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Saft Intensium®
Flex & Evolion
Lithium-Ion batteries for UPS,
Switchgear and Telecom applications
Saft America Inc. – Industrial Standby Division – 2016
Agenda
1. Li-Ion Technology
2. Saft Intensum ® Flex System
3. Evolion
4. Saft Li-Ion into Standby applications Already in the Field….
Saft
Intensium
Flex for UPS
applications
2 Saft proprietary information – Confidential
LITHIUM-ION TECHNOLOGY
Saft
Intensium
Flex for UPS
applications
3 Saft proprietary information – Confidential
1
Li-Ion Basics - History
The future of batteries – Lithium-ion
– 1991: Sony introduced the first Li-ion cell (18650 format)
– 1992: Saft introduced its commercially
available Li-ion cell
– 1976: Exxon researcher – Whittingham
described lithium-ion concept in Science
publication entitled “Electrical Energy
Storage and Intercalation Chemistry”
– Saft Large format cells in 2004.
1792 1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990
Saft
Intensium
Flex for UPS
applications
4 Saft proprietary information – Confidential
Li-Ion Chemistries
– Positive (cathode)
• LiCoO2 (LCO)
• LiNiCoAlO2 (NCA)
• LiNiMnCoO2 (NMC)
• LiMn2O4 (LMO)
• LiFePO4 (LFP)
– Negative (anode)
• Graphite
– Emerging anodes
• Lithium titanate
• Silicon-based
195 Ah/kg 145 Ah/kg
125 Ah/kg
162 Ah/kg
3,00
3,20
3,40
3,60
3,80
4,00
4,20
4,40
0,00 50,00 100,00 150,00
CAPACITY (Ah/kg)
200,00 250,00
VO
LT
AG
E (V
)
LiNiO2
LiCoO2
LiMn2O4
LiFePO4
Saft
Intensium
Flex for UPS
applications
5 Saft proprietary information – Confidential
Major Lithium Ion Chemistries
Tradeoffs among the four principal lithium ion battery technologies
The furthered colored shape extends along a given axis, the better the performance along that dimension
Source: Battcon Paper J.McDowall
Saft
Intensium
Flex for UPS
applications
6 Saft proprietary information – Confidential
Li Ion Cell Construction
Prismatic Cylindrical
Saft
Intensium
Flex for UPS
applications
7 Saft proprietary information – Confidential
Cathode
Based on the
application and
battery usage
Anode
Others
Current
interruption
Venting
Thermal
Mgmt
Electronics
Software
Mechanical
Architecture Ma
teria
ls a
nd
Pro
ce
ss C
on
tro
l
Ch
oic
e o
f C
he
mis
try
Sy
ste
m D
esi
gn
Ce
ll D
esi
gn
Particle contamination of incoming materials
Particle and humidity
control
Process
validation/ control
LIB Safety - A System design Approach
– Four critical pillars of safety
Saft
Intensium
Flex for UPS
applications
8 Saft proprietary information – Confidential
C/100
1
C/10
C
10C
100C
10
100
160 180 200
Po
we
r
[W/k
g]
1000 Medium Power Li-ion (VLM)
10 000
100 000
0 20 40 60 80 100
Energy [Wh/kg] 120 140
Super capacitor
Ni-MH
Ni-Cd
High Power Li-ion (VLP)
High energy Li-ion (VLE)
Very-high power Li-ion (VLV)
AgO-Zn
Ultra-high power (VLU)
Li-Ion Flexibility
Ragone diagram
Standard Lead-Acid
Main energy
storage options
Saft
Intensium
Flex for UPS
applications
9 Saft proprietary information – Confidential
Saft proprietary information – Confidential
Lithium-ion vs Traditional Chemistries
2 0a fIntensium Flex for UPS applications
Lead has derating from +35°C and below -10°C
– Better energy dentisty: lower footprint compared to lead
– High cycling life and calendar life
4000
10-40
40-60
INTENSIUM ® FLEX
PRODUCT RANGE For Industrial UPS, Switchgear
Saft
Intensium
Flex for UPS
applications
11 Saft proprietary information – Confidential
2
Saft Intensium® Flex – The Li-ion flexibility for your Mission Critical
Intensium Flex is a complete lithium-ion battery system from Cells, to Electronic
Management, through system design, hardware/software and cabinets. This
integrates those 3 main building blocs:
– Li-ion module (Synerion® range)
• 48V: 48P, 48M, 48E
• 24V: 24P, 24M, 24E
• Cells only + electronic (cell balancing, sensors,.;)
• Module selection based on discharge profile
– BMM (Battery Management Module)
• 300A continuous
• Electronics: management of the string, communication,..
