Tecate Training

By:

Maxwell Technologies - San Diego

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 About Maxwell

Capacitor Manufacturer since 1965

www.maxwell.com

Manufacturing facilities:
Maxwell is a leading developer
and manufacturer of innovative, US, Europe, Asia
cost-effective energy storage
and power delivery solutions.

Certifications:
ISO 9001:2000
ISO/TS 16949
ISO 9002

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Table of Content

1. When can I use an Ultracapacitor?

2. What is an Ultracapacitor?
3. Ultracapacitor Market
4. Ultracapacitor Applications
5. Sizing your System
6. Sizing Examples
7. Guidelines to Designing an Ultracapacitor System
8. Summary

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 When can I use an Ultracapacitor?

• Applications that require high reliability back-up power

solutions
• Short term bridge power 1 - 60 seconds for transfer to
secondary source or orderly shut down

• Power quality ride-through to compensate for

momentary severe voltage sags

• Power buffer for large momentary in-rush or power

surges

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Power vs Energy

What is the difference between Power and Energy?

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Application Model

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Peak Power Shaving

Peak Power Shaving

• Ultracapacitors provide peak power ...

Available
Power

Required Power
Ultracapacitor Peak Power

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Back-up Power
Back-Up Power Support

• Ultracapacitors provide peak power…

...and back-up power.

Available Power Ultracapacitor Backup Power

Required Power

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 What is an Ultracapacitor?

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracapacitor Performance Characteristics

• Ultracapacitors perform mid-way between

conventional capacitors and electrochemical cells
(batteries).
• Fast Charge and Fast Discharge Capability
• Highly reversible process, 100,000’s of cycles
• Lower energy than a battery
~10% of battery energy
• Greater energy than electrolytic capacitors
• Excellent low temperature performance

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 What is an Ultracapacitor?

Ultracapacitors are:
 A 100-year-old technology, enhanced by modern materials
 Based on polarization of an electrolyte, high surface area electrodes and
extremely small charge separation
 Known as Electrochemical Double Layer Capacitors and Supercapacitors

Dielectric Electrolyte Separator

C = er A/d
Minimize (d)
Maximize (A)
E = 1/2 CV2

Film foil Electrode

ECDL

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Technology Comparison

Available Lead Acid Conventional

Ultracapacitor
Performance Battery Capacitor
-3 -6
Charge Time 1 to 5 hrs 0.3 to 30 s 10 to 10 s
Discharge Time 0.3 to 3 hrs 0.3 to 30 s 10-3 to 10-6 s
Energy (Wh/kg) 10 to 100 1 to 10 < 0.1
Cycle Life 1,000 >500,000 >500,000
Specific Power (W/kg) <1000 <10,000 <100,000
Charge/discharge 0.7 to 0.85 0.85 to 0.98 >0.95
efficiency

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Technology Comparison (page 2)

1000

Fuel
10h Cells 1h
0,1h

100 Li- 36sec

Battery
Ni/Cd
Lead Acid
Energy Density/[Wh/kg]

Battery 3,6sec
10

U/C
Double-Layer Capacitors
1

36msec

0,1

0,36sec Al-Elco

0,01
10 100 1000 10000

Power Density/[W/kg]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracap vs Battery Technologies
Efficiency
4
Charge Acceptance Self Discharge
Ultracaps
3 Pb-AGM
Temperature Range Availability NiMH
2 Li Ion

Environment 1 Cycle Stability

Recycling Energy Density

Safety Power Density

System Cost Energy Cost

Power Cost

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracapacitor Market

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracapacitor Market

Ultracapacitor World Market

Consumer Products Industrial Transportation

Digital Camera UPS Hybrid Bus/Truck

PDA Windmill Engine starting
Toys Stationary Fuel Cell Light Hybrid
Memory back-up Automation/Robotics Local Power
Rail

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Available Products

• Aqueous Electrolyte: ESMA, Elit, Evan, Skeleton Technologies and Tavrima

• Advantages:
• High electrolytic conductivity
• No need for tight closure to isolate
• Low environmental impact
• Disadvantages:
• Low decomposition voltage (1.23V)
• Narrow operational range (freezing point of water)
• Organic Electrolyte: Maxwell Technologies, Panasonic, EPCOS, Ness Capacitors,
ASAHI GLASS
• Advantages:
• High decomposition voltage
• Wide operating voltage
• Disadvantages:
• Low electrolytic conductivity
• Need for tight closure to isolate from atmospheric moisture

