Fast Charging Battery Life Summary

• Life Cycle Testing
• Independent Laboratory verification of 1500+ 80% DOD cycles
• Periodic cell autopsies were performed
• Warranty
• All US forklift battery companies have a fast charge warranty
• 3 years full (better than conventional warranty)
• Expect warranties to migrate towards an AhThroughput basis
• Field Testing
• 1000s of batteries and dozens of sites have exceeded 3 years of
fast charge operation
• Some are approaching 5 to 6 years of successful operation
• Automotive, Food Producers, DCs and GSE
!
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##
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• Fast Charge prices will continue to drop
• Better Connectors
• 400
Amps in a single connector
• Integrated Watering
• Next Generation Battery Monitors
• Provides
accurate SOC
• Presently BDIs get fooled by Opportunity Charging
• CAN communication to the truck
• Convey SOC, Lift Lock-out, Power Available, Faults, ect
• In Situ Battery Testing
• Real Time battery health and remaining life updates
•
&&
'
!( )
• Better Cold Storage Batteries
• Insulation
and built in heaters
• Charger powers heaters during facility shutdown
• Minimal Charge Time (< 3 hours)
• Faster
charge rates (Lower IR batteries)
• Fast Charge Ready Trucks
• Plug and Charge
• Automation
• Automatic battery watering and maintenance
• Auto charge connection
• Mechanical and Inductive
• HEVs
• Battery Replacement Hybrids (ICE, Fuel Cells, ??)
**
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Normalized Impedance (mohms*Ahs/cell)
,
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450
45 to 90 Minutes
400
30 to 45 Minutes
300
250
200
20 to 30 Minutes
150
3 to 15 Minutes
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• Zero In-plant emissions
• Quick Re-fueling
• Higher vehicle utilization
• Less floor space
• Consistent vehicle performance
• 24/7 Operation
• Reduced hazardous material
• Capital and Lifecycle Costs
• Fuel Costs
• Warranty and Life
• 5000 hr life
• Peak Power duration w/caps
• 2nd and 3rd Stage lifts
• Re-fueling station
• Indoor Permitting issues
• Ratio of vehicles to dispensers
• Operation in Cold Storage or
confined environments
• Water production
• Hydrogen ”leaks”
)
!
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• Cellex
• Battery replacement
• Fuel Cell/ NiMH battery hybrid
• Using BOC hydrogen fuel delivery system
• General Hydrogen
• Battery replacement
• Fuel Cell/Capacitor hybrid
• Using Air Products hydrogen fuel delivery system
• Hydrogenics
• Integrated Fuel Cell engine
• Fuel Cell/Capacitor hybrid
• Developing in house hydrogen generators
• Nuvera/East Penn
• Battery replacement (Plan to use battery distributors)
• Fuel Cell/Lead Acid Battery hybrid
•Developing in house hydrogen generators
##
9
%%
:
• 12 kWs cont, 48 kWs peak
• 60 kWhs
• 3 min Refuel (3.8 kg of hydrogen)
&&
:
-
• 10 kWs cont, 30 kWs peak
• 33 kWhs
• 1.8 kgs of hydrogen
**
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<.
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5 .5
C la ss I T ru ck - H yd ro g e n
5 .0
C la ss II T ru ck - H yd ro g e n
Hydrogen Use per Truck (Kg/day)
4 .5
C la ss III T ru ck - H yd ro g e n
4 .0
3 .5
1 0 0 C la s s III T ru c k s w o u ld
re q u ire :
- 1 to 2 T u b e tra ile rs p e r d a y
- 1 liq u id ta n k tra ile r p e r w e e k
3 .0
2 .5
2 .0
1 .5
1 .0
0 .5
* A ssu m e s 5 5 % E n e rg y E fficie n cy fo r F u e l C e ll E n g in e
0 .0
0
0 .5
1
1 .5
B a ttery C h an ges p er D ay (#)
2
2 .5
3
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$ 20 ,00 0
300
$ 3 1 ,5 0 0
T otal Co sts
270
Total Costs per Vehicle ($/year)
P rim ary En e rg y
$ 16 ,00 0
240
$ 14 ,00 0
210
$ 12 ,00 0
180
$ 10 ,00 0
150
$8 ,00 0
120
$6 ,00 0
90
$4 ,00 0
60
$2 ,00 0
30
$0
0
ICE
B a t te ry H a n d lin g
P a rt ia lly A ut o
B a t te ry H a n d lin g
F u lly A u to
V e hic le T ech nol og y
F a s t C h a r gin g
F ue l C e ll
Primary Energy Consumed per Vehicle (kWhs/Day)
$ 18 ,00 0
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• Productivity Improvements
• Advantage = Fast Charging (Most applications)
• Advantage = Fuel Cells (Some 3 shift operations)
• Zero Emissions
• Advantage = None
• Vehicle Performance
• Advantage = None
• Fuel Efficiency and Operating Costs
• Advantage = Fast Charging
• Installation and Infrastructure Requirements
• Advantage = Fast Charging
-
• To be cost competitive, Fuel Cells of the future needs to attain:
• $250/kW (full engine, PP device, DC/DC and on-board storage)
• 10,000+ hr life
• 60% engine energy efficiency and 75% generation efficiency
• Hydrogen costs of $1.50 delivered to the vehicle
• Need to be able to carry enough H2 for one re-fueling per day
• Keep in mind that ICEs & HEVs, Battery Changing and Fast Charging
will become more cost effective in the future
• But, I do believe there are applications with Zero Emission
requirements that only fuel cells will be able to meet
• Extremely Heavy duty with little charge time
• Outdoor or remote operations (ports, military, ect)
)