R&D Symposium 3

Chemistry & Materials for Lead-Based Batteries Symposium

Next Generation Lead-Based Batteries for Electrified Vehicles

29 - 30 January 2018 | Congress Centrum Mainz | Mainz, Germany


A significant spike in technological advancements have created smaller, light weight and long lasting lead-based batteries that are critical to the development of the next generation of zero emission and hybrid electric vehicles. Using new composite materials and innovative design approaches, researchers are developing high specific energy batteries with long cycle life and low cost. In addition, creative improvements in the use of standard raw materials for lead-acid have led to a dramatic increase in the performance of these batteries. This session will provide an in-depth international overview of the industry including the latest trends, competitive analysis and examination of the key players and their strategies for market growth.

Final Agenda

Monday, 29 January

8:30 Symposium Registration and Morning Coffee

ADVANCED LEAD-BASED BATTERIES R&D ROADMAP

10:00 Chairperson’s Opening Remarks

Paolina Atanassova, Ph.D., Global Applications Development Manager, Energy Materials, Cabot Corporation

10:05 OPENING KEYNOTE PRESENTATION: The Future of Automotive Batteries – Challenges and Opportunities for Lead-Acid

Eckhard Karden, Ph.D., Technical Expert Battery & Energy Storage Technology, Advanced Power Supply & Energy Management, Ford Research & Advanced Engineering, Europe

Lead–acid batteries as automotive low-volt storage technology are being challenged by new vehicle functions like electrified chassis systems, by growing powertrain electrification, and by maturing new storage technologies. This talk will provide an overview of changing requirements and competing storage system options. The process of deriving technology-specific component test methods and pass criteria from new or evolving vehicle or system requirements will be discussed.

10:45 Advanced Lead Batteries for Traditional and New Applications That Are Lighter with Longer Life

Boris Monahov, Ph.D., Program Manager, Advanced Lead-Acid Battery Consortium (ALABC) – a program of the International Lead Association (ILA)

The growing battery market offers good opportunities for advanced, carbon enhanced lead batteries which are dominating the market in their traditional applications like starter and marine batteries, telecom, stationary and back-up power, renewable and grid support energy storage systems. In their effort to keep the strong position of lead batteries, researchers and manufacturers both in and outside ALABC are successfully developing new ways to make lead batteries lighter but more powerful, and extend by times their cycle and calendar life in traditional but also new, partial state of charge cycle operation.

11:05 Networking Coffee Break with Poster Viewing

TECHNOLOGY & INNOVATION: NEW BATTERIES

11:35 Innovations in Truck Batteries – The Silent Revolution

Christian Rosenkranz, Ph.D., Vice President Engineering & Product Development EMEA, Johnson Controls Autobatterien GmbH

Emission regulations beyond the present Euro 6 and 2017-EPA standards for light- and heavy-duty trucks drive the electrification of auxiliary loads and power train components. JCI has developed the next generation of lead-acid truck batteries with higher robustness to the requirements. These innovations have been tested in our OE customers fleets and series application and provide significantly longer life times and reliability. In addition, we will conclude our paper with highlights in the progress of passenger car batteries leading the way for the increasing expectations of our customers.

11:55 Progress and Next Challenges with UltraBattery for 14-V Hybrids

Koshin Takemoto, R&D, The Furukawa Battery Co., Ltd.

The advantages of the 2nd Gen UltraBattery are its excellent charge acceptability and superior durability under HR-PSOC condition. The 2nd Gen UltraBattery has been adapted by new Japanese OE manufacturer. New applications of the 2nd Gen UltraBattery will be discussed.

12:15 New Technologies to Improve the Performance and Production of Lead-Acid Batteries

Bob Sullivan, CEO, iQ Power AG

Boris Shirov, Project Manager, Research and Development, TASC, Ltd.

Through use of innovative technologies, the performance of lead-acid batteries can be significantly improved and the production process can be optimized. By combining these innovations, synergies can be achieved and this presentation will show some examples.

