Abstracts
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A Two-Dimensional Transient Thermal and Potential Model For VRLA Battery Grids
Parisa Amiri
VFERI InstitutePredicting transient behavior of lead-acid batteries during charge and discharge processes is an important factor in many applications including hybrid electric vehicles (HEVs). Some of the major problems of lead acid batteries, high potential drop and high temperature, are referred to grids which hold the active material in the battery. The conventional mathematical models, which are used to predict the battery dynamics, are either inaccurate or time-consuming. In this study, two dimensional modeling was carried out to predict both temperature and voltage disribution of lead acid battery grids due to charging cycles. The model not only accounts for the amount of temperature and potential loss but also considers the effect of temperature and potential loss on each other.
In order to validate the results, the present approach is verified by previous CFD models and experimental data. The model could be used to help design grids for decreasing the amount of potential loss and the risk of thermal runaway which are harmful for charge efficiency of battery.
Biography: She is a masters degree student in Kashan University, Iran. Her research area is about lead-acid batteries. She also works on her master project in Vehicle, Fuel and Environment Research Institute (VFERI) in the school of mechanical engineering of the University of Tehran.
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Wet performance of AGM and its application in VRLA batteries
Yaozong Bai
Sinoma Science & Technology Co., LTD. Shuangwei DivisionThis paper research the wet performance of the AGM separator and its application to the VRLA battery. For the different kinds of VRLA battery or for the different battery with the different application, AGM play the different roles, whereas there are definitely some similarities. From this report we will disclose the relationship between recipes of the AGM raw materials, the compression sustain capability, the acid absorption under the pressure, the wet resilience and the frequency of the resilience to that of behaviors of the battery. So the suitable fine fiber and coarse fiber ratio and some recommending wet performance of the separators are introduced.
In this paper we also make some research to the AGM separator which adds some synthetic fiber and also comparing this special separator to the whole fiberglass separator.
Biography: Yaozong Bai, graduated from Nanjing University of Technology, Specialized in inorganic materials researching and developing. In 2004 he was awarded the bachelor degree. Since 2004 he began to work in Sinoma Sciecen & Technology Co., LTD. Now he is the director of the AGM workshop of the company. He has many years experience in AGM researching and production management.
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Suitability of gel lead– acid batteries for diverse applications
David Brown
Battery Energy Power Solutions Pty LtdBattery Energy, with significant assistance from the Commonwealth Scientific and Industrial research Organisation (CSIRO), has been engaged in the advancement of gelled lead–acid batteries for almost 17 years. This programme has resulted in the development of a unique gel battery technology. Over time, the technology has been shown to be suitable for a wide range of different applications, e.g., solar-based remote-area power supplies ('solar-RAPS'), general float/standby service, uniterruptible power supples (UPSs), railway start and traction/semi-traction applications. The suitability of gel against the use of AGM or flooded versions of the lead– acid battery will be discussed for these different applications, with particular emphasis newer requirements such as fast charge and partial state-of-charge duty.
Biography: Dr David Brown has over 35 years experience in battery technology and related areas with respect to both alkaline and lead– acid systems. This has included leading a large team in the UK engaged in the research and development of electric vehicle batteries, and several years as Technical Manager for Besco Batteries in Australia. In 1987, Dr Brown and a colleague founded Battery Energy. He presently acts as a consultant for Battery Energy.
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Low-gassing soft lead for lead–acid battery active material
Ulf Buggelsheim
Ecobat TechnologiesRecent investigations, as well as research funded by the Advanced Lead–Acid Battery Consortium (ALABC), have outlined the influence of impurities in the base lead on the gassing behaviour of battery active material.
In past years, the silver and bismuth contents of the lead were considered to be harmful because they were indicative of poorly refined lead. Such lead contributed to gassing in lead–acid batteries and the resulting water loss limited service life.
Soft lead with low levels of elements that promote gassing ('impurities') can now be produced in pyro-metallurgical refineries. The minimal requirements for these refineries are:
• proper equipment and reagents
• sufficient laboratory analytical equipment and support
• highly-skilled and experienced workforce
In past years, only primary lead smelters could support these requirements due to economies-of-scale and uniform refining methods. Modern secondary smelters can now guarantee the same low levels of gas-causing impurities in soft lead that are necessary for today’s demanding gassing standards for the active material used in sealed batteries.
The paper evaluates the performance of low-gassing soft lead employed in the manufacture of alloys and active material for modern lead–acid batteries, and evaluates the true gassing potential of impurities.Biography: Ulf Buggelsheim was born in Villach, Austria. He holds a Diplom-Ingenieur in Materials Science from the University of Leoben. From 1978, he undertook various activities in the Leadsmelter Arnoldstein Austria. Since 1998 , Ulf has been the Managing Director of BMG Metall & Recycling GmbH (a secondary lead smelter in EcoBat group). n 2008, Ulf became the MD Technical Coordinator of EcoBat Europe.
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Studies on the failure mechanism of VRLA batteries under high-rate partial state-of-charge (HRPSoC) operation
Dr. Edward Buiel
Axion Power International, Inc.Recent regulatory changes in Europe and the US A towards lower gCO2/mile and higher mileage vehicles will result in a significant proportion of start-stop and mild-hybrid vehicles in both markets as early as 2012. VRLA batteries are currently the first choice for OEM automakers for micro-hybrids. As regulations become more stringent, hybridization of vehicles will include regenerative braking. This will result in higher demands on the battery that wikll include charging events at higher rates for prolonged periods. During such events, VRLA batteries suffer from a buildup of sulfation in the negative electrode, poor round-trip energy efficiency, and premature failure. The addition of carbon to the negative paste material has been shown to improve the high-rate partial state-of-charge (HRPSoC) performance. This work is focused on understanding the behaviour of VRLA batteries under HRPSoC cycling, identifying the role of carbon in improving battery cycle performance, and developing negative electrodes based on Axion’s PbC Technology™ that eliminate the sulfation problem.
Biography: Edward Buiel, Ph.D. is the CTO and VP of Axion Power International Inc., and has 12 years of experience in the development of lithium-ion batteries, supercapacitors, asymmetric lead-carbon supercapacitors and carbon-based materials for various electrochemical applications. Dr. Buiel received his BS in Engineering and Physics from Queen’s University in Kingston, Ontario, Canada, and received a PhD in Physics from Dalhousie University, Halifax, Nova Scotia, Canada where his research was focused on “The Development of Disordered Carbon Materials as Anode Materials for Li-ion Battery Applications.”
