flooded (vla ), sealed (vrla), gel, agm type, flat … · dr. wieland rusch keith vassallo gary...
TRANSCRIPT
E N E R G Y F R O M B A T T E R I E S
BATTCON 2006
FLOODED (VLA ), SEALED (VRLA), GEL, AGM TYPE, FLAT PLATE, TUBULAR PLATE:
THE WHEN, WHERE, AND WHY. HOW DOES THE END USER DECIDE ON THE BEST
SOLUTION?
Dr. Wieland Rusch Keith Vassallo Gary Hart
Research & Development General Manager Entrepreneur
BAE Batterien GmbH BAE Corporate G.K. Hart POWER Inc.
Berlin, Germany North America Ontario, Canada
E N E R G Y F R O M B A T T E R I E S
GLOBAL MARKET – GLOBAL BATTERIES ?
-AGM vertical
VLA tubularGEL
VLA flatAGM horizontal
300 to 3000Ah
12V AGM block
12V AGM block
12V AGM block
25 to 200Ah
Far EastEuropeNorth America
E N E R G Y F R O M B A T T E R I E S
TYPE COMPARISON
OGiVOGiOPzVOPzS
VRLAVLAVRLAVLA
FLATTUBULAR
PERFORMANCE AND ENDURANCE
GELAGM
E N E R G Y F R O M B A T T E R I E S
POSITIVE PLANTÈ PLATE
• High power output• Long operational life• Low cycle stability (ca. 200 cycles)• High cost battery, old-fashioned
• Gravity cast grid with enlarged surface by lamellas
• Active mass (PbO2) is produced by corrosion
E N E R G Y F R O M B A T T E R I E S
POSITIVE TUBULAR PLATE
• Highest operational life
• Highest endurance of cycles
• 8mm thickness of the electrode restricts the high power performance
• Gauntlets: radial pressure, no horizontal bars
• Circular rods, pressure cast,Lead-selenium (OPzS), Lead-calcium (OPzV)
• High porosity by read-lead filling
E N E R G Y F R O M B A T T E R I E S
POSITIVE ROUND - GRID FLAT PLATE
• High power output• Good cycle endurance • Long operational life
• Circular rods like in tubular plates; but 50% more plates
• Lead-selenium alloy, fine grains, low corrosion
E N E R G Y F R O M B A T T E R I E S
COMPARISON
VLA TUBULAR PLATE VERSUS VLA FLAT PLATE
E N E R G Y F R O M B A T T E R I E S
PERFORMANCE COMPARISON
0,23 mOhm0,125 mOhmInner resistance
12 pos. plates, 8,0mm
18 pos. plates, 4,8mm
Plates, thickness
L x W x H = 215 x 277 x 710 mmSize
88 kg, 193,8 lb102 kg, 224,7 lbWeight
1340Ah1350AhC10, 25°C, 1,80V
12 OPzS 120018 OGi 1440Type
TUBULARFLAT
E N E R G Y F R O M B A T T E R I E S
DISCHARGE POWER: FLAT VS TUBULAR
0
500
1000
1500
2000
2500
3000
3500
4000
10 min 100 min 1000 min
Dis
ch
arg
e p
ow
er
W / c
ell
12 OPzS 1200 18 OGi 1440
Flat: 66% more power / volume
E N E R G Y F R O M B A T T E R I E S
POWER PER COST: FLAT VS TUBULAR
50%
60%
70%
80%
90%
100%
110%
120%
130%
140%
150%
10 min 100 min 1000 minCell p
ow
er
per
co
st
rela
ted
to
OP
zS
12 OPzS 1200 18 OGi 1440
TUBULAR: 20% more W / $
E N E R G Y F R O M B A T T E R I E S
ACCELERATED LIFE TIME TEST
QUALIFICATION FOR NUCLEAR POWER PLANTS:
IEEE 535-1986: 20 days at 145F (62,8°C) equals 1 year
E N E R G Y F R O M B A T T E R I E S
ACCELERATED LIFE TIME TEST: SAMPLES
3 cells 1520Ah3 cells 2000Ah6 cells 2000Ahsamples
3 cells 800Ah3 cells 490Ah6 cells 490Ahsamples
3 cells 480Ah3 cells 200Ah6 cells 200Ahsamples
1,24g/ml 2,23V1,24g/ml 2,25V1,24g/ml 2,23Vdensity float V
flattubular - GELtubulartype
OGi
