Additive Manufacturing

MALNAD COLLEGE OF ENGINEERING, HASSAN – 573 202, KARNATAKA

(An Autonomous Institution under VTU, Belgaum)

Seminar

On

“Batteries-Nickel Based, Sodium Based, Lithium Based Batteries”

Department of Mechanical Engineering, MCE, Hassan

Department of Mechanical Engineering, MCE, Hassan 1

BATTRIES

A battery is a device that converts chemical energy contained within its active materials
directly into electric energy by means of an electrochemical oxidation-reduction (redox)
reaction. This type of reaction involves the transfer of electrons from one material to another
via an electric circuit.
The Batteries Used In EV’s Can Be Classified as,
 Lead Acid Batteries
 Nickel Based Batteries
• Nickel Metal Hydride Battery
• Nickel Cadmium Batteries
 Sodium Based Batteries
• Sodium Sulphur Batteries
• Sodium Metal Chloride Batteries
 Lithium Based Batteries
• Lithium Ion Battery
• Lithium Polymer Battery

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Nickel-Based Batteries
Introduction
 A range of commercial batteries, using nickel in the positive electrode, have been developed
since Edison’s work in the late nineteenth century.
 These batteries include nickel iron, nickel zinc, nickel cadmium and NiMH batteries.

Nickel Cadmium
 The nickel cadmium (NiCad) battery was considered to be one of the main competitors to the
lead acid battery for use in EVs and these batteries have nearly twice the specific energy of
lead acid batteries.
 The NiCad battery uses a nickel oxyhydroxide for the positive electrode and metallic
cadmium for the negative electrode. Electrical energy is obtained from the following reaction:
Cd + 2NiOOH + 2H2O ↔ Cd(OH)2 + 2 Ni(OH)2
 The reactions at each electrode, which also helps to explain ‘where the electrons come from’
and how the battery works, are shown in Figure 1

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 Fig.1 Reactions during the discharge of a nickel cadmium cell.

 The NiCad battery has advantages of high specific power, a long life cycle (up to 2500 cycles), a wide range
of operating temperatures from −40 to +80oC, a low self-discharge and good long-term storage.

 The NiCad battery can be purchased in a range of sizes and shapes, though they are not easy to obtain in the
larger sizes required for EVs, their main market being portable tools and electronic equipment.

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Nickel Metal Hydride Batteries

 The NiMH battery was introduced commercially in the last decade of the twentieth century. It
has a similar performance to the NiCad battery, the main difference being that in the NiMH
battery the negative electrode uses hydrogen, absorbed in a metal hydride, which makes it free
from cadmium.
 An interesting feature of this battery type is that the negative electrode behaves exactly like a
fuel cell.

 The reaction at the positive electrode is the same as for the NiCad cell; the nickel oxyhydroxide
becomes nickel hydroxide during discharge. At the negative electrode hydrogen is released
from the metal to which it was temporarily attached, and reacts, producing water and electrons.
The reactions at each electrode are shown in Figure 1.1.

 The metals that are used to hold the hydrogen are alloys, whose formulation is usually
proprietary. The principle of their operation is exactly the same as in the metal hydride
hydrogen stores used in conjunction with fuel cells.

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 Figure 1.1 The reactions during the discharge of the nickel metal hydride cell.

 The NiMH battery has slightly higher energy storage capacity than NiCad systems, and is also a
little more costly. There is one area where its performance is notably worse than that for NiCad
batteries, and that its self-discharge properties.

 One area where the NiMH is better than the NiCad is that it is possible to charge the battery
somewhat faster. Indeed, it can be charged so fast that cooling becomes necessary. As well as
heat energy being created by the normal internal resistance of the battery.

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Advantages and Disadvantages of Nickel Based Batteries

Advantages:

 Light weight (High energy density)

 Rechargeable up to 1000 times
 Tolerate trickle charging
 Low internal resistance, can produce higher current

Disadvantages

 Cadmium is heavy and toxic metal

 Need extra careful in handling and disposing

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Sodium-Based Batteries

Sodium Sulphur Batteries

 The development of these batteries started in the 1970s and they run at temperatures between
300 and 350C. In order to keep the heat in the battery, the cells are enclosed in an evacuated
case. The basic sodium Sulphur cells have a high specific energy, six times that of lead acid
cells, but in experimental batteries the mass of the enclosure typically halves this potential
improvement.

 The electrical energy is obtained from combining sodium with Sulphur to form sodium
sulphide. The basic chemical formula for the reaction is 2Na + xS ↔ Na2Sx

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 Because of the need for good thermal insulation small batteries are impractical. The battery
heating and cooling needs careful design and management.
 Although the sodium Sulphur battery has considerable promise, worries about the safety of two
reactive materials separated by a brittle ceramic tube have largely resulted in the batteries not
appearing on the commercial market.

Sodium Metal Chloride (ZEBRA) Batteries.

 The sodium metal chloride or Zebra3 battery is in many ways similar to the sodium sulphur
battery and has many of this battery’s advantages. However, with this system most (and some
would say all) of the safety worries associated with the sodium sulphur battery have been
overcome.
 The principal reason for the greater safety of the Zebra cells is the use of the solid positive
electrolyte which is separated from the molten sodium metal by both solid and liquid
electrolytes.

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 The electrical energy on discharge is obtained by combining sodium with nickel chloride to give
nickel and sodium chloride. The overall chemical reaction which takes place in the Zebra battery
is: 2Na + NiCl2 ↔ Ni + 2NaCl

 Figure 2 shows the reactions at each electrode during the middle and early part of the discharge
of the cell. This reaction produces an open-circuit voltage of about 2.5V per cell.

Fig: 2 The reactions at each electrode of the sodium metal chloride battery during discharge

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 In the later stages of the discharge the reactions become more complex, involving aluminum
ions from the electrolyte, and resulting in a lower voltage. Indeed an unfortunate feature of
this type of cell is the way that the cell voltage falls during discharge, from about 2.5V down
to around 1.6 V

 A major problem with the Zebra battery is that it needs to operate at a temperature of about
320oC, similar to the sodium Sulphur battery. Heat insulation is maintained by the use of a
double-skinned stainless steel box, with 2–3 cm of insulation between the two skins. All the
air is removed from the insulation, and the vacuum is maintained for several years.
Nevertheless, unless it is for a very short period.

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Advantage and Disadvantages of Sodium Based Batteries.

Advantages

 Sodium Resources are more abundant, and global distribution is even.

 The cost of sodium-ion batteries is about 30% lower than that of lithium
batteries
 Sodium-ion Batteries are safer and are not easy to produce lithium dendrites

Disadvantages

 Lower energy density of sodium ion batteries

 Short cycle life.

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Factors Affecting The Performance of The Batteries

 Temperature: Warmer climates can negatively impact the lifespan of an EV battery.

 Charge cycles :As the battery is discharged while driving and charged while plugged in, it
loses maximum potential.
 Charging rate: Charging rates that don't exceed half of the battery's capacity per hour can
achieve a good battery lifespan.
 Electronics :Navigation and infotainment systems, USB ports, and rear passenger screens
all use the battery.
 Tires :Underinflated tires can create more friction with the road, causing the vehicle to use
more energy.
 Other factors include: Vehicle care, Weight, State of charge, Current, Internal resistance.

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Thank You

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