temperature Characteristic

• C&D Carbon battery has superior performance in terms of thermal

management, which results in better heat‐transfer characteristics of the carbon/graphite.

• Carbon battery can not only dissipate the heat generated on itself, but

also absorbs heat away from the positive plate and out of the cell. Thus, batteries made with Carbon enhanced electrodes will transfer heat, generated by the electrochemical reactions taking place, out of the battery rapidly, thus making thermal runaway less likely and enabling

• verall “cool” operation compared to conventional lead‐acid batteries.

22

C&D Technologies Property

C&D Carbon Battery: Charge Acceptance Performance

The C&D Carbon battery with Carbon enhanced electrode can accept a charge current up to 300% over that for standard Lead Acid. For example: For example: – C&D Carbon battery 5hrs vs. Standard VRLA 10hrs @ C15min discharge, 100% Recharge – C&D Carbon battery 10 hrs vs. Standard VRLA >17hrs @ C/10 discharge, 100% Recharge Recharge Time has been shortened by about 50%!

23

C&D Technologies Property

C&D Carbon Battery: Charge Acceptance Performance

120%

Carbon C15min

100% 110%

Carbon, C10 STD C15min

90% 100%

Carbon Battery-% Recharge @ C15min STD-% Recharge @ C15min Carbon Battery-% Recharge @ C/10

STD,C10

• f Charge

70% 80%

STD-% Recharge @ C/10

State

50% 60% 1 3 5 7 9 11 13 15 17 19 21 23 25 27

Time/hrs

24

C&D Technologies Property

/

C&D Carbon Battery: Charge Time vs. DOD

Charge time vs. Depth of Discharge (hour) Time

C&D Technologies Property

25

DOD

PSoC Operation

• The battery needs to accept opportunity charging with high efficiency
• Charging at float voltage for limited time results in Partial State of

Charge (PSoC) operation.

• The repeated operation of VRLA cells at a PSoC leads to “irreversible”

capacity loss.

• PbSO4 crystals that form on the negative electrode re‐crystallize and

form “hard sulfates”, large crystals with low surface area, that are difficult to covert to Pb under ordinary circumstances and operating difficult to covert to Pb under ordinary circumstances and operating conditions.

• Ericsson test simulates typical PSoC

26

• Ericsson test simulates typical PSoC

C&D Technologies Property

How the Carbon additives increasing the PSoC Cycling?

• 1. Electronic conductivity

The carbon particles maintain the conductivity of the active material in the presence of increased amounts of PbSO4, which are electrically

• insulating. These conductive pathways then facilitate charging despite

the increased resistance of the plates.

• 2. Restriction of crystal growth

y g Carbon prevents the progressive growth of PbSO4 crystals, maintaining surface area and improving charging characteristics

• 3. Hydrogen over potential impurities

Certain forms of carbon contains elements that can suppress the evolution of hydrogen at the negative improving charge efficiency

27

evolution of hydrogen at the negative improving charge efficiency.

C&D Technologies Property

How the Carbon additives increasing the PSoC Cycling?

• 4. Capacitive contribution

The added Carbon acts as an asymmetric super capacitor, storing charge at high rates in the electric double layer and spontaneously discharging, converting PbSO4 into lead.

• 5. Intercalation of hydrogen into the graphite structure

The graphite structure allows for intercalation sites for the hydrogen The graphite structure allows for intercalation sites for the hydrogen atoms that support the cell’s capacity.

