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Dr. Nanjan Sugumaran Battery ConsultantMr. Steven Swogger Black Diamond Structures, USADr. Paul Everill Black Diamond Structures, USA

MOLECULAR REBAR™ INCREASES LIFE OF BATTERIES IN DEEP CYCLE APPLICATIONS

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Battery

Factors that impact the Life/Ah Throughput of a Battery

Battery Life / Ah

Throughput

Battery Design

Duty Cycle

Charging Algorithm

Charger Quality

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Active MaterialShedding (Battery)

Sulphate Growth(Battery)

Hydration Short(Battery)

Positive PlateCorrosion(Charger)

Active MaterialLoosening(Charger)

Water-loss(Charger &

Battery)

Acid Stratification(Charger)

General Failure Modes: With a Good Charger & Charging Algorithm

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Active MaterialShedding (Battery)

Sulphate Growth(Battery)

Hydration Short(Battery)

Positive PlateCorrosion(Charger)

Active MaterialLoosening(Charger)

Water-loss(Charger &

Battery)

Acid Stratification(Charger)

General Failure Modes: Over-Charging

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1) Control based on battery charging voltage

2) Ah input is 130% of previous discharge

3) CC1- CC2 charger and battery do not have any role in Ah acceptance

4) Water loss and corrosion are the major issues

5) Moderate life for battery

Charger Induced Failure: Over-Charging

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Charger Induced Failure: Under-charging

1) Control based on Battery EMF

2) Ah input is <100% of previous output

3) Variable current and battery do not have any role in Ah acceptance

4) Stratification and sulphation are the major issues

5) Very low life for battery

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MOLECULAR REBAR™ (Pb2100N) in Deep Cycle Batteries

E-Rickshaw Solar

Trial Programs

+ - + -Tubular Plate Pb2100N Tubular Plate Pb2100N

0.16% wrto 0.16% wrto

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Solar Battery Trial Program

• Positive Plate: Tubular

• Negative Plate: 0.16% wrto / 56L of Pb2100N

• Compared vs. Control without Pb2100N

• 150Ah Rated Capacity

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Solar Batteries: Capacity at Various Discharge Rates

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ControlPb2100N

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Solar Batteries: TOC Voltage at C/10 Charging Rate

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Pb2100N lowers TOC Voltage by 300 mV at C/10 rate ControlPb2100N

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Solar Battery: 60% DOD Cycle Throughput

Inverter (Tubular Plate)

Recharge times decreased 35%+

20-30% decreased water loss on cycling

Av. CON = 14.84 hAv. MR = 9.66 h

Hours to Charge 100Ah @ 15V/15A from 60% DOD

ControlPb2100N

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IEC 61427 NF 58510 PPER QUALIBAT 10% SOC 40% SOC DRE

Stratification/ Hydration Short

L H L L H H M

Sulfation M M M M H M M

Corrosion/Water loss/ Active

Material Loosening

M L L

Active Material Shedding

L M H H L L M

DRE (Decentralized Rural Electrification) test selectedto exercise all key failure modes

Solar Batteries: Various Life Cycle Tests & Failures

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Solar Batteries: DRE - Life Cycle Test Procedure

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Step Mode Protocol Cycles Potential Failure

1 Preparation1) Fully charge the battery

2) Discharge at C/10 A till 10.5V

2Undercharge

cycles

1) Charge at C/10A till 14.1V

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Acid stratification

2) Rest for 3 hrsSulphate growth

3) Discharge at C/10A till 10.5V

AM shedding4) Rest for 3 hrs

3 Overcharge cycles

1) Charge at C/10A till 120% Capacity

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Corrosion

Active Material loosening2) Rest for 3 hrs

Sulphate growth

3) Discharge at C/10A till 10.5V Active Material shedding

4) Rest for 3 hrs Waterloss

Repeat sequences 2 and 3 until discharge capacity in overcharge cycle drops below 70% of C/10 capacity

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Solar Batteries: DRE Capacity Evolution

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ControlPb2100N

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Solar Batteries: DRE Cycling

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ControlPb2100N

ControlPb2100N

20.15

18.8518.46 18.57

17.50

18.00

18.50

19.00

19.50

20.00

20.50

dCNT Control

Ltrs

Fate of Excess Ah

Blue = TheoreticalRed = Actual

Pb2100N Control

1) sp.gr in Pb2100N is higher than in Control 2) In Control, increased sp.gr after 300 cycles by

20pts indicates excess Ah goes to water splitting as per Faradays law

3) In case of Pb2100N, 21% of excess Ah is getting converted in to H atom which prevents PbSO4 formation and sulphation formation

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Solar Batteries: Value Creation of Pb2100N