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Effect of alcohols on the electrochemical behaviour of gel lead–acid batteries
Meiqiong Chen
City College of Dongguan University of TechnologyIt is well known that gel valve-regulated lead–acid (GEL-VRLA) batteries offer many advantages such as high reliability, no electrolyte stratification, and long service life. On the other hand, the forming of a gel results in high internal resistance and low battery capacity compared with traditional flooded-electrolyte batteries. Consequently, researchers have examine various additives as a means to improve battery capacity and cycle life, and to decrease the internal resistance of gel electrolyte.
There have been reports of the addition of propanetriol to colloidal silica gel to serve as a stabilizing agent. Less attention, however, has been directed to the addition of alcohols and their mechanism in fumed silica gel. This study examines the effect of polyethylene glycol and several short-chain alcohols (including: ethanol, glycol, propanetriol, pentaerythritol) on fumed silica gel.
The electrochemical behaviour of gel electrolyte is investigated by means of cyclic voltammetry (CV) , electrochemical impedance spectroscopy (EIS), and linear sweep voltammetry（LSV). The experimental results indicate that the addition of polyethylene glycol destroys the thixotropy of the gel and thereby leads to a decrease in gel capacity. By contrast, short-chain alcohols give rise to improvements. The optimum concentration of alcohol is related to the amount and structure of the hydroxyl species in the alcohol molecule . The mechanism of alcohols in fumed silica gel is discussed.Biography: Meiqiong Chen graduated from the South China Normal University in 2008 with a Master's degree in Physical Chemistry. She is now working in the City College of Dongguan at the University of Technology in Dongguan, China. She has published research papers on lead–acid batteries, and received awards for excellent papers at the Chinese National Storage Battery Conference in 2006 and the Chinese Power Sources Conference in 2007.
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Lowering the emissions and costs of urban deliveries with advanced VRLA technology
Allan Cooper
European Advanced Lead Acid Battery ConsortiumThere appears to be an increasing desire in the UK and Europe towards encouraging low emission vehicles for use in city centres by the introduction of fiscal initiatives.
The project reported here seeks to adapt a standard light commercial vehicle to include a zero-emission capability over a limited range. A two-stage approach has been adopted: a Vauxhall Combo van is first used to demonstrate the zero-emission functionality with full hybridisation to follow later.
The van has been modified to have independent electric wheel motors at the rear. These are employed with an advanced VRLA battery pack to provide the 20 km zero-emissions range required for the vehicle by the Project Call. Re-charging of the battery pack is achieved either by operating the vehicle as a 'through-the-road' hybrid, or by employing a plug-in recharging facility powered via a standard electrical outlet.
One essential differentiator for this project is that the technology is modular in design and thus can be fitted to existing production vehicles with minimum impact. This significantly reduces one of the main barriers to the introduction of zero-emission vehicles.
The project commenced in August 2007 and has been progressing well. Vehicle integration is well advanced and initial testing is taking place on a dynomometer at Cranfield University. Once finished, the van will be transferred to the Millbrook Proving Ground for track testing under specified cycles as laid down by the Call. Results to date, with their implications for the use of advanced valve-regulated lead–acid batteries in load-carrying light commercial vehicles, will be reported.
Biography: Allan Cooper graduated from the University of Cambridge in 1961 with a degree in metallurgy. After a brief period in the steel industry, he joined Associated Lead Manufacturers in 1964 that later became Cookson Industrial Materials. Allan became the Research and Development Director before moving into the parent Cookson Group as Technical Development Manager. He retired in 1991 and became an independent consultant. In this capacity, Allan has worked closely both with the Lead Development Association and with the Adanced Lead– Acid Battery Consortium (ALABC). In this context, he has co-ordinated several major European and UK Projects on the application of VRLA batteries for electric vehicle and hybrid electric vehicle applications. Allan has recently been involved with the European Hybrid Electrical Vehicle Demonstration Program.
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Development of a float cycling telecommunication battery for emerging markets in regions with very unstable electricity grids
Ben Craft
NorthStar BatteryThe emerging telecommunication markets in Southeast Asia require a battery to have excellent high-temperature float performance, while at the same time be capable of frequent cycling in an undercharge to partial state-of-charge (PSoC) condition. The unstable electricity grids in these areas are frequently off-line for up to 50% of the time, with several daily outages that range from 15 min to 4 h. In addition, there is often limited recharge capability due to the rectifiers providing power for the transmission equipment. When operated under such conditions, standard AGM batteries are subject to undercharging and thereby can fail within a few months. Using a boost voltage of at least 2.35 V per cell (VPC) to charge the battery improves the cycling capability of standard AGM batteries, but can severely limit life during float duty. NorthStar Battery has developed an AGM battery that is capable of float cycling with deep discharges, or float cycling operated in a PSoC condition, while using only 2.27 VPC as the charging voltage limit. The positive grid alloy has been modified to maintain deep-cycling performance, and the negative active material has an optimized concentration of selective additives. The modifications to the negative electrode maximize charge acceptance and PSoC capability. An evaluation is given of a laboratory cycle that simulates the power quality in Southeast Asia and actual performance in Bangladesh.
Biography: Ben Craft has been the Electrochemical Manager at Northstar Battery for a little over two years. His responsibilities are designing lead acid batteries for specific markets along with looking at new technologies that are applicable to the telecommunication markets. Before Northstar Battery his primary focus was developing materials for the lead acid and super capacitor markets. Mr. Craft’s academic background is a Masters Degree in Material Science Engineering from the University of California Irvine and a Bachelors degree in Chemistry specializing in electrochemistry.
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Positive tubular electrodes for lead–acid batteries with a specific capacity of 180 Ah kg-1
Juliano de Andrade
Institute of Technology for Development - LACTECThe poor specific power and poor specific energy of lead–acid batteries place the technology at a major disadvantage compared with competing battery chemistries. Some attempts to lower battery weight had been made, for example, by decreasing the number of grids through the use of bipolar plates, or by replacing conventional heavy grids with either thin lead foils or a lighter material.
This paper reports work that aims to increase the proportion of the positive active-material that effectively participates in the discharge process, without degrading performance or cycle-life.
