Document zd8ZymNaYDMQRkrRq9pYqo0d0

w'fci iTIlfcli fcJi 4 l Q LEAD INDUSTRIES ASSOCIATION It* MAOKON AVtNUI HIW TO#* IT, H. V. Au*uat 8, I960 gt'BJICT! 8TCPACE BATTPOTa to Witira of tha Lead Xaduetrlee Aeaoelatlooi Ha Hltm you >U1 bo lotoTootod la the attached copy of a paper delivered befor# the annual oeetlnf of tho Aeeoclatlco of Arcerlcaa lottery Moaufacturera et loo Aocele* on June 2, i960. It *ne prepared and pretested by the lete Cllft00 0, Crloea, lea prettiest, research, of the Klectrle Storage Battery Oaapeny and wtdoubtedly 00a of the beat Informed aaa la tbe aouatry 00 tba eubject. Additional eopiee ora orallabia aa Iona oa our Haltad aupply loota. Vary truly youre. nzijn Att. Saeratary :0 eaiio'imat LIA19277 0 m quaere w ww p a h t k t gYtnrm C. 0. Crimes Th* Carl f. Berber* Rettarch Center Th* Dectrlo Storage Battery Caepeny Tarlley, Pennsylvania It Is quit* spproprlst* aa thl* centennial of th* flrtt practical lead-acid *toras* battery to review the field and evaluate the potential threat posed by th* nor* prominent coopetl'lve system*. Over th* year* th* lead-acid battery ha* been tb* neinstay and th* wort-bore* la th* field of tecotvdary batteries. Th* relative simplicity of th* electrochemical reaction, high cell voltage, absence of criticality In physical configuration, and a geoerou* supply la nature of rather Inex pensive basic aatsrial* are all factor* vhlch have contributed to th* cccaaadlng position of lead-scId batteries. Lacking this fortunate com bination of good technical and economic features, ether system* vers mors or less relegated to a position of secondary Importance, vhlle industrial development emphasized th* lead acid vork. And contrary to the remark so often heard to th* effect that the battery la your auto mobile today la no different than those used tom* forty year* ago, th* facta are quite different. There hat been a great lnprovement in the battery during this period-- improvement la lte electrochemical performance, 9 la the eneror-denslty ratio, la packaging, and la Ilf*. Most of thl* Im provement he* beam the result of years of development vherela progress bee been achieved by Incremental Improvement* as opposed to any profound advance which could be attributed to research. The letter has been very much neglected. In general. It might be said that research In lead-add ccuplaa has become a reality only In the current poetvar period. Cbe seldom hears any reference to th* electrochemical efficiency of the lead-add battery. This Is quit* understandable vhen, after a hundred year* of development, the efficiency 1* about one-half of vfaat It could, and should be. Because of th* rapidly growing appreciation of th* value of research, even to those Items of long standing acceptance, Z fully anticipate that th* advance In th* technology of th* lead-acid battery vlll be greater during th* coming decade than during th* past half century. During th* part two decades th* generation of electrical energy In this cowtry has had a phenomenal growth--from 130 billion KWH In 19l*0 to aa astlmatsd 600 billion In I960. An Increase of 36of. This growth Is also reflected In th* pcrtahle or packaged electrical energy sources. At the sea* time, there has been a rapidly growing demand for portable power units, or betterlss, for specialised uses. In this myriad of new uses, the criteria by which batteries formerly were evaluated have been pretty well upset. In most cases a single characteristic is of Presented at the meeting of th* Association of American Battery Manu facturers, Inc., Loe Angeles, California, June 2, i960. flmiiirs-mimiin sees*. iiisiSMm * 2361.0] LIA19278 C. 0. Qrimsa > The Challenge by In Battery Ijntw 9 primary tad vital Importance to the successful application of the battery, other factors being mad* quit* secondary considerations. for example, perhaps la t specialty application tb energy-velght ratio tty be alllmportant) la another, it nay be cycle lift, or thtlf lift, or energyv o Iu m ratio, or coat. Tbit situation bat aroused nsv tad intensified Interact la the development of aav battery systems to Mat tbaaa spaltllMd requirements. early til of theta "orv" battery systems art not aav, but Barely a aav look at aa old ltaa. Tba nickel-cadmium tad nickel-Iron call constructions