The Benefits of Lithium-Ion Batteries in Electrifying ...

Using lithium-ion batteries in material handling equipment isn’t exactly a new concept, but it has been a severely under-tapped market that is continuing to pick up some serious steam today. More and more companies are starting to realize that electrifying their industrial equipment is more sustainable for work and the environment, all while gaining higher performance from their machines. 

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Lithium-Ion Batteries Vs. Lead Acid Batteries

Commercially viable lithium-ion batteries became available in 1991, and have surpassed the traditional lead-acid battery to become the dominant rechargeable battery in nearly all industries. To break it down, a lithium-ion battery refers to a battery with a negative electrode (anode) and a positive electrode (cathode) that transfers lithium ions between the two materials. Lithium ions move from the anode to the cathode during discharge and deposit themselves (intercalate) into the positive electrode, which is composed of lithium and other metals. This process is reversed while the battery is being charged. The lead-acid battery creates its electrical charge when the sulphate in the sulphuric acid becomes bonded to the lead. This is a process that creates more wear and tear on the battery and requires maintenance to keep the battery’s life going, maintenance that is not required in lithium-ion batteries, which also leads to more efficiency and a longer lifespan. 

The Sustainable Cost-Effective Solution

Now, for many, sustainability has become as important as operational efficiency. Today we can show the pathway towards 81% cost savings over a five-year period compared to the lead-acid battery systems a customer may be using to power material handling equipment. While a lithium-ion solution may have come at an “initial” increased cost compared to lead-acid batteries, lithium-ion battery packs provide a significantly lower total cost of ownership, especially for demanding forklift fleets. Lithium-ion cells provide longer run times and lower operating costs. They also simplify operations, eliminate water maintenance, and significantly cut emissions compared to lead-acid batteries and propane engines. Industrial lithium-ion batteries have revolutionized the way business is