MOLECULAR REBAR® - Black Diamond Structures · Adoption of dCNT in lead acid batteries Mohamed...
Transcript of MOLECULAR REBAR® - Black Diamond Structures · Adoption of dCNT in lead acid batteries Mohamed...
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MOLECULAR REBAR® Adoption of dCNT in lead acid batteries
Mohamed Sharif, Venkat B
Black Diamond Structures, Austin TX USA
Who We Are
Black Diamond Structures is a developer, manufacturer, and marketer of innovative nanomaterial products and solutions based on
revolutionary carbon nanotube (CNT) technology, MOLECULAR REBAR®
Our Partners
MOLECULAR REBAR®: Global Adoption
Global Adoption:
– Products Commercially Available and being sold to Lead Acid Battery Manufacturers– Working with >100 battery manufacturers worldwide, each at various stages of development
and/or commercial sales.– Recent approval for use in major Automotive OEM batteries. (SLI)– Have proven that Molecular Rebar can help battery manufacturers meet new OEM requirements
for “Advanced Automotive Battery” applications. – Large amount of data on full-scale production batteries, not just 2V hand-built cells– Approved to discuss three Mfr’s publicly at this time (Eastman – India, Pacific Battery – Fiji, Tianjin
Lantian Power Sources – China)
Why the rapid adoption?– Technology is innovative, cutting-edge, and scientifically sound– Cost effective performance improvements over a wide variety of applications– Low risk to use– No (or very low) capital expenditure by manufacturer; very easy to use and implement– Highly technical staff works hand in hand with your company during ramp up.– World-class technical support from Black Diamond Structures
Clumps of Dirty, Entangled CNT’s
Bulk Carbon
Nanotubes
Clean, Detangled MR Discrete, Individual Tubes
Key Competitive Advantage
Detangling/ Separation
Formulation -Dispersion
MasterBatch -
Concentrate
MOLECULAR REBAR® Technology
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MR in Lead Paste(or other substrates)
Customer Integration
w/ End-Product
Key Features:
• Used in Negative Electrode or Negative & Positive Electrodes
• Improved Consistency in Capacity & CCA Throughout Life
• Extended Cycle Life / Reduced Warranty Failures
• Increased Electrical Performance
• Enhanced Plate Strength / Durability
Batteries provided by Pacific Batteries Ltd (NS40)
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Flooded SLI BatteriesPb1100 Series Products
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Flooded SLI BatteriesPb1100 Series Products: Base Performance
C20 Measurement (EN-50432-6)
• Pb1100 Series has no negative effect on capacity
• Also true for RC measurements
CCA Performance (EN-50432-6)
• Pb1100 Series elongate discharge; Ah-out higher
• CCA remains consistent throughout life and cycling
Control Pb1100N Series Pb1100N SeriesControl Pb1100N Series Control Pb1100N Series
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Protocol Stress factor Improvements by Molecular Rebar
SAE-J240@70C
Ability of battery to perform lightload endurance @75C
50-60% cycle life increase
SAE-J2185@50C
Ability of battery to perform heavy dutycycling
12-35% cycle life increase
VDA-RC Endurance
Enhanced ability to retain the rated capacity through out life
20% cycle life increase
VDA-Repetitive over discharge
Ability of battery to recover after parasitic loads (Very deep discharge)
6-25% cycle life increase
SAE J240-LLE SAE J2185-HLE
^12%
^35%
VDA-RCE VDA-ROD
Summary
Flooded SLI BatteriesPb1100 Series Products: Life cycle tests
^50%
^60%
^20%
Enhanced Flooded Battery: Pb1200 Series
• Product = Pb1200Nx & Pb1200Px
• Key Features:– Use in Negative and/or Positive Electrode
• Pb1200 Series provides balancedperformance increases across the following tests: – CCA/Capacity– Charge Acceptance– Durability Life Cycle Tests– Micro-Hybrid Life Cycle Tests– Gassing Tests
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Nissan 90% SoC Charge Acceptance
• Current measured relative to C20 current
• Pb1200 negative recipe improves response; further
EN-50342-6 Dynamic Charge• Pb1200 Series improves DCA metric by
~15%
• Test mimics detailed, real-life, start-stop duty cycle
Flooded EFB BatteriesPb1200 Series Products
Increases SBA S0101 Cycle Life
Pb1200Nx and Pb1200Px increases cycle life up to 500%
Pb1200Nx increases cycle life up to 60%
The failure mode in MR batteries shifted to separators
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SBA S0101 Cycle Life
Flooded EFB BatteriesPb1200 Series Products: Life cycle tests
HRPSoC Cycle Life
Pb1200Nx increases HRPSoC cycling 60%
Pb1200Nx lowers charging voltages
Reserve Capacity measurements taken after each segment show MR batteries remain healthier, longer
Pb1200 Series: Actual Customer Production line Produced 12V testing example
Formulated for Balanced Performance Enhancements
80%
100%
120%
140%
160%
180%
17.5% DOD Endurance₁
50% DOD Endurance₁
J2185 - Heavy Duty Life Cycle₃
CPT CCA Duration₂
Water Consumption₂ ₃
J537 Static Charge
Acceptance₃
Dynamic Charge
Acceptance₁
Pb1200 Series Control Batteries
1 - EN 50342-6
2 - EN 50342-1
3 - SAE
Pb1200 vs Control Battery Performance
J537 Cold Charge Acceptance₃
Many innovations targetimproving one aspect ofperformance, often atthe detriment of others.
The Pb1200 Series aimsto bring a balancedsolution to your batterydesign, enhancingperformance to meetyour customers’requirements withoutcompromising existingqualities.