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracapacitor Applications

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Applications

Automotive Traction
 14/42 V systems  Regen braking
 HEV  Voltage stabilization
 Electrical Subsystems  Diesel engine starting Large Cells

Consumer Electronics
Industry  AMR
 PDAs
 Power quality
 Digital cameras
 Pitch systems
 2-Way pagers
 Actuators
 Scanners Small Cells
 Toys

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Today’s Markets

Electric Rail Pack Wind power plant pitch Small cell applications
Braking Energy Recapture systems Digital cameras, AMR,
Diesel engine starting Burst power Actuators, Memory boards

TRACTION INDUSTRY CONSUMER

Ultracapacitors l Microelectronics l High-Voltage Capacitors

Ultracapacitors l Microelectronics l High-Voltage Capacitors
 SITRAS® SES - Solution

Energy storage system:

Stationnary or on the vehicle

Time t1 Time t2
Vehicle 1 is braking Vehicle 2 is acccelerating
Energy storage system stores the Energy storage system delivers the energy
braking energy

Application: Time shifted delivery of the stored braking energy for vehicle re-
acceleration
Solutions: Possible with either stationary or on-vehicle energy storage system
Advantage: Cost savings through reduced primary energy consumption
Ultracapacitors l Microelectronics l High-Voltage Capacitors
 SITRAS® SES - Benefits

kWh/h Saved energy

50
 Reduction of
the power
40 need by 50
kW
 Energy
saving of
30
340.000 kWh
per year and
per
20 installation

 thermal limit
10 68 kWh/h

0
04.08.01 07.08.01 10.08.01 13.08.01

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 MITRAC of Bombardier Transport

MITRAC energy saver

Ultracapacitors l Microelectronics l High-Voltage Capacitors
 Diesel Engine Cranking by Stadler

Ultracap module for diesel engine vehicles

 Robust construction with voltage balancing
 Easy to scale up for additional cranking power
 Easy to integrate in existing housing
 Easy to use, maintenance free

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Wind Turbine Pitch Systems

 Modern wind turbines

consist of three-
bladed variable
speed turbines
 Independent
electro-mechanical
propulsion units
control and adjust
the rotor-blades
 Latest technology
uses the wind not
only to produce
wind energy but
also for its own safety
Ultracapacitors l Microelectronics l High-Voltage Capacitors
 Pitch System Storage Systems

 Each pitch systems is Switch box

including 2600F
ultracapacitors
equipped with an
ultracapacitor emergency
power supply

 Ultracapacitors represent
an optimum emergency
power supply system due 75 V, 81 F
ultracapacitor module
to their
4 modules are put in
• Enhanced level of series to power 300 V
pitch systems of 3-5
safety MW wind power plants
• High reliability
• Efficiency
• Scalability

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Fuel Cell Powered Fork Lift
• Fork lift equipped with a
fuel cell
• Cell system and an
ultracapacitor module

• BOOSTCAP module:
 48 BCAP0010
 112 V, 55 F
 40 kW peak power

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Sizing Your System

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Data sheet

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Data sheet

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 How to measure Ultracapacitors

• To measure UC you need:

• bi-directional power supply (supply/load) OR
• separate power supply and programmable load (constant current capable)
• voltage vs. time measurement and recording device (digital scope or other data
acquisition)

• Capacitance and Resistance:

Capacitance = (Id * td)/(Vw - Vf) = (Id * td)/Vd
ESR = (Vf - Vmin)/Id

Vw = initial working voltage Vmin = minimum voltage under load

Id = discharge current Vf = voltage 5 seconds after removal of load.
td = time to discharge from initial voltage to minimum voltage

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Basic Equations

Definition of Capacitance: C = Q/V (1)

Charge = current * time: Q = I*t C = I*t/V (1a)

Solving for voltage: V = I*t/C (2)

Dynamic Voltage: dV/dt = I/C (3)

Stored Energy E = ½ C*V2 (4)

At initial voltage Vo, Eo = ½ C*Vo2

At final voltage Vf, Ef = ½ C*Vf2
Delivered energy = Eo – Ef ΔE =½ C*(Vo2 – Vf2) (5)