Positive tubular plates, assembled with nanostructured PbO2, are submitted to different 'curing' procedures to promote aggregation of the particles. The plates are then submitted to charge and deep-discharge cycles to evaluate their specific capacity and cycle-life. Specific capacities higher than 180 Ah kg-1 are achieved The nanostructured positive material is characterized at different stages of the total process.
Biography: Julianode Andrade graduated in Chemical Engineering in 2003, and received a M S in Material Science in 2005, at the Paraná Federal University in Curitiba, Brazil. He now studying for a doctorate at the Batteries Laboratory of the Institute of Technology for Development - LACTEC. To date, his research has focused on the advancement of lead–acid battery technology.
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Recycling Lead Acid Batteries
Oscar De Marco
Engitec Technologies S.p.A.The presentation by Engitec Technologies examines the worldwide lead production and the importance of the scrap recycling as well as the technologies applied in the past and in the most advanced solutions for the used lead-acid batteries processing.
Engitec Technologies is a worldwide known company providing the complete engineering service and Original Equipment Manufacturing of the system for the recycling of lead-acid batteries.
The reasons that make the “Engitec CX® Technology” the most recognized and appreciated among lead metallurgists and battery recyclers are in this mix:
- the fulfilment of the exigencies of the End-User;
- the full respect of environmental parameters;
- the attention to operators health and safety;
- the minimization of production cost;
- the guarantee on productivity and on products quality;
- the guarantee on the durability of the equipment.
The complete line for the recycling of lead-acid batteries includes the automatic crushing and separation of the components, the desulphurization of paste, the whole smelter with production of lead and alloy ingots.
The Engitec CX® System is implemented among more than 50 Clients, ranging from low capacities of 6-8.000 ton/year, up to the largest installations of 250-300.000 ton/year of processed batteries.
Biography: Oscar De Marco started his professional occupation in 1974 as maintenance coordinator within the Tonolli Company, one of the largest European Groups involved in the non ferrous metal recycling.
In the 1980 entered in the new branch of the Group that acquired the name of Engitec, with duties in the commercial activity.
After a period from 1990 to 2001 of different experience, he joined back Engitec as Sales Manager, also acting as the Chief representative of the China Engitec office in Shanghai.
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Building a 'Hybrid Electric Vehicle Technical Roadmap' for The Advanced Lead–Acid Battery Consortium (ALABC)
Timothy W Ellis
RSR TechnologiesOver the past 15 years, an industry-funded group known as the The Advanced Lead – Acid Battery Consortium( ALABC) has been promoting and supporting research and development work in advanced lead – acid (PbA) cells. This effort in part was due to the restriction in various government sponsored battery development programs for hybrid electric vehicles (HEVs), such as USCAR/USABC, to funding work in advanced PbA technology. In the ALABC programme , several Honda 'Insights' were converted from nickel – metal-hydride (Ni– MH) to PbA batteries to demonstrate the applicability of the latter to this demanding application. The technical success of this program has brought to light the difficulty of PbA becoming a chosen technology due to the lack of information on multiple adoption issues, e.g., matching performance migration in use, performance modelling, and manufacturing development. The insecurities expressed by possible adoptors of PbA battery technology were not only present performance, but, assurance that the PbA technology can keep pace with the aggressive needs of the automotive sector. With this backdrop, the ALABC has chosen to undertake the development of a technical roadmap to draw together the requirements of PbA in HEV applications, at present and in the future, versus the state of the technology. The hope is to demonstrate the ability to meet the HEV challenge today and tomorow by assuaging the concerns of the automotive industry in adopting the technology.
Biography: Dr. Ellis (Tim) is currently the Vice President for Research and Development for RSR Technologies in Dallas TX. RSR Technologies is the Research and Development arm for Eco-Bat Technologies one of the world premier secondary Lead (Pb) producers. Prior to joining RSR Technologies, Dr. Ellis was the R&D Director of Kulicke and Soffa Industries, a producer of semiconductor packaging solutions. Dr Ellis started his career at the USDOE’s Ames Laboratory at Iowa State University. He has a PhD in Metallurgy from Iowa State University and a Master's degree in Technology Management from the University of Pennsylvania, both of which were acquired after a Bachelor'sdegree in Metallurgical Engineering and a Master of Science degree in Chemistry from Michigan Technological University. Dr. Ellis has more than 40 technical publications and 18 patents
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Testing times for lead
Neil Hawkes
CRU InternationalAfter rocketing to record highs in late 2007, LME lead prices plunged in 2008. Investor activity has undoubtedly been a major factor in the scale of the swing in prices, but their ultimate direction has been underpinned by lead’s own industry fundamentals.
CRU will highlight the key dynamics at play in the physical lead market that have pulled prices down. Uppermost has been the sharp contraction in lead demand in many key lead-consuming nations. Unlike other metals, lead supplies have been slow to respond. The recycling of lead scrap is continuing on an upward path, and now accounts for over half of the world production of refined lead. On the primary side, whereas lead mine output has fallen away on a mounting zinc/lead mine casualty list, cuts at primary smelters outside China have been slow to emerge. Major changes are underway within China, with demand still growing but being increasingly met by more secondary lead. An environmental purge and export tax changes are also causing primary lead production to slow. Consequently, there is a reduction in the excess that was previously shipped overseas.
So where do we go from here? Will there be another downside in the short-term? Are prices in the long-term set to trade in a higher range than before?
This presentation will outline some of the likely developments in lead demand and supply, and thereby will provide some insight into the future direction of lead prices.
Biography: Neil Hawkes has worked in CRU’s base metals team for over 20 years, where he has overall responsibility for lead market analysis. Arming its clients with knowledge and insight, CRU provides fundamental analysis, market forecasts, cost surveys and topical studies for the mining and metals sectors. Since its establishment in 1969, CRU has become a leading supplier of commercial and economic analysis to the world’s natural resource industries.
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Fundamental studies of new lignin derivatives for lead –acid batteries
Nobumitsu Hirai
Department of Materials and Manufacturing Science, Osaka UniversityThe organic component of the expander, e.g., lignosulfonate, is an indispensable additive to the negative electrodes of lead–acid batteries. To extend the present performance of these batteries, a superior expander is a key requirement.
