Publications

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This report describes the status of research being performed under CRADA No. SC10/01771.00 (Lead/Carbon Functionality in VRLA Batteries) between Sandia National Laboratories and East Penn Manufacturing, conducted for the U.S. Department of Energy's Energy Storage Systems Program. The Quarter 2 Milestone was completed on time. The milestone entails an ex situ analysis of the four carbons that have been added to the negative active material of valve-regulated lead-acid (VRLA) batteries for the purposes of this study. The four carbons selected for this study were a graphitic carbon, a carbon black, an activated carbon, and acetylene black. The morphology, crystallinity, and impurity contents of each of the four carbons were analyzed; results were consistent with previous data. Cycling on a subset of the received East Penn cells containing different carbons (and a control) has been initiated. Carbon has been explored as an addition to lead-acid battery electrodes in a number of ways. Perhaps the most notable to date has been the hybrid 'Ultrabattery' developed by CSIRO where an asymmetric carbon-based electrochemical capacitor is combined with a lead-acid battery into a single cell, dramatically improving high-rate partial-state-of-charge (HRPSoC) operation. As illustrated below, the 'Ultrabattery' is a hybrid device constructed using a traditional lead-acid battery positive plate (i.e., PbO{sub 2}) and a negative electrode consisting of a carbon electrode in parallel with a lead-acid negative plate. This device exhibits a dramatically improved cycle life over traditional VRLA batteries, as well as increased charge power and charge acceptance. The 'Ultrabattery' has been produced successfully by both The Furukawa Battery Co. and East Penn Manufacturing. An example illustrating the dramatic improvement in cycle life of the Ultrabattery over a conventional VRLA battery is shown.

This report describes the status of research being performed under CRADA No. SC10/01771.00 (Lead/Carbon Functionality in VRLA Batteries) between Sandia National Laboratories and East Penn Manufacturing, conducted for the U.S. Department of Energy's Energy Storage Systems Program. The Quarter 1 Milestone was completed on time. The milestone entails conducting a thorough literature review to establish the current level of understanding of the mechanisms through which carbon additions to the negative active material improve valve-regulated lead-acid (VRLA) batteries. Most studies have entailed phenomenological research observing that the carbon additions prevent/reduce sulfation of the negative electrode; however, no understanding is available to provide insight into why certain carbons are successful while others are not. Impurities were implicated in one recent review of the electrochemical behavior of carbon additions. Four carbon samples have been received from East Penn Manufacturing and impurity contents have been analyzed. Carbon has been explored as an addition to lead-acid battery electrodes in a number of ways. Perhaps the most notable to date has been the hybrid 'Ultrabattery' developed by CSIRO where an asymmetric carbon-based electrochemical capacitor is combined with a lead-acid battery into a single cell, dramatically improving high-rate partial-state-of-charge (HRPSoC) operation. As illustrated below, the 'Ultrabattery' is a hybrid device constructed using a traditional lead-acid battery positive plate (i.e., PbO{sub 2}) and a negative electrode consisting of a carbon electrode in parallel with a lead-acid negative plate. This device exhibits a dramatically improved cycle life over traditional VRLA batteries, as well as increased charge power and charge acceptance. The 'Ultrabattery' has been produced successfully by both The Furukawa Battery Co. and East Penn Manufacturing. An example illustrating the dramatic improvement in cycle life of the Ultrabattery over a conventional VRLA battery is shown in the graph.

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The addition of certain forms of carbon to the negative plate in valve regulated lead acid (VRLA) batteries has been demonstrated to increase the cycle life of such batteries by an order of magnitude or more under high-rate, partial-state-of-charge operation. Such performance will provide a significant impact, and in some cases it will be an enabling feature for applications including hybrid electric vehicles, utility ancillary regulation services, wind farm energy smoothing, and solar photovoltaic energy smoothing. There is a critical need to understnd how the carbon interacts with the negative plate and achieves the aforementioned benefits at a fundamental level. Such an understanding will not only enable the performance of such batteries to be optimzied, but also to explore the feasibility of applying this technology to other battery chemistries. In partnership with the East Penn Manufacturing, Sandia will investigate the electrochemical function of the carbon and possibly identify improvements to its anti-sulfation properties. Shiomi, et al. (1997) discovered that the addition of carbon to the negative active material (NAM) substantially reduced PbSO{sub 4} accumulation in high rate, partial state of charge (HRPSoC) cycling applications. This improved performance with a minimal cost. Cycling applications that were uneconomical for traditional VRLA batteries are viable for the carbon enhanced VRLA. The overall goal of this work is to quantitatively define the role that carbon plays in the electrochemistry of a VRLA battery.

