ECCAP Symposium: Large EC Capacitor Technology and Application. AABC Europe 2012 - Session 3

EC Capacitor modules are designed to optimally meet energy-storage requirements of specific applications at the highest level of reliability and lowest possible cost. In some applications, the EC Capacitor is the only energy-storage technology used while in others it is combined with power generation or battery storage. We review in this session EC module design and system engineering to meet performance goals of key applications, including those related to transportation, to industrial energy conservation, and to the utility grid.

Session Chairman:
Michael Meinert, Head of R&D-group energy storage systems, Mobility Division, Industry Sector, Siemens AG

Michael Meinert graduated in electrical engineering, Electrical Railway Systems, from Dresden University of Technology, Germany in 1995 and received his doctorate in electrical engineering from Darmstadt University of Technology, Germany in 2007. His employment experience included the Siemens AG, Erlangen since 1995 in the field of Rolling Stock and Railway Power Supply as well as the Darmstadt University of Technology from 2001 to 2004. He is currently the Head of the R&D-group for energy storage units/systems as well as overhead contact line free systems at the Siemens AG, Infrastructure & Cities Sector. His special experience include railway systems, High Temperature Superconductivity and innovative energy systems.

1. Environmentally Friendly DLCAP^TM Technology Challenging Package Design for Automotive Application
   Toshihiko Furukawa, Senior Manager, DLCAP Technical Support & Business Development, Nippon Chemi-Con Corporation
   Abstract 

   

   Demand of ESS ( Battery or Ultracapacitor ) have been increased quite bit now for automotive application point of view such as Micro Hybrid, Mild Hybrid, EV, PHEV, and Full HEV because of the global requirement for the minimization to the environmental impact, improvement of fuel consumption and GHG emission reduction. At this moment, CO₂ emission at the worldwide is Gt level according to the governmental organization IPPC. The energy saving/recycling should be seriously taken off from YR2010 – 2020. The major contributor to the GHG emission is passenger vehicles. There are millions of cars out there. ESS module will be one of solution for the hybridization vehicle for it. This presentation will be discussed for ESS packaging design to minimize the design work load, overall development cost and improve accuracy of the engineering design.

   Focusing pints here in this presentation are:

   • Background for ESS demand
   • Key points for packaging design
   • Requirements
   • Mechanical design
   • Thermal design
   • Abuse test for automotive requirements

   The module packaging design will be important for total cost reduction, but it is linked to the key parameters each other which are safety, durability and the cost. Also the open discussion between the engineering at the component side and the engineering team at automotive customer as an application side will be very important to come out the best solution for both of the component and system point of view. The tight engineering communication to share the critical information exchange between component and application side will be the key.

   Example of FEA analysis for the mechanical structural design and thermal simulation will be discussed for understanding how it will be important to use the advanced software tool.
   Abuse test will be also discussed for automotive requirements.

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2. Ultracapacitors: A Mature Energy-Storage Alternative in a Dramatically Expanding Application Set
   Michael Everett, Vice President / Chief Technology Officer, Maxwell Technologies
   Abstract 

   

   It was not long ago that anyone would consider ultracapacitors as a mature technology. Lacking was experience, industrialization, field data, reliability data, application understanding and market visibility among other things. Today that perception is dramatically changed. In fact, it is no longer appropriate to consider it a perception, the reality has changed dramatically. Addressed in this presentation is the evidence and the data that the ultracapacitors are mature in the technologically active industry of energy and power delivery. , Maturity will be illustrated technologically as well as from commercial perspective. The case for technical maturity will be built on the exhibits detailing some of the following characteristics:

   • Lifetime performance and understanding
   • Improving Power Capability
   • Materials and their performance
   • Expanding the envelope of technical performance
   • Aging and degradation mechanisms
   • Stability and predictability of performance

   Commercially, the ultracapacitor is making similar gains on maturity. Continually finding their way into new markets and new applications along with expansion of the “old standby’s”, those applications that have been prevalent for some time, information will be displayed to evidence their place in energy storage for years to come. On the commercial side, the following topics will be covered at a minimum:

   • Cost reduction progression
   • High Volume production data
   • Quality and Reliability benchmarks
   • The ultracapacitor supply chain from a manufacturers perspective
   • New application demands on the ultracapacitor

   As a summary, a short description of the applications that are expanding and looking to make full use of ultracapacitors and their extraordinary capability will be reviewed. This is all leading to the understanding that the technology and the commercial aspects of the ultracapacitor are mature and can meet needs never before imagined.

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3. Ioxus Ultracapacitors and Modules for Automotive Start/Stop Applications
   Chad Hall, Vice President of Sales, Ioxus
   Abstract 

   

   This presentation will focus on the new vehicle requirements resulting from the adoption of start/stop technology and how EDLCs can help OEMs address these new requirements. In particular, the efficiency of start/stop vehicles is significantly limited by the poor charge acceptance of lead acid batteries, which prevents many start/stop events from occurring. Chad will discuss the application of EDLCs to provide the hotel load during the start/stop event and present data showing near ideal performance when tested using the new VDA start/stop testing specification that was outlined by Ford-Moll-BMW in a recent ELBC presentation.