This presentation reports an investigation of the behaviour of a series of lignin derivatives that contain amino, sulfomethyl, etc. groups with respect to the electrochemical reaction taking place at a lead electrode in sulfuric acid solution. The performance of the lignin derivatives is evaluated by means of electrochemical methods such as electrochemical atomic force microscopy (EC-AFM) and cyclic voltammetry (CV), which are supported by scanning electron microscopy (SEM) and X-ray diffraction (XRD) phase analysis.Biography: Dr. Nobumitsu Hirai is an Associate Professor in the Department of Materials Science and Processing at Osaka University in Japan. He holds a B. Eng. and a M. Eng. from Kyoto University, and a Dr. Eng from Osaka University. Dr Hirai received the Young Researcher Award from the Japan Institute of Metals in 2001, and the Young Researcher Award from the Molten Salts Committee of the Electrochemical Society of Japan in 2005. He is a member of the Electrochemical Society of Japan, the Japan Institute of Metals, the Iron and Steel Institute of Japan, and the Japan Society of Applied Physics.
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Price Risk Hedging for Lead Acid Battery Producers - One Step Beyond the Basics.
Rick Holmes
Mitsui Bussan Commodities (Aust)This presentation will describe the London Metal Exchange, the way it works and metal price determination.
It will try to identify where the Battery Maker has most price risk, and how to use hedging to cover these risks.
Finally it will mention a few essentials in setting up hedging departments.
Biography: Rick Holmes has worked for Mitsui for 13 years. He runs the Sydney office of Mitsui Bussan Commodities Limited, an Associate Broker Clearing Member of the LME.
He worked for Rio Tinto in their Copper mines and later for their Aluminium division in Trading Physical and Futures non ferrous metals.
From Rio he moved to Alcoa where he was the Trading Manager in Asia before moving to Knoxville and again trading Futures and Physical Aluminium. He then joined Mitsui & Co. He is trained as an Economist and an Industrial Engineer.
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The relationship between the coup de fouet and capacity in VRLA batteries
Shou-nan Hua
Shandong Sacredsun Power Sources Co., LtdAn investigation has been undertaken of the voltage minimum at the beginning of the discharge curve of a fully-discharged lead–acid battery, namely, the coup de fouet (CDF). The occurrence of this phenomenon could disturb the use of some electric equipment. The true cause of the CDF has yet to be totally understood; several different explanations have been advanced in the literature. It would appear that the mechanism of the CDF is most likely related to crystallization of the discharge product, lead sulfate, and to interphase phenomena of the active materials.
Specifically, the voltage falls rapidly at the initial stage of discharging , reaches a minimum, and then rises gradually to a plateau. This process can last from a few seconds to a few minutes. In this study, the parameters (Vd, Vp) of the CDF effect are measured under different discharge conditions. The resulting data reveal a linear relationship between Vd (Vp) and battery capacity. The CDF effect could be used for estimating battery capacity, as well as for and evaluating battery state-of-charge and state-of-health.
Biography: Professor Shou-nan Hua graduated from the Shandong University in 1961 and continued there as a postgraduate until 1964. Since then, he has been engaged in teaching and research activities at the university in the fields of electrochemistry and chemical power sources. Pofessor Hua worked at the CSIRO Division of Minerals, Australia, from 1980 to 1982 as a visiting researcher scientist, and at the Juelich Research Center (KFA, Germany) in 1996 as a visiting scholar.
Now he an emeritus professor is the consultant of Shandong Sacredsun Power Sources Company, working on lead-acid batteries.
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Sovema's Philosophy About Technological Updating
Massimiliano Ianniello
Sovema S.p.A.Sovema’s philosophy about the development and updating of the lead grid production systems, used as support for the active material for both positive and negative plates, is explained below.
At present two main grid production typologies are widespread:
1) the Expanded Metal technology: Sovema proposes its patented “Performer” machine – which is the mechanical evolution of the reciprocating system; the Performer allows End Users to produce both negative and positive expanded metal plates on the same machine.
2) For those End Users wanting to produce grids with a higher resistance to corrosion and increased expansion during the charging cycles, Sovema proposes a system with roller and puncher, for the production of positive Punched Grids. As regarding the production of negative Punched Grids, less susceptible to corrosion, there is no need for any following thickness reduction, so they’re produced with the roller only.
In conclusion, Sovema offers two main systems for the grid production:
1) ROLLED STRIP + PERFORMER
for Positive and Negative grids (Ca Alloy), “standard” type
2) ROLLED GRID + ROLLED STRIP + PUNCHER
for Negative + Positive (Ca Alloy) Grids, owing high resistance to corrosion and expansion
ROLLED STRIP + PERFORMER EXPANDED
ROLLED GRID + ROLLED STRIP FULL FRAME.
Biography: Massimiliano Ianniello has been an employee of Sovema S.p.A. since early 1998. Firstly involved as a technical assistances supervisor, in 2001 Massimiliano became Sale Manager. 2003 saw him move to his current position of General Manger for Sovema Spa, Managing Director for Sovema USA, and President of Bitrode Corp., USA.
Massimiliano achieved a degree in Electronic Engineering (Padova, Italy) in 1993 and an MBA at Bocconi University, Milan in 2008.
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Fast charging of e-bike batteries with a pulse charger
Dr. Shashikant Joshi
Lalit Consulting ServicesFast charging of battery-operated vehicles is desirable to improve the utility of the vehicle without damaging the battery. Unfortunately, present-day chargers for e-bikes do not perform satisfactorily. Typically, the batteries fail prematurely due to under / overcharging. Some of the chargers fail to function under very severe field conditions such as high ambient temperature, high humidity, dust, and low-quality a.c. input voltages.
This presentation describes a new design of charger that overcomes all of the above difficulties. Pulse charging, together with temperature compensation, is the main feature of the device.
VRLA batteries have been subjected to both bench and on-board vehicle tests to evaluate the performance of the new charger in comparison with that of existing designs. The pulse charger is found to be superior in terms of maintaining the highest battery state-of-charge which, in turn, leads to greater discharge times and an expected longer battery service life. The charger is now available commercially for e-bikes that are equipped with 36 or 48 V system and batteries of up to 20 Ah capacity.Biography: Dr. Shashikant Joshi holds a M Sc in analytical chemistry and a Ph D in electrochemistry from the University. of Bombay. He undertook post-doctoral research at the Electrochemical Research institute in Meinsberg (Germany) during1982 – 1983, and at the Institute of Inorganic & Physical Chemistry, Berne, Switzerland, during 1983 – 1984. He has gained a wide experience in industrial research and development, quality improvements, the recycling of lead, and environmental issues with rechargeable batteries.
