Development of Zinc/Bromine Batteries for Load-Leveling Applications: Phase 1 Final Report
The Zinc/Bromine Load-Leveling Battery Development contract (No. 40-8965) was partitioned at the outset into two phases of equal length. Phase 1 started in September 1990 and continued through December 1991. In Phase 1, zinc/bromine battery technology was to be advanced to the point that it would be clear that the technology was viable and would be an appropriate choice for electric utilities wishing to establish stationary energy-storage facilities. Criteria were established that addressed most of the concerns that had been observed in the previous development efforts. The performances of 8-cell and 100-cell laboratory batteries demonstrated that the criteria were met or exceeded. In Phase 2, 100-kWh batteries will be built and demonstrated, and a conceptual design for a load-leveling plant will be presented. At the same time, work will continue to identify improved assembly techniques and operating conditions. This report details the results of the efforts carried out in Phase 1. The highlights are: (1) Four 1-kWh stacks achieved over 100 cycles, One l-kWh stack achieved over 200 cycles, One 1-kWh stack achieved over 300 cycles; (2) Less than 10% degradation in performance occurred in the four stacks that achieved over 100 cycles; (3) The battery used for the zinc loading investigation exhibited virtually no loss in performance for loadings up to 130 mAh/cm{sup 2}; (4) Charge-current densities of 50 ma/cm{sup 2} have been achieved in minicells; (5) Fourteen consecutive no-strip cycles have been conducted on the stack with 300+ cycles; (6) A mass and energy balance spreadsheet that describes battery operation was completed; (7) Materials research has continued to provide improvements in the electrode, activation layer, and separator; and (8) A battery made of two 50-cell stacks (15 kWh) was produced and delivered to Sandia National Laboratories (SNL) for testing. The most critical development was the ability to assemble a battery stack that remained leak free. The task of sealing the battery stack using vibration welding has undergone significant improvement resulting in a viable production process. Through several design iterations, a solid technology base for larger battery stack designs was established. Internal stack stresses can now be modeled, in addition to fluid velocity and fluid pressure distribution, through the use of a finite element analysis computer program. Additionally, the Johnson Controls Battery Group, Inc. (JCBGI) proprietary FORTRAN model has been improved significantly, enabling accurate performance predictions. This modeling was used to improve the integrity and performance of the battery stacks, and should be instrumental in reducing the turnaround time from concept to assembly.
- Research Organization:
- Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Sandia National Lab. (SNL-CA), Livermore, CA (United States)
- Sponsoring Organization:
- US Department of Energy (US)
- DOE Contract Number:
- AC04-94AL85000
- OSTI ID:
- 9466
- Report Number(s):
- SAND99-1853; TRN: AH200124%%381
- Resource Relation:
- Other Information: PBD: 1 Jul 1999
- Country of Publication:
- United States
- Language:
- English
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