vara patented before tba end of tba 19th century. Tba Mrcury call ewes lta origin to tba Area call vhara It via flrat pro* poeed aa storage battery la 1E66. Tba uae of aliver oxide as a positive active material vu proposed by Jungner la 1699, and tba call iru first patented by Morrlaoa la 1910. Certain type* of prlsazy calls alto bare applications vblcb art part of tba traditional Barksting area of lead-acid batteries. The nodarn fuel cell It a direct descendant of drove' vail known gaa battery vblcb be described first la 1039. and later as a battery of JO calls In 1612. Rechargeable u Hm calls la dry call configuration, can be traced to tba vork of LeClancbe la tba 1650's. Another aav fora of portable electrical energy of concern to ns Is tberaoelectrlclty, discovered by Seebeck la 1621. In giving tba "aav" battery systems a dusting off It la apparent that tba challenge to the lead-acid battery ccmes, not fro* a oev chemistry, but from tba application of aodern technology to old and vail kaova systems. Advances la telenet and engineering have cede possible tba fabrication of battery systems characterized by high asergy-velght ntloa, long shelf Ufa, long cycle life, resistance to extra-anrlrocacntal conditions, ate. They have also made available la any Instances quantities of sons elements and compounds at acceptable coats--materials vblcb formerly vara considered price prohibitive. Soma of tba aav specialised applications will be best satisfied by the nev battery systems. Beam of them can ba satisfied sort economically and efficiently by lead-acid batteries. She electrochemical systems moat prominently considered today for storage battery use are lead-acid, nickel-iron, nlckal-cadmltaa, silversine, silver-cadmium, and fuel cells. The latter Is, sleetrochemically, a battery. Sack In 1639 It vas known as a gas battery, quite a fitting and adequate description. Today It baa been glamorised by a nev name, vblcb la my opinion la Inappropriate. But nevertheless, it has great potential and one must not disregard this fact simply because of Its fltiyWi Za considering tbs choice of a battery system to best fulfill re quirements of an application, many factors other than capacity must be velgbed. Usually it Is a ccmprcmlse of away characteristics, among vblcb are weight, volts*, availability, rechargeabiUty, cycle life, stand life, coat and maintenance. In Table Z are listed values for WJJP-W# mmaik **-** L IA19279 0. 0. Orlmes Tbe Challenge by Xev Battery Oystsme 0 ICO anpere-bour ilw batteries at tbe 10 hour rata for k m of these battery systems. It la Interesting to not* that tbe lead-acid call haa ooa characteristic which aata It apart from thoaa lyitua vlth which It la eooparedj that la, lta high call voltage. Ihla factor offsets tha higher density of tha lead, aad gives la fact a batter aaeror-vxlght ratio than la found la tha other "vcrV type" batteries-- nlekal-cadalum and nlckel-lron. It la alao observed from Table I that tha stiver systems offer rery greet weight and volxne advantage* over tha lead-acid. Bovever, this elmpla comparison la hut tha flret approxlcmtloa aa to choice of battery ayatem for a particular application. Extended tablet of tha performance aad ecoacmlc factora for aach ayatan, under varloua conditions of load aad temperature vould be naccaaary to pernlt logical selection of tha optima system for a specific applica tion. levertheless, It ta apparent that vbera weight and alta are critical factora, and cycle Ufa or coat are of leaaer importance, tha aliver-line and ellver-cadaitm lyrteae era to ba preferred to lead-acid. Other factora vhieh affect tha choice of a ayatan are ebovn la Table II. These factora Include ease of recharge, life and coata. When v consider Ufa and coata v* find that tha Industrial type leadacid battery la better than tha other ayateaa on tha baale at coat par unit energy output over the life of the battery. Autcootire type leadacid batterlee will hare a lover Initial coat this any of the eystems, hut because of lta better cycle life, the industrial type is the acre economical. It la unnecessary to detail the advantages and disadvantages of the leal-acid battery. Tou are all familiar vlth Its characteristics, and knov quite thoroughly vfaat It vlll do, and likewise