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Integration of a Low Cost Lead-Carbon Battery in a Mild Hybrid Honda Civic
Donald Karner
Electric Transport ApplicationsWith the increasing population of hybrid-electric vehicles (HEVs), the need for low cost replacement battery packs for power-assist HEVs and low-cost OEM battery packs for mild and start-stop HEVs has become acute. Work conducted by the Advanced Lead Acid Battery Consortium (ALABC) has shown promising results for lead-acid batteries to meet this need, provided that carbon is added to the negative active material to improve partial-state-of-charge operation.
This paper presents the progress on development work conducted by Electric Transportation Applications in conjunction with the ALABC and the United States Department of Energy. In this program, four different advanced lead-carbon battery types will be evaluated in the laboratory under a duty cycle that simulates operation in a Honda Civic HEV. One of these variations will then be installed in a Honda Civic and operated on road for 100,000 miles. Real time data will be collected during vehicle operation and then analyzed to provide information on the battery and vehicle performance. The development of the simulated laboratory profile, along with battery cycling data obtained to date are reported.Biography: Mr. Karner serves as President of Electric Transportation Applications, specializing in advanced fuel vehicle and infrastructure development for both on and off road battery electric, hybrid electric, plug-in hybrid electric and hydrogen-fueled vehicles. In addition to his management responsibilities, Mr. Karner also serves as Technical Manager for the US Department of Energy Advanced Vehicle Testing Activity. In this capacity, he has directed more than 5 million miles of vehicle testing and evaluated more than fifty advanced fuel vehicles.
Mr. Karner holds a Bachelor of Science degree in Electrical Engineering from Arizona State University and a Master of Science degree in Nuclear Engineering from the University of Arizona. He is also a graduate of the Public Utility Executive Program of the University of Michigan School of Business. -
A lead monoxide precursor of high surface-area for lead–acid battery paste.
R. Vasant Kumar
University of CambridgeBy reacting spent lead battery paste with organic reagents and then combusting the organic crystallites, lead monoxide (PbO) of high surface-area is directly available for making pastes for new lead– acid batteries. This innovation could eliminate all the steps and the equipment involved in the present complex practice of converting soft lead to a PbO paste. The properties of the PbO precursor are discussed in this paper.
It is also possible to produce lead and lead dioxide (PbO2) of high surface-area from the organic crystallites. This would eliminate the energy-intensive plate formation step, which requires six times more energy than that available from the battery itself.Biography: Dr Kumar has over 12 years of research experience in materials chemistry at the University of Cambridge — particularly in electrochemistry, and in metal production, refining and recycling. He has published over 125 papers, holds 8 patents, and has supervised more than 25 PhD students. Dr Kumar is the Editor of the Institute of Materials (UK) / AusIMM Journal of Mineral Processing & Extractive Metallurgy. Many of his research findings have led to industrialization. Dr Kumar was awarded an Honorary Professorship at the Hebei Polytechnic Institute, Tansheng, China, in September 2006. He is the Director of Environmental Monitoring and Control Ltd and Catalysts Group Ltd, which are two start-up companies producing sensing instruments as well as safety, pollution and process control devices. He is the Director of the University of Cambridge's MPhil course on Micro- and Nanotechnology Enterprise.
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Influence of Residual Elements in Lead on Oxygen and Hydrogen-Gassing Rates of Lead Acid Batteries
Dr L Lam
CSIRO Energy TechnologyRaw lead materials contain many residual elements. With respect to setting ‘safe’ levels for these elements, each country has its own standard, but the majority of the present specifications for the lead used to prepare battery oxide apply to flooded batteries which employ antimonial grids. In these batteries, the antimony in the positive and negative grids dominates gassing characteristics so that the influence of residual elements is of little importance. This is, however, not the case for valve-regulated leadacid (VRLA) batteries which use antimony-free grids and less sulfuric acid solution. Thus, it is necessary to specify ‘acceptable’ levels of residual elements for the production of VRLA batteries.
In this study, seventeen elements are examined, namely: antimony, arsenic, bismuth, cadmium, chromium, cobalt, copper, germanium, iron, manganese, nickel, selenium, silver, tellurium, thallium, tin, zinc. The following strategy has been formulated to determine the acceptable levels: (i) selection of a control oxide; (ii) determination of critical float, hydrogen and oxygen currents; (iii) establishment of a screening plan for the elements; (iv) development of a statistical method for analysis of the experimental results.
The critical values of the float, hydrogen and oxygen currents are calculated from a field survey of battery failure data. The values serve as a base-line for comparison with the corresponding measured currents from cells using positive and negative plates produced either from the control oxide or from oxide doped with different levels of the seventeen elements in combination. The latter levels are determined by means of a screening plan which is based on the Plackett-Burman experimental design. Following this systematic and thorough exercise, two specifications are proposed for the purity of the lead to be used in oxide production for VRLA technology.Biography: Dr Lam obtained his Bachelor of Engineering and Master of Engineering degrees at Yokohama National University, and his Doctor of Engineering degree at Tokyo Institute of Technology, Japan. He joined CSIRO in 1988 and is now a Project Manager in the Energy storage Group of the CSIRO Energy Technology. Since 1988, he has been the research leader of many projects that have been well sponsored by either domestic or international companies/research organizations with the aims to advance the leadacid batteries for automotive, industrial, electric vehicle and hybrid electric vehicle applications. Recently, he has developed a hybrid lead-acid and supercapacitor storage device, known as ‘UltraBattery’. This type of battery has demonstrated successfully in the Honda Insight HEV and is currently evaluated under wind-energy applications.
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Comparison of a Pb–Ca–Sn–Al–Ag alloy with mixed rare-earths and a traditional Pb–Ca–Sn–Al-Ag alloy as positive grids for lead–acid batteries
RuiZhen Li
School of Chemistry and Environment, South China Normal UniversityThe anodic behaviour of Pb–0.07 wt.% Ca–1.2 wt.% Sn–0.05 wt.% Al–0.1wt.% Ag –(0, 0.01, 0.15, 0.5) wt.% mixed rare-earth alloys in sulfuric acid solution is examined by means of linear sweep voltammetry, electrochemical impedance spectroscopy (EIS), a.c. voltammetry , open-circuit potential–time, and cyclic voltammetry.