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Voltage & Current vs. Time
C = 15 farad; Resr = 100 milliohm
Vo = 48V; I = 30A
50 50
Vo
Voltage
ΔEtotal=½
dV
dV/dtdV ==VI*dt/C
C*(V
I/C
esr==;Q/C
I*R
dV 2 –I*dt/C
o =+esr Vf2esr
I*R ) -
45
45
40
Resr
i
35
40 +
Voltage (V)

30

Current (A)
+
35 C 25
-
20
30
15
Vf
25
Vmin 10

5
Current
20 0
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Time (sec)
Ultracapacitors l Microelectronics l High-Voltage Capacitors
 Basic Model

• Series/Parallel configurations
• Changes capacitor size; profiles are the same
• Series configurations
• Capacitance decreases, Series Resistance increases
• Cs=Ccell/(#of cells in series) Rs=Rcell*(# of cells in series)
• Parallel configurations
• Capacitance increases, Series Resistance decreases
• CP=Ccell*(# of cells in parallel) RP=Rcell/(# cells in parallel)

• Current controlled
• Use output current profile to determine dV/dt
dV = I * (dt/C + ESR)
• Power controlled
• Several ways to look at this:
Pterm = I*Vcap –I2*ESR (solve quadratic for I)
I = [Vcap - sqrt(Vcap2-4*ESR*Pterm)]/(2*ESR)
• Solve for dV/dt as in current-controlled
• J=W*s=1/2CV2 Solve for C.
Ultracapacitors l Microelectronics l High-Voltage Capacitors
 Applications with a single
energy storage component

• Applications in which little total energy is

required (i.e. memory backup)
• Possibly used with other energy sources
• Short duration, high power (i.e. pulse transmit)
• Long duration, low power (i.e UPS backup)
• Opportunities for high charge rates (i.e toys)

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Applications with two
energy storage components

• Power vs. Energy design trade

when using two components
• Single component vs. two components
• Engines/Fuel cells/Batteries/Solar Arrays are energy rich/power poor
(or poor response)
• Size these components for enough energy, system may be limited in
power
• Size these components for power, system may have surplus of energy
• Ultracapacitors are power rich/energy poor
• Size an ultracapacitor for enough energy, system may have a surplus of
power
• Size an ultracapacitor for power, system may be limited in energy
• Two components
• A primary source for energy; Ultracapacitor for power
• Requires appropriate definition of peak power vs. continuous power

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Ultracapacitor Aging

• Unlike batteries, Ultracapacitors do not have a hard end

of life criteria.
• Ultracapacitors degradation is apparent by a gradual
loss of capacitance and a gradual increase in resistance.
• End of life is when the capacitance and resistance is out
of the application range and will differ depending on
the application.
• Therefore life prediction is easily done.

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Capacitance and ESR vs Frequency

Capacitance vs. Frequency ESR vs . Frequency

3,50E+03 7,00E-04

3,00E+03 6,00E-04

2,50E+03 5,00E-04
Capacitance [F]

ESR [mOhm]
2,00E+03 4,00E-04

1,50E+03 3,00E-04

1,00E+03 2,00E-04

5,00E+02 1,00E-04

0,00E+00 0,00E+00
1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03
Frequency [Hz] Frequency [Hz]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 C and ESR Temperature Dependency

1,2 2000

1,1
1800
1

Capacitance [F]
ESR [mOhm]

0,9
1600

0,8

1400
0,7

0,6
1200
ESR BCAP0008 (DC)
0,5
Capacitance BCAP0008
0,4 1000
-60 -40 -20 0 20 40 60 80 100
Temperature [°C]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 BCAP Self Discharge

Self Discharge vs Temperature

100,0

90,0

80,0
% U (t = 0)

70,0

60,0
- 35 °C
50,0 + 5 °C
+ 25 °C
40,0 + 65 °C

30,0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Time [days]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 BCAP Cycling Capacity

90 A CC, 1.15-2.3 V, 25 s, RT
110.0 2.0E-03
1.8E-03
100.0
Change in Capacitance

1.6E-03
1.4E-03
90.0

ESR [Ohm]
1.2E-03
Capacitance
[%]

80.0 1.0E-03
8.0E-04
70.0
6.0E-04
ESR 4.0E-04
60.0
2.0E-04
50.0 0.0E+00
0 20000 40000 60000 80000 100000

Cycle Number

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 BCAP Cycling

500’000 cycles between 1.8 and 2.7 V, 100 A

ESR (1 Hz) increase 140 % (0.49 to 0.79 mOhm
Capacitance decrease 38 % (2760 to 1780 F), 30% compared to rated capacitance

