EnerSys Storage System

for Off-Grid Hybrid application

 WELCOME

Choon Heung HO
Product Manager, S.E.A
from
Outline
Lead Acid Batteries
Technology
 TPPL technology Introduction

Flooded - AGM - GEL

Electrolyte absorptive
Liquid electrolyte Gelled electrolyte
glass mat

Conventional cell AGM cell Gel cell

 TPPL technology Introduction

Factors That Affect Battery Life – VRLA

Main Contributors:

➢ Sulphation

➢ Naturally occurs when the active material is in contact with sulphuric acid

➢ Grid corrosion

➢ Can’t be avoided. One of the basic electrochemical reaction of lead acid

batteries: lead is transformed into lead dioxide

➢ Active material degradation

➢ After numerous charge discharge the active material can lose its cohesion and porosity

➢ Acid stratification

➢ Not really a failure mode in itself, but accelerate the failure mode described before
 TPPL technology Introduction

illustration on while charging or discharging

a standard lead acid battery
Fully Charged Discharging Fully Discharged
Positive and negative plates Positive and negative plates Positive and negative plates
have no sulfation picking up sulfation have reach maximum
Sulfuric acid content in Sulfuric acid content in sulfation
electrolyte as it maximum. electrolyte is decreasing. Time to charge!

!!! If a lead acid battery is not immediately recharged, the lead sulfate will
begin to form hard crystals, lead to irreversible loss of battery capacity.
 TPPL technology Introduction

Plate Construction

Grid Plate Tubular Plate Plate

Most A frame structure A flat plate
commonly use consisting of a series of composed of
2 to 4 mm thick vertical spines pure lead
connected to a
common bus.
 TPPL technology Introduction

Thin Plate Pure Lead Technologies

Advanced 99.9% Pure Lead: High Purity Materials

GRID PLATE
TPPL – Thin Plate Pure Lead
(1 mm)
 TPPL technology Introduction

Thin Plate Pure Lead (TPPL) Design

EnerSys manufacturing process allows Conventional battery bookmold casting
processing of pure lead grid requires artificial hardeners to process grid
Result: 1.0 mm THIN Result: 2 - 4 mm THICK

PowerSafe SBS Standard AGM book-mold casting

More plates in each 2 volt cell

Result = more cranking amps and superior power & energy density
 TPPL technology Introduction

Thin Plate Pure Lead (TPPL) Design

✓Low self-discharge delivers -
longer storage life (up to 24 months vs 6 months)
 TPPL technology Introduction

Thin Plate Pure Lead (TPPL) Design

✓Fast charging-
accept upto 1C10 charging current
Function of Current Limit and Depth of
Discharge recharge at 2.40 Vpc (Fast Charge)

18
0.1C10A
16
14
TIME (HRS)

12
10
0.2C10A
8
6 0.3C10A

4 0.5C10A
1.0C10A
2
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110%
DEPTH OF DISCHARGE
 TPPL technology Introduction

Faster Recharge Times of

TPPL Technology®

Time to Full State of Charge as a Function of Current Limit & Depth of Discharge

The deeper the discharge,

The greater TPPL benefits over GEL

Gel battery
TPPL battery
 TPPL technology Introduction

Factors Determining VRLA

Batteries’ Working Life
▪ Typical Evolution of a Standard Lead-Calcium Positive Grid.
▪ Test base on IEC 602896-21 & 22

Day 1 160 days 240 days 320 days

at 55°C at 55°C at 55°C
 TPPL technology Introduction

Positive Grid Corrosion: Typical Evolution

Test according to IEC60896-21/22

TPPL SBS® PbCa cast grid after

after >480 days at 55° 400 days at 55°C
(15 yrs) (12 yrs)
 TPPL technology Introduction

TPPL Float Life – Reliable Grid

TPPL FLOAT LIFE
(RECOMMENDED FV FOR 20°C)

TPPL

Standard
Lead-
Calcium
 TPPL technology Introduction

TPPL Cycles Life – Hybrid-Off Grid

✓High Cycles
Cycle Life versus Depth of Discharge
Number of Cycles

9000 cycles
@ 20% DoD

2700 cycles
@ 50% DoD

Depth of Discharge (%)

