Prepared for 7 x 24 Exchange

What do you know about EnerSys?

• World’s largest Industrial battery company

• Headquartered in Reading, Pennsylvania USA

• Annual revenue in excess of $2.0 Billion; over

9000 Employees worldwide

• Manufactures and distributes industrial batteries

in three markets

– Reserve Power – Motive Power –

Aerospace & Defense

• Broadest product portfolio in industry

• Nationwide Service Group

UPS

Product Applications Reserve Power

Telecom – Wireline

Telecom - Wireless Wind & Solar Railroad Crossing Backup

Extended Run time

Purpose of Batteries

• Once AC power is lost, batteries pick up the load until the generator starts or until power is regained

• Batteries provide power for both AC and DC equipment during outages

• Benefits of using batteries – Immediate response (compared to

generator)

– Do not require fuel source to be replenished

– Noiseless (no muffler)

– Only emissions are Oxygen & Hydrogen – no Carbon or Nitrous emissions

Lead acid battery components

• Lead-acid battery consists of two dissimilar metals in acid solution

– Positive plate – PbO2 (black or dark chocolate brown when healthy)

– Negative plate – Pb (light gray or gray)

– Acid – H2SO4 (clear – water and sulfuric acid mixture)

– Separator (keeps positive and negative plates from touching)

– Jar/Cover (you have choices)

Lead acid battery construction

8

Typical Lead Acid Plate

Primary

failure of a

lead acid

battery is

due to Grid

Corrosion

Grid Pasted Plate

Pros Cons

Low maintenance technology Relatively low energy density (heavy)

Long float life, specially pure lead Cannot be stored in discharged state

for too long

Quick charge and discharge

capability Lower cycle life than NiCd cells

Charging and orientation flexibility

Thermal runaway possible with

excessive overcharge or improper

thermal management

Wide operating temperature (-65ºC

to +80ºC)

More sensitive to high temperature

than flooded lead acid cells

No “memory” effect

State of charge easily measured

(OCV)

Low cost of ownership

Pros & Cons of VRLA

VRLA metallurgy

• Pure lead

– Grid metallurgy used when VRLA technology was

introduced in the 1970s in a cylindrical format

• Lead calcium

– Introduced mainly to overcome manufacturing issues

with pure lead

• “Pure” lead-tin

– Combines strengths of pure lead and lead calcium

technologies while minimizing their weaknesses

12

Conventional Lead Calcium Battery Grids

Provides stiffness and strength

for handling and manufacturing

Grid is Cast

Costs less to manufacture

Accelerates grid corrosion

Accelerates self-discharge

Requires thicker plates for longevity

Use of a hardening alloy:

13

Conventional Pb-Ca-Sn “Book Mold” Cast

Grid Prone to growth and corrosion at grain boundaries

Must be 3 to 4 times thicker than Pb-Sn or Pb grids for same

life. High internal losses = short storage life

The Difference can be see in the Grain Structure

Cold Rolled Pb Strip High purity lead (no hardening agents or

tin) Cold rolling process produces finest

grain structure. Highest resistance to

anodic corrosion.

High purity grids and electrolyte for long

storage life

14

Corrosion the oxidation of the battery grid

▼Oxidation of the lead grid

causes plate growth and

eventually destroys the grid

Lead Acid Battery Failure Mode

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15

Typical VRLA Batteries

Positive grid alloy is Pb-Ca-Sn

Corrosion at the grain

boundaries leads to:

• Grid corrosion

• Grid growth

• Reduction in current carrying capacity

• Loss of contact between grid and active material

EW/Thin Plate/10/02

16

Pure Lead Crystalography

TPPL Pure Lead Grid

The very fine grain structure makes

the grid far more resistant to corrosion

• Pure lead grids with the same

design life can be much thinner

than Pb-Ca grids

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17

Virgin Lead

Oxide

Medical Grade

Acid Virgin Lead

High Purity Materials

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18

The advantages of high purity materials are:

• Low rate of self discharge = Long Shelf Life

• Thinner positive grids = High Energy Density

High Performance

High Purity Materials

High purity materials are more expensive….

but the advantages outweigh the extra cost!!!

