Ultracapacitors Seminar

Technology at glance
Dipl Ing Simona Vrabiescu - Marketing Europe
Dipl Ing Galle Tipaka - Application Engineer
Ultracapacitors Seminar Istanbul
09/02/2012

Technology at a glance

Ultracapacitor definition
Basic formula
Topology (Power and Current)
Ageing
Building stacks
Batteries
Ultracaps vs. Batteries
Why using Ultracapacitor

Maxwell Technologies Ultracapacitors

Maxwell ultracapacitors provide the longest life, low maintenance

energy storage for short duration power requirements resulting in the
lowest total cost of ownership

Designed to meet the life of the application maintenance-free

Module technology to meet environmental conditions
Production capability to meet high volume needs
Green materials

What is a supercapacitor?

THEY STORE MASSIVE AMOUNTS

OF ENERGY

AND THEN RELEASE IT:

FAST

They store Energy

lots of it

Ultracapacitor technology: The film capacitor

The plate capacitor

Capacitor:
2 electrodes separated by a dielectric (plastic film, paper, aluminium oxyde)
Charge are accumulated on the surface of the electrode. So the higher surface the higher capacitance

Electrode A
Electric conductivity

_
_
_
_
_
_
_
_
_

+
+
+
+
+
+
+
+
+
Dielectric

C=
Electrode B

S
d

Electric conductivity

How to increase capacitance ?

Ultracapacitor technology
Electrode
fabrication

Grind

Coating
Rolling
Kneading
Pasting

Activation

Separator

++

_
_
_
_ _
_
_
_
_
_
_ _
Electrode

_ _

_
Electrolyte

+
+
+
+
_
+
+
_ ++ +
+
+
+
_
+ +
Electrode

Capacitance ~

Surface area
Thickness

Thickness of Helmholz layer ~ 1nm

Carbon powder surface area up to 3,000m2/g

Capacitors up to 3,000F

Construction of Maxwell Ultracapacitor

The most important element of the ultracapacitor is the electrode assembly

the jelly roll structure.

Aluminum foil tab end

Carbon electrode film
Paper separator
Opposite electrode

10

Electrochemical Capacitors (EC) - Symmetric

EC Physical energy storage

Adsorption of ion
Solvated ions
Conductivity, (SOC)
E = f(electrode surface area)
Non-Faradaic, no mass transfer

Re

11

Ri
C(U)

Re
C(U)

Ultracapacitor Technology

Size

Scaled

Carbon electrode

100 mm

10 km

Mt. Everest

Carbon particle

5 mm

500 m

Petronas Towers

Micro-pores

2 nm

20 cm

Bucket

Ions

0.7 nm

7 cm

Grapefruit

Ultracapacitors Key Features

102

1 Million cycles
10 years lifetime

Standard form factors

Highly efficient energy transfer

Cost effective in terms of Whcycles

Stable performance over large
temperature range

Safety certifications

100

UL certified
EU norms
Automotive standards

98
96
94
-40 -20

20 40
T [C]

0.008
0.007
0.1 Hz
0.006
0.005
0.004
0.003
0.002
100 Hz
0.001
0
-40 -20 0 20 40
T [C]

60

80

60

80

Real []

Capacitance [%]

Excellent power density

High durability and long lifetime

Basic formula

Basic Formulas
Definition of Capacitance:
C = Q/V (1)
Charge = current * time:

Q = I*t

Solving for voltage:

V = I*t/C (2)

Dynamic Voltage:

dV/dt = I/C (3)

E = C*V2 (4)

Stored Energy
At initial voltage Vo,

Eo = C*Vo2

At final voltage Vf,

Ef = C*Vf2

Delivered energy = Eo Ef

15

C*V = I*t (1a)

E = C*(Vo2 Vf2) (5)

