life cycle testing and evaluation of energy storage devices
TRANSCRIPT
Life Cycle Testing and Evaluation of
Energy Storage Devices
October 21, 2011
Summer Ferreira, Wes Baca, Tom Hund
and David Rose
Sandia National Laboratories
Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia
Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S.
Department of Energy’s National Nuclear Security Administration under contract DE-AC04-
94AL85000.
Energy Storage Test Pad (ESTP) (April 2010)
SNL Energy Storage System Analysis Laboratory
Providing reliable, independent, third party testing and
verification of advanced energy technologies for cell to MW
systems
System Testing
• Temperature chambers for thermal control
• New Energy Storage Test Pad (ESTP) expands
testing capabilities to include megawatt (MW)
scale energy storage. This versatile facility is
capable of testing in several configurations for
many different applications.
Testing Capabilities Include:
Cell Testing
• Temperature chambers for thermal control
• 100+ cell and battery testing channels:
– 72 V 1000 A Bitrode (2 Channels)
– 60 V 200 A Arbin (2 Channels)
– 36 V 100 A Bitrode (3 Channels)
– 36 V 25 A Bitrode (5 Channels)
– 10 V 10 A Arbin (48 Channels)
– 5 V 3 A Arbin (48 Channels)
72 V 1000 A Bitrode (2 Parallel Channels)
SNL Battery Abuse Testing Laboratory
Battery testing, cell measurements, and materials development to
support the development of inherently safe lithium-ion chemistries
5 Wh failure
event
50 Wh failure event
• Safety and abuse tolerance evaluation
of energy storage devices from cells
to kWh batteries:
– Mechanical abuse
– Thermal abuse
– Electrical abuse
• Understanding degradation
mechanisms that lead to cell failure
• Provide experimental data to support
abuse and thermal modeling
• Cell prototyping facility for materials
development
Understanding abuse tolerance
FY 2011 testing activities
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
East Penn Ultrabattery®
Modules
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
Furukawa Ultrabattery®
Modules
Altairnano Lithium-
titanate oxide cells
60 Ah and 11 Ah
East Penn Advanced
Battery Cells (D. Enos 4:00 pm Thur.)
RedFlow 10kWh Zn-Br
flow battery module (D. Rose 10:00 am Friday)
Cell Level Testing Module Level Testing
International Battery
Li-FePO4 Cells
FY11 Testing of Ultrabattery® modules
• Both Ultrabattery® designs incorporate a
supercapacitor in parallel with the negative
electrode in a VRLA 12 cell, 1,000 Ah, 24V
battery module.
• Tested with both a ‘PV’
and ‘utility’ cycle.
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
East Penn
Furukawa
Cycling protocols employed in testing
VRLA Life cycle data S. Drouilhet, B.L. Johnson, 1997 NREL
Frequency Regulation
PV Output Shifting
0
20
40
60
80
100
-1.0
-0.5
0.0
0.5
1.0
0 10 20
DO
D
C R
ate
Time (Minutes)
Fast Utility Cycling
0
20
40
60
80
100
-1.0
-0.5
0.0
0.5
1.0
0 50
DO
D
C R
ate
Time (Hours)
Slow PV Cycling
0
20
40
60
80
100
-1.0
-0.5
0.0
0.5
1.0
0 50
DO
D
C R
ate
Time (Hours)
Fast Utility Cycling
354 Cycles
East Penn Ultrabattery® performs much longer than VRLA
40
50
60
70
80
90
100
110
120
130
0 5000 10000 15000
% I
nit
ial C
ap
acit
y
Cycle #
PSOC utility cycling
VRLA
Battery
10% DOD
cycle
* After Recovery
*
• Ultrabatteries® 1,000 AH, 0.4 C and 0.3 C 5% PSOC cycling
• VRLA 30 AH, 1C 10% PSOC cycling
• Temperature rise in Ultrabattery® modules required reducing current for further testing
80% Initial Capacity
East Penn Ultrabattery® performs much longer than VRLA
40
50
60
70
80
90
100
110
120
130
0 5000 10000 15000
% I
nit
ial C
ap
acit
y
Cycle #
PSOC utility cycling
East Penn Ultrabattery®
Furukawa Ultrabattery®
5% DOD cycle
VRLA
Battery
10% DOD
cycle
* After Recovery
*
East Penn Ultrabattery® shows
no capacity loss after more
than 13,000 cycles without
recovering the battery
Furukawa Ultrabattery®
operated at elevated
temperatures, leading to
thermally activated degradation.
Filled symbols (l) cycled at 400 A
Open symbos (☐) cycled at 300 A 40
50
60
70
80
90
100
110
120
130
0 5000 10000 15000
% I
nit
ial C
ap
acit
y
Cycle #
PSOC utility cycling
VRLA
Battery
10% DOD
cycle
• Ultrabatteries® 1,000 AH, 0.4 C and 0.3 C 5% PSOC cycling
• VRLA 30 AH, 1C 10% PSOC cycling
• Temperature rise in Ultrabattery® modules required reducing current for further testing
80% Initial Capacity
40
50
60
70
80
90
100
110
120
130
0 200 400 600
% I
nit
ial C
ap
acit
y
Equivalent complete discharges
PSOC utility cycling
East Penn Ultrabattery® performs much longer than VRLA
• Ultrabatteries® 1,000 AH, 0.4 C and 0.3 C 5% PSOC cycling
• VRLA 30 AH, 1C 10% PSOC cycling
• Temperature rise in Ultrabattery® modules required reducing current for further testing
* After Recovery
*
East Penn Ultrabattery® shows
no capacity loss after more
than 13,000 cycles without
recovering the battery
Furukawa Ultrabattery®
operated at elevated
temperatures, leading to
thermally activated degradation.