– MBMM (Master Battery Management Module)
•Electronic inside: management of the parallelism, communication,..
Saft
Intensium
Flex for UPS
applications
13 Saft proprietary information – Confidential
Synerion architecture
SMU board: conducts information (V,A,T°) to
BMM
Lithium ion cylindrical cells: Saft
technology
Saft
Intensium
Flex for UPS
applications
14 Saft proprietary information – Confidential
BMM 300A
– Ensures communication and operation in the designed voltage, current and temperature ranges
– Operating voltage 190V to 960V
– 300A (400A peak 10 sec)
– Pre-charge, self power and HMI as standard
– Manual disconnect (2 poles) on front face
– 3U height
Saft
Intensium
Flex for UPS
applications
15 Saft proprietary information – Confidential
MBMM Characteristics
– Manages the parallelism and communications when system configuration involves more than 1 string
– Manual disconnect on front face
Saft
Intensium
Flex for UPS
applications
16 Saft proprietary information – Confidential
Intensium® Flex, example:
120V, SYN24E or M, 360Ah / ~43.2kWh
Racks and
cabinets
Containers
Components
Saft
Intensium
Flex for UPS
applications
17 Saft proprietary information – Confidential
MBMM
Charger
DC Panel
Saft proprietary information – Confidential
Intensium® Flex, example:
480V, SYN48P, capable of ~500kW for 5 min
17 Saft Intensium
Flex for UPS
applications
Saft Intensium® Flex vs High Power VRLA
Saft
Intensium
Flex for UPS
applications
19 Saft proprietary information – Confidential
375kW / 3 Minutes
VRLA SafT Intensium
Flex
Delta Related Benefits
kWh installed 280 130 ‐53.57% Energy savings : less energy consumptions in floating mode and charge
Footprint (sq Ft) 21 10 ‐52.38% Improve TCO : lower real estate cost, other equipement can be installed
Weight (lbs) 10000 2000 ‐80.00% Improve TCO : lower infrastruture cost, easy and quicker to maitain
Calendar
Life 25degC
5 to 7 20 2.5 to 3
times less
Improve TCO : less replacement over 20 years
Eficiency 83 to 87% 96 to 99% Energy savings & Improve TCO : less energy consumptions in floating
mode and charge, les power/energy installed
Optimal
Operating
temperature
range
20 to 30 DegC 15 to 45DegC HVAC consumptions savings & Improve TCO : extend the operating
temperature of the battery room and save HVAC consumptions and
related costs
Recharging time 5 to 7hrs 1.5hr 3 to 5
times
better
Improve System availability
Communication To be added Included Improve Predictive Maintenance and System availability :SOC, SOH,
Alarms and custonized battery information alaready avaialble
Electrochemistry L/A Li‐Ion Improve System availability : No sudden death
Improve Environemental footprint : CO2 reduction
(~40%) Improve TCO : less maintenance
Saft Intensium® Flex vs High Power VRLA
Saft
Intensium
Flex for UPS
applications
20 Saft proprietary information – Confidential
here below a analyze we did for a Customer within a particular case which describe Maintenance Task and compare VLA and Li-ion
Uninterruptible Power Supplies (UPS)
>8x lighter installed weight compared to lead-acid
>4x smaller Installed footprint: compared to VRLA
>95% roundtrip efficiency
>5x faster recharge than lead-acid types
>3000 cycles to 80% Depth-of-Discharge (DoD)
>17 years life duration at room temperature
Modular system integrating cells, balancing and supervision
Integrated supervision (state-of-charge/health, alarms, etc.)
