1A_Monahov Presentation REV2

Transcription

The ALABC is a Program of the International Lead Zinc Research Organization, Inc.
Advanced Lead Acid Battery Consortium
Hybrid Electric Vehicles –
Challenge and Future
for Advanced Lead-Acid Batteries
Boris Monahov, ALABC, U.S.A.
Copyright: ALABC
Agenda
1. Why Hybrid Electric Vehicles (HEV)?
2. Sales trends and variety of HEVs
3. Requirements to the battery in HEVs
4. The ALABC and the lead-carbon batteries
5. The ALABC HEV demonstration program
6. Building the ALABC roadmap
2
Albena, June 09, 2014
Copyright: ALABC
Trends in car production (2010 to 2040)
1) Energy source transition from fossil to renewable
2) Turn from danger to nature to a planet improving tool
Consumers
Government
► dynamics, safety, fun
► acceptable price
► low additional costs
► long autonomy range
► immune to energy
carrier price
► environmentally
friendly
Car producers
► ensure customer satisfaction
► keep “green” and safety value
► sale
more new vehicles
3
► safety for people
and nature
► less fuel
► low CO2
► “green” loop:
raw materials –
production –
use – recycling
Market
► growing demand for cars
► sustainable development
Copyright: ALABC
Trends in car production (2010 to 2040)
Solution: replace ICE engine by machines powered from
energy produced without changing the environment
Propulsion
Electric motor (good)
gas turbine (expensive)
compressed air
(not mature)
solar energy (expensive)
wireless power transfer
El. energy storage
- grid (not enough capacity)
- batteries (not mature)
- capacitors (expensive)
- fuel cells (expensive)
(not mature)
Which battery?
Lead-Acid
NiMH
Li-ion
NiZn, Zn-air, post Li-ion…
Trends?
- ICE:
stepping slowly down
- ZEVs:
rather slowly growing
market
Transition 2010 - 2040: HYBRID ELECTRIC VEHICLES
4
Copyright: ALABC
Trends in low carbon car development
1. Use alternative fuels or mix with gasoline / diesel
2. Engine: enhanced cylinder filling, multi valves, new designs
3. Hybridize internal combustion engines with electric motors
♦ Optimize hybridization architecture
♦ Use better batteries for SLI and for energy storage
4. Optimize transmission and clutch:
5. Utilize the energy of the exhaust gases
6. Optimize the body
♦ reduced weight (aluminum (Ford), composite materials (BMW i8))
♦ low rolling resistance tires, aerodynamics
♦ more efficient lubricants
5
Copyright: ALABC
Car Manufacturer’s Values of HEV Batteries
Battery features important for car manufacturers:
1. Safety
♦ PbA and NiMH: safe, Li-ion to improve (cell design, cell control, cooling)
2. Environment
♦ PbA are fully recycled, NiMH not yet, Li-ion need to develop recycling
♦ PbA have the smallest production CO2 emissions footprint
3. Energy and power parameters
♦ Li-ion - light and strong,
♦ NiMH - long cycle life
♦ PbA - steadily improving
4. Last but not least: production costs
♦ $150 - $200 per kWh considered as a long term target for Li-Ion
♦ PbA remain about $100/kWh, NiMH and Li-ion are more expensive
♦ Li-ion expect cost reduction if produced in large series
Lead-acid: not considered for full, plug-in and range extended hybrids.