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Deep Cycle Batteries: The Challenges of Today
Inconsistent in performance throughout life
Capacity/backup loss in 1 year as seen in inverter batteries
Capacity/backup loss in 3 months as seen in E-rickshaw batteries
Poor charge acceptance / always on deficit charging
Due to poor charging efficiency of battery active materials
Due to power outages/ improper chargers
E-rickshaw batteries needs a day-charge after 3 months
Results in sulphation/ reduces life
Heavy water loss/ needs maintenance
Due to poor charging efficiency of battery active materials
Power supplied wasted in gassing
Sulphated negative plate
Key Features:
• Used in Negative plate
(Pb2100N-Flat; Pb2200N-Tubular)
• Improved Ah-in during charge
• Increases time between charges
• No daytime recharge needed
• Reduced water consumption
• More consistent capacity through life
Batteries provided by Eastman (80Ah Tubular)
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Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products
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15 A/14.4 V
Av. CON = 10.2 hAv. MR = 7.9 h
15 A/15.2V
Av. CON = 15.6 hAv. MR = 12.0 h
10 A/15.2 V
Av. CON = 32.3 hAv. MR = 20.9 h
Note Axis Scale
ControlPb2100N
ControlPb2100N
Pb2100 and Pb2200 Series Products: Shorter recharge time with any chargerDeep Cycle Flooded: E-Rickshaw
• To fully charge, a flooded battery must absorb >110% of its last discharge
• Pb2100 and Pb2200N series product decreases the time to reach this 110% return at various current and voltage settings as available in the market charger
Recharge time taken by E-rickshaw battery to restore 110% of capacity with and without MR
• Pb2100 and 2200 Series Products:
– Delay onset of daytime charge, enables more productive workdays
– Convert more of Ah Input into useable capacity
– Improve charge Efficiency
• Control batteries experience capacity decay sooner across all recharge scenarios
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>300% Improved
Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products: Lab Simulation Testing
>170% Improved
Protocol: “Workday” = 10 “trips” defined as 5x[30 min DCH + 10 min RST] resulting in 80% DOD over 10 h. At “Night”, battries are charge by one of 3 recharge scenarios: locked at 8 h, 10 h, or 110% Ah-return of previous DCH.
Observations by Drivers & Owners using Pb2100N:
Drivers using 4x80Ah Pb2100 batteries monitored for voltages, charging time and water loss
Pb2100N batteries DID NOT NEED A DAYTIME RECHARGE (~11hr run before charging)
Control batteries needed a 2-3 hour recharge (~5.25hr run before charging).
Water consumption dramatically reduced (less maintenance)
Drivers’ earnings increased ~100 Rs/day due to lack of day time charge (+80km more)
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Shaded Area Shows Charge Periods
Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products: Field Trial Data
Key Features:
• Reduced Deficit Charging
• Extended Life
• Faster Recharge Times
• Lower Water Consumption
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Stationary: SolarPb3200 series product
Decentralized Rural Electrification (DRE) Test
Stationary: SolarPb3200 series product: DRE Life cycle test
• Pb3200 series product extends capacity retention more than 70% • Decentralized Rural Electrification simulation replicates real-world failures which
Pb3200 series product delays (H2O loss, deficit CHR, sulfation, AM loss)• Pb3200 series product is taking in more Ah per charge without increasing water loss
Stationary: SolarPb3200 series product: DRE Life cycle test (Tear Down)
Pb3200N Negative
• Non-uniform material utilization• Material soft and puffing/falling out• Heavily sulfated surface• Large insulative Sulphate crystals
• Shiny surface, plate still usable • No sulfate present on surface• Smaller and uniformly sized crystals
Control Negative
How to use
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• Material is shipped as a black pourable aqueous Solution which is added directly to the paste mixer
• MOLECULAR REBAR® products are formulated for ease of use and incorporation
• Sold in • 10L jugs for Samples• 55 gallon (208 L) Drums• 1,250L totes.
• A volume of pasting water is replaced with the MOLECULAR REBAR® liquid so total liquid volume remains the same
Paste Mixer
Summary
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Formulated Products Available for:• Automotive
• Flooded SLI: Pb1100 Series
• Enhanced Flooded: Pb1200 Series
• Adv. Auto VRLA: Pb1300 Series
• 2W Automotive VRLA: Pb1400 Series
• Deep Cycle / Motive
• Fld e-Rickshaw: Pb2100/2200 Series
• VRLA for Mobility: Pb2300 Series
• Stationary
• Inverter Flooded: Pb3100 Series
• Solar Flooded: Pb3200 Series
• Renewables VRLA: Pb3300 Series
MOLECULAR REBAR® Enhances:• Performance of cyclic battery
– More consistent capacity through life
– Improved Ah-in during charge
– Increases time between charges
– No daytime recharge needed
– Reduced water consumption
• Mechanical Durability
• CCA & Capacity Consistency Thru Life
• Charge Acceptance– EN 50342-6 DCA
– SAE J537 Charge Acceptance
– Nissan 90% SOC Recharge
• Cycle life as defined by:– VDA Repetitive Over Discharge
– VDA Reserve Capacity Durability
– SAE J2185
– eRickshaw Lab Simulations
– Decentralized Rural Electrification Model
– EN 50342-6 17.5% DoD
– EN 50342-6 50% DoD
– EN 50342-6 MHT
– SBA S0101
– Many OEM and Other Specifications
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THANK YOU FOR YOUR ATTENTION!Venkat B: [email protected] Sales Manager+91 85279 88890 (Office)
Mohamed Sharif: [email protected] Development Engineer+91 75062 73409 (Office)
Special Thanks to Our Partners: ®