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 BCAP DC Life

Capacitance and ESR variation at U, T = 40 °C

105,0 200,0
2.5V 40°C
100,0 180,0
2.1V 40°C
160,0 2.3V 40°C
95,0
140,0
90,0
120,0
85,0

% ESR (t = 0)
100,0
% C (t = 0)

80,0
80,0
75,0
60,0
70,0
40,0
65,0 20,0
60,0 2.5V 40°C
0,0
2.1V 40°C
55,0 2.3V 40°C -20,0

50,0 -40,0
0,0 100,0 200,0 300,0 400,0 0,0 100,0 200,0 300,0 400,0
duration [days] duration [days]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 BCAP DC Life

Capacitance and ESR variation at U, T = 65 °C

120,0 120,0
2.5V 65°C
100,0 2.1V 65°C
100,0
2.3V 65°C
80,0
80,0
60,0

% ESR (t = 0)
% C (t = 0)

60,0 40,0

20,0
40,0

2.1V 65°C 0,0

20,0 2.3V 65°C
2.5V 65°C -20,0

0,0 -40,0
0 100 200 300 400 0 100 200 300 400
duration [days] duration [days]

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Sizing Examples

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Example sizing
1) Define System Requirements
15 W delivered for 10 seconds
10V max; 5V min
2) Determine total energy needed: J=WS=10W*10sec=150J
a) Determine Capacitance based on: J=1/2CV2
b) Substitute the energy from above: 150J=1/2C(Vmax2-Vmin2)
c) Solve for C: C=300/(102-52)=4F
3) Add 20-40% safety margin to cover I2R losses Csystem = 4.8F
4) Calculate number of cells in series (since maximum cell voltage = 2.5V)
10V/2.5V = 4 cells in series
5) Calculate cell-level capacitance
C = Csys * # of series cells = 4.8F* 4 = 19.2F per 2.5V “cell”
6) Calculate number of cells in parallel (we will assume a 10F cell)
# in parallel = 19.2/10F = 2 x 10F cells in parallel

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Product Strategy

BOOSTCAP® Products
PC Product
Product Family MC Product Family BC Product Family
Family

Product Type Energy Power Energy Power Energy

Modules

Modules

Modules

Modules

Modules
Cells

Cells

Cells

Cells

Cells
Product

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Product Portfolio Offerings
Enhance application cost effectiveness by filling the product portfolio
ladder - Initial focus: MC Series

Power Ladder Energy Ladder

3000 F 3000 F

2600F 2600F

2000 F 2000 F

1500 F 1500 F

1200 F 1200 F

650 F 650 F

11 New Ultracapacitor Cells

Ultracapacitors l Microelectronics l High-Voltage Capacitors
 New Product Portfolio for MC Series

Type MC Series BMOD Series

Cells 16 V Modules 48 V Modules
3000 F √ √
2600 F √ √
Energy

2000 F √ √
1500 F √ √
1200 F √
650 F √
3000 F √ √
2600 F √ √
Power

2000 F √ √
1500 F √ √
1200 F √
650 F √

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Summary

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Benefits Summary

Calendar Life
• Function of average voltage and temperature
Cycle Life
• Function of average voltage and temperature
Charge acceptance
• Charge as fast as discharge, limited only by heating
Temperature
• High temp; no thermal runaway
• Low temp; -40°C

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Benefits Summary

No fixed Voc
• Control Flexibility; context-dependent voltage is permitted
• Power Source voltage compatibility
• Examples; Fuel cells, Photovoltaics
No Vmin
• Cell can be discharge to 0V.
• Control Safety; No over-discharge
• Service Safety
Cell voltage management
• Only required to prevent individual cell over-voltage
State of Charge & State of Health
• State of Charge equals Voc
• Dynamic measurements for C and ESR = State of Health
• No historical data required

Ultracapacitors l Microelectronics l High-Voltage Capacitors

 Useful Links

• Useful links on Maxwell Technologies Web-site:

• White Papers
• Technology Overview
• Sizing worksheet
• Application Notes
• Data Sheets

www.maxwell.com

Ultracapacitors l Microelectronics l High-Voltage Capacitors