ventedOPzV
valve-regulatedOPzS
vented
3 cells 1520Ah3 cells 2000Ah6 cells 2000Ahsamples
3 cells 800Ah3 cells 490Ah6 cells 490Ahsamples
3 cells 480Ah3 cells 200Ah6 cells 200Ahsamples
1,24g/ml 2,23V1,24g/ml 2,25V1,24g/ml 2,23Vdensity float V
flattubular - GELtubulartype
OGi
ventedOPzV
valve-regulatedOPzS
vented
E N E R G Y F R O M B A T T E R I E S
SEISMIC TEST IN THREE DIMENSIONS
5 times seismic test à 30s,
1 times air plane crash test à 30s
E N E R G Y F R O M B A T T E R I E S
AIRPLANE CRASH TEST
E N E R G Y F R O M B A T T E R I E S
TUBULAR PLATE CELLS: 550 days at 145F
0
20
40
60
80
100
120
140
160
0 50 100 150 200 250 300 350 400 450 500 550 600
float at 62,8°C with 2,23V / days
3h
- c
ap
ac
ity
at
20
°C / %
16OPzS 2000 7OPzS 490 4OPzS 200
Seismic test
IEEE 535-1986:27,5 years at 77F
E N E R G Y F R O M B A T T E R I E S
FLOAT CURRENTS OF TUBULAR AND FLAT
0
50
100
0 5 10 15 20 25 30
OPERATIONAL LIFE AT 25°C
FL
OA
T C
UR
RE
NT
AT
2,2
3V
IN
m
A/1
00A
h
OPzS 2000
OPzS 490
OPzS 200
OGi 1520
OGi 800
OGi 480TUBULAR PLATE VLALEAD SELENIUM
FLAT PLATE VLALEAD SELENIUM
E N E R G Y F R O M B A T T E R I E Swrus 30082005
PLATES AFTER 550 DAYS AT 145F
Positive plate 94.6% PbO2
Negative plate 2.8% PbSO4
E N E R G Y F R O M B A T T E R I E Swrus 30082005
Growth of OPzS poles at life‘s end
E N E R G Y F R O M B A T T E R I E Swrus 071004
• Labyrinth in the lead pole
• Primer onto the labyrinth
• ABS injection-moulding like a panzer
• Sliding pole: during growth a clean uncorroded pole shaft is moving upwards and maintains the 100% seal of the rubber ring.
• Washers in polarity colors
• Service ring for impedance measurements, IP25 protected
• Copper inserts for OGi, brass inserts for OPzS and OPzV.
Cross section of the terminal
16 mm
E N E R G Y F R O M B A T T E R I E S
TUBULAR VLA (OPzS) CYCLE TEST
6 OPzV 420 Ah
Discharge 3h with 84Ah (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A
C10
Dec 1994 Cycles Jun 1999
0
20
40
60
80
100
120
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
Dezember 1994 Juni 1999
IEC 896-1 OPzS 420 AhDischarge 3h with 84A (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A
E N E R G Y F R O M B A T T E R I E S
ENDURANCE COMPARISON
17001200Cycles IEC 60 896-1
75% DOD C4
Factor 3Factor 2Float current
increase in 20 years
42,7 years at 20°C33 years at 20°C
27,5 years at 25°C21,3 years at 25°CIEEE 535-1986
550 days425 daysOn float with 2,23V at
62,8°C
Tubular plate OPzSFlat plate OGi
E N E R G Y F R O M B A T T E R I E S
COMPARISON VRLA VERSUS VLA
E N E R G Y F R O M B A T T E R I E S
ADVANTAGES VRLA VERSUS VLA
• GAS EVOLUTION ONLY 10%, VENTILATION REQUIREMENT ONLY 20% (EN 50 272-2)
• LESS PROVISION AGAINST ACID LEAKAGE
• NO HANDLING WITH ACID AND WATER
• NO IMPURITY PROBLEMS WITH REFILLING WATER
• NO SHORT CIRCUITS DUE TO ACCUMULATED MUD
E N E R G Y F R O M B A T T E R I E S
DISADVANTAGES VRLA VERSUS VLA
• OXYGEN INGRESS DISCHARGES THE NEGATIVE PLATE
• OXYGEN RECOMBINATION REDUCES NEGATIVE POLARISATION: IN UNFAVOURABLE DESIGNS DISCHARGE OF NEGATIVE DURING FLOAT!