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4. Stationary Supercapacitor Applications for City Transport
   Anton Varakin, Head of Engineering Department, JSC Elton
   Abstract 

   

   This paper describes some variants of a stationary energy storage device based on ELTON’s elec-trochemical capacitor modules for traction network of city electric transport (CET).

   ELTON’s electrochemical capacitors (EEC) are known as asymmetric capacitors which have a polarizable electrode made of activated carbon material, a non-polarizable (Faraday) electrode containing nickel hydroxide active material and aqueous alkali solution as electrolyte.

   Such design makes it possible to obtain EEC’s specific characteristics comparable with the char-acteristics of capacitors with organic electrolyte. However, EEC have a number of advantages that make it possible to efficiently employ energy storage devices based on EEC in the systems of CET traction power supply (trams, trolley buses) for the purposes of using electric vehicles’ braking energy, reducing voltage sags in contract network during peak loads, etc.

   ELTON’s stationary energy storage device (SESE) for CET is an integrated built-up structure. The main unit is a cabinet which is capable of standalone functioning.

   The cabinet includes an assembly of capacitor modules and commutation equipment control, power supply of cooling, monitoring and diagnostics system.

   The cabinet contains 60EC400-90 capacitor modules of new series with 90 V operating voltage, which are equipped with a standalone cooling and diagnostics system.

   Direct connection to traction network in parallel with traction substation (TSS) without DC-DC converters is a typical feature of SESE. Such direct connection has a number of advantages.

   Due to low depth of operation, SESE shall provide for a required high cycle life (over 10 million cycles) and long service life (over 20 years).

   SESE’s excessive capacity makes it possible to recuperate the energy of several units of the roll-ing stock simultaneously, which may happen from time to time, particularly in busy lines.

   The absence of expensive additional equipment reduces SESE’s dimensions and its cost does not in fact change as compared with the energy storage device which has optimal energy reserve and which is equipped with DC-DC converters. Besides, the direct connection of SESE to traction network, due to streamlining of the electric cir-cuit, improves reliability of operation of the energy storage device as a whole, not interfering with devices of the electric transport’s traffic, signaling and communications control in the contact network.

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5. Typical Applications of the First Generation Supercapacitor in Transportation
   Alexey Beliakov, Chief Executive Officer, ELITECH
   Abstract 

   

   Elitech LLC is a company engaged in development and manufacturing of electrochemical Supercapacitors, mainly based on aqueous electrolyte solutions. Elitech LLC is on the EC market for more than 20 years and has a number of implemented applications in automotive sphere.

   • Main Parameters and Advantages of EC of the 1st Generation:
     • High power (> 2 kW/kg) and energy efficiency ratio (> 90%);
     • Reliability during operation, fire and explosion safety, stability/tolerance to short circuit and repolarity;
     • Not very high (<1Wh/kg) but acceptable specific energy;
     • High cycle life time, ecological purity.
      
   • ICE Starting Application:
     • Ideology;
     • Design peculiarities of EC;
     • Advantages of use for reliable ICE starting at any weather condition and on-board battery state;
     • Advantages of EC of the 1st generation if compared with other EC;
     • Peculiarities of starting if high power engines (>1000 hp).
      
   • Start-Stop Hybrid Application:
     • Peculiarity of start-stop mode is a great number of cycles – hundreds of thousands cycles per year;
     • Advantages of EC with aqueous electrolyte solutions over other EC and storage batteries (high service life, safety, ease of use);
     • Application for cars;
     • Application for city buses.
      
   • Conclusions:
     Use of the 1st generation EC for ICE starting and start-stop hybrids is the most cost-effective if compared with other power sources.

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6. DLC Applications in a Challenging Railway Market
   Michael Meinert, Head of Energy Storage Systems, Siemens
   Abstract 

   

   Energy efficiency is the key to innovative railway systems. Mobile and stationary Energy Storage Systems (ESS) are one contribution which increases the energy efficiency while reducing overall energy consumption of a modern railway system, especially for urban public transport.
   The use of ESS on trams and streetcars can avoid using the catenary’s system entirely along segments of the track. This system helps to reduce the daily and overall system energy because it ‘recycles’ the vehicle’s braking energy then stores it for later usage by the propulsion and other necessary vehicle auxiliary loads.

   Less energy consumption leads to lower CO₂ and “greenhouse gas” emissions. Reduced “visual impact” leads to an appropriate integration of Light Rail Vehicles (LRV) into the already existing infrastructure. Therefore a participation in environmental protection and “smooth” integration of newly established LRV-systems is guaranteed.

   The market requirements for ESS based on Double-Layer Capacitors (DLC) can be derived from different applications and operating modes for mobile and stationary units/systems. Some market requirements are:

   • ROI (Return On Invest) within a short time for operators,
   • Fulfillment of new functionalities,
   • Safe and certified / homologated,
   • High availability and reliability and
   • Low LCC (long lifetime, easy maintainability).

   Additionally to these requirements influencing and challenging parameters have to be considered in order to set up an appropriate design for DLC-ESS (modules, units, systems).

   The presentation will focus on some mentioned issues above and will close with a prospective view.

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