12:35 Q&A

12:50 Networking Lunch

MARKET & APPLICATIONS

14:15 Chairperson’s Remarks

Alistair Davidson, Ph.D., Products and Sustainability Director, International Lead Association

14:20 Multi-Use Concept for Uninterruptible Power Supply Systems: How Extra Revenues Could be Earned with a Security Back-Up

Julie Badeda, Ph.D., Stationary Storage Systems, BatterieIngenieure GmbH

The talk will go into details on current revenue streams for battery storage systems. On this basis, the application considering dimensioning of the UPS system as well as the resulting load profiles and aging characteristics will be elaborated. Furthermore, the control unit for a battery diagnostic and adaptive steering management system will be presented.

14:40 Lead Battery Technology: Future Opportunities for Automotive Applications

Alistair Davidson, Ph.D., Products and Sustainability Director, International Lead Association

There is a growing consensus of opinion which suggests that advanced stop start technology and low voltage mild hybrids will do more for vehicle exhaust emission reduction than pure EV and strong hybrid technology combined in the coming decade and beyond. Yet, the next generation of mild hybrids will offer more electrical functionalities and this favours a higher voltage electrical system — 48 volts. The paper will present new work undertaken, collecting performance data for advanced lead batteries under real world driving conditions, and also discuss the sustainability benefits of lead batteries.

15:00 High DCA Lead-Acid Batteries, Field Test Evidences, Performance Evolution and Analysis of Benefits and Trade-Offs

Luca Brisotto, Director Project Management, Advanced Applications, Exide Technologies and Jesús Valenciano, Manager R&D Lab, Exide Technologies

15:20 Sponsored Presentation (Opportunity Available)

15:40 Q&A

16:00 Refreshment Break with Poster Viewing

MODIFIED ADDITIVES, MATERIALS & MODELLING

16:35 Chairperson’s Remarks

Jochen Settelein, Ph.D., Research Scientist, Center for Applied Electrochemistry, Fraunhofer Institute for Silicate Research ISC

16:40 Approach to Lower Water Consumption: Modified Carbon Materials for Lead-Acid Batteries

Begüm Bozkaya, Ph.D., Scientist, Fraunhofer R&D Center Electromobility, Fraunhofer Institute for Silicate Research ISC

The electrochemical properties of carbon materials are mainly determined by the surface chemistry and accessibility of active sites. Incorporation of surface functional groups into the carbon materials attracts an attention in this context. This approach could be an efficient way for further optimization of carbon materials in order to reduce water consumption in lead carbon batteries. For that purpose, this presentation will focus on the investigation of carbon materials with different surface modifications and the electrochemical performance of the corresponding lead-carbon electrodes.

17:00 Simulation of a Thin Porous Lead-Dioxide Electrode with Fast and Inexpensive Computation Tool

Mikael Cugnet, Ph.D., Project Manager, CEA, France

Expensive finite element modeling tools are not necessary to achieve sufficiently accurate simulation results, as long as the geometry stays simple. There is still room to improve existing electrode models, even for such a mature technology as lead-acid. But believe it or not, physics-based modeling requires much more time and knowledge than money.

17:20 What Can We Learn from Electrode Surface Investigations for Battery Performance: An Overview of Various Battery Types and the Consequences for Lead Acid Batteries

Sven Ole Steinmueller, Ph.D., Instrumental Chemistry Specialists, Institute for Applied Materials, Energy Storage Systems, Karlsruhe Institute for Technology

Within the last year, a global-driven change of reducing energy consumption and increasing energy efficiency is still present and an ongoing challenge. Analysis examples from different finished and ongoing battery projects are presented including the surface analysis belonging to a project correlated with the design of artificial solid electrolyte interfaces revealing the analytical power of the combined approach with ToF-SIMS and XPS. At the end a comparison of the different battery systems and the conclusions for the investigation of lead acid and advanced lead acid battery systems are presented.