Conclusion on Ultracapacitors

An UCAP is a CURRENT SOURCE: means the voltage across the

terminal changes while the current remains constant during charge /
discharge

=> Variation of energy = CHANGE of voltage => Voltage Window

No Transformation of Matter (no chemical reaction) during charge /

discharge, but displacement of ions
Temperature
Usage cycles occurrences

16

Topology

Topology
Constant current

Constant current: recurent shape

I

dT
T

T
D

Q Quantity of charge
<I> Mean value
I2t Normalized energy
IrmsEffective current

19

Period
Duty Cycle in the range 0<d<=1
=> I x dT
=> IxdT/T = Ixd or Q/T
=> IxIxdT
=> square root(I2t/T)

[As, C]
[A]
[A2s]
[Arms]

Constant current: complex shape

I1
I2

t1

t2
T

Period

Quantity of charge

=> I1x t1 + I2 x t2

[As, C]

<I>

Mean value

=> Q/T

[A]

I2t

Normalized energy

=> I1xI1x t1 + I2xI2 x t2

[A2s]

Irms Effective current

=> square root(I2t/T)

[Arms]

20

Ultracapacitor Available Charge & Energy

Apply energy storage fundamentals:

Q, charge in Coulombs
U, potential in Volts
I, current in Amperes
T, time in seconds

Q = CU = IT
Fuel Gauge

Umx

U(t)

i(t)

Umx/2

Q/2

Io

0
21

Q/2

E/4

Q=0

E=0

Ageing

Factors affecting life

BOOSTCAP Devices

ESR

Heating up due
to losses by
Joule effect

Ambiant

High RMS
current

CAP

RP

Temperature

Open
Fire
Radiant

Internal Stress

Venting
Gaz production
by dissociation

External
Stress

Over voltage
Mechanical
damage /
Deformation

Punch
through

Crunch

23

Determination of thermal stress

Get the RMS current value or the I2t value

Estimate the temperature rise using the value of the thermal resistance given on the Datasheet

And applying the equation: Temp rise [C] = Rth x Irms x Irms x ESR

Add that value to the highest ambient temperature to determine the cell body temperature

Compare the cell temperature with life time expectation and max admissible temperature

Increase the capacitance (next bigger cell) or add on more branch in parallel if the rise is too
important

24

Cell ageing

DC life

The cell is kept continuously at a given voltage and exposed to a temperature. This is the
typical field of UPS application or very low cycling systems.

The life is affected by Voltage and temperature

At low temperature the ion mobility is low and some stay trapped in the pores or separator.
There is a fast decay due to the inactivation of the pores but a fast decay due to the
temperature => again both phenomena adds up and capacitance decay

At higher temperature the ion mobility increases and trapped ions moves again so the
performances recovers but the decay due to the aging increases

Gaz production due to the impurities decay in time affected by voltage and temperature. At
high voltage the temperature determine the aging. If voltage is reduced then gaz production
may decay as well so the life is not strictly affected by voltage

Cycle Life

Higher current affects decay by gaz production (temperature)

Lower average voltage lower the decay due to voltage

25

Building stacks

Serialising cells/modules: why a balancing?

Single cell
=
Low Voltage
Several cells must be connected in serie
U
Multiple branches could be paralleled
E, P
But a cell is affected with variation and changes of
Capacitance

ESR
By
With
With
By

27

Manufacturing process
Temperature
Cell Voltage
Sollicitation (cycled or steady)

Leakage

Building Stacks: Risks

Cap1

Cap2
ESR1

Capn
ESR2

A1
B2

B1

Rp1

Ucell1

ESRn

A2
Bn

Rp2

Rpn

Ucell2

Ucelln

U Stack

Cell Voltage => ageing accelerates, gassing

Opening
Temperature => ageing accelerates, gassing
Sollicitation (cycled or steady)

28

An

Goals of the ideal balancing

Limit the voltage dispersion along a stack
Reduce the exposure time to voltage higher than admissible
by the system design
Dont degrade the system efficiency
Be simple and Reliable

29

Balancing

Cell strings should theoretically maintain voltage balance

Current through all cells in a series string is always the same.