Its shortcoming*. Considering the lead-acid battery as a standard, vhat ccnparatlva feature* of the so-called new systems have given rise to the renewed end Intensified Interest In these batteries! The nlckal-cadslimi system la, of course, no stranger end has maintained a relatively strong competitIt s position for many years. It has several attractive features, among which are lcng cycle life, good charge acceptance, scalability, and the ability to withstand abuse. While these desirable character istics are offset to a great extant by lta coat and low energy-weight and roluse ratios, nonetheless In certain applications Its advantages are such as to make It tha logical choice. Xo practical system today eaa match tha energy-weight and volume ratios of the silver-tine battery. It le also characterised by excellent high rate capability and It la sus ceptible to ready operation In the sealed condition. Blgh cost and short cycle life, however, preclude Its widespread use except In those very special applications, chiefly military usage, wherein weight and volime are of overriding importance. The silver-cadmium cell Is In general similar to the ellrer-tine. It le superior to the latter In cycle life, but because of a lover cell voltage the energy-weight ratio le lees. The positions vhieh the leading types of batteries have established In the market are shewn in Table III. Primary cell* have beta Included SbmMiaitiiia .'Wim O'1 -'-'lU11 ..s.'jr j|WJ iiTm^Tssah^hediefcMwiMMmi wiii.iim* "/ue mm 1 i LIA1928 0 C. 0. 0rin* The Challenge by In NtUry IjnUM Lb the table la ord*r to Indicate tb* extent of tb* packaged power field covered by this general type of ctll. The dividing line which dlffrntlta brtveea prlrary and *coodAry batteries 1* indeed broad, grey *ra. Becent development* la prInary batteries bays produced successful recbargssbl* cell*, or secondary batterlee. likewise, certain type* of actirated silver-tine batt*rla coy be ccrJidered a* primaries, vbll* *al*d erecelery battarle* bar* been produced In tb* pact fev year* vblcb *xe marketed la tb* primary battery field. If v* are to consider any of tb* rinX eyrtea* a* poaalbl* replace* Mat* for ell or ** a significant part of tb* lead-acid production, because of any sup liVcr electrochemical performance, then let u* consider tb* availability cr neteriols. Shewn In Tmbl* IV are tb* figure* on national and world production of ratal* used In batteries in 1979. Frcm tb*** figure* n*y b* deduced see* Interesting conclusion*. If it la asstaed, for example. that but 30 of the lead used in lead-acid batteries eater* Into tb* eleccrocbemical reaction In tb* cell*,--tb* remainder be ing utilised for grid*, port*, connectors, *nd "Inactive" active material*,tb* aacKst of l*ad used annually in tb* United States for tb* eleetrochadcally active component of lesd-acld batteries vould be 3>$ of 380,700, * cr 111,200 tan*. Taking Into account tb* difference in densities betveen lead and cadalua, tb* faraday capacities, and the fact that cadslm la used cnly In tb* negative plates. It is determined that 31,000 tens of eadmdua vould b* required annually for batteries to replace tb* lssd-aeld 0 typ*. This requirement for batteries aloa* represents about three tines tbs world's annual production, or nore than seven tines tbs annual output la tb* Obited State*. 81slier consideration* apply to nickel and silver. Battery usage la to widespread today that any ryrtea to be vilely used bust utilise only those materials which are plentiful. Bo far, we bare considered tb* challenge to tb* lead-acid battery posed by cnly electrochemical syetcaa which are generally considered a* storage betteri**. Tber* 1* also a challenge fron other systems vblcb, although not considered a* storage batteries, are capable of fulfilling any of tb* aaa* requirements for portable packaged power. These include nuclear batteries, thermoelectric clls, air or gee depolarised cells, aaall rechargeable alkaline cells In dry cell configuration, and the ga* battery or fuel cell. Bucleer batteries offer a great potential but tb* development of high rat*, high energy-den*1ty, inexpensive batteries mist await tb* development of new knowledge, for tb* foreseeable future, tb* nuclear battery will have application a* a high-potential source, but will be seriously limited In rat* performance, watts per p>ound, and cost. Thermo electric cells, used for tb* conversion of beat energy to electrical energy, are rarely a new approach to an old problem. The technical art la this field la still undeveloped and currently tb* systems suffer from low efficiencies, low energy-density figure, and cost. bh*n fully de veloped, It* applications id 11 be chiefly In stationary generating equip ment where, because of efficiency limitation* loosed by the thermal cycle. It will meet stiff competition. man usmne mM 1-141 9281 6. 