The challenge for PbA: the battery choice for start-stops, micro,
mild HEVs, keep strong market positions in next decades
6
Copyright: ALABC
Diversity of hybrid electric vehicles
Hybrid
Regular
Car example
Base
CO2 Reduction, %
0
3-8
8 - 12
Sales forecast 2020
DECLINE
DOMINANT
RAPID RISE
PARAMETERS
Vehicle Type
7
El. Function
El. Power, kW
Voltage, V
SLI
2-4
12
Micro-1
Micro-2
Mild-1
Mild-2
Moderate
Strong
Parallel PHEV
Extended
Range PHEV
most new
EU cars
Mazda
Suzuki
Coming soon
GM Malibu
Eco
Honda Civic
Toyota Prius
Ford Fusion
Ford C-max
Chevy Volt
12 - 20
20 - 35
> 35
> 50
Start/Stop Regen Brake Launch assist
2-4
12
2-4
12 - 24
5 - 12
48
MODERATE RISE
LIMITED RISE
Mild Power
Assist
Moderate Limited Electric
Extended Largely Electric
Power Assist
Drive
Electric Drive
Drive
10 - 15
45 - 120
12 - 20
100 - 150
25 - 60
150 - 350
40 - 100
150 - 600
70 - 130
200
Copyright: ALABC
Various HEV types sales forecasts (Valeo)
Stop-Start (+mild) sales will dominate: Europe - till 2025+, worldwide - longer
Cummulative:xHEV + full + mild + St/St
Source: 2013 Valeo Powertrain Forecast, D. Benchentrite, EEHE meeting, Bamberg, Germany, May 2014
8
Copyright: ALABC
2012 market forecast for 2020: micro hybrids
The electric vehicle of the coming 10-15 years will be the
micro hybrid with increased electric functionalities.
Forecasts for 2020 – 2025: between 35 and 90 million micro hybrids
Avicene 2020 OEM forecast:
HEV: < 5 %; p-HEV & EV: < 2 %
Source: Chr. Pillot, Avicene Energy, France, 2013 Advanced
Automotive Batteries Conference, Strasbourg, June 2013
Micro hybrid: > 50%
Micro HEV
Full HEV
Advanced
lead-acid
NiMH or Liion
Battery cost, $
300
3000
Fuel saving
5%
20%
35,000,000
3,500,000
Battery
Sales in 2020
9
Copyright: ALABC
Car production rate and 48V micro HEVs
The global production rate is growing
steadily and is expected to continue:
• 3.6% a year worldwide
• 5.7% in developing and
• 1.2% in the developed countries
• Rapid growth is forecasted for 48V
micro hybrids in the coming 10 years
by LUX research.
• By 2025 48V micro hybrids are going
to reach 10% of all micro hybrids
• Till 2030 this ratio will probably
rapidly grow
10
Copyright: ALABC
Battery chemistry selection (no ALABC)
PbA
PbA, Li-Ion, PbA+
PbA, NiMH, Li-Ion
NiMH, Li-Ion
Li-Ion
PbA issue in HEVs:
negative plate
sulfation
11
Copyright: ALABC
How is the battery operating in a 48 LC SH ?
12
Copyright: ALABC
ALABC program: defeating PCL-3 effect, LC
Added carbon
13
Copyright: ALABC
ALABC program: demonstrating LC batteries
100,000 miles
150,000 miles
12V and 48V LC Super Hybrids
48V LC Kia Optima turbo Diesel
RAM 1500 HFE Natural Gas Hybrid Vehicle
14
Copyright: ALABC
Ultrabattery in a mild hybrid: our lessons
1. 150,000 miles on the road in Phoenix, Arizona
2. Battery shows almost no capacity loss
3. The battery serves as long as the vehicle!
15
Copyright: ALABC
The battery in the: a) car; b) micro HEV
a
Engine
Alternator
Starter
Regulator
U(max)
•
•
•
•
12V battery
“free will”
mystery
Loads
Ignition
Lights
Security
Audio
b
Engine
Start-Stop
ISG
16
Microprocessor
Computer
Protocols
U(max), U(min)
boost charge
BMS
SOC, SOH
mystery
no standards
12V / 48V battery
Dual chemistry
Ultracapcior
•
•
•
•
•
•
•
•
•
Loads
Ignition
Lights
Security
Infotainment
HVAC
Brakes
Clutch
Suspension
E-motor
Copyright: ALABC
Ultrabattery in mild hybrid: our lessons
1.
2.
3.
17
4.
Cycle life of UB in mild hybrid as long as of NiMH
Fuel economy (charge acceptance) same and better than of NiMH
Energy throughput required: about 4,000 * Cn
Albena, June
2014 temperature
The ALABC is a Programsubject
of the Internationalof
Lead further
Zinc Research Organization,
Inc.
