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Development of Ultra Long-Life (6000 cycles) VRLA for Deep-Cycle Service

Development of Ultra Long-Life (6000 cycles) VRLA for Deep-Cycle Service. 13 th Asian Battery Conference Macau China 2 September,2009. Hideaki Yoshida ， Tohru Mangahara ， Hiromasa Noguchi Daisuke Kikuchi ， Wataru Tezuka ， Masaru Miura Jun Furukawa The Furukawa Battery Co.,Ltd

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Development of Ultra Long-Life (6000 cycles) VRLA for Deep-Cycle Service

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  1. Development of Ultra Long-Life (6000 cycles) VRLA for Deep-Cycle Service 13th Asian Battery Conference Macau China 2 September,2009 Hideaki Yoshida， Tohru Mangahara ， Hiromasa NoguchiDaisuke Kikuchi ， Wataru Tezuka ， Masaru Miura Jun Furukawa The Furukawa Battery Co.,Ltd Japan

  2. Environmental problems 　 　・Global Warming ・CO2 Emission →Efficient use of energy →Practical use of natural energy Development of distributed power supply system

  3. Distributed power supply system 1. Natural energy 　　　・PV ・Wind power 2.Load leveling 3. FC , Cogeneration 4. Biomass

  4. Demand of distributed power supply system ※ No replacement of batteries during system operating period But・・・ Cycle life of conventional VRLA under deep discharge condition・・・・・・only1000cycles Improvement of cycle life of VRLA!!

  5. Comparison of various batteries

  6. ・High density ・Softening of PAM ・Additives ・Compression ・New alloy ・Grid corrosion ・Additives ・Sulfation of NAM ・Additives for NAM ・Water loss ・Declined compression of AGM separator ・Mechanical elasticity ・Horizontal placement ・Stratification Failure modes of cycle use battery and measures for improvement Failure modes measures

  7. Cycle life performance(1) Influence of PAM Density 4.5g/cc> 4.4g/cc> 4.3g/cc 20HR Capacity Ratio(%) ・Battery type:2V-2Ah ・Discharge:0.25CA,2hr ・Charge:2step CC,110% Number of cycles

  8. Cycle life performance(2) Effect of New additive for PAM Additive A>No Additive 10HR Capacity Ratio(%) ・Battery type:12V-50Ah ・Discharge:1CA,21min ・Charge:multi step charge,104% Number of cycles

  9. Cycle life performance(3) Effect of compression to plate group 60kPa>30kPa 10HR Capacity Ratio(%) ・Battery type:2V-17Ah ・Discharge:1CA,21min ・Charge:multi step charge,104% Number of cycles

  10. Conventional grid alloy Corrosion layer PAM Grid New grid alloy Corrosion layer Grid PAM Cycle life performance(4) Effect of positive grid alloy 10HR Capacity Ratio(%) ・Battery type:2V-33Ah ・Discharge:0.60CA,1.6Vcut ・Charge:multi step charge,104% SEM images of grid corrosion layer in PAM at 2200th cycle Number of cycles

  11. Cycle life performance(5) Effect of carbon content in NAM C.B. 1.0%> C.B. 0.4%> No Additive 10HR Capacity Ratio(%) ・Battery type:12V-50Ah ・Discharge:1CA,21min ・Charge:multi step charge,104% Number of cycles

  12. H2 evolution rate Influence of carbon materials in NAM ・Charge Potential：test value ・State：full charged ・Temperature：test value Hydrogen evolution rate various potentials［Hg/Hg2SO4］ I (mA) C.B.1<C.B.2 Temperature( ﾟC )

  13. Initial After cycle After cycle Conventional Optimized Charge acceptability Optimized Additives in NAM Optimization of the quantity of lignin and BaSO4 Prevention of growth of PbSO4 crystal Improvement of charge acceptability

  14. AGM separator Mechanical elasticity behavior A>B>C Initial thickness ratio(%) Number of cycles

  15. Separator B Separator A Separator C SEM observation Separator A ⇒ Fine fiber and coarse fiber Separator B ⇒ Fine fiber Separator C ⇒ Fine fiber and additive

  16. Cycle life performance(6) Influence of AGM materials A>B>C 20HR Capacity Ratio(%) ・Battery type:2V-17Ah ・Discharge:1CA,21min ・Charge:multi step charge,104% Number of cycles

  17. Cycle life performance(7) Effect of placement of VRLA Horizontal Horizontal>Vertical 10HR Capacity Ratio(%) Vertical ・Battery type:2V-200Ah ・Discharge:0.25CA,2.8hr ・Charge:2 step cc,110% Number of cycles

  18. Developed VRLA

  19. Cycle life performance of developed VRLA 10HR Capacity Ratio(%) Still on test ・Battery Type:12V-50Ah ・Discharge:0.25CA, DOD70% ・Charge:0.25CA, 3 step charge, 104% ・Temp:25ﾟC Number of cycles

  20. New Front of VRLA Ni-MH Developed VRLA Conventional VRLA FLA

  21. Cycle life performance(8) PSOC condition ･Battery type: 12V-50Ah ･Discharge: 1CA, DOD80% ･Charge:PSOC (90-10%)/A*5+B*1 A. 1CA, 4 step charge, 100% B. 1CA, 4 step charge, 118% ･Charge:Normal (100-20%) 1CA, 4 step charge, 103% 10HR Capacity Ratio(%) Number of cycles

  22. Evaluation of energy efficiency under PSOC condition PSOC condition（vs Normal condition) 　 ・Wh efficiency +3% 　・cycle life +30%

  23. Application to battery energy storage system for wind power generator Developed battery strings Appearance of wind turbine

  24. – + Separator PbO2 – + Pb PbO2 Carbon electrode Lead–acid cell Asymmetric supercapacitor – i + i1 Pb i i2 Carbon electrode Ultrabattery Introduction of UltraBattery technology Configuration of UltraBattery Appearance of UB1000

  25. cycle pattern Charge Current(A) Discharge Wind power profile Time(hr) Wind power profile Current(A) Time(sec) pulse pattern Current(A) Charge UB1000:under evaluation Discharge Time(sec)

  26. Conclusions The Furukawa Battery successfully developed the ultra long-life VRLA for deep-cycle service applications. • The developed VRLA achieved cycle life of 7000 cycles or more under deep discharge cycle life test. The developed VRLA is still on test. • Cycle life of the developed VRLA has approached that of the Ni-MH battery for EV. • The developed VRLA has longer cycle life and higher energy efficiency than conventional VRLA under PSOC cycle life test. 4) The developed VRLA is being evaluated in the battery energy storage system for wind power generator.

  27. Thank you for your attention

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