0> Orimss The Oiollsngs by Ilev Battsry Systems lemarkabl* progress hae been mr la tb peat tea years la the de- velopmsat of a practical fuel cell, * of the reported fuel cell work done to date Involvea the use of hy . or mixtures of hydrogen and hydrocarbon aa the fuel, and oxygn 4m oxidizer. While ecit of the Interest la fuel cells Is focused oa Its use as a pover generating source. It has considerable potential, vhen utilising carbonaceous fuels, as a chemical reactor producing both pover and a useful by-product. Ukevlse the fuel cell electrode eyetea Is readily adaptable to use In chemical processing. Other features of the fuel cell make it very attractive to certain ailltary applications, ranging from submarine propulsion to auxiliary pover units la specs satellitee, sad silent pover sources for ground use. la considering the lepsct of a practical fuel cell oo the lead-acid battery market one must keep la mind the fact that a fuel cell la in fact aa electrochemical battery vbereln the "active caterlals" are stored externally to the cell and are capable of being fed continuously thereto. Za other vords. It la a battery capable of continuous discharge for ex tended periods of time. Consider therefore thal the fuel cell consists of tvo major components--first, the "active materials' or fuel and oxidant, and seccod, the assembly of catalytic alectrodes, fuel and oxidant Karvinnj systems, and product disposal system, electrical connections, electrolyte, and container. This second component I vlll term the "reactor." Bence, regardless of the vatt-hour capacity of the unit there Is a definite fixed velght end volume attributable to the reactor. This In turn la directly related to rate and voltage. The fuel cell la therefore at a decided disadvantage, velght and voluae-viee, vhen applied to uses vbereln the dr-rand for continuous pover supply Is of relatively short duration. A comparison of the energy-densities versus duration of con tinuous discharge for storage batteries, fuel cells,, and solar converters Is ahovn In Figure I. Pros this figure It la evident that the theoretical hydrogen-oxygen fuel cell employing fuel storage In the solid state to reduce velght vlll have a lover vatt-hour per pound rating than vlll a sealed sllver-tlnc battery vhen the duration of continuous power Is less than six hours. Compared to the lead-so Id battery the eroeacver point is slightly In excess of one hour. For the solar converter in 100^ light the values are 10 hours end 1.5 hours respectively. There are many possible types of fuel cells, varying In complexity as veil as efficiencies. And Just as In the case of batteries, no one type vlll beet fulfill ell applications. The more complex types vlll In general he best suited to fixed Installations while the simpler ones vlll have more use la portable units. At the present state of the art, It Is extremely difficult to predict the economic factors. Yet, to gain videspread use the fuel cell must be economically competitive vith other systems and, because of the greet Increase in efficiency possible in such a system, X am confident that eventually It vlll be not only cost competi tive hut vlll result la significant economic advantages. There has been a great amount of publicity relative to the fuel cellpublicity vhlch has aroused widespread Interest end excitement, and has resulted In many very extravagant claims. Z think that perhaps tha siijftriWiflfiiiisk imiM 8Ht LIA19282 C. 0. Orlnes The Challenge by ev kUi7 Byete o underlying mio o for all thli may be attributed to the glamour attached to the name "fuel Cell.' UnfortunaCely, feu of the clalns can be subtantlated by factual data on actual performance. To