lithium-ion introduction...• lead acid or nickel • lithium, sodium and flow • other...

Lithium-ion IntroductionNicholas Shanley

Raleigh, NC

March 5th

Saft proprietary information – Confidential

New mention

Agenda

1. Saft Overview

2. Lithium Technology

3. Lithium-ion Safety, Codes and Standards

4. Case Studies – Data Center

5. Beyond the UPS batteries

Saft 7x24 Exchange Presentation -Carolinas Chapter2

Saft proprietary information – Confidential3

SAFT IN MISSION CRITICAL1

Saft 7x24 Exchange Presentation -

Carolinas Chapter


Who is Saft today?

GROUP PROFILE

3,000+ customers

GLOBAL PRESENCE - SALES

100 years of history. 25 Years experience with Lithium-Ion

Leadership position

on 75-80% of revenue base

9.7% invested in R&D with 3 main technologies; primary lithium, lithium-ion

& nickel-cadmium,

Products for Data Centers: wide range of

NiCd for switchgear, SPH for Engine

Starting, Flex’ion for UPS

4,100+ people

35%North

America

32%Europe

33%Asia, MEA,

LatAm

4


Mature, reliable technology

Saft 7x24 Exchange Presentation- Carolinas Chapter5

– #1 worldwide in Li-ion satellite batteries

– Mercedes S400 hybrid

• First production vehicle with Li-ion

– Ferrari F1 KERS (and 4 other teams)

– F-35 Joint Strike Fighter

– Airbus A350 XWB

– Total Pangaea Super Computer *Flex’ion


INDUSTRIAL BATTERY

TECHNOLOGY2


Carolinas Chapter


Why are batteries important for critical facilities?

7

– Batteries play a critical role in each phase of power stability and they increase ability to

operate the facility.

– They Support Critical Loads:

• Loss of Revenue, Uptime, Business Ability, Customer Satisfaction

– Future Battery Applications within critical infrastructure: Battery as an Asset, Renewables, power on the rack

Utility

Gen-setUPS

3. Switchgear

1. Short Duration

backup

4. Engine Starting

Saft 7x24 Exchange Presentation -Carolinas Chapter

Critical Loads

2. Station Battery


Battery Composition

8

Energy Storage Active Material

=

Electrolyte

+

A battery is an electrochemical energy storage device.



Battery technology differentiation

9

Conventional batteries

e.g. Lead-acid, Ni-Cd,

Ni-MH

Remove

water Lithium batteries

e.g. Li-ion, Li-polymer,

Li-metal polymer, Li-S

Add

heat

High-temperature batteries

e.g. Na-S, Na-NiCl2

Separate power

from energy

Flow batteries

e.g. Vanadium redox, Zn-Br


Carolinas Chapter


VLA (Vented lead-acid)

– Flooded lead acid (liquid electrolyte)

– Tubular / Pasted

• Lead is mixed with other additives

– Planté

• Pure lead plate (as opposed to pasted or tubular)

• Superior life BUT high cost, large and heavy

VRLA (Valve regulated lead-acid)

– AGM (Absorbed Glass Mat)

• Electrolyte is absorbed in glass fiber separator which hold the electrolyte in its place by capillary action

– Gel

• Gelified electrolyte (sulfuric acid is mixed with silica, which makes the resulting mass jelly-like and immobile)

VRLA contributes to more than 70% of demand, as it is the most widely used

battery type in stationary applications covered in this deliverable

Lead-acid for Industrial Standby Markets


10


Technologies comparisonMain performances

Service life =

Field data, typical valueField data

* Service life at continuous temperature to 80% capacity

** Short life (UPS / power), long life (Telecom / energy)

*** Filled & charged (short) / dry discharged (long)


11

Traditional LA Li-ion Ni-Cd

TechnologyVRLA

VLAIron-

PhosphatePocket Plate

AGM Gel

Service Life*

@ 68 oF 4 - 10 Y** 10 - 15 Y 10 - 15 Y 20 Y 20+ Y

@ 100 °F 1 - 3 Y** 3 - 4 Y 3 - 4 Y 7 Y 14+ Y

Operating

Temperature

14 to 14 to 14 to -4 to -4 to

+100 oF +113oF +113 oF +100 °F +40 °C

Storage

1 Y 2 Y

3 M /

2 Y

***

1Y > 2 Y@ 77oF

w/o recharge

Lab & field data


Li-ion History

12

– 1976 – Exxon researcher M.S. Whittingham describes Li-

Ion concept in Science publication entitled, “Electrical

Energy Storage and Intercalation Chemistry.”