28

C&D Technologies Property

Ericsson Cyclic Test

29

Company Logo

C&D Technologies Property

Ericsson Cyclic Test

140Ah for example

1. 39.0WPC Discharge for 2 Hours 2. 2.27VPC Charge for 2 Hours 3. 39.0WPC Discharge for 3 Hours 4. 2.27VPC Charge for 4 Hours 5 39 0WPC Discharge for 5 Hours

One day equals 3 cycles

5. 39.0WPC Discharge for 5 Hours 6. 2.27VPC Charge for 8 Hours 7. Repeat 6 Steps Above

30

Company Logo

C&D Technologies Property

Ericsson Cyclic Test

140Ah PbC Ericsson CL Test:

• 39.0WPC Discharge for 2 Hours
• 2.27VPC Charge for 2 Hours
• 39.0WPC Discharge for 3 Hours
• 2.27VPC Charge for 4 Hours
• 39.0WPC Discharge for 5 Hours
• 2.27VPC Charge for 8 Hours
• Repeat 6 Steps Abo e

So far 800x3 = 2400 Cycles So far total delivered 156800 AH

• Repeat 6 Steps Above

31

196 AH Delivered/Day – 140% of 8 Hour Capacity C&D Technologies Property

30%‐80% PSOC Test

1 Pick batteries that passed C8 test 2 24 5A di h f 3 5 h t C/5 t

Test procedures:

2 24.5A discharge for 3.5 hours at C/5 rate 3 Recharge to 62.5AH using current limits of 35A max and voltage limits of 2.27VPC 4 24.5A for 2.5 hours 5 Recharge to 62.5AH using current limits of 35A max and voltage limits of 2.27VPC 6 Repeat steps 4 & 5 for total 500 cycles 7 After 500 cycles, check the residual C8 capacity y , p y

• Fully charge cells using a string voltage limit of 2.27VPC/20A

for 48 hours

• Run 8-hour to 1.75vpc capacity test at C/8 rate
• Fully charge cells using a string voltage limit of 2.27VPC/20A to

Fully charge cells using a string voltage limit of 2.27VPC/20A to return 110% of Ah out 8 Repeat steps 2 to 7 and stop cycle test until EODV in cycle lower than 10.5V or C8 capacity lower than 80%.

C&D Technologies Property

32

30%‐80% PSoC Test

33

Company Logo

C&D Carbon Battery Excellent Cycling Performance at 25degC & 35degC

The C&D solution improves Battery Performance!

34

C&D Technologies Property

C&D Carbon Battery vs other Batteries C&D Carbon Battery vs. other Batteries

35

C&D Technologies Property

Comparisons of Carbon Battery vs. Pure Lead

• Carbon Battery vs. Pure Lead Battery Accelerate Float Life Test Result

12years vs. 7years !!

Carbon Battery Vs. Pure Lead 60degC AFL TEST REPORT (Refer to IEC60896 ‐ 21、22)

150% 110% 120% 130% 140% city% 80% 90% 100% Capac

Pure Lead Carbon (#1,#2)

60% 70% 1 2 3 4 5 6 7 8 9 10 11 12 Segments (Equal to years)

36

C&D Technologies Property

Comparisons of Carbon Battery vs. Pure Lead Failure Mode Analysis Failure Mode Analysis

• One of the key failure modes for battery is PGC. Pure lead technology is

favorable on reducing the positive grid corrosion rate, due to the lack of impurities which also contributes to the low float current and low water loss, thus improving the float service life theoretically. However, the f il d h i h d f i l h i b h failure mode has switched from PGC to negative sulphation because the float current is too low and thus cannot compensate for the battery self‐ discharge. S l d h l did l i b i lif So pure lead technology did not greatly improve battery service life as expected.

• C&D Carbon battery, not only negative enhanced with carbon to slow

down the sulphation, but also the polarization on positive has lowered which helps to reduce the PGC corrosion rate. Based on this positive i fl h i ll i b lif

37

influence, there is an overall improvement on battery life.