evaluate the possible challenge to the lead-acid battery posed by the fuel cell one suet beep In Bind the tvo points vhlch I have already Mntloaed--vlt., that a fuel cell la Just another battery vhlch, first. Is capable of long sustained dis charge periods; and second, for short periods of discharge It le at a decided velght end volm disadvantage compared to the conventional type secondary batteries. Consequently, 1 believe that the fual cell vlll la general create lte ova narkets aa aa exteaalon of battery application rather than as a replacement. Z don't aeen to Imply that the fuel cell to vhlch Z have Just re ferred le Just around the corner. Such a cell Is nany years away, and a tremendous amount of work in restarch and development has yet to be done before such a systea Is developed to the point where It ray fulfill the role Z have predicted. Bovever, In vlrv of today's technological ellnate and the confidence characteristic of science and engineering, the fact that such a cell Is theoretically feasible constitutes sufficient Incentive to Insure eventual success. Za 1059 Gaston Plante vrots, "Thai secondary electromotive force obtained vlth lead plates In voter, acidulated vlth sulfuric acid, ves greater and persisted longer than that of other canblaatlona.* A hundred o years of battery development vork, on vhlch has been built a giant In dustry, has felled to upeet that statement. Z believe that for nany years to c o m the lead-acid battery vlll continue to aalntaln Its posi tion la the storage battery field. { * LIA19283 C. 0. Ortat* 0 n OiaU(n( by Ba* Battery Byatene TABU I Eaer*y Dtoaltlea of Cannon Battery flyatena too AH Site Battery Type LEAD*ACTS Arlatloo Voltage Par Call toergr Dmiity for 12 V Battery. Open Circuit" Av. Voltage ho. cf Celia vhr/lb v-or/lir 2.1 1-9 6 13.1 1.0 Zrooclad 2.1 1.9 6 13.1 135 Artonotlra 2.1 1.9 6 15.0 1.3 noaX-CATHUN Bockat 1.2C-1.30 1.2 10 U.O 0.6 Sintered 1.26-1.93 1.2 10 11.5 0.68 JH03X-IFKH Tuba Type ravts-ziac 1-5 1.66 Cb Ugber plat*.** 1 58 Ca lower plateau 1.2 1.55 10 10.6 .92 6 65-100 3.0 BTLYER-CAHaUN l..' Cn alfbar platan* 1 12 On l^r^r plateau 1.06 U 50-75 2.5 Oj-Hg run. CELL (Cry Qxse. fuel Storage) o-r 16 *120 Baaed on Boon Tanperature Dlechargee at the 10 hour rata ! * r C. 0. OrlM* Tbs Challenge by Bev BatU*7 #rt' TABU H Coepariloo of Battery Systeoa ----------------------------1---0--0---AH Ba-t--t-a---r--l-*--*----------1--2-TV-~- Battery Type let. Ufa Initial Coat LEAD-ACID Cocatact Potent lal rechart* or etepped currant recharge la 3-10 hour* Autcaotlv* 530 cycles 3 jrws to. Irvtuatrlal $-10 years 1600 cycles 70. naaLCADMIUM Pocket Bscharce at Constant Potential 7*0 hours 10-20 years 2000 cyrlss 150. Coat Taar 13. $ 9. $ 6. Coet Cycle 13 4 t*3 4 7-5 4 Mistered Tented cells can be re charged la 2 hours. Sealed cells can he re charged in 10 hours. Acquire so eater. 10-20 years JOOO cycle* 300. $ 20. io 4 HiaCEHROH Tubular Cherce at Constant Potential la 6-7 hours 13-20 years 2000 cycles $ 130. 7-5 fi.5 4 BILVER-ZUfC Bechance at Constant Potential la k-20 hours 1 year 200 cycles $ 600. 1800. too 4 SILVERCATHTUM Bschans at Constant Potential la t-20 hours 2-3 years 300 cycles $1000. |tco. son 4 LIU9285 0. 0. Orta** tba Chall*6** by Vv BatUry 8y*t* TABLE m Katlnatad Battery Sale* In tb* UbltM State* - 1959 IZAD-ACIP $629,000,000 . Including nr* then . 30,000,000 uto- otir* batt*rl* valued at apjotadataly $"*00,000,000. ncxzieCAamii EICXH.EC3 120,000,000 n large suabar of larsa-ilcally aealed call* of tba button type. surea-usc PRIWJTT CM $18,000,000 $150,000,000 Ho*tly for llltaxy JIBPOMI, Ccnprlilng about 1-1/2 billion unit* aoatly of tba Ledancbt type and about 300,000 bearing aid battarlaa $ , , .(EgO/Zn) valued at 30 000 000 0 LIA19286 0 C 0. Orlnaa ft* 0*U*d (* by hv Battery Byitana TABU IV 1959 Production figure* for Battery Metal* (In Short Toe*) VBA Production World Production DBA Dm DBA Dm for Storage Battarlaa Percentage of total Dm Arango Prlc* ($ par lb) LEAD 239,*oo 2,ll20,2DO 1,091,100 3,7DO 3*-9 0.122 rrocn, n,6oo 309.000 112,700 500 o.k 0.1* CATKIOM *,300 10,000 7,000 BUYER Boo 7,900 *.900 me *17,000 3,071,000 933,800 ICO 120 25,000* 1.* i.*0 *5 13-30 *7 0.115 Including dry enlX battarlaa. 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