• Low rate of grid corrosion

• Low float charge current

• Low gassing rate

= Long Service Life

EW/Thin Plate/10/02

19

VRLA Grid Thickness

Thick vs Thin

Equivalent Float Life Products

TPPL Technology

SBS Pb-Ca

Cells are: • Large • Heavy Grids are: • Prone to corrosion and growth

Cells are:

• Smaller

• Lighter

Grids are: • Resistant to corrosion and growth

Positive Grid Corrosion

Lead Calcium Tin (Pb-Ca-Sn) Pure Lead (Pb)

Battery service life is limited by the positive grid which slowly corrodes

The rate and the nature of corrosion is effected by float/charging current,

grid material and design

Pure Lead vs Lead Calcium Positive Grids

21

The SBS Benefit - A Longer

Life Battery

22

Another Major Difference for TPPL

2 V 2.5 AH D CELL

SEALED-LEAD

RECHARGEABLE

BATTERY

Typical Lead Calcium – Grid

is Cast

TPPL - Grid is Cold Rolled

or Chill Cast and Punched

EW/Thin Plate/10/02

23

TPPL Models

Thin grid technology requires

special manufacturing techniques

A thin strip of lead is fed into a

perforating machine, which

punches out the holes that will

contain the paste pellets

Warrensburg, SBS J production

EW/Thin Plate/10/02

24

The perforated strip is fed

through a pasting machine

A thin layer of paper applied to

each side of the pasted plate to

retain the paste in the grid

The strip is then cut into plates

Because the grid is so soft the

plates are easily damaged and

must be handled carefully

Warrensburg, SBS J production

TPPL Processing

Why pure lead-tin VRLA?

Feature Benefit

Low internal

resistance

• Great high rate discharge capability (25C or more)

• Quick charge capability (100% capacity in 30 min.)

• Good discharge capability even at –20ºC

High purity

system

• Low self-discharge (2 yrs. shelf life at 25ºC)

• Longest float life among VRLA batteries (10+ years at 25ºC)

High

compression

• Allows higher cyclability (1,300 JIS cycles)

• Higher resistance to vibration

High temperature

capability • Widest operating temperature range (-65ºC to +80ºC)

Small amount of

tin

• Excellent overdischarge recovery capability

• Allows charging flexibility (CC, CV or combination)

High vent

pressure

• Accepts very aggressive charging

• Can be used in space (only VRLA acceptable to NASA)

Pure lead-tin vs. lead calcium VRLA

Feature Pure lead-tin

(Genesis XE)

Lead calcium

(Genesis NP)

Calendar life @ 25ºC 12+ yrs. for XE 3 to 6 yrs.

Cycle life 1300 625

Temperature range -40ºC to 80ºC for XE with jacket -20ºC to 60ºC

Charging @ 25ºC Float: 2.25-2.30 VPC; no CL

Cyclic: 2.40-2.50 VPC; no CL

Float: 2.25-2.30 VPC; no

CL

Cyclic: 2.40-2.50 VPC;

0.25C CL

Quick charge

capability 100% SOC in < 30 min.

Limited by current limit

(CL)

Shelf life @ 25ºC Recharge every 24 months Recharge every 6 months

Capacity @ -20ºC (%

of 10-hr rate)