– SONY introduced the first Li-ion 18650 cell in 1991

– Saft introduced Li-ion to the market in 1992, large

format in 1995.

1792 1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1976 1991



Li-ion battery a mature and fast growing technology

Lithium-ion Battery:

• In the Market before 2000

• Highest growth since 2000

→ From less than 1% to more than 14%

in 15 years, (global battery market)

• Major funding and investments

• Mainly driven by EV market*

Source : Avicienne Energy2016

13 Saft 7x24 Exchange Presentation -Carolinas Chapter

*No. of Cars Battery Size Energy per week Annual Capacity

5000 75 375 19.5

per week kWhr MWhr GWhr

https://www.google.cz/amp/www.independent.co.uk/environment/global-warming-data-centres-to-consume-three-times-as-much-energy-in-next-decade-experts-warn-a6830086.html?amp


Li-ion: Many Flavors


– Currently Used Cathodes

• LiCoO2 = LCO – Cell Phones, Tablets, Cameras (consumer grade)

• LiNiCoAlO2 = NCA – Energy Storage, EV’s

• LiNiMnCoO2 = NMC – UPS, E-bikes, Medical Devices, EV’s

• LiMn2O4 = LMO – UPS, Power Tools, Medical Devices

• LiFePO4 = LFP – UPS, many applications

– Currently Used Anodes

• Graphite = Carbon (C)

– Emerging anodes

• Li4Ti5O12 = Lithium Titanate Oxide (LTO)

• Alloy anodes = Si and Sn based (Silicon and Tin)

195 Ah/kg145 Ah/kg125 Ah/kg

162 Ah/kg

3,00

3,20

3,40

3,60

3,80

4,00

4,20

4,40

0,00 50,00 100,00 150,00 200,00 250,00

CAPACITY (Ah/kg)

VO

LT

AG

E (

V)

LiNiO2

LiCoO2

LiMn2O4

LiFePO4


Major Lithium Ion Chemistries

15Saft 7x24 Exchange Presentation -

Carolinas Chapter

Tradeoffs among the four principal lithium ion battery technologies

The furthered colored shape extends along a given axis, the better the performance along that dimension

Source: Battcon Paper J.McDowall

• Calendar life at 68°F to 77°F

• Calendar life at high

temperature

• Capacity availability at low

temperature

• Safety of positive active material

• Energy density

• Power density


Cell Formats

16

– Cylindrical

• Provides best support for expansion and contraction of electrodes during cycling

• Suitable for higher capacity levels per cell

• Less factory handling required

– Prismatic

• Better energy density with thermal barriers

– Pouch

• Difficult to seal for long life

– Capacities determined by geometry (up to 80Ah per cell)

– Varying the winding process results in different battery performance (Energy vs High Power)



From Cells to Modules

17

Lithium-Ion Modules

– 12V, 24V, 36V, 48V common Voltages

- Packs of Lithium-ion cells

- Typically contains:

- Li-ion Cells

- Bus Bars

- Electronics

- Monitoring

- Communications



Battery Management Functions


Carolinas Chapter18

– Management vs Monitoring – Defined.

– Operations supervision (U, I)

– Charge / discharge management

• IMR / IMD

– Thermal management

– Warnings / Alarms

– SOC

– SOH

– 1st level safety

– Watchdog

– Blackbox

– Maintenance / Diagnostic


System Architecture: Main Components


BMM

Inter-face Box

Battery Module

Non-seismic or Seismic BatteryCabinet

HMI & E-stop

Master Controller


C/100

C/10

C

10C

100C

1

10

100

1 000

10 000

100 000

0 20 40 60 80 100 120 140 160 180 200

Energy [Wh/kg]

Po

wer

[W/k

g]

Super capacitor

Ni-MH

Ni-Cd

High Power Li-ion (VLP)

Medium Power Li-ion (VLM)

High energy Li-ion (VLE)

