BATTERY ENERGY AND Advanced SuperGEL Battery Technology By Dr DJ Brown

AGENDA  Industrial Battery Overview  Customer Technical Requirements  Battery Energy’s SuperGel Battery Programme  - Background  - Purpose  Results  - Float Performance  - Cyclic Performance  - Resistance to abuse  Advantages of SuperGEL  Question and Answer Time

Industrial Battery Overview Lead Acid Batteries are under increasing threat from Lithium (ion) in a number of traditional areas such as standby and cyclic markets. Lead Acid batteries have been replaced in newer markets such as PHEV’s and increasingly in electric bikes. BATTERY ENERGY VIEW: Lead acid batteries will continue to dominate if:- a)Cost and not energy density is important, and b)Customer technical and commercial requirements are met or exceeded.

Customer Technical Requirements  Good starting performance  Good float Capability  Excellent cycling performance  Good resistance to abuse  Fast charge capability  PSOC (partial state of charge) capability  Long life – especially in inclement conditions  Standard footprint

Rail Market  Traditionally uses vented traction batteries or some Ni-Cad for starting and standby applications.  Newer requirements are for:-  Minimal maintenance  Passenger compartment security  Long life (>6-8 years)  Cycling at low states of charge

Traction/Utility Market  Newer requirements are for:-  Fast charge capability  PSOC capability  Opportunity charging  In Traction - Long life/low cost (3-4 years) at double shift  In utilities – Long life/low cost (>10 years service)

Solar/Raps Market  PSOC capability (20 – 30% daily DOD)  Good abuse resistance capability  System predictability  > than 10 years service life ONLY ADVANCED SUPERGEL BATTERIES CAN MEET ALL THESE REQUIREMENTS.

Battery Energy Gel Battery Programme Battery Energy Gel Battery Programme  Started 1992 with CSIRO*.  Worked with them and others through to mid 2000’s.  Programme aim – to develop sealed gel batteries at similar cost to vented but with major performance advantages. *Commonwealth Scientific & Industrial Research Organisiation

SuperGel Technology The basis for the Battery Energy SuperGel Technology is as follows:-  In jar formation – provides lower cost, improved OH&S and performance advantages  Optimised paste mixing/curing process  Thick plate technology (5.3mm positive and 3.9mm negative)  High fumed Silica concentration (6%)  Optimised material selection process (VRLA lead, corrugated separators) GEL PRODUCTS INTRODUCED COMMERCIALLY 1996

Gel Programme Achievements Battery Energy has developed a sealed SuperGel battery with high conversion of active material in formation The final products are characterised by:- a)High degree of Ah efficiency (102 – 103%) b)Capable of PSOC operation over long periods of charge/discharge cycles with minimal overcharge. Starts out at 101%, probably 102% at end of life

PSoC cycle no. SoC / % Regime 1 Regime 2 Regime 3 PSOC Example Parameters: - PSoC window- charge rate - battery temperature- battery condition - conditioning charge

Float Performance Characterised by:- - Very low float currants - Good high rate performance - Typically 2-3 times longer life on accelerated tests compared to AGM

Battery Energy SuperGEL Float Currents OperatingTemperature Degrees C° Cell Voltages Per 100Ah in mA

Cyclic Performance (1)  Initial CSIRO test results 1200 cycles at 100% DOD – failure due to negative plate. Positive plate - 14% corrosion after 800 cycles.  High temperature tests (45 degrees) 555 (100% DOD) cycles – no loss of capacity.

Cyclic Performance (2) PSOC  ETEC (US) 2001 – fast charge/PSOC 70% DOD (100% - 30%) - >1000 cycles. Battery Energy SuperGel is 2-3 times life of competitor gel products.  ETEC Current testing – utility profile 80% - 30% SOC ~ 2000 cycles and still operating. AGM batteries 300 – 400 cycles under same profile.  Solar – PERU ILZRO – RAPS daily ~ 35% DOD (80% - 45% SOC) in 240Vstrings. Still operating after 7 years (requirement 8 years).

Abuse resistance  Overcharge – 2.6V for 8.5 months ~ 3 times longer than AGM battery.  Operating in the discharge state - charge to 2.45V/discharge to 1.75V – battery walks down to 30% SOC. 150 – 200 cycles (PSOC without equalisation). Recovery process – 100% capacity X 2.  Water loss – much less than other batteries. (See next slide for example)  No stratification observed.

Water loss Data Duty Battery type Tem p. (°C) RWL gev (ml/Ah/cell/year) WL crit (ml/Ah/cell) Years to reach WL crit (with WL corr50 ) Simulated 1-day RAPS service CSIRO (o) * CSIRO (o) * (m) * (m) (n) (n) Field service (m)  * (n) 

Conclusion  Advanced SuperGel technology together with advanced control techniques and further battery optimisation will lead to a bright future for industrial lead acid batteries.  Independent of lithium battery technology advances

BATTERY ENERGY Australian Made Products, Designed for the harshest of Australian Conditions Australian owned company, employing Australians. QUESTION TIME?