 TPPL technology Introduction

vs Vented: Flooded Tubular Plate

Pros Cons
✓ Very good cycling ❖ Time to recharge is not as fast
performance as TPPL (Thin Plate Pure Lead)
✓ Well established product on ❖ Number of available cycles is
the market reduced with increased
✓ Capable to install under high temperature
temperature environment. ❖ Need maintenance
❖ More frequent watering
required with daily cycle
 TPPL technology Introduction

vs VRLA: Gel Tubular Plate

Pros Cons

✓ Very good cyclic ability

❖ Time to recharge is not as fast
according toIEC 60896-2
as Advanced TPPL AGM
✓ Well established product on
❖ Maximum operating
the market
temperature is lower than TPPL
✓ Capacity up to 3170Ah
❖ Number of available cycles is
reduced with increased
temperature
❖ Less power and energy density
 TPPL technology Introduction

vs VRLA AGM Flat Plate

Pros Cons

✓ Establish technology for ❖ Time to recharge is not as fast

stable and semi stable grid as TPPL (Thin Plate Pure Lead)
application ❖ Not suitable for sub 5 minutes
✓ Flexible voltage & small to discharge rate
large capacity configurations ❖ Large footprint
❖ Less power and energy density
❖ Short design life
 Enersys Energy Storage Solutions

Grid Conditions – Regional Variations

Reliable grid

Reliable grid
Off grid Reliable grid
Unreliable grid
Off grid

Reliable grid,
Off grid Unreliable grid
Off grid Reliable
grid
Off grid
 Enersys Energy Storage Solutions

Renewable Operating Modes

• Reliable Grid / Stand-by

• Unreliable Grid

• Off Grid - Hybrid

 Enersys Energy Storage Solutions

Key Characteristics of Off-Grid Hybrid

• Off-grid applications can be powered by various energy sources

• Key characteristics:
- Typically diesel generator and battery hybrid (“simple hybrid” systems)
- Can also incorporate renewable energy sources such as wind turbine or
photovoltaic array (“complex hybrid” systems)
- Controlled operation
- Warm ambient temperature
- High cyclic use

• Battery can be operated in two modes: controlled full state of charge

(FSOC) and controlled partial state of charge (PSOC)
– FSOC operation involves recharging the battery to full state of charge after each
discharge
– PSOC operation involves returning the battery to a state of charge less than 100%
after each discharge micro-cycle
 Enersys Energy Storage Solutions

Off-Grid - Hybrid Operation

➢ Often in remote areas electricity is provided by diesel generators only

➢ To prevent failures, critical sites often use two diesel generators in parallel

➢ Using a hybrid system with VRLA batteries can generate significant

savings:

▪ Batteries provide power in alternance with the genset

▪ Reduced generator time → fuel savings

▪ Extended generator maintenance intervals

▪ Use one generator instead of two

▪ Reduced pollution (CO2 and noise)

 Enersys Energy Storage Solutions

OPEX & CAPEX Relationship for

Off-Grid Hybrid System

GENSET ONLY

GENSET & BATTERY

GENSET, BATTERY, SOLAR

OPEX

GENSET, BATTERY, SOLAR, WIND

CAPEX
 Enersys Energy Storage Solutions

Off-Grid - Hybrid Operation

• In a Hybrid cyclic application (hybrid), a battery operation life is

determined by cycle use.

• The battery cycles shall not de-rated for higher operating

temperatures.

• Provides significantly energy throughput / cycle life

• Operation in controlled partial state of charge (PSOC) to reduce

genset operation runtime for additional OPEX savings

• Exceptional fast charge acceptance capability for short

recharge times
 Enersys Energy Storage Solutions

Full SOC or PSOC?

Final 20% of recharge process takes as long as the first 80%

Would be beneficial to Opex to operate the battery in partial state of charge –
but this creates challenges for the battery
 Enersys Energy Storage Solutions

Controlled PSoC Hybrid

Regime:
1. DCH to 30% DoD
2. Recharge to 95% SoC (current limit)
3. Repeat for 60 cycles
4. Charge to 100% SoC + equalization (time)
5. Repeat steps 1 through 4 until discharge voltage <
10.8V

25% reduction in charge time compared with full SOC cycle

 Enersys Energy Storage Solutions

Hybrid Partial State of Charge:

Benefits
• Significantly reduce the time between discharge cycles

• Increase ratio of battery to generator operation

• Improves generator operation efficiency

• Can help to extend maintenance periods

• Reduced fuel consumption – improved OPEX values

• Increase system flexibility.