Copyright: ALABC
DCA
at 09,low
improvement
Ultrabattery in mild hybrid: our lessons
After 100,000 miles in a road test, 12 Ultra Battery modules:
Voltage profiles all the same, no cell equalization needed!
Benefits of Ultrabatteries: - no cell management electronics
- no cooling at the cell level
18
LABAT’2011, Albena, Bulgaria,
June ALABC
7 – 10
Copyright:
The LC super Hybrid: a strong new concept
System ►
Metric ▼
Micro HEV
LC Super
Hybrid
Mild Hybrid
Full Hybrid
Plug-in HEV
200 - 270V
300 - 400V
Voltage
12V
12 - 48V
24new
concept 130V
OEM on-cost
*estimate
€ 150 - 700
€ 750 1,500
€ 1,600 –
3,000
€ 3,000 – 5,000
€ 6,000 –
10,000
CO2 Benefit %
4 -7 %
15-30%
8-15%
15-30%
30%+
OEM Cost per
€ 35 - 100
€ 50 - 60
€ 200 - 250 € 200 - 250
1% CO
Albena,
Benefit
June
09,
2014
The
ALABC
is
a
Program
of
the
International
Lead
Zinc Research Organization, Inc.
19
2
€ 300 - 500
Copyright: ALABC
How is the battery operating in a 48 LC SH ?
• Charge / discharge pulse
duration: 1 to 10 s
48 V
Pulse duration
• Energy throughput in one
NEDC cycle: ≈ 0.03 Cn
(one Cn in 33 cycles)
• 1 hour a day ≈ 2,000 Cn a year
• Battery life: 20,000 x Cn
48 V
12 V
Energy In and Out
State of Charge
20
1,500*Cn for
150,000 miles
Copyright: ALABC
Pb-A Batteries in SLI and in HRPSoC duty
21
Solution for HRPSoC: combine Faradaic capacity and EDL capacitance
The energy throughput
of the battery needs substantial increase
Copyright: ALABC
Failure of lead-acid batteris in DCA tests
DCA: Dynamic Charge Acceptance, (A (charge)/Ah (Cn)), 2012
Test B: Simulated Microhybrid Duty: Run-In
I recu / Cn (A / Ah)
ambient air 23oC
EFB “plus”
AGM
poor flooded
Charge acceptance of
lead-acid batteries
degrades rapidly in
this simulation test
(Dynamic)
In 2012 enhanced
lead-acid batteries
already showed DCA
improvements
0.6 A/Ah achieved
today
OEM: 2 A/Ah, 3 A/Ah…
time / days
E. Karden, F. Jöris, H. Budde-Meiwes, D.U. Sauer, Test Methods for Dynamic Charge Acceptance (DCA) of Microhybrid Starter Batteries,
13ELBC European Lead Battery Conference, Paris, France, September 2012
22
Copyright: ALABC
LC Batteries with Enhanced DCA – Shin Kobe
Improvement in DCA: performance closer to target
 DCA problem in “regular” lead-acid batteries
 Improvement 50% and more
 Advanced LC batteries able to resolve
the problem soon
T. Okoshi, Shin Kobe El. Machinery, Japan, 2013 Advanced Automotive Batteries Conference, Strasbourg, June 2013
The major issue of Pb-A batteries - shorter life due to low DCA gets rapidly improved by inexpensive technology steps
Source: David Weinberg, Wiley Rein LLP, What’s New in the lead Battery Policy World, presentation at the 124 BCI convention, Scottsdale, April 30, AZ, 2012
23
Copyright: ALABC
Battery for micro/mild HEVs? LC batteries
Hybrid
Vehicle Type
Regular
CO2 Reduction, %
Micro-1
Micro-2
Mild-1
3-8
0
Mild-2
8 - 12
12 - 20
Moderate
Strong
Parallel PHEV
Extended
Range PHEV
12 - 20
20 - 35
> 35
> 50
12 - 30
ALABC LCSH, %
Costs, $ / % CO2
Sales forecast
base
45 - 130
DECLINE
DOMINANT
65 - 80
265 - 330
RAPID RISE
400 - 660
MODERATE RISE
LIMITED RISE
El. Function
SLI
Start/Stop
Regen
Brake
Launch
assist
Mild Power Moderate
Limited
Extended
Largely
Assist
Power Assist Electric Drive Electric Drive Electric Drive
El. Power, kW
Voltage, V
2-4
2-4
2-4
5 - 12
10 - 15
12 - 20
25 - 60