Significantly lower environment impact than lead-acid
Optimised performance for different applications (HP/MP/E)
21
Benefits
Industrial Lithium-ion
Saft Intensium Flex for UPS applications
Saft proprietary information – Confidential
Saft’s support and commitment to reach the Li-ion battery for UPS
breakthrough
Warranty : 10 years full on the battery (Modules, Chemistry) / 5
years full on the overall system.
Integration Guidelines : overview of how to integrate the Saft
Intensium® Flex lithium ion battery system in a standby
application.
General Safety Recommendations - Saft Intensium® Flex (Lithium‐ion) Batteries for UPS Applications in Indoor
Environments The purpose of this document is to inform our customers about
particular safety recommendations in order to properly install
and operate our lithium‐ion batteries.
22 Saft Intensium Flex for UPS applications
Saft proprietary information – Confidential
Saft’s support and commitment to reach the Li-ion battery for UPS
breakthrough
NFPA Saft Safety Recommendations for Li-ion Battery
Systems :
: This document contains Saft safety recommendations for the use of lithium‐ion chemistries, following the guidelines of
the National Fire Protection Association (NFPA).
UL-listed Lithium-Ion Batteries for UPS Applications : Saft is
pleased to announce this update for our lithium-ion
battery systems for the UPS market related to UL
qualification.
Saft Li-ion Recycling Policy : Saft’s position and
commitment regarding Li-ion battery recycle
23 Saft Intensium Flex for UPS applications
Saft proprietary information – Confidential
EVOLION : main features overview
25
VL80E cell (Li-ion, NCA)
77 Ah (C8), 3.9 kWh
48V
4,857 Wh/ft3
66lb
59 Wh/lb
Paralleling Only
BMS built in (BMST)
RS485/MODBUS communication
Standard accessory kit :power & communication wires, fuse
Produced in Jacksonville, FL, since 2013
10.24 inch.
8.50 inch. 15.90 inch.
Saft Intensium Flex for UPS applications
25 Saft proprietary information –
Confidential
Certification & conformance status
26 26
Saft Intensium Flex for UPS applications
26 Saft proprietary information – Confidential
Massive Paralleling configuration : from 1 to 80 Modules
27
83.9 inch.
20.5 inch.
16.15 inch.
27
Saft Intensium Flex for UPS applications
27 Saft proprietary information – Confidential
SAFT LI-ION INTO STANDBY
Saft
Intensium
Flex for UPS
applications
29 Saft proprietary information – Confidential
4
Critical Power center for Southern Company/Crim, Utility Company – 120 VDC
Market Segment : Industrial/Utility – backup for substation
equipments
Application requirements Critical Power Center – 2hrs backup time @ 55A
+ 30s @150A 120VDC – 160Ah to 820Ah, from 20kWh to
100kWh 20 years life time
Systems in the field : 30 since 2013. large deployment on going
Lithium-ion L&L
30 Saft proprietary information – Confidential
Critical Power center for Southern Company/Crim, Utility Company – 120 VDC
Lithium-ion L&L
Li-Ion benefits expected and Market trends
NERC and FERC Regulations to log and track critical systems information (Batteries)
Large deployment expected within Utility Company
Saft Li-Ion offer
Iflex batteries in a system kit from 2 to 10 strings in parallel of 5 Modules 24M in series 120VDC – from 20kWh to 100kWh
Why Saft
Strong capabilities in US, customize and active support Active is IEEE, UL comitee
31 Saft proprietary information – Confidential
Primax/Broselco , Primax/Manitoba Hydro , FDA Lab, Switchgears – 120VDC
Market segment: Industrial – backup for electrical equipement
Application requirements > Switchgear applications – ex. 8hrs
backup time @ 5A + 1min @60A – 120 VDC
Li-Ion benefits expected > Foot print savings, > TCO approach, > Low maintenance > 20 years lifetime
Systems in the field : 5 since 2015
Lithium-ion L&L
32 Saft proprietary information – Confidential
FDA Lab & Primax/Broselco - Switchgears – 120VDC
Saft Li-Ion offer
• IFlex batteries in a system or in kit from 2 to 10
strings in parallel of 5 Modules 24M or 24E in series
• 120VDC – from 10kWh to 100kWh
Current business market and Trends
• 5 systems in the field with Honeywell, Primax, Jacobs
Eng.