Battery Manufacturers

Solar Provider / Distributor

End-Consumer

Reduction in Warranty Cost and/or

Increased Warranty

Reduction in CapEx

Increased Battery Life

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e-Rickshaw Trial Program

• Positive Plate: Tubular

• Negative Plate: 0.16% wrto / 56L of Pb2100N

• Compared vs. Control without Pb2100N

• 80Ah Rated Capacity

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e-Rickshaw Battery: Recharge Factor

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14.8V/20-hour charging step (16A limit)Pb2100N increases charge factor by 5% over Control

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Step Mode Protocol Cycles Potential Failure

1 Preparation 1) Fully charge the battery

2 Discharge1) Discharge at 0.15 C for 1 hr

5Sulphate growth

2) Rest for 1 hr

3 Charge Charge at 14.8 V/0.15C for 6 hrs Acid stratification

Repeat sequences 2 and 3 until discharge capacity sustains 3 cycles in step 2.

e-Rickshaw Battery: Life cycle test procedure

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e-Rickshaw Battery: Life Cycle Simulation

• e-Rickshaw Daily Duty Cycle Simulation

• Pb2100N Charges @ 14.8V & Maintains Capacity & End-of-Discharge Voltage

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Unit #Charging Voltage No. of Cycles Remarks

Control Pb2100N Control Pb2100N

9 14.8 14.8 5 5 Control failed in 9th unit

10-140 15.2 14.8 5 5

Control nor Pb2100N provided 5 cycles after 140 units due to very cold weather; night temp < 10 C

141-157 15.2 14.8 5 5 Continued

157-220 15.2 14.8 4 4Cycle #s reduced to 4.Control failed. Water topped.

220-242 15.2 15.2 4 4Charging Voltage for Pb2100Nchanged to 15.2V

Total Water consumption till 242 cyclesControl 1545 ml

Pb2100N 930 ml

e-Rickshaw Battery: Life Cycle Simulation Result Analysis

1) So far 13,500Ah has taken out from battery which is equivalent to running E-rickshaw for 225 days

2) Pb2100N battery is much more healthier than Control; in the field it would have give more Ah output in given days

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e-Rickshaw Battery: Field Trial Results

• Scope• 3 e-Rickshaw drivers w/ 4ct 80Ah Pb2100N Tubular batteries• Water consumption, OCV, average charging times and other

parameters monitored bi-weekly• Voltage meters installed; monitored weekly

• Major Observations by Drivers & Owners using Pb2100N

• Pb2100N batteries DO NOT NEED A DAYTIME RECHARGE; Standard/Control batteries needed a 2-3 hour recharge

• Water consumptions dramatically reduced

• Drivers’ daily earnings increased ~100 Rs/day • Due to full 80km use without a 2-3hr recharge

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e-Rickshaw Field Trial Results: Voltage log data

Shaded Area Shows Charge Periods

Pb2100N

• Standard batteries go ~5.25 hrs before charging• Pb2100N batteries go ~11.0 hrs before charging

• Field chargers used (see above images)

Pb2100N batteries allowa full day of use beforeneeding to recharge

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0100200300400500600700800

0 5 10 15 20 25 30 35

IRs

% Overcharge

Energy Cost of Charging/Battery/Annum (12V/80Ah 75% DOD)

Existing

Pb2100N

Impact of Pb2100N on Energy Cost with Proper Charger

• With 5% overcharge, Pb2100N can sustain capacity maintenance while existing batteries need minimum 15% overcharge; 10% overcharge energy cost can be saved.

• Rs. 200 - 600 can be saved per annum per battery in charging energy cost alone (Unit cost electricity Rs. 6.50/- Total days per annum = 300)

• For 200,000 E-rickshaw in Delhi alone, with Pb2100N the total savings in terms of power consumption is 48,000,000 units /Annum. This is major savings for the country.

• The above units is equivalent to total energy consumption of 47,524 persons in India in a year (1,010 units/person/annum)

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e-Rickshaw Batteries: Value Creation of Pb2100N

Battery Manufacturers

Distributor

e-Rickshaw Owner/Agent

Reduction in Warranty Cost and

Increased Price Capture

Cost Savings ₨400 per yearand

Increased Battery Life

e-Rickshaw Driver ₨50+ per day Revenue

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ProblemDeep Cycle Batteries have two main failure modes: Sulphation and Active Material Shedding

Solution Altering Battery chemistry by adding MOLECULAR REBAR™ delays both the Sulphation and Active Material Shedding phenomena

MOLECULAR REBAR™ (Pb2100N) for Flooded Deep Cycle Batteries:1. Increases life in Solar Applications by 35% to 50%2. Increases throughput in e-Rickshaw Applications bu 35% to 50%3. Reduces warranty costs by >30% for a given time period4. Reduces overall wasted Energy

Conclusions

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Thanks to Our Friends and Partners:

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Thank You for Your Attention

Please see Black Diamond Structures at their Booth

for additional questions, suggestions, or product inquiries.

nanjans@hotmail.comswswogger@bd-structures.compeverill@bd-structures.com