dr. mario conte head, technical-strategic support unit ... · dte-usts/mc/workshop...

DTE-USTS/MC/Workshop Frascati/13052016

1

Dr. Mario ConteHead, Technical-Strategic Support Unit

Energy Technology Department

ENEA, Frascati, 13 May 2016

DTE-USTS/MC/Workshop Frascati/13052016 2

Presentation Outline

ENEA historical background on SC activities

Integrated test facilities

Basic research: EC SCOPE and ILHYPOS Projects

Application-oriented activities

Conclusions


Introduction Historical background

End 1980’s > ENEA started investigation on the energy-

intensive applications of SCs in electrically-powered

vehicles and in electricity grid applications

A scientific, technological and market survey was

commissioned.

Technology Status

Carbon DLC Commercial product

Pseudocapacitors with ceramic electrodes composed of transitional-metal oxides

Advanced research

Solid-state electrolyte (e.g. sodium-silver-iodide) SC

Initial research


Initial Experimental Studies at ENEACharacterization testing on commercial products/1

Definition of test procedures for EUCAR Test (BMW, Daimler, FIAT, VW)

PARAMETER TEST

1. Physical measurements

2. Initialisation

3. Capacity determination

4. Capacity determination at different current rates

5. Internal Resistance determination

6. Self discharge

7. Fast charge (behaviour in braking energy recovery)

8. Fast discharge (behaviour in acceleration)

9. Peak power in constant current

10.Peak power in constant power

11.Reaction to high frequency

LIFE CYCLE TEST

1. Initialisation

2. Short parameter test

3. Life cycle test

4. Range extender profile

5. Power assist profile

6. Parameter check-up

EUCAR Battery Working Group

0,1

1

10

10 100 1000

Specif ic Current [mA/F]

Speci

fic E

ne

rgy

[Wh/k

g] 800F

800F/10

1500F

1500F/10

ESRdch=I1

V1 –V2

ESRch=I2

V3 – V4


Initial Experimental Studies – ENEA SC test facilityCharacterization testing on commercial products/2

Set up of a dedicated testing station

A dedicated facility for electrical and thermal tests on cells

was designed, realized and used in various projects


Research-oriented activitiesSCOPE (SuperCapacitors Of Power and Energy) EC Project

ENEA tested SC prototypes

based on a new hybrid design

with the positive electrode

based on a p-doped

conducting polymer and the

negative electrode on a high-

surface area activated carbon.

Target: 3V polymer SC

prototype which outperforms

the DLCSs by delivering

specific energy of 7-10 Wh/kg


Research-oriented activitiesSCOPE EC Project – Experimental results

PropertiesSample

prototype

Capacitance 1450 Farads

Weight 400 g

Peak Power

density1800 W/kg

Maximum

specific energy4,5 Wh/kg


Research-oriented activitiesILHYPOS EC Project – The core is the use of Ionic Liquids (ILs)

Electrochemical window > 5V

SC Energy content V2

Green and stable material

no measurable vapor pressureno flammablehigh thermal stability high chemical stabilityrecyclablehigh ionic conductivity


Research-oriented activities ILHYPOS Breakthrough results/ High ionic cond. of IL @ Low and High T

Organic solvent


Research-oriented activities ILHYPOS Cell asymmetric design


Research-oriented activities Estimated performances for ILHYPOS SCs based on only electrode weights

Cell design

Specific

energy,

Wh/kg

Specific power,

kW/kgAim

Symmetric (Mid-term goals)

24 5Unplanned-Verify

assembly process

Hybrid 51 13 Project targets

Asymmetric 40 13New design

unplanned

Targets >32 10 Under verification


Research-oriented activities ILHYPOS SCs prototypes and results

0 5000 10000 15000 20000 250000

5

10

15

20

25

20 mA cm-2; 60°C

Vmax

3.0 V

3.4 V

3.5 V

3.6 V

3.7 V

3.8 V

Csc /

Fg

-1

cycle number


Current and future applications of SC

Industrial applications

Electric utility applications (e.g. Smart grids)

Automotive applications


Application-oriented activities (Research for the Electric System)

Vehicle-stationary applications – Gantry Crane

The maximum energy saving was measured in certain defined conditions at 31% of the total

electrical energy consumed from the grid by the system without the SC storage system.


IMPLEMENTATIONVALIDATION - IMPLEMENTATION

Block diagram for electrical test sequence + abuse testingSC cells and modules in EU HCV (Hybrid Commercial Vehicles) Project

15

4. Parameter test

5. Life cycling

6. Parameter check up (periodic)

Basic characterization

for HCV demonstrator

7. High power cycling

8. Storage (Calendar life)


Ageing –

accelerated life testing

9. Short cycling

10. Thermal behaviour


Management oriented tests

(on small sets of 5-10 cells)

11. Charge and discharge MST (Multiple-Step test)


Input measurements

for model development

General preparation tests

1. Cell identification & Initial inspection

2. Electric formation

3. Final inspection

Test sequence for SC cells & modules

VALIDATION - IMPLEMENTATION IMPLEMENTATION


Application-oriented activitiesTesting activities in EUCAR EC Project (ASTOR)

Characterization tests on asymmetric/hybrid SC of

American production were performed

Commercial SC were directly coupled (without electronics

interface) to a lead-acid battery to analyze the effect on the

cycle life

A remarkable increase in cycle life was observed after a

comparative test without SC


Application-oriented activitiesVehicle applications – IESS

A 12V Integrated Energy Storage System (IESS) was

developed and patented to comply with power/energy

requirements of the Stop/Start function of a passenger car,


The e-forklift with and without SC

Forklift with a weight of 1500 kg equipped with a lead acid storage unit of 48 V and a 575 Ah rated capacity

lead-acidbattery

Equivalent ActiveDC Loads:- 3 phases induction motors- auxiliaries

DC/DC

DC/AC

supercapacitor

lead-acidbattery

Equivalent ActiveDC Loads:- 3 phases induction motors- auxiliaries


Life-cycle cost assessment for the e-forklift with SC

The end-of-life cost reduction of the storage system with SC introduction is 30%

Configurations

SC andpowertrain

modification cost (in €)

Total battery cost at forklift

end-of-life (in €)

Total cost of storage system

(in €)

Life-cycle cost reduction with SC at end-of-

life

Battery+165F SC

3,000 4,000 7,000

30%Only 30 kWh lead-acidbattery

10,000


Application-oriented activitiesVehicle applications – MAGICA II

Magica II rolling chassis

Magica II body


Application-oriented activitiesVehicle applications – Zero-filobus

The “Zero Filo-bus” concept

was studied and patented.

SCs in trolleybuses may

combine electric powertrain

with a distributed charging

system able to “refill up” the

small on-board storage

devices in short time during

temporary stops.

A national project is now

underway to verify the

practical application of this

concept


Conclusions

SC are devices able to meet technical and economical requirements in various mobile and stationary applications

SC cells, modules and complete systems are still under development in various configurations (symmetric, asymmetric, hybrid) to mostly improve specific energy at reduced costs.

Since end of ‘80s, ENEA has been working on the entire R&D and applications chain and is available to collaborate to verify and confirm the significant advantages in using SC in various applications.


Present and potential applications of supercapacitors

Thank you for your attention !!!

[email protected]

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