Filled symbols (l) cycled at 400 A
Open symbos (☐) cycled at 300 A
East Penn Ultrabattery®
5% DOD cycle
Furukawa Ultrabattery®
5% DOD cycle
VRLA Battery
10% DOD cycle
80% Initial Capacity
Elevated temperatures occurred in Furukawa Ultrabattery®
Furukawa Ultrabattery® operated at elevated
temperatures, leading to thermally activated
degradation.
1.5
1.6
1.7
1.8
1.9
2.0
6350 6550 6750 6950Dis
ch
arg
e C
ell V
olt
ag
e (
V)
Cycle #
Cell voltage during cycling
30
35
40
45
50
55
60
6350 6550 6750 6950C
ell T
(C
) Cycle #
Cell T during cycling
Ultrabatteries® also perform much longer in PV cycling than VRLA
60
65
70
75
80
85
90
95
100
105
0 100 200 300 400 500 600
% I
nit
ial C
ap
acit
y
Days Cycling
PV Hybrid Cycle-Life Test
VRLA Battery
30 Day Deficit Charge
80% Initial Capacity
60
65
70
75
80
85
90
95
100
105
0 100 200 300 400 500 600
% I
nit
ial C
ap
acit
y
Days Cycling
PV Hybrid Cycle-Life Test
VRLA Battery
30 Day Deficit Charge
VRLA Battery
7 Day Deficit Charge
80% Initial Capacity
60
65
70
75
80
85
90
95
100
105
0 100 200 300 400 500 600
% I
nit
ial C
ap
acit
y
Days Cycling
PV Hybrid Cycle-Life Test
Even at 40 day deficit charge, Ultrabatteries® have performance
far surpassing traditional VRLA batteries even with as low as a
7 day deficit charge (without recovery by taper charge).
.
East Penn Ultrabattery®
40 Day Deficit Charge
Furukawa Ultrabattery®
40 Day Deficit Charge
VRLA Battery
30 Day Deficit Charge
VRLA Battery
7 Day Deficit Charge
Filled symbols (l) 10 hr taper charge
Open symbos (☐) 12 hr taper charge
80% Initial Capacity
Cell level testing underway
FY11 testing on battery cells
• International battery Li-ion FePO4 large
format prismatic cells (160 Ah, 3.2 V)
• Altairnano lithium-titanate oxide cells
(60 Ah and 11 Ah, 2.3 V)
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
International battery cell capacity remains high after 15K+ cycles
11% capacity loss after 15,000+ cycles
International battery Li-ion
FePO4 large format
prismatic 160 Ah cells
. Two International Battery cells
currently operating under utility
cycle testing protocol: 10% SOC
cycles at 100 A current
0
20
40
60
80
100
120
140
160
180
200
0 5000 10000 15000 20000
Cap
ac
ity (
Ah
)
# Cycles
Capacity during cycling
80% Initial Capacity
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
International battery cell performed well under aggressive abuse
Under overcharge abuse the cell vented and the case
deformed but remained intact without catastrophic failure
and thermal runaway did not occur.
Sandia Battery Testing
Introduction FY-10
East Penn
UltraBattery®
Lead-Acid/Supercap
Furukawa UltraBattery®
Lead-Acid/Supercap
International Battery
Li-FePO4
GS Yuasa
granular silica
tubular gel
0
20
40
60
80
100
120
0
5
10
15
20
25
100.0% 140.0% 180.0%
Tem
pera
ture
(C
)
Vo
ltag
e (
V)
%SOC
Voltage(V)TC0
Characterization of Altairnano cells
1
10
100
1000
1 10 100 1000
Sp
ecif
ic P
ow
er
(W/K
g)
Specific Energy (Wh/Kg)
Initial Capacity 12.58 ± 0.06
Ah
3 Month Self-
Discharge
4.82 ± 0.03%
FY12 Planned Evaluation
Hybrid Pulse Power Tests
Utility PSOC Pulse Cycling
Abuse Testing
Extend testing to 60Ah cells
60 Ah cells pulse charge
and discharged testing
used to develop battery
impedance models for
power electronics (D. Fregosi Poster Session)
Simon P , Gogotsi Y Phil. Trans. R. Soc. A
2010;368:3457-3467
0
2
4
6
8
10
12
14
-50 0 50
Cap
ac
ity (
Ah
)
Temperature (C)
Capacity as a function of T
0.5C
1C
Summary/conclusions to date
• East Penn Ultrabattery® performs best in fast utility
cycling, completing over 13,000 5% cycles with no
loss in capacity.
• Furukawa Ultrabattery® performs best under deep
DOD slow PV cycling, even at 40 day deficit
charging.
• International Li-ion FePO4 cells have lost 11% of the
initial capacity after over 15,000 10% cycles.
• Altairnano Li-titanate oxide cells have had initial
characterization and will be cycled in FY12.
FY-12 testing activities
• Complete cycling of UltraBattery® modules and International Li-FePO4 Cells
Continue Utility Cycle Test; end condition of 20% capacity
loss or 365 days cycled
• Utility Cycle Altairnano Li-Titanate Oxide Cell
Utility Cycle Test end condition of 20% capacity loss or
1 yr is complete
• Bring flow battery testing online with:
– Red Flow Zn-Br modules
– CUNY Ni-Zn modules
– Thank you to Dr. Imre Gyuk for funding energy storage
testing
– Thank you to collaborating battery manufacturers
Summer Ferreira David Rose
[email protected] [email protected]
SNL Energy Storage System Analysis Laboratory
Contact Information
Acknowledgments
Providing reliable, independent, third party testing and verification
of advanced energy technologies for cell to MW systems