Very-high power Li-ion (VLV)

AgO-Zn

Ultra-high power (VLU)

Li-Ion Flexibility

20

Ragone diagram

Standard Lead-Acid

Saft 7x24 Exchange Presentation- Carolinas Chapter


LITHIUM SAFETY, CODES

AND STANDARDS3


Carolinas Chapter


CathodeBased on the application and battery usage

Anode

Others

Current

interruption

Venting

Thermal

Mgmt

Electronics

Software

Mechanical

Architecture

Ma

teria

ls a

nd

Pro

ce

ss C

on

tro

l

Ch

oic

e o

f C

he

mis

try

Sy

ste

m D

esi

gn

Ce

ll D

esi

gn

Particle contamination of incoming materials

Particle and humidity control

Process validation/control

Li-ion Safety


• No Li-ion chemistry is intrinsically safe!

• Saft approach• Prevent safety events

• Minimize level of event

• Limit consequences

• Inter-linked efforts

• Multiple redundant layers• System level – active communication for

safe operation & alarm management

• String level – protective devices &

algorithms

• Module level – no propagation!

• Cell level – safe venting

• Auxiliary systems – thermal management;

fire detection & suppression


Codes prior to 2018 (reference IFC) – Carolina Codes



Codes and Standards

24

NFPA 1, Chapter 52

IFC 608

2018 editions

Applies to large installations

Updates and modifications

Source : Laurie Florence Battcon 2018 paper

Some Limitations imposed on Energy Storage Systems in the 2018 ICC IFC

Parameter Limitation Imposed

Exceptions

Threshold Quantities that must

comply with IFC requirements of

Section 1206:

• lead acid or nickel

• lithium, sodium and flow• other technologies

70 kWh

20 kWh10 kWh

Hazard mitigation analysis per 1206.2.3

Size of Individual Array (BESS unit)

50 kWh • Lead acid and nickel cadmium technologies,

• 250 kWh for other technologies pre-engineered

and pre-packaged if Listed

• > 250 kWh for other technologies if Listed and if LSF testing &AHJ approval

Separation distances between

BESS arrays or between arrays and structure

≥ 3 ft • Lead acid and nickel cadmium technologies

• Smaller separation distances for other

technologies if Listed and if LSF testing & AHJ approval

Outdoor installation separation from exposures

≥ 5 ft Smaller separation distances if LSF testing & AHJ approval

Maximum Allowable Quantities:

• lithium, flow or sodium• other

600 kWh200 kWh

• Lead acid and nickel cadmium technologies

• Group H-2 Occupancy

• Hazard mitigation analysis is conducted, LSF testing & AHJ approval

Installation floor level limits:

• above lowest level of fire

vehicle access

• below lowest level of exit discharge

≤ 75 ft

≥ 30 ft

• Lead acid and nickel cadmium technologies

• > 75 ft above fire vehicle access if installed on

noncombustible rooftop, does not restrict FF rooftop operations and if AHJ approval

AHJ – authority having jurisdiction

LSF – large scale fire testing, which can be addressed by the 9540A test methodFF – fire fighter



Codes and Standards – NFPA 52.3.2.7-8


– Suppression:

• 2015 editions did not explicitly required suppression

• 2018 required for all battery spaced w/ exceptions for telecommunication installations

– Gas Detection

• Alarming for 25% of the lower flammability level of gas as well as 50% of the IDLH (immediately dangerous to life or health) for toxic or highly toxic gases.

• Must have visible and audible alarms in the battery room

• Approved transmission to specific location

• De-energizing of the battery rectified

• Activation of the ventilation


Applicable Codes / Standards


– NFPA-1 Fire Code, 2015

– NFPA-1 Fire Code, 2018

– IFC International Fire Code, 2015

– IFC International Fire Code, 2018

– NFPA-855, 2017 Pre-Draft Discussions

– NFPA-111, 2014

– NFPA-111, 2017 First Draft

– NEC-70 National Electric Code, 2017

– International Building Code, 2015

– International Mechanical Code, 2015

– NFPA-76, Standard for the Fire Protection of Telecommunications Facilities, 2015

– UL1973, 9540, 9540(A)