40 - 100
70 - 130
12
12
12 - 24
48
45 - 120
100 - 150
150 - 350
150 - 600
200
Lead-acid
Ni MH
Li - ion
Battery combination
Lead Carbon
Meeting 2020 CO2 targets: - inexpensive SUSTAINABLE batteries < 60V
- in the best selling car design and price range
- for mass transition, in short time
24
Copyright: ALABC
ALABC roadmap for the next 20 years
Total energy throughput and DCA are key parameters
•
•
•
•
25
Advanced LAB have sufficient cycle life and energy throughput (Honda Civic)
Next target: a full hybrid (like Toyota Prius), and why not a low-end plug-in
DCA is already about 0.6 A/A, will soon reach 1 A/Ah.
We need rapidly more A/Ah for getting durable, reliable and light enough batteries
Copyright: ALABC
ALABC roadmap for the next 20 years
Overview of required TET, DCA and cycle life (in years)
Blue scale – service life, red scale – DCA, black scale – TET
1.
2.
26
ALABs have lower parameters than Li-ion ones
To make them compatible we need to enhance technical performance but keep
the benefits: - low material and production costs
Albena, June 09, 2014- complete
The ALABC isrecycling
a Program of the International Lead Zinc Research Organization, Inc.
Copyright: ALABC
Cost benefit of PbA vs. Li-Ion batteries
Keeping cost low: a critical
condition for the success of LAB
1.
2.
3.
LAB: 75-150 $/kWh depending on design
Li-ion: more expensive, depending on design. Their
costs are expected to decrease if in production.
About 2030 Li-ion might costs low as lead-acid
Advanced LABs need rapid enhancement.
New designs can cost more.
To keep costs low, ALAB can afford only
limited extra costs.
LAB have some extra cost space but only temporary
and under conditions:
1. Case A. Slow increase in cost. Critical year 2025.
2. Case B. Rapid increase in cost. Critical year 2020.
3. Expensive new technology rises costs. Due to
massive sales cost drop rapidly again.
No critical year.
Remark: Only Li-ion sown here, no NiMH, no NiZn.
Albena,
JuneAABC,
09, 2014
The ALABC
a Program
of the
International Lead Zinc Research Organization, Inc.
27
Sources:
a) Chr. Pillot,
Atlanta, February
2014;isb)
ALABC data
bank.
Copyright: ALABC
Conclusions
1. Micro and mild hybrids to dominate the market at least till 2020 - 2025
2. The new generation of advanced (Lead-Carbon) batteries has been
tested in micro and mild hybrid electric vehicles. Battery performance:
energy and cycle life sufficient (better mileage, 150,000+ road miles)
3. LC batteries can be further enhanced by 3D plate design; by negative
and positive active mass improvement (adding carbon and other additives,
enhanced local electrolyte supply)
4. The LC batteries for micro/mild hybrids are as good as other advanced
chemistries and have long enough cycle life at HRPSoC cycling. They have
also lower cost, higher safety, are produced from domestic materials, and
are totally recycled
5. The combination of LC batteries and optimized micro hybrid electric
vehicles offers an affordable market alternative and can change the HEV
market in the coming two decades.
28
Copyright: ALABC
Thank you very much
for your kind attention!
Dr. Boris Monahov
ILZRO - ALABC
E-mail: [email protected]
Web: www.alabc.org
29
Copyright: ALABC

1A_Monahov Presentation REV2

Transcription

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