Cells in a string should come from the same capacitance bin, and age similarly.

Therefore, ideally the voltage on each cell should always be the same.
(dV/dt)=I/C= same for all cells

In reality, small differences in capacitance, ESR, and leakage current can

cause voltage imbalance

Impact of imbalance

Cells overvoltage when string is fully charged

Cells reverse voltage when string is discharged

Passive Balancing
Passive systems are those which bypass a portion of current across each cell
Passive this method will constantly bleed energy away from the system. Install bleed resistor(s) in parallel with each cell.
Choose resistors so that the bleed current is 10-20x the cells leakage current at the rated voltage.
Example of calculation:
Balancing Resistance (Rbal1) = Cells voltage / (10 to 100 * I leakage).

Rbal2

Rbal1

Rbaln

Cap2

Cap1

Capn
ESR2

ESR1
A1
B2

B1

Rp1

Ucell'1

ESRn

A2
Bn

Rp2

Rpn

Ucell'2

U Stack

Advantages
Good performance, particularly in standby systems

Disadvantages
Continuous power drain
Slower response to overvoltage situations

Ucell'n

An

k bal =

Rp
Rbal

Active Balancing
Active systems are the one controlling the individual cell voltage

Active dissipating this method is used to prevent a cell from being over-voltaged. When the cell is charged to a predetermined level, the circuit will turn on and start bleeding energy away from the cell. Install a circuit board and set a
threshold voltage.

Voltage Detector
Reverse Voltage
Protection

Dissipative
components
One circuit
per cell
Two circuits
per board

ESD Protection

LED Balancer ON

Advantages
Can lower overvoltage cells more quickly
Low parasitic loss when not activated

Disadvantages
System must reach high voltages for balancing to occur

Conclusion on balancing

For a given stack voltage the number of cell is a

function of the parameter dispersion
The use of balancing circuitry will affect the steady
state but may not be efficient during transition state
A simple dissipative solution should be preferred in
respect of cost, reliability and simplicity

33

Batteries

Storage of electrical Energy

35

Common Chemistries/Technologies

G. Delille, B. Franois, A Review of Some Technical and Economic Features of Energy Storage Technologies for Distribution System Integration, in Proc. International
Conference on Electrical Machines and Power Systems (ELMA08), Sofia, Bulgaria, vol. 1, pp. 67-72, Oct. 2008.

36

Secondary Batteries I

37

Secondary Batteries II

38

Example: discharge curves

Source: FIAMM FGH

39

Pb Battery: Cold performances

Source: Saft

40

Major contributors to performance change

41

Conclusion on Batteries

A battery is a VOLTAGE SOURCE: means the voltage accross the

terminal remains about constant during charge / discharge

=> Variation of energy = Stable voltage

Transformation of Matter (chemical reaction) during charge / discharge

Temperature Usage cycles occurencies charge phase

42

Ultracaps vs. Batteries

Ultracapacitor vs. Battery

Battery/Ultracapacitor Technical Discussion

Ratio of ultracapacitor to battery depends upon the drive cycle -usage pattern of the system

Optimize ultracapacitor size beyond such size, adding more does not add to
performance

Passive configuration

No technical hurdles

Does the addition of ultracapacitors provide sufficient performance improvement
(fuel consumption, battery life, battery savings)

Active configuration

Requires DC-DC converter to allow the battery and ultracapacitor to operate at
different voltages

Microprocessor to control power flow from each type of energy storage

Batteries and ultracapacitors are complementary technologies

Optimize size and cost

Take advantage of ultracapacitor power and cycling capabilities and battery
energy capability

45

Comparison: Ultracaps vs. Batteries

Ragone Power and Energy

Source: Ralph Brodd, The Future of Batteries, ACG meeting, Chicago, IL, 17 May 2008