17:40 Performance Improvements from Discrete Carbon Nanotube Additives in Advanced Automotive Lead-Acid Batteries

Paul Everill, Ph.D., Vice President, Research and Development, Black Diamond Structures

Discrete carbon nanotubes can be dispersed in an aqueous solution and added directly to the pasting mix for either negative or positive lead-acid battery plates. These additives markedly improve the ability for batteries to be charged quickly without gassing, and to withstand many characteristic cycling protocols. These nanotubes, known as MOLECULAR REBAR®, can easily be incorporated into existing pasting lines. They have yielded benefits in full-scale production batteries in automotive applications. We show results for both flooded and VRLA configurations, and discuss the implications on battery design and performance in the field.

18:00 Q&A

18:20 Welcome Reception with Poster Viewing

19:20 Close of Day

Tuesday, 30 January

7:30 Symposium Registration and Morning Coffee

TECHNOLOGY & INNOVATION: DCA VS. HIGH-TEMPERATURE DURABILITY

8:30 Chairperson’s Opening Remarks

Eberhard Meissner, Ph.D., Senior Technical Leader, Electrochemistry, Johnson Controls Power Solutions

8:35 Investigation of Water Consumption Mechanism of Flooded Type ISS Batteries to Balance with Charge Acceptance

Daisuke Hosaka, Staff Engineer, Global R&D Department., Advanced Battery & System Development Center, R&D Headquarters, Hitachi Chemical Co., Ltd.

Gases generated from batteries were analyzed to investigate the water consumption mechanism during static over charge and micro cycling. The results will be compared and discussed to find a way to balance water consumption property and charge acceptance.

8:55 New PBX® Performance Additive for High DCA Start Stop Batteries

Paolina Atanassova, Ph.D., Global Applications Development Manager, Energy Materials, Cabot Corporation

Carbon additives are successfully used in commercial start-stop lead acid batteries for achieving high charge acceptance and cycle life, but higher emphasis on dynamic charge acceptance (DCA) and high temperature operation are needed to compete with Li-ion batteries and to maintain a competitive advantage of lead acid batteries for next generation micro-hybrid cars. PBX® 52 carbon additive is a formulated material that delivers excellent DCA and can provide up to 50% less water loss compared to Cabot’s PBX 51 carbon additive.

9:15 ArcActive’s Carbon Fibre-Based Negative Electrode: Latest Data

Stuart McKenzie, CEO, ArcActive, Ltd.

ArcActive began developing its novel Carbon Fibre-based negative electrode in 2011 with the ambition of delivering an LAB that delivered high and sustained DCA. Since this time, many technical challenges have had to be addressed, including scale up, achieving good performance on all standard tests (not just DCA) and manufacturing solutions. At this talk, the latest data, demonstrating excellent DCA (both sustained and WLTP) while delivering low water consumption, along with other test results, will be shared.

9:35 Development of an Improved Dynamic Charge Acceptance (DCA) Test for European Standardization

Jonathan Wirth, Research Associate, Chair for Electrochemical Energy Conversion and Storage Systems, RWTH Aachen University

New additives and innovative plate designs can significantly improve dynamic charge acceptance (DCA) of automotive lead-acid batteries and help to further reduce CO2 emissions. Existing lab tests, however, do not always accurately predict real-world performance of these lead-acid batteries in a run-in state. The presented study focusses on the development of a simplified DCA test for European norm EN 50231-6 while improving correlation to run-in performance in a 11 weeks reference test.

9:55 Q&A

10:10 Grand Opening Coffee Break with Exhibit & Poster Viewing



TECHNOLOGY & INNOVATION: DCA VS. HIGH TEMPERATURE DURABILITY

11:00 Chairperson’s Remarks

Eberhard Meissner, Ph.D., Senior Technical Leader, Electrochemistry, Johnson Controls Power Solutions

11:05 Scalability of Impedance and DCA for Different Sizes of Lead-Acid Cells

Julie Kowal, Ph.D., Research Scientist, University of Berlin

Cells with different electrode configurations are tested and compared concerning impedance and charge acceptance. The cells are cut from commercial starter batteries. The aim of the investigation is to analyze if measurements from smaller cells are representative for larger batteries.