42% @ 15 min. rate

70% @ 1-hr. rate

4% @ 15 min. rate

38% @ 1-hr. rate

27

Automation of plate manufacture

allows processing of thin Pb°

grid Result : 1mm Thin

Bookmold casting requires

inherent grid strength - thick

with added hardeners

Result: 2 - 4 mm Thick

Higher Energy Density

Thin = Greater Surface Area = More Power

Means the

difference

between a

155AH lead

calcium to

a 170Ah

Pure Lead

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28

FLOAT CURRENT & RECOMBINATION EFFICIENCY

SBSC11

MONOBLOC 1 MONOBLOC 2

INITIAL WEIGHT (Kg) 26.532 26.44

OCV 13.123 13.108

CHARGE 2.27V/CELL : 168H

Ah IN 3.6 3.53

STABILISED FLOAT CURRENT (mA) 20 20

WEIGHT AFTER CHARGE 26.529 26.438

% RECOMBINATION 99.6 99.7

Recombination Efficiency

Low float current and high efficiency recombination means there

is virtually no gas emission under normal operating conditions

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SBS Technology

SBSC11 GAS EVOLUTION TESTS AT ELEVATED TEMPERATURE

TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED

40 C 2.45Vpc N/A 0.580 LITRES/HOUR

50 C 2.45Vpc 610mA 0.880 LITRES/HOUR

65 C 2.45Vpc 900mA 2.020 LITRES/HOUR

TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED

40 C 2.375 Vpc 250mA 0.111 LITRES/HOUR

50 C 2.375 Vpc 450mA 0.190 LITRES/HOUR

65 C 2.375 Vpc 560mA 0.45 LITRES/HOUR

TEMPERATURE FLOAT VOLTAGE (V) FLOAT I GAS EVOLVED

40 C 2.27Vpc 40mA 0.00 LITRES/HOUR

50 C 2.27Vpc 80mA 0.00 LITRES/HOUR

65 C 2.27Vpc 270mA 0.00 LITRES/HOUR

At 40C & 2.45Vpc data f ile corrupted so no f loat current value recorded

At 20C & 2.27Vpc float current ranged betw een 10 - 20mA

EW/Thin Plate/10/02

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TEMPERATURE DEGREES CELSIUS

MONTHS/YEAR 20C 25C 30C 35C 40C 45C 50C 55C

1 15 14.6 14.2 13.8 13.4 13 12.6 12.3

2 15 14.2 13.4 12.6 11.9 11.3 10.6 10

3 15 13.8 12.6 11.6 10.6 9.7 8.9 8.2

4 15 13.4 11.9 10.6 9.5 8.4 7.5 6.7

5 15 13 11.3 9.7 8.4 7.3 6.3 5.5

6 15 12.6 10.6 8.9 7.5 6.3 5.3 4.5

7 15 12.3 10 8.2 6.7 5.5 4.5 3.7

8 15 11.9 9.5 7.5 6 4.7 3.8 3

9 15 11.6 8.9 6.9 5.3 4.1 3.2 2.5

10 15 11.3 8.4 6.3 4.7 3.6 2.7 2

11 15 10.9 8 5.8 4.2 3.1 2.2 1.6

12 15 10.6 7.5 5.3 3.8 2.7 1.9 1.3

Long Service Life

TPPL typical service life expectancy to 80% of rated capacity

Quick charging lead-tin VRLA

3.1C10 1.6C10 0.8C10

30 min. 50 min. 90 min. 100%

14 min. 28 min. 57 min. 80%

10 min. 20 min. 44 min. 60%

Charge current, amps Capacity

returned

C10 = amp-hour capacity at the 10-hour rate; 0.8C10 = 80A for a 100Ah battery

Cycle life comparison

Thermal runaway comparison

35

3X Increased Shelf Life

OPEN CIRCUIT VOLTAGE/STATE OF CHARGE DECAY AS A FUNCTION OF TEMPERATURE

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

0 6 12 18 24 30 36 42 48

70

74

79

83

87

91

96

100

Open

Circuit

Voltage

per Cell

+10°C+20°C+30°C+40°C

Months

Approx

% state

of

charge

+25°C

SBS Self Discharge Characteristics

Up to 18 months of

storage vs. 6

months for lead

calcium.

Stop installing dead

batteries when

deployments take

longer than

expected

XE Battery Features

• 12V pure lead-tin VRLA AGM battery

• UL94 V-0 flame retardant case and cover

• Rugged construction (optional metal jacket

available, except for XE60 and XE95)

– -40ºC to 80ºC (-40°F to 176°F) with metal jacket

• Approved for shipping as non-hazardous,

non-spillable

Batteries for Flywheels

• Advanced lead technology TPPL (XE)

• Battery cabinets sized for <20 second loads

• 480V strings

• 600kW for 30 Seconds

– More Power and Run Time

Flywheel – TPPL Comparison

• Lower operating costs – 250W float charge for flywheel

– 25W float charge for battery

– Flywheel Uses 1,971 KW Annually

– Flywheel Extra 1,944 lbs CO2 Annually

• Capital costs – $30k for 750kW batteries

– $200k for 750kW flywheel

– 15% Cost (Initial) 30% Life (2X)

• 10 year life expectancy

• Solutions based approach

Where is pure lead-tin used?

• Anywhere a conventional lead calcium AGM is used plus where customer is looking for:

– Quick charge capability

– Longer float life than conventional AGM

– Longer cycle life than conventional AGM

– Wide operating temperature range

– Long shelf life

– High rate discharge capability in a smaller package

– High rate discharge & excellent cycle life in the same battery

42

360,000 sq. ft.

33 acres

330+ employees

~30,000 Batts./day

Warrensburg, Missouri Facility

First battery plant in the world to be certified as

ISO 14001Environmental Management System

ISO 9001 Certified Quality Management System

1995-1997 Gold Pretreatment Award Missouri Water

Environmental Association

1997 Industrial Water Quality Achievement Award

FAA Certified Production Approval Holder (PAH/PMA)

Approved Supplier to the Military Automated Line

•EnerSys provides a complete range of recycling support services. With logistics

recovery you can contact us to arrange a drop off time, or to have us pick up your

batteries.

•EnerSys follows fully compliant processing and batteries are only sent to lead

smelters operating under Part B hazardous waste facility permits.

•EnerSys accepts all lead acid batteries. EnerSys exceeds state and federal

requirements by giving you complete recycling documentation, including Recycling

Certificates.

•“Its good for business and good for the environment”

Recycling

Thank you !