C&D Technologies Property

C&D Carbon Battery Vs North Star Blue Battery

Model C10 DOD 100% Charging Charging Voltage NSB100BLUE 84 330 Float Cycling 2 25 2 29 NSB100BLUE 84 330 Float Cycling 2.25-2.29 Carbon 140Ah 140 650 Float Cycling 2.27

Summary: 1.C&D 140 AH C10 vs. NSB 84 AH 2.C&D DOD 100% 650 float charging when cycle

• vs. NSB 330 Float cycling
• 3. C&D PSoC Cyclic performance better than Blue Battery

So far 800x3 = 2400 Cycles So far total delivered 156800 AH

38 38

C&D Technologies Property

SE Asia Test Cycle=PSoC Cyclic Test

C&D Carbon Battery vs. Sonnenshein A600 Solar Battery

• Carbon
• Sonnenshein GEL

– Excellent Cyclic life

– Medium cost – Excellent Cyclic life – Expensive cost – Large space – Small space – Large space

Model IEC C10 Cyclic life Size Cost SHC12-100FT 90Ah 80% DOD 1000 237*110*511 More Economy S12/130A 104Ah 80% DOD 1000 286*269*230 Expensive S12/130A 104Ah 80% DOD 1000 286 269 230 Expensive

Comparison: Same Cycle Number Carbon battery Space decrease 33% Carbon battery with better cost performance

39 39

C&D Technologies Property

C&D Carbon Battery for Renewable Energy C&D Carbon Battery for Renewable Energy Storage Program

40

C&D Technologies Property

Importance of Energy Storage

• Large‐scale, low‐cost energy storage is needed to improve the reliability,

resiliency, and efficiency of next‐generation power grids.

• Energy storage can reduce power fluctuations, enhance system

gy g p , y flexibility, and enable the storage and dispatch of electricity generated by variable renewable energy sources such as wind, solar, and water power.

41

C&D Technologies Property

Why do you need batteries? Loss of Revenue, Unstable Generation

• ss of Revenue, Unstable Generation

42

C&D Technologies Property

Peak Load Shaving

43

C&D Technologies Property

Asian Unstable AC Grid Countries and Telecom MKT size

Very unstable grid PSOC cycling required

TEL Market TAM Country

2011 2012 2013 2014 2015

Unstable **Rank 2013 2014 2015 Japan 132 147 165 185 207 1 China 223 250 280 313 351 3 112 125 140 India 188 210 236 264 296 5 189 211 236 Australia 44 49 55 61 68 4 33 37 41 Korea 40 45 50 56 63 2 10 11 13 Indonesia 24 27 30 33 37 5 24 27 30 T i 20 23 25 29 32 2 5 6 6 Taiwan 20 23 25 29 32 2 5 6 6 Thailand 13 15 17 19 21 4 10 11 13 Malaysia 11 12 13 15 17 4 8 9 10 Hong Kong 10 11 13 14 16 1 Philippines 9 10 11 12 14 5 9 10 11 Singapore 9 10 11 12 14 1 44 44 Singapore 9 10 11 12 14 1 New Zeland* 2 2 3 3 3 3 1 1 1 Vietnam 7 8 9 10 12 5 7 8 9

732 819 917 1027 1150 407 456 511

* estimated ** most unstable 5

C&D Technologies Property

China Energy Storage Market

US Investment Back Piper Jaffray forecasts in the coming 10‐12 years global storage market is 600 Billion USD, in which China has share of 1/3 1.Energy Storage Technology

• Physical Storage (CAES, pumped Hydro, fly wheel)
• Chemical Storage (Lead Acid, Carbon battery, Li‐ion, Molten Salt, etc)
• Electromagnetic Storage (Super capacitance, superconductor etc)
• most of technology are under RD or trial production, having limits of

cost, geographic constraints etc, difficult to be industrialized

• 2. TAM of Storage Market in 10 years
• Wind power: till 2020, Wind power installation 150GW, 22.5GW

equipped with energy storage system, unit price 650 USD per kw, t t l 15 billi USD total 15 billion USD

• from CY2012‐2020, solar battery application up to 1000MW each

year, 9000MW total in 9 years

45 45

C&D Technologies Property

Pick a growth number – all are promising

NanoMarkets 46

C&D Technologies Property

Carbon Battery Vs Other Storage System

System <$500/KWh （KWH cost） Mobile High Energy High Power Carbon Battery Yes Yes Yes Yes Li‐ion No Yes Yes Yes Molten Salt No Yes Yes No Fly Wheel No No No Yes CAES CAES Yes No Yes Yes Pumped Hydro Yes No Yes No