• MAX. TEMPERATURE 45°C INSTEAD of 55°C
• LESS INSPECTION METHODS – LESS AWARENESS OF HEALTH
E N E R G Y F R O M B A T T E R I E S
PERFORMANCE COMPARISON
1,6mOhm1,8 mOhmInner resistance
6 pos. plates,8,0mm
6 pos. plates, 8,4mm
Plates, thickness
L x W x H = 380/3 x 205 x 380 mmSize
23kg, 50,7lb23,3 kg, 51,3 lbWeight
317 Ah326 AhC10, 25°C, 1,80V
6 OPzS 3006 OPzV 300Type
VLA TUBULARVRLA TUBULAR
GEL
E N E R G Y F R O M B A T T E R I E S
POWER PER COST VRLA VERSUS VLA
70%
80%
90%
100%
110%
120%
130%
10 min 100 min 1000 min
Cell
po
wer
per
$,
OP
zV
set
to 1
00%
6 OPzV 300 6 OPzS 300
TUBULAR GEL: HERE THE SAME W / $
E N E R G Y F R O M B A T T E R I E S
TUBULAR GEL: 450 DAYS AT 145F
0
20
40
60
80
100
120
140
160
180
0 50 100 150 200 250 300 350 400 450 500
float at 62,8° with 2,25V / days
3h
ca
pa
cit
y a
t 2
0°C
/ %
16OPzV 2000 7OPzV 490 4OPzV 200
Seismic test
IEEE 535-1986
22,5 years at 77F
0
20
40
60
80
100
120
140
160
180
0 50 100 150 200 250 300 350 400 450 500
float at 62,8° with 2,25V / days
3h
ca
pa
cit
y a
t 2
0°C
/ %
16OPzV 2000 7OPzV 490 4OPzV 200
Seismic test
IEEE 535-1986
22,5 years at 77F
E N E R G Y F R O M B A T T E R I E S
TUBULAR GEL (OPzV) CYCLE TEST
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
0 200 400 600 800 1000 1200 1400 1600 1800
cycle: discharge with 84 A during180 min (nearly 60% C10)recharge characteristic: IUcharging voltage: 2,4Vcharging time: 21 hinitial charging current: 84A
IEC 60 896-2 OPzV 420 Ah
Discharge 3h with 84A (app. 75% DOD C4)Recharge 21h with 2,40V, initially 84A
C10
16.6.1999 Cycles 8.6.2005
E N E R G Y F R O M B A T T E R I E S
ENDURANCE COMPARISON VRLA VS VLA
Factor 2Factor 1Float current
increase in 20 years
> 1700> 1700Cycles IEC 60 896,
75% DOD C4
42,7 years at 20°C35 years at 20°C
27,5 years at 25°C22,5 years at 25°CIEEE 535-1986
550 days450 daysOn float with 2,23V
at 62,8°C
VLA tubular OPzSVRLA tubular GEL
OPzV
E N E R G Y F R O M B A T T E R I E S
COMPARISON VRLA: GEL VERSUS AGM
Lifetime
Stable capacity
Thermal run-away
Endurance of cycles
Tubular plates possibleDeep discharges possible
Low resistance
High power density
Low costs
AGM
GEL
E N E R G Y F R O M B A T T E R I E S
GEL - AGM thermal-runaway-simulation
• Tmax = 50°C after 28 h
• total current increases to 5A
• 6V 68Ah GEL
• Tmax = 80°C after 4,5 h
• total current increases to 40A
• 6V 68Ah AGMcited from: D. Berndt, E. Meißner, W. Rusch, Aging effects...., Proceedings 15.INTELEC, Paris, 1993
E N E R G Y F R O M B A T T E R I E S
CONCLUSION
• For applications with high safety level, like utilities, bank data centers, telecom central stations etc. VLA is preferred.Flat plate batteries < 60 min < tubular plate batteries
• UPS: bridging time < 60 min, life < 10 years, low cost: AGM is preferredlife > 10 years, high safety: GEL flat plate is preferred.
• TELECOM: bridging time > 60 min, life 20 yearsTUBULAR GEL is preferred.
• SOLAR: high cycle lifeTUBULAR GEL is preferred.