The experimental data show that the presence of a mixed rare-earth in Pb–Ca–Sn– Al–Ag system can inhibit the growth of the corrosion layer (PbO2) formed on the alloy. Moreover, the mixed rare-earth increases both the hydrogen and the oxygen overpotential at the respective electrode. The results further reveal that the addition of a rare-earth can inhibit the growth of Pb(II) oxides and a PbO2 film , and improve the corrosion resistance. It is found that rare earth elements can suppress premature capacity loss.Biography: Rui Zhen Li holds a Master of Science degree in physical chemistry from the School of Chemistry and Environment at the South China Normal University. His dissertation received First Prize at the 11th Academic Conference of Lead–acid Batteries held in Hangzhou in February 2009.
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Room-temperature ionic liquids as electrolyte additives for gel lead–acid batteries
He Li
School of Chemistry and Environment, South China Normal University, Guangzhou 510006In this study, room-temperature ionic liquids (RTIL, such as hydrophobic ionic liquids and hydrophilic ionic liquids) hare used as electrolyte additives to a gel electrolyte for use in lead–acid batteries. The consequent performance is evaluated by means of cyclic and linear sweep voltammetry . The morphology of the grid surface after cycling is examined scanning electron microscopy. The mechanism of the effect of RTILs on the performance of gel batteries is elucidated.
Biography: Dr. He Li was awarded a bachelor's degree in Chemistry Education at Hunan Normal University (ChangSha, Hunan, China) in 1998, anda doctorate in analytical chemistry at Sun Yat-Sen (ZhongShan) University (Guangzhou, Guangdong, China) in 2003. Presently, he is conducting research on lead–acid batteries as a Postdoctoral Fellow at Zhejiang University and an Associate Professor at the South China Normal University.
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The Lead Price Dynamic
Helen Matthews
Brook HuntThe cost of lead is one of the largest raw materials costs faced by battery manufacturers. Pre 2005, the lead price followed a reasonably steady path, giving consumers little to worry about. Since 2006, however, the lead price has reached new and largely unexpected heights, driven by strong fundamentals and substantial investor interest. This gave rise to major concerns amongst consumers, notably how to balance inventory supplies and cashflow, whilst still being able to fulfil orders promptly. Higher prices have already taken their toll, prompting a rash of battery plant closures and consolidations, particularly in Asia, and especially in China.
Going forward, the higher cost environment which grew from the upturn has not receded and will remain a challenge into the next decade and beyond. Fundamental supply issues and an ongoing growing demand for lead (notwithstanding the current economic downturn) mean that the lead price is unlikely to return to pre 2005 levels. Consumers therefore need to have a greater awareness of the mechanisms which influence the lead price, as well as a better understanding of what instruments they can use to help them weather lead price fluctuations.
This paper aims to highlight the major indicators which can be monitored to determine the future direction of the lead price. This included industry statistics, leading economic indicators and technical trading patterns. How to interpret trading volumes and open interest will also be covered.
Biography: Helen Matthews is a senior metals market analyst specialising in lead for UK-based mining and metal industry consultants Brook Hunt. Before joining Brook Hunt in 2003, Helen was an editor for the Mining Journal in London, having worked previously for the company as a gold mining industry analyst. Prior to this she worked as an industry consultant specialising in mine project cash flow analysis.
Helen holds a degree in Geology from the University of Gloucestershire and a Masters degree in Mineral Project Appraisal from The Royal School of Mines, Imperial College, London.
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A comparison of two commercial organic expanders: Vanisperse A and Vanisperse HT-1
Tim McNally
Borregaard LignoTechOrganic expanders influence critical lead–acid battery performance criteria such as capacity, cold cranking, charge acceptance, water loss, and life. Therefore, when selecting an organic expander, it is essential to understand their relative performance for various battery designs under different service conditions.
In response to industry interest, this presentation will provide information on the manufacture of Vanisperse A and Vanisperse HT-1, their structural differences, and their relative performance in flooded and VRLA battery designs under automotive and industrial duty.
Biography: Tim McNally is a Senior Research Associate with Borregaard LignoTech. He is the company's world-wide Technical Application Manager for organic expanders in lead–acid batteries. Tim has been with Borregaard LignoTech for 13 years and has 23 years experience in the field. He has presented papers at meetings of the ELBC in Warsaw, Athens, Berlin, Rome and Dublin, and holds a patent for organic expander compositions.
He is a contributing author to Encyclopaedia of Polymer Science and Technology, 3rd Ed.
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New modular VRLA battery with an advanced management system for industrial applications
K-D Merz
Hitebat Ltd.The demand for power- and energy systems for motive power and standby applications is changing due to the requirements for greater energy in shorter time, better control - and management, and more economic operation.
This presentation describes the development of a new modular design of a battery that incorporates AGM and GEL technology, as well as lithium-Ion systems. Several new components have been developed for this product. I In particular, these include a new advanced safety valve and an electronic monitoring system with the option of wireless data transmission. All components can be combined to an energy system to meet the demands in field operation. Some examples of applications where this battery is in use, and can be used, are also discussed.Biography: Klaus-Dieter Merz is a chemical engineer who started a career in battery technology in 1980. For seven years, he was engaged in the research and development of VRLA and GEL lead-acid batteries. This was followed by 6 years in the product management of Motive Power batteries. In 1998, Klaus-Dieter became the Marketing Director for Motive Power products in Europe. Since 2008, he has been working independently on new battery designs and components.
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Selection of appropriate batteries for power-assist and plug-in hybrid electric vehicles
Patrick Moseley
Advanced Lead–Acid Battery ConsortiumThe batteries in power-assist hybrid electric vehicles (HEVs) are required to operate from a partial state-of-charge baseline, and to provide, and accept, charge for short periods at very high rates. Under this regime, conventional lead–acid batteries accumulate lead sulfate on the negative plate and fail quickly. The failure mode can be effectively countered by the inclusion of certain forms of carbon in the negative plate at greater concentrations than have been used in the past. This preventive measure is so effective that VRLA batteries benefitting from the inclusion of such carbon have been able to substitute for nickel–metal-hydride batteries in power-assist HEVs with no significant loss of performance.'