 Enersys Energy Storage Solutions

Hybrid Partial State of Charge:

Challenges

• Frequency of full recharge cycle is critical

• Need to avoid irreversible sulphation build up

• Consideration of OPEX savings vs. CAPEX cost (early

battery replacement)

• Bespoke case by case solutions maybe required.

 Enersys Energy Storage Solutions

TCO – Controlled PSOC vs Full SOC

Operating to a 95% partial state of charge with periodic full charge

can provide additional benefit to Opex value but must be
considered on a case by case basis
 TPPL technology Introduction

TPPL Battery Range

NOMINAL NOMINAL
MODEL APPLICATION
VOLTAGE CAPACITY

12V 92 – 180 Ah Standby

93 – 180Ah
12V Standby

12V 31 to 190Ah Standby

Standby
12V & 2V 62 to 3900Ah Un-realiable
Off-Grid Hybrid

12V & 2V 190 to 1560Ah Off-Grid Hybrid

ENERSYS Warrensburg, US
FACTORY
• Thin Plate Pure Lead (TPPL) cell for
transportation, Flat plate and Round cell
Manufacture.

• ISO9001 and ISO14001 certification

• Plant Size of 540,000 ft²

• More than 670 staff in the factory.

ENERSYS
Tijuana, Mexico
FACTORY

• Thin Plate Pure Lead

(TPPL) cell and Flat plate
cell Manufacture.
• ISO9001, ISO14001 and UL
certification
• Plant Size of 144,000 ft²
• More than 450 staffs in the
factory.
ENERSYS Newport, UK
FACTORY
• Thin Plate Pure Lead (TPPL) cell
Manufacture.

• ISO9001, ISO14001 and UL

certification

• Plant Size of 229,185 ft²

• More than 490 staffs in the factory.

ENERSYS Arras, France
FACTORY

• Thin Plate Pure Lead (TPPL) cell

& Tubular cell Manufacture.

• ISO9001, ISO14001 certification

• Plant Size of 512,297 ft²

• More than 490 staffs in the

factory.
 thank you
questions?
C H Ho
Product Manager, Energy System
Mobile No. +65 9339 0137
Email: choonheung.ho@enersys.com.sg

VISIT US AT BOOTH 171/174

 visit our website at
www.enersys.com

EnerSys Global Headquarters EnerSys EMEA EnerSys Asia

2366 Bernville Road EH Europe GmbH 152 Beach Road
Reading, PA 19605 Baarerstrasse 18 Gateway East Building #11- 03
USA 6300 Zug Singapore
Tel. +1-610-208-1991 Switzerland 189721
+1-800-538-3627 Tel: +65 6508 1780
Fax +1-610-372-8613

© 2016 EnerSys. All rights reserved. All trademarks and logos are the property of EnerSys or licensed to EnerSys and its affiliates unless otherwise noted.
Subject to revisions without prior notice. E.&O.E.
Forward Looking Disclaimer Statement
This presentation includes forward-looking statements and / or information, which are based on the
Company’s current expectations and assumptions, and are subject to a number of risks and
uncertainties that could cause actual results to materially differ from those anticipated. Such risks
include, among others, risk associated with competitive actions, technology development and
implementation, intellectual property infringement, failure to integrate acquired businesses,
penetration of existing markets, expansion into new markets, hiring and retaining high quality
management and key employees and general economic conditions including the risks described in
the Company’s most recent annual / quarterly report, as applicable, on Form 10-K / 10-Q
respectively, filed with the SEC, along with other unforeseen risks. Nothing that we say today should
be interpreted as an update to the information or guidance that we provided in our most recent
investor call, our most recent quarterly / annual report, as applicable, on Form 10-Q/10-K
respectively, filed with the SEC, and our current reports filed with the SEC on Form 8-K since
quarterly / annual report.