Publications

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Two 100 kW min-1 (1.67 kW h-1) Li-ion battery energy storage systems (BESS) are described. The systems include a high-power Li-ion battery and a 100 kW power conditioning system (PCS). The battery consists of 12 modules of 12 series-connected Saft Li-ion VL30P cells. The stored energy of the battery ranges from 1.67 to 14 kW h-1 and has an operating voltage window of 515-405 V (dc). Two complete systems were designed, built and successfully passed factory acceptance testing after which each was deployed in a field demonstration. The first demonstration used the system to supplement distributed microturbine generation and to provide load following capability. The system was run at its rated power level for 3 min, which exceeded the battery design goal by a factor of 3. The second demonstration used another system as a stand-alone uninterrupted power supply (UPS). The system was available (online) for 1146 h and ran for over 2 min. © 2005 Elsevier B.V. All rights reserved.

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Exploration of the fundamental chemical behavior of the AlCl{sub 3}/SO{sub 2}Cl{sub 2} catholyte system for the ARDEC Self-Destruct Fuze Reserve Battery Project under accelerated aging conditions was completed using a variety of analytical tools. Four different molecular species were identified in this solution, three of which are major. The relative concentrations of the molecular species formed were found to depend on aging time, initial concentrations, and storage temperature, with each variable affecting the kinetics and thermodynamics of this complex reaction system. We also evaluated the effect of water on the system, and determined that it does not play a role in dictating the observed molecular species present in solution. The first Al-containing species formed was identified as the dimer [Al({mu}-Cl)Cl{sub 2}]{sub 2}, and was found to be in equilibrium with the monomer, AlCl{sub 3}. The second species formed in the reaction scheme was identified by single crystal X-ray diffraction studies as [Cl{sub 2}Al({mu}-O{sub 2}SCl)]{sub 2} (I), a scrambled AlCl{sub 3}{center_dot}SO{sub 2} adduct. The SO{sub 2}(g) present, as well as CL{sub 2}(g), was formed through decomposition of SO{sub 2}CL{sub 2}. The SO{sub 2}(g) generated was readily consumed by AlCl{sub 3} to form the adduct 1 which was experimentally verified when 1 was also isolated from the reaction of SO{sub 2}(g) and AlCl {sub 3}. The third species found was tentatively identified as a compound having the general formula {l_brace}[Al(O)Cl{sub 2}][OSCl{sub 2}]{r_brace}{sub n}. This was based on {sup 27}Al NMR data that revealed a species with tetrahedrally coordinated Al metal centers with increased oxygen coordination and the fact that the precipitate, or gel, that forms over time was shown by Raman spectroscopic studies to possess a component that is consistent with SOCl{sub 2}. The precursor to the precipitate should have similar constituents, thus the assignment of {l_brace}[Al(O)Cl{sub 2}][OSCl{sub 2}]{r_brace}{sub n}. The precipitate was further identified by solid state {sup 27}Al MAS NMR data to possess predominantly octahedral A1 metal center which implies {l_brace}[Al(O)Cl{sub 2}][OSCl{sub 2}]{r_brace}{sub n} must undergo some internal rearrangements. A reaction sequence has been proposed to account for the various molecular species identified in this complex reaction mixture during the aging process. The metallurgical welds were of high quality. These results were all visually determined there was no mechanical testing performed. However, it is recommended that the end plate geometry and weld be changed. If the present weld strength, based on .003' - .005' penetration, is sufficient for unit performance, the end plate thickness can be reduced to .005' instead of the .020' thickness. This will enable the plug to be stamped so that it can form a cap rather than a plug and solve existing problems and increase the amount of catholyte which may be beneficial to battery performance.