Specific Power, W/kg at Cell Level

100,000
Super
capacitors

10,000

Li-Ion
High Power
Ni-Cd

1,000

Ni-MH

Li-ion
High
Energy

100

LiM-Polymer

10
Lead acid
1
0

20

40

60

80

100

120

140

Specific Energy, Wh/kg at Cell Level

47

160

180

200

Ragone Power and Energy

Future combinations of Ultra capacitors & Batteries

Specific Power, W/kg at Cell Level

100000
Li-Ion
High Power
with UC

Ultra
capacitors

10000

1000

Li-ion
High Energy
with UC

Lead acid
with UC

100

10

1
0

20

40

60

80

100

120

140

160

Specific Energy, Wh/kg at Cell Level

48

180

200

Cycling Capabilities: Ultracaps vs. Batteries

Lead acid

3000 load cycles (20% DOD)

Nickel Cadmium

10,000 load cycles (40% DOD)

Lithium Ion

20,000 load cycles (40% DOD)

More than

Ultracapacitors

1000000 load cycles

How to combine?

Potential

Batteries

Charge / Discharge
No absolute limits between batteries & capacitors
Intercalation = mechanical expansion = aging

Coupling requires active or passive devices to maximize the energy use from / to
Ultracapacitors

Standard configuration
Braking chopper
Primary Source

Braking Resistor

ICE, Fuel Cell, other

1
BCAP

Auxiliaries

Other loads and

users

Hoist Drive

Motor

Gantry Drive

Motor

DC-DC converter
Buck/Boost

BOOSTCAP
storage unit

Denotes unidirectional energy flow

Denotes bidirectional energy flow

Trolley Drive

DC-Link Bus

Motor

nnnn

Denotes efficiency level for the function

Forklifts
Advantages








52

Battery replacement (Fuel cell + Ultracaps)

Deliver and receive power peaks
Optimizing the primary energy source size
Full energy recuperation
Fuel savings
Longer operating hours
Increasing Battery life

Conclusions

Ultracapacitor can contribute to reduce the stress on the battery

Ultracap can extend the durability of the battery

The "hybridization" Typology can be optimized for each application(s)

Direct coupling will benefit to the battery if there is a internal

resistance ratio >1.0

Low power and low cycled application (ie portable devices) can benefit
from Ultracapacitor pulse enhancement

In various field application the battery stress release is demonstrated

53

Why using supercapacitors?

Our world

We need to be efficient
- reduce CO2
- produce Clean Energy
- deliver it efficiently

Supercaps liability
Maxwell has today more than 5 millions supercaps cells installed in windmill for
safety reason.
They work (among other functions)
as UPS (uninterrupted Power
Supply) for the pitch system. The
liability of the supercaps must be
excellent to avoid catastrophic
failure...

Application Model
Losses = Heat

Energy Capture

Primary Energy
source
(Internal Combustion
Engine, Fuel Cells,
Batteries, etc)
Slow Time Constant

Peak Power
demand
Peak power delivery
Continuous low power

Continuous
Power
Usage

Application

Limited

Power in
excess

Application Model
Losses = Heat

(BOOSTCAP)
Fast Time Constant

High efficiency

Energy Capture

Peak power delivery

Peak Power
demand

Charging as needed

Primary Energy
source
(ICE, FC, Batteries, etc)
Slow Time Constant

Power in
excess

Continuous low power

Continuous
Power
Usage

Application

Dynamic
Energy Storage

Our product range

Standard Cells & Modules (multi-cells)

HC Line 1F to 150F

Heavy Transportation Module

HTM125

56V UPS Modules

K2 Line 650F to 3000F

PC Line 10F
BC Line 310F to 350F

75V Module

16 V Modules (Large & Small Cells)

48 V Module Series

Large Cell Overview

Maxwells industry leading large

capacity ultracapacitors
continue to innovate and lead
the industry in energy and
power density, reliability and
lifetime