Biography: Pat Moseley was awarded a PhD for crystal structure analysis in 1968 by the University of Durham, UK, and a DSc in 1994 by the same university for his research publications in materials science. Pat worked for 23 years at the Harwell Laboratory of the UK Atomic Energy Authority where he brought a background of crystal structure and materials chemistry to the study of lead–acid batteries, and thereby supplemented the traditional electrochemical emphasis of the subject. Since 1995, he has been Manager of Electrochemistry at the International Lead Zinc Research Organization in North Carolina and Program Manager of the Advanced Lead–Acid Battery Consortium. In 2005, he also became President of the Consortium. Pat has also served as an Editor the Journal of Power Sources since 1989.
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Corrosion Of negative–plate straps In VRLA batteries
C.Z. Qiu
School of Chemistry and Environment,South China Normal UniversityLead and lead–tin (Pb–Sn )alloys are used mostly for the negative straps in VRLA batteries. Nevertheless, the degree of corrosion of such straps gave rise to serious concern when the welding by performed manually. With the addition of tin, the fluidity of the alloys increased and the weldability improved, but the corrosion resistance decreased. Thus, those Chinese manufacturers of VRLA batteries who hand-weld straps required a new alloy. This paper reports the viability of a Pb–0.8 wt.%Sn–0.0 to 0.1wt.% Se alloy for such application.
The microstructure of each Pb–0.8wt%Sn–Se alloy was characterized with a polarizing microscope. Following corrosion tests, the surfaces of the alloys were analyzed by means of scanning electron (SEM) and X-ray photoelectron (XPS) spectroscopy. The mechanism of strap corrosion was examined by comparing the nature and corrodability of the lead-tin and Pb–0.8 wt.%Sn–0.0 to 0.1wt.% Se alloys.Biography: C.Z.Qiu is is a graduate student in School of Chemistry and Environment at the South China Normal University.
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A novel gel electrolyte: preparation and application in lead–acid batteries
Guang Shi
College of Chemistry and Environment, South China Normal Univercity,Gas nano-SiO2 hydro gel has been widely used in gel lead–acid batteries. Nevertheless, this material has many shortcomings, e.g., it is expensive, has a fast rate of gelation when mixed with sulfuric acid, and is difficult to distribute evenly in water.
This presentation reports the development of a novel, low-cost, gel electrolyte. The gelation rate of the material in sulfutic acid is slow and can be well controlled; when containing an optimum amount of the material, sulfuric acid solution gels slowly after being poured into a battery. The mechanism of gelation of the novel electrolyte has been analyzed, and its electrochemical performance has been characterized. Results show that the electrolyte is a good candidate for gel lead–acid batteries.Biography: Associate Professor Shi Guang is a member of the College of Chemistry and Environment at the South China Normal University. She has wide experience in the fields of polymer chemistry and physics.
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Electrochemical Performance of a Novel Ca–Sn–Al–Ti Alloy Grid for Lead–Acid Batteries
L.P. Tang
School of Chemistry and Environment at South China Normal UniversityThere have been some studies of the application of conventional grids with sodium and with lightweight grids based on titanium in lead–acid batteries. Such grids have been found to exhibit great improvements in electrochemical performance and mechanical properties. By contrast, however, there have been few reports of the effect of titanium and sodium additives in lead–acid batteries.
This paper discusses the synthesis of several types of master alloy for addition to the Pb–Ca–Sn–Al system. The new lead alloys have been formed into positive grids. The corrosion behaviour of these grids in a 0.5M H2SO4 solution at three different temperatures has been examined by means of electrochemical impedance spectroscopy (EIS), cyclic voltammetry, potentiodynamic polarization curves, and equivalent circuit analysis. The results show that the novel calcium–lead alloys have good corrosion resistance. Moreover, the strength of the alloys is improved through the addition of titanium and sodium.Biography: Tang Liping is a postgraduate student at the South China Normal University.
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Numerical simulation of lead–acid battery grids
Farschad Torabi
VFERI InstitueLead–acid batteries are commonly required to operate under both low and high rates of charge and discharge. A major problem is a loss in charge efficiency due to a fall in voltage, which is attributed mainly to the grids that support the active materials. Thus, to reduce voltage loss, battery grids should be optimized. The conventional approach to grid optimization is to conduct a programme of experimental tests, but this is both expensive and time-consuming . An alternative is numerical simulation; the method can provide an accuracy similar to that of experimental evaluation and at much less a cost.
There are two different models for grid simulation, viz., the wire and the differential methods. The former is very fast and simple in terms of programming, but is not sufficiently accurate for high-rate processes. By contrast, the latter is quite accurate but time-consuming compared with the wire method. To evaluate the accuracy of each method and their respective limitations, the two methods have been applied andcompared in the study reported here.
The results are presented for different shapes of conventional grid used by the battery industry. In particular, an examination is made of the effect of geometry and the positioning of the lug on electrode performance. The comparison shows that the wire method gives good results at low rates of discharge, and can be employed with only minor errors in a very short time. The differential model should be used for high rates.Biography: Farschad Torabi graduated from the University of Tehran (Iran) in 2008 with a degree in mechanical engineering. His research interests include the modelling and simulation of electrochemical systems, batteries and fuel cells. He is currently the head of the battery simulation department of the Vehicle, Fuel and Environment Research Institute (VFERI) in the School of Mechanical Engineering of the University of Tehran.
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Separator design, formula and construction to maintain lead–acid battery performance
J. Kevin Whear
Daramic LLCMaintaining the electrical performance of the lead–acid battery throughout service life is an issue of concern for both battery manufacturers and end-users. Among the many factors that can degrade the electrical performance are: depolarization of the negative electrode, excessive gassing, positive-grid corrosion, expansion and shedding of the positive active-material, and electrical shorting between electrodes. One strategy to counteract these adverse effects is to choose an appropriate separator. This presentation will explore options in terms of separator formula, design and construction as a means to sustaining electrical performance throughout battery service life . Various applications of separators in automotive, stationary and motive power batteries will also be reviewed.