Grid tied PV energy smoothing was implemented by using a valve regulated lead-acid (VRLA) battery as a temporary energy storage device to both charge and discharge as required to smooth the inverter energy output from the PV array. Inverter output was controlled by the average solar irradiance over the previous 1h time interval. On a clear day the solar irradiance power curve is offset by about 1h, while on a variable cloudy day the inverter output power curve will be smoothed based on the average solar irradiance. Test results demonstrate that this smoothing algorithm works very well. Battery state of charge was more difficult to manage because of the variable system inefficiencies. Testing continued for 30-days and established consistent operational performance for extended periods of time under a wide variety of resource conditions. Both battery technologies from Exide (Absolyte) and East Penn (ALABC Advanced) proved to cycle well at a Partial state of charge over the time interval tested.

The performance of the Neosonic polymer Li-ion battery was measured using a number of tests including capacity, capacity as a function of temperature, ohmic resistance, spectral impedance, hybrid pulsed power test, utility partial state of charge (PSOC) pulsed cycle test, and an over-charge/voltage abuse test. The goal of this work was to evaluate the performance of the polymer Li-ion battery technology for utility applications requiring frequent charges and discharges, such as voltage support, frequency regulation, wind farm energy smoothing, and solar photovoltaic energy smoothing. Test results have indicated that the Neosonic polymer Li-ion battery technology can provide power levels up to the 10C{sub 1} discharge rate with minimal energy loss compared to the 1 h (1C) discharge rate. Two of the three cells used in the utility PSOC pulsed cycle test completed about 12,000 cycles with only a gradual loss in capacity of 10 and 13%. The third cell experienced a 40% loss in capacity at about 11,000 cycles. The DC ohmic resistance and AC spectral impedance measurements also indicate that there were increases in impedance after cycling, especially for the third cell. Cell No.3 impedance Rs increased significantly along with extensive ballooning of the foil pouch. Finally, at a 1C (10 A) charge rate, the over charge/voltage abuse test with cell confinement similar to a multi cell string resulted in the cell venting hot gases at about 45 C 45 minutes into the test. At 104 minutes into the test the cell voltage spiked to the 12 volt limit and continued out to the end of the test at 151 minutes. In summary, the Neosonic cells performed as expected with good cycle-life and safety.

Grid-tied PV energy smoothing was implemented by using a valve regulated lead-acid (VRLA) battery as a temporary energy storage device to both charge and discharge as required to smooth the inverter energy output from the PV array. Inverter output was controlled by the average solar irradiance over the previous 1h time interval. On a clear day the solar irradiance power curve is offset by about 1h, while on a variable cloudy day the inverter output power curve will be smoothed based on the average solar irradiance. Test results demonstrate that this smoothing algorithm works very well. Battery state of charge was more difficult to manage because of the variable system inefficiencies. Testing continued for 30-days and established consistent operational performance for extended periods of time under a wide variety of resource conditions. Both battery technologies from Exide (Absolyte) and East Penn (Advanced Valve Regulated Lead-Acid) proved to cycle well at a partial state of charge over the time interval tested.