This report documents Phase 2 of a project to design, develop, and test a zinc/bromine battery technology for use in utility energy storage applications. The project was co-funded by the U.S. Department of Energy Office of Power Technologies through Sandia National Laboratories. The viability of the zinc/bromine technology was demonstrated in Phase 1. In Phase 2, the technology developed during Phase 1 was scaled up to a size appropriate for the application. Batteries were increased in size from 8-cell, 1170-cm{sup 2} cell stacks (Phase 1) to 8- and then 60-cell, 2500-cm{sup 2} cell stacks in this phase. The 2500-cm{sup 2} series battery stacks were developed as the building block for large utility battery systems. Core technology research on electrolyte and separator materials and on manufacturing techniques, which began in Phase 1, continued to be investigated during Phase 2. Finally, the end product of this project was a 100-kWh prototype battery system to be installed and tested at an electric utility.

The Zinc/Bromine Load-Leveling Battery Development contract (No. 40-8965) was partitioned at the outset into two phases of equal length. Phase 1 started in September 1990 and continued through December 1991. In Phase 1, zinc/bromine battery technology was to be advanced to the point that it would be clear that the technology was viable and would be an appropriate choice for electric utilities wishing to establish stationary energy-storage facilities. Criteria were established that addressed most of the concerns that had been observed in the previous development efforts. The performances of 8-cell and 100-cell laboratory batteries demonstrated that the criteria were met or exceeded. In Phase 2, 100-kWh batteries will be built and demonstrated, and a conceptual design for a load-leveling plant will be presented. At the same time, work will continue to identify improved assembly techniques and operating conditions. This report details the results of the efforts carried out in Phase 1. The highlights are: (1) Four 1-kWh stacks achieved over 100 cycles, One l-kWh stack achieved over 200 cycles, One 1-kWh stack achieved over 300 cycles; (2) Less than 10% degradation in performance occurred in the four stacks that achieved over 100 cycles; (3) The battery used for the zinc loading investigation exhibited virtually no loss in performance for loadings up to 130 mAh/cm{sup 2}; (4) Charge-current densities of 50 ma/cm{sup 2} have been achieved in minicells; (5) Fourteen consecutive no-strip cycles have been conducted on the stack with 300+ cycles; (6) A mass and energy balance spreadsheet that describes battery operation was completed; (7) Materials research has continued to provide improvements in the electrode, activation layer, and separator; and (8) A battery made of two 50-cell stacks (15 kWh) was produced and delivered to Sandia National Laboratories (SNL) for testing. The most critical development was the ability to assemble a battery stack that remained leak free. The task of sealing the battery stack using vibration welding has undergone significant improvement resulting in a viable production process. Through several design iterations, a solid technology base for larger battery stack designs was established. Internal stack stresses can now be modeled, in addition to fluid velocity and fluid pressure distribution, through the use of a finite element analysis computer program. Additionally, the Johnson Controls Battery Group, Inc. (JCBGI) proprietary FORTRAN model has been improved significantly, enabling accurate performance predictions. This modeling was used to improve the integrity and performance of the battery stacks, and should be instrumental in reducing the turnaround time from concept to assembly.

This report describes the results of a study that investigated the synergy between electrochemical capacitors (ECs) and flywheels, in combination with each other and with batteries, as energy storage subsystems in photovoltaic (PV) systems. EC and flywheel technologies are described and the potential advantages and disadvantages of each in PV energy storage subsystems are discussed. Seven applications for PV energy storage subsystems are described along with the potential market for each of these applications. A spreadsheet model, which used the net present value method, was used to analyze and compare the costs over time of various system configurations based on flywheel models. It appears that a synergistic relationship exists between ECS and flywheels. Further investigation is recommended to quantify the performance and economic tradeoffs of this synergy and its effect on overall system costs.

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This report reviews a number of issues specific to stand-alone AC lighting systems. A review of AC lighting technology is presented, which discusses the advantages and disadvantages of various lamps. The best lamps for small lighting systems are compact fluorescent. The best lamps for intermediate-size systems are high- or low-pressure sodium. Specifications for battery charging and load control are provided with the goal of achieving lamp lifetimes on the order of 16,000 to 24,000 hours and battery lifetimes of 4 to 5 years. A rough estimate of the potential domestic and global markets for stand-alone AC lighting systems is presented. DC current injection tests were performed on high-pressure sodium lamps and the test results are presented. Finally, a prototype system was designed and a prototype system controller (with battery charger and DC/AC inverter) was developed and built.