Biography: J. Kevin Whear graduated with a degree in Chemical Engineering from the University Tulsa and then was employed in the petrochemical industry for a number of years. Approximately 20 years ago, Kevin joined Daramic and has worked in manufacturing, quality and technology. Kevin is now the Vice President Technology for Daramic, in which role he guides and directs customer technical support and new product development efforts world-wide. Kevin has had the opportunity to make presentations at many venues including previous Asian Battery Conferences, European Lead–Acid Battery Conferences, and BCI Conventions. He has numerous granted patents. Most notably, Kevin is a co-author of a chapter on lead–acid separators in the Encyclopedia of Electrochemical Power Sources, to be published in September 2009.
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Latest Technology in AGM and GEL Filling Equipment
Michael Wipperfuerth
CMW TEC Technologie GMBHThe patented VACBOX filling system from CMW TEC technologie allows a successful and precise filling technology for AGM and VRLA Batteries. We use the same filling system for different battery technologies, with higher vacuum than on usual systems decreasing the filling time.
Filling holes do not have to be sealed for evacuation so that filling does not have to be interrupted. The filling can be done in one shot, so the interrupting time is saved.
Best air evacuation results are achieved from high vacuum and allow best penetration of the electrolyte, preventing the air spots on the plates. Good flow meter technology for metering the liquid volume makes high filling precision +/-0,5% of volume.
Optional controlling of the filled quantity by scales positioned under the filling table is also possible as individual scale units before and after the filling machines. Short setup time increases the productivity as well.
Our anti-dripping elements make the system clean and environment-friendly. Customized design of the VACBOX guaranties optimized efficiency for our customer. Semiautomatic and Fully Automatic Machine conceptions are available to fulfil customer requirements to guarantee high productivity and best quality.
Biography: Michael Wipperfuerth has been with CMW TEC Technologie GMBH for 8 years first as a Purchasing Manager and then as the Sale Manager for Europe. Michael is now the Sales Manager covering Europe, East Europe, Asia and Africa.
Michael’s academic qualifications including Business Economist IHK.
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Lazy Old Lead. – Savior of the Planet?
John Wood
EcoultThe Need
Economic, Utility Scale Energy Storage remains the biggest challenge to making renewable generation the central part of a nation’s energy mix
- Definition and Description of the specific needs to be addressed.
The Economics
Only Lead Acid has the depth of resource and established industry capability to deliver the required economics and respond at the pace needed.
- Introduction of new economic models for deployment of Lead Acid based solutions
The Solution
Transform Lead Acid technology to the need.
- UltraBattery performance characterization, and pilot results…. Delivering on both the Need and the Economics
Biography: Mr John Wood was recruited from San Francisco to become CEO of Ecoult in Australia in 2008. Ecoult was formed out of CSIRO with support from Cleantech Ventures to commercialize the UltraBattery technology invented by Dr. Lan Lam in the field of stationary energy storage applications. John has extensive experience in developing companies and establishing industries built on technology breakthroughs. John founded Keycorp in Sydney and took this to a public company valued at over $400m. As an active participant and Chairman (for 7 years) of the global MULTOS smartcard consortium John worked alongside the secretariat and partners as MULTOS was established as a leading global security identity solution issued to and utilized by more than 100M people around the world.
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Lead price forecast
Hu Yongda
Beijing Antaike Information Development Co.,Ltd.Both the LME lead price and the Chinese lead price slumped in 2008. Because of the low price, China’s lead mines and smelters, as well as those in other countries, were forced to cut or even suspend production. Lead price is the key to whether those mines and smelters will resume full operation this year.
Where will lead price go -- up, down or remain stationary? In this presentation, Antaike will propose reasons for the slump in the lead price last year. The exogenous factors were the American financial crisis, and fluctuations in the oil price and the US dollar. The fundamental cause was the weakening lead demand and over-supply in key consuming countries, especially China. Consequently, any change in China’s lead supply and demand will have a strong influence on future lead prices, both domestically and overseas. Antaike will also present a detailed analysis and forecast for the world lead market situation.Biography: Hu Yongda conducts lead market analysis in the Beijing Antaike Information Development Co.,Ltd. He is also a PhD student in the Investment Department of the Chinese Academy of Social Science. Since its establishment in 1992, Antaike has built a reputation for its authoritative, strategic and in-depth analysis of the Chinese metals industries and markets. It also provides news, trade and production data, and price forecasts.
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Development of an ultra long-life (6000 cycles) VRLA battery for deep-cycle service
Hideaki Yoshida
The Furukawa Battery Co., LtdConventional VRLA batteries offer a life performance of around 1000 cycles under the conditions of deep-discharge cycle test. This, however, does not meet the expectation of a battery life of more than ten years. Following a progressive programme of research and development, Furukawa has produced a VRLA design that can withstand more than 6000 cycles at 70% depth-of-discharge. This has been achieved through several advances in VRLA technology that include: moderation of the voltage drop at the electrodes by simulation technology; the adoption of a lead alloy with a corrosion resistance superior to that of conventional alloys; improvement in the charge-acceptance characteristics via an additive to the negative active-material; and the adoption of an AGM separator with greater mechanical elasticity.
Biography: Hideaki Yoshida was born in 1979 in Fukushima, Japan. He joined The Furukawa Battery Company in 2002 and is presently a member of its Research and Development Division.
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Carbon nanotubes as an electrolyte additive for gel lead–acid batteries
RUI RUI ZHAO
School of Chemistry and Environment, South China Normal University, Guangzhou, GuangdongIn this study, multi-walled carbon nanotubes (MWCNTs) are used as an additive at a mass ratio of 0.02 wt.% in gel valve-regulated lead-acid (GEL-VRLA) batteries. The electrochemical performance of the gel electrolytes is evaluated by means of cyclic voltammetry (CV), linear sweep voltammetry (LSV), and electrochemical impedance spectroscopy (EIS). The experimental data show that the MWCNTs exert an influence on both the oxygen evolution potential and the hydrogen evolution potential. The gel-electrolyte network structure and the grid surface morphology after cycling are investigated by means of scanning electron microscopy (SEM). The mechanism of the effect of MWCNs is discussed. The presence of MWCNs also increases the viscosity of the gel electrolyte, and the three-dimensional network structure becomes more stable.
Biography: From 2004 to2008, Rui Rui Zhao was an undergraduate student in Chemistry and Environment College of the South China Normal University, and is now a graduate student in the same institution
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