11:25 The External Surface Area of Carbon Additives as Key to Enhance the Dynamic Charge Acceptance of Lead-Carbon Electrodes

Jochen Settelein, Ph.D., Research Scientist, Center for Applied Electrochemistry, Fraunhofer Institute for Silicate Research ISC

Specially synthesized carbon powders with a variation in the specific external surface area were investigated for the use as additive in the negative active material. Results from cyclic voltammetry on negative electrodes reveal that the external surface area of amorphous carbons exhibits a clear correlation to the electrochemical activity of lead-carbon electrodes. Higher DCA values can be observed for higher external surface area carbons.

12:05 Investigation on the Impact of Additives Given to Active Material in Order to Improve DCA of EFB with High Cycling Performance

Boris Steiner, Manager, Development and Product Management, MOLL Batterien

Over the past years, MOLL developed advanced EFB fulfilling the significantly increased technical requirements of car manufacturers for Micro-Hybrid Batteries. These batteries have virtually the same performance level as AGM design. This is contrary to the generally held belief that only AGM design can fulfill the rather difficult combinations of various technical requirements, particularly the combination of high cold cranking power and very good cycling performance. This paper gives new results of detailed investigations on the impact of additives on DCA, and about latest developments for further improvements of EFB.

12:25 Sponsored Presentation (Opportunity Available)

12:45 Q&A

13:00 Networking Lunch

14:15 Dessert Refreshment Break with Exhibit & Poster Viewing

The Future of Lead-Acid Batteries in the Face of Market and Environmental Challenges

15:00 Chairperson’s Remarks

Christian Rosenkranz, Ph.D., Vice President, Engineering & Product Development EMEA, Johnson Controls Autobatterien GmbH

15:05 PANEL DISCUSSION: Automotive Lead-Acid: Advancing Technology to Compete with Lithium-Ion

Moderator: Christian Rosenkranz, Ph.D., Vice President Engineering & Product Development EMEA, Johnson Controls Autobatterien GmbH

The growth in start-stop batteries for the vehicle market has provided lead acid with opportunities for growth. This panel will examine what the technological advancements that will allow lead-based batteries to gain market share and compete effectively in the energy storage marketplace.

15:45 Leveraging Bipolar Batteries for High DCA 48V Hybrid Systems

Dan Moomaw, Lead Mechanical Engineer, Engineering, Gridtential Energy

As next-tier emissions regulations go into effect, 48V mild hybrid systems will proliferate the market, especially in the EU. Currently, lead batteries have difficulty addressing this market due to challenges with DCA and packaging restrictions. This presentation will detail recent test results in high-power automotive applications. Lead batteries remain a compelling solution for 48V mild hybrid powertrains when leveraging lightweight and efficient bipolar architectures.

16:05 Improvement of Lead Acid Battery Performance by Morphological Control and DCA Improvement Using SUPERSOFT-HYCYCLE™ and Specific Carbon Additives

Matthew Raiford, Ph.D., Process Engineer, RSR Technologies

The growth in grid storage and hybrid vehicle markets has presented many possibilities for lead acid batteries. However, improvements in cycling, gassing activity (water loss), and dynamic charge acceptance (DCA) must be achieved to adequately fulfill performance requirements. Water loss measurements and DCA-centered studies showed that improvements in DCA are possible from the leady oxide alone. Further improvements in DCA will be presented focusing the qualification and improvements offered by different carbon additives.

16:25 Lead Acid Batteries - Safety and Environmental Considerations

Juergen Garche, Ph.D., CEO, FCBAT

Lead acid battery production numbers are still growing, therefore quantitatively, also safety and environmental problems. Environmental problems during production and recycling of LABs still occur in developing countries but these problems are strongly reduced in industrial countries. But caused by general health problems of lead, the European Commission gives for the production of LABs only temporary derogations, which will be extended every 5 year as long there is unavailable a more health compatible and economically competitor product (Li-ion battery).

16:45 Q&A

17:05 Networking Reception with Exhibit & Poster Viewing (Sponsorship Opportunity Available)

18:05 Close of Symposium

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