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In this paper the performance of the LiFeBatt Li-ion cell was measured using a number of tests including capacity measurements, capacity as a function of temperature, ohmic resistance, spectral impedance, high power partial state of charge (PSOC) pulsed cycling, pulse power measurements, and an over-charge/voltage abuse test. The goal of this work was to evaluate the performance of the iron phosphate Li-ion battery technology for utility applications requiring frequent charges and discharges, such as voltage support, frequency regulation, and wind farm energy smoothing. Test results have indicated that the LiFeBatt battery technology can function up to a 10C{sub 1} discharge rate with minimal energy loss compared to the 1 h discharge rate (1C). The utility PSOC cycle test at up to the 4C{sub 1} pulse rate completed 8,394 PSOC pulsed cycles with a gradual loss in capacity of 10 to 15% depending on how the capacity loss is calculated. The majority of the capacity loss occurred during the initial 2,000 cycles, so it is projected that the LiFeBatt should PSOC cycle well beyond 8,394 cycles with less than 20% capacity loss. The DC ohmic resistance and AC spectral impedance measurements also indicate that there were only very small changes after cycling. Finally, at a 1C charge rate, the over charge/voltage abuse test resulted in the cell venting electrolyte at 110 C after 30 minutes and then open-circuiting at 120 C with no sparks, fire, or voltage across the cell.

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A comprehensive evaluation and experimental optimization of the FireFly{trademark} 600 off-grid photovoltaic system manufactured by Energia Total, Ltd. was conducted at Sandia National Laboratories in May and June of 2001. This evaluation was conducted at the request of the manufacturer and addressed performance of individual system components, overall system functionality and performance, safety concerns, and compliance with applicable codes and standards. A primary goal of the effort was to identify areas for improvement in performance, reliability, and safety. New system test procedures were developed during the effort.

A new valve regulated lead-acid (VRLA) gel motive power battery and PV system power center have been tested in the laboratory and at a PV hybrid telecommunication site. The power center provides battery charge control, system remote communications, and data acquisition at the field test site. Extensive laboratory and field-test data were used to improve battery performance by optimizing regulation voltages, finish-charge, and system design. After 1.5-years of service, battery and charge controller performance have met all performance requirements for the remote communications site at Sandia National Laboratories.

An amp-hour counting battery charge control algorithm has been defined and tested using the Digital Solar Technologies MPR-9400 microprocessor based photovoltaic hybrid charge controller. This work included extensive laboratory and field testing of the charge algorithm on vented lead-antimony and valve regulated lead-acid batteries. The test results have shown that with proper setup amp-hour counting charge control is more effective than conventional voltage regulated sub-array shedding in returning the lead-acid battery to a high state of charge.

A survey of US system integrators, charge controller manufacturers, and battery manufacturers was conducted in 1996 to determine market and application trends. This survey was sponsored by the USDOE. Results from 21 system integrators show a 1995 PV battery sales of $4.76 million. Using the survey results, a top down market analysis was conducted with a total predicted US battery market of $34.7 million and a world wide market of US $302 million. The survey also indicated that 71% (of dollars) were spent on VRLA and 29% on flooded lead-acid batteries. Eighty percent of charge controllers were ON-OFF, vs. PWM or constant voltage.

The performance of an amp-hour (Ah) counting battery charge control algorithm has been defined and tested using the Digital Solar Technologies MPR-9400 microprocessor based PV hybrid charge controller. This work included extensive field testing of the charge algorithm on flooded lead-antimony and valve regulated lead-acid (VRLA) batteries. The test results after one-year have demonstrated that PV charge utilization, battery charge control, and battery state of charge (SOC) has been significantly improved by providing maximum charge to the batteries while limiting battery overcharge to manufacturers specifications during variable solar resource and load periods.

This report presents the results of a development effort to design, test and begin production of a new class of small photovoltaic (PV) charge controllers. Sandia National Laboratories provided technical support, test data and financial support through a Balance-of-System Development contract. One of the objectives of the development was to increase user confidence in small PV systems by improving the reliability and operating life of the system controllers. Another equally important objective was to improve the economics of small PV systems by extending the battery lifetimes. Using new technology and advanced manufacturing techniques, these objectives were accomplished. Because small stand-alone PV systems account for over one third of all PV modules shipped, the positive impact of improving the reliability and economics of PV systems in this market segment will be felt throughout the industry. The results of verification testing of the new product are also included in this report. The initial design goals and specifications were very aggressive, but the extensive testing demonstrates that all the goals were achieved. Production of the product started in May at a rate of 2,000 units per month. Over 40 Morningstar distributors (5 US and 35 overseas) have taken delivery in the first 2 months of shipments. Initial customer reactions to the new controller have been very favorable.