• More systems expected mainly driven by Utilties
and Industrial companies
Why Saft
• Flexible and customized LIB solutions, local and
active support
Lithium-ion L&L
33 Saft proprietary information – Confidential
Backup for PV Systems – CAT, HCI Energy
Market segment: Off grid PV backup
Application requirements > Mining or Supervision Utilizes 48Volt bus, Evolion batteries - 560Ah
battery, for UPS load. 10kW for 8hrs with APC Schneider or CAT PV inverter
Li-Ion benefits expected > TCO approach (20years ife , No Maintenance), Footprint and weight savings,
Systems in the field : 1 + 10 to 20 additional systems quoted
Saft Li-Ion offer > From 1 to 50 Evolions in parallel as a system kit or turnkey system in
racks, incl Saft recommandation for electrical architecture (safety perspective)
> Current business market and Trends
> PV system growth required backup
Why Saft > Strong capabilities in US, customize and active support > Large experience : More than 50,000 Evolions in the filed since 2012
Lithium-ion L&L
34 Saft proprietary information – Confidential
FCB : UPS Data Center – 50kW/15min backup time
Market segment: UPS Data Center
Application requirements Replace VRLA batteries, with existing Eaton’s UPS – 432 VDC nominal 50kW, 15min backup time – UPS Data Center located at FCB headquarter
Li-Ion benefits expected Maintenance cost reduction, weight savings, TCO approach, introduce innovation
and improve environmental image.
Systems in the field : 1
Saft Li-Ion offer 1 strings of 9 modules Syn48MFe in series
market and Trends Since this system is approved, opportunity to scale to large FCB Data Centers Recurrent business expected : from 10 to 50 systems/year
Why Saft Strong capabilities in US, Customize turnkey system and active support Li-ion power performances
Lithium-ion L&L
35 Saft proprietary information – Confidential
Filmwerk : UPS Trailer– 160kW/5min backup time
Market segment: Large UPS/Modular or containerized UPS for Data Center
Application requirements Replace VRLA batteries, with existing Eaton’s UPS9390 – 480 VDC nominal 1600kW, 5min backup time – UPS located into a trailer
Li-Ion benefits expected Maintenance cost reduction, weight savings, TCO approach, introduce innovation and improve environmental image.
Systems in the field : 1 Work in progress +4 expected in 2016
Saft Li-Ion offer 2 strings of 10 modules Syn48PFe in series
market and Trends Interesitng trend of Modular/containerized UPS for industrial or Data Center applications
Recurrent business expected : from 2 to 10 systems/year
Why Saft Strong capabilities in US, Good Industrial Image, Li-Ion power performances Customize turnkey system and active support
Lithium-ion L&L
36 Saft proprietary information – Confidential
AVL – ECO-H – Peak shaving for O&G Driling
Market segment : O&G – Drilling Application requirements
> Fuel saving > High cycling & power application, Hybrid Power Management system – battery
allows immediate on demand power and the levelling of power usage peaks for rigs,
Li-Ion benefits expected > High power efficiency at discharge and charge level to reduce fuel
consumption, fuel emissions and operating expenses > TCO approach Systems in the field : 1 + 2 under discussion
Lithium-ion L&L
37 Saft proprietary information – Confidential
Saft Li-ion end-to-end capability
– Technology
• More than 15 years experience
• Criteria : Performance, Safety and Service Life
– Manufacturing
• Process control is key for life and reliability
• Cell manufacturing and System assembly
• 4 production sites (France and U.S.)
– System Capability
• System Design, development, qualification
• Mechanical, Electrical, Qualification and Testing
• Pre-project & project management
Saft
Intensium
Flex for UPS
applications
38 Saft proprietary information – Confidential