DATA CENTER

EXAMPLE4



Data center sizing example 1

– 500 kVA UPS, 5 minutes, BOL

– Standard 480Vnom DC

– Consider 85°F

– Safety considerations

• Large battery installation

• Manned facility

– LFP chemistry is a close match to the application requirements

• Long calendar life, while being optimized for high power

• 55% of VRLA footprint

• 28% of VRLA weight

28Saft 7x24 Exchange Presentation -Carolinas Chapter


Case Study: 500kW

29

A path to savings…


Carolinas Chapter

500kW / 3 MinutesHigh Power

VRLA

Saft Flex'Ion

4 506 11.Flex46PFeDelta Related Benefits

kWh installed 290 58 5 Energy savings : less energy consumptions in floating mode and charge

Footprint (sq Ft) 21 10 2 Improve TCO : lower real estate cost, other equipement can be installed

Weight (lbs) 13000 2500 5 Improve TCO : lower infrastruture cost, easy and quicker to maitain

Calendar Life

25degC5 to 7 20 3 1/2 Improve TCO : less replacement over 20 years

Eficiency 83 to 87% 96 to 99%Energy savings & Improve TCO : less energy consumptions in floating mode and

charge, les power/energy installed

Optimal

Operating

temperature

25C/77F20C to 30C/68F to

86F

HVAC consumptions savings & Improve TCO : extend the operating

temperature of the battery room and save HVAC consumptions and

related costs

Maintenance few hours

every year

few hours over

lifetimeTo be evaluated

Recharging time 5 to 7hrs 1.5hr 4 Improve System availability

Communication To be added IncludedImprove Predictive Maintenance and System availability :SOC, SOH, Alarms and

custonized battery information alaready avaialble

Electrochemistry L/A Li-Ion

Improve System availability : No sudden death

Improve Environemental footprint : CO2 reduction (~40%)

Improve TCO : less maintenance


Power

Vo

ltag

e

Lithium-ion: Modular system example

30

Flex’ion 5 x 506 11.46PFe

BMM

Flex’ion 46 PFe

506 Vnom

Intelli-Connect®

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

BMM

Flex’ion 46 PFe

506 Vnom

Intelli-Connect®

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

Flex’ion 46 PFe

24 in

84 in

Load profile: 500W for 5 min at 506Vnom

Note: Cabinets can be mounted back to back


Carolinas Chapter


TCO Analysis

1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

CA

PEX

/ O

PEX

YEARS

TCO: FLEX'ION VS 10Y, HIGH-RATE VRLA

VRLA

Flex'ion

VRLA VRLA Replacements

VRLA Replacements (every 5 years)

Roughly 2x VRLA Price

Year 20:

represents

60% savings

Flex’ion vs 10Y, high-rate VRLA

Battery Price 2.0 - 2.5x

Installation Cost 0.7 - 0.8x

Annual Maintenance 0.4 - 0.6x

Payback

Year 5

Year 10:

represents

40% savings


5


Carolinas Chapter

Beyond UPS Batteries


Energy Storage and Renewables – 3 solution levels

– Make it compatible

– Make it predictable

– Make it dispatchable when needed

Seconds Minutes Hours

Power-to-energy ratio

Ancillary services

Energy managementNon-

Renewables

Smoothing

Shaping

Shifting

Renewables



Energy Storage and Renewables

– Compatibility

• Ramp-rate control & frequency response

• Low energy requirement

• Important for weak grids

– Predictability

• Firming to forecast

• Moderate energy requirement

• Weak grids and grid management

– Dispatchability

• Shifting to grid peak

• Hours of energy

• Competition with conventional generation



Solid-State

– Replaces liquid electrolyte with solid compound, but allows Lithium-ions to move within it.

35

What is it?

What are the advantages?

– Safety is key. Inorganic solid electrolytes are non0flammable when heated. This technology also permits the use of innovative, high-voltage, high-capacity material, enabling denser, lighter batteries.

When can we expect it?

– Several kinds of all-solid-state batteries are likely to come to market as technological progress continues. First will be graphite-based, but with much higher safety and performance.

– Lots of grants and research already in place

Saft 7x24 Exchange Presentation - Carolinas Chapter


Learn more about Saft

36

Stay tuned!

Saft International

Magazine

Corporate

Brochure


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