47 47

C&D Technologies Property

Why do you need C&D Carbon Battery



Frequent AC breakout Vs. Power Stability and Reliability



Frequent AC breakout Vs. Power Stability and Reliability



Uncontrolled Site Environment Vs. Endurable Power System with longer service life Low Recharging Capability on‐site Vs Fast Capacity Recovery for Next



Low Recharging Capability on‐site Vs. Fast Capacity Recovery for Next Cycle



Smaller Initial Investment but Heavier Service expense Vs. Minimized Total Ownership Cost

48 48

C&D Technologies Property

C&D Carbon Battery Energy Storage Technology

• For transmission utilization, Lead Carbon technology provides the only

effective solution compared to other energy storage systems

• The Carbon Battery Energy Storage System is mobile allowing the system to

b l t d ti i t h be relocated as congestion points change

• Increased cycle life allows the system to provide contingency reserve power

and peak price sales in addition to transmission utilization without the need and peak price sales in addition to transmission utilization without the need to over size the system reducing cost and adding value

• Carbon batteries are manufactured with 95% recycled
• Carbon batteries are manufactured with 95% recycled

materials and are fully recyclable at the end of service.

49

C&D Technologies Property

Battery Building Blocks & System

In modular containers

System Arrangement for y g large scale systems

50

24 per stack C&D Technologies Property

Battery Building Blocks & System

Carbon Batteries

Modular Systems A t

51

Arrangement

C&D Technologies Property

C&D Carbon Battery Energy Storage System 20MW / 25MWH 0MW / 5MWH

• Energy Units (Batteries) 40’

Container  25 container system, 25MWH  400kW for 150 minutes  Air conditioned  Air conditioned  Stackable six high

• Power Units (Inverters) 20’

( ) Container  Five containers, 4MW Each  20MW k  20MW peak power  Control systems  SCADA communication systems

52

y  Air conditioned

C&D Technologies Property

12V Front Terminal Battery Installation

53

2V Battery Installation

54

Application Benefit – Telecom Remote Site

123M USD Saving in 5 years for Regional Users!!

Standby Power‐ Telecom Remote Site 150A/‐48V for example Autonomy Time 3h Carbon Battery STD Lead‐Acid Autonomy Time 3h Carbon Battery STD Lead Acid Cyclic Number 50%DOD 2250 80%DOD 1000 100%DOD 650 50%DOD 1200 80%DOD 300 100%DOD 180 If every month 4 times power outage, each time for 3hours, then theoretical service life 13.5 3.8 Each Site Battery Investment/USD 8,608 10,880 Installation Cost/USD 200 400 Maitainance Cost/USD 4,000 4,000 Each Site Users Cost/USD 12,808 15,280 Use Indonesiya as example, total 100K sites, 50K sites in the Ustable grid 50000 50000 in the Ustable grid 50000 50000 User battery related total cost for 5years/USD 640,400,000 764,000,000 Carbon Battery total saving for Users/USD 123,600,000

* Battery price calculate by list price; ** Information from NEWS.CN

55

C&D Technologies Property

Application Benefit – Solar Light

About 9M USD Saving in 5years for regional users!!

Energy Storage ‐ Solar light 12V 100Ah 1 block per light 12V 100Ah 1 block per light Running time 8h/day, 5year service Carbon Standard VRLA Cyclic number 50%DOD 2250 80%DOD 1000 100%DOD 600 50%DOD 1200 80%DOD 300 100%DOD 180 Theoretical service life (80%DOD) 2.7 0.8 ( ) Battery Investment/USD 702 1,568 Maintanance/USD 30 180 User cost per light 732 1,748 Use Beijing parks for example, installed 8843 sets of solar light in 2012 8,843 8,843 Carbon Battery total saving for Users/USD 8,984,488

* Battery price calculate by list price; ** Information from Alibaba

56

C&D Technologies Property

Thanks!

57 57

C&D Technologies Property