Large Cell Overview

KEY FEATURES

De-facto standard capacities and
form factor

Multiple terminal configurations for
customer usability

High reliability welded connections

TARGET MARKETS

Heavy Transportation bus, train,
construction, mining, cranes

Backup Power

Wind

Automotive stop-start, micro
hybrids

Grid storage

Medium Cell Overview

Maxwells technology
leadership in high capacity
cells is duplicated in medium
capacity cells to bring high
density, high reliability, and
the longest lifetime

Medium Cell Overview

KEY FEATURES

High reliability cell construction

Terminal design for high current,
high power applications

TARGET MARKETS

Wind turbines

UPS <2kW

Valves and actuators

Small Cell Overview

PC and HC Series
ultracapacitors feature Maxwell
Technologies patented
electrode with superior reliability
and lifetime

Small Cell Overview

KEY FEATURES

HC Series
Industry standard form factor
PC10 Line
Thin form factor
High reliability package

TARGET MARKETS

Smart Meters, Automated Meter
Reading

Server, solid-state disk drives

Valves, actuators

Engine Start Module Overview

Maxwell Technologies Engine

Start Module is an easy to
install solution to enhance
starting reliability in mission
critical trucking environments.

Overview Engine Start Module

KEY FEATURES

Lowers Total Life cycle cost for
engine start

Green initiatives for private fleets

Easy integration into existing
starting systems with multiple
batteries

Life of the truck starting power

Standard battery size

TARGET MARKETS

Large trucks, 9-15L diesel engines

Diesel motor generator sets

Marine

16V Module Overview

Maxwell Technologies 16V

energy storage modules
incorporate industry leading
large cells with rugged
enclosures to provide superior
reliability and lifetime for both
cycling and backup power
applications.

16V Module Overview

KEY FEATURES

Rugged housing

Water resistant

Passive or active balancing
models

16V rating matches systems
designed around batteries

TARGET MARKETS /
APPLICATIONS

Engine starting

Wind turbine pitch control

UPS

48V Module Overview

Maxwell Technologies 48V

energy storage modules
incorporate industry leading
large cells with rugged
enclosures to provide superior
reliability and lifetime for both
cycling and backup power
applications.

48V Module Overview

KEY FEATURES

Passive balancing for high power
cycling

Rugged aluminum case

Light weight

Water and dust resistant

TARGET MARKETS/ APPLICATIONS

Hybrid bus

Construction and mining
equipment

UPS

125V Module Overview

Highly ruggedized module

which meets all requirements
for heavy transportation
applications with digital
monitoring

125V Module Overview

KEY FEATURES

Ruggedized construction to meet
heavy transportation requirements

E-mark certification for to meet
EMI/EMC requirements

CAN digital communications and
monitoring

Dust, vibration and water resistant

TARGET MARKETS

Hybrid bus, trolley bus

Construction and mining

Cranes, RTGs

56V UPS Module Overview

A long life energy storage

module for datacenter, hospital
and industrial transition power
backup with the Lowest Total
Cost of Ownership

56V Module Overview

KEY FEATURES

Form factor for easy installation
into standard equipment racks

Maintenance free

Green, environmentally clean
technology, especially compared
to lead-acid batteries

Long lifetime (8-14 years)

Fast recharge

TARGET MARKETS

Datacenter UPS with Fuel Cell or
Motor-generator

Hospital UPS with Fuel Cell or
Motor-generator

Large industrial manufacturing for
flat panel displays, integrated
circuits

Low Duty Cycle Modules

A long life energy storage

module for wind turbine pitch
control and DC-DC link voltage
support with the high reliability
and Lowest Total Cost of
Ownership

Low Duty Cycle Modules

KEY FEATURES

16V, 64V and 75V operating
voltage

Maintenance free

Green, environmentally clean
technology, especially compared
to lead-acid batteries

Long lifetime (up to 15 years)

Mechanical design built to survive
nacelle vibrations

TARGET MARKETS

1-10MW wind turbines

Low voltage or high voltage
pitch motors

Renewable energy farms DC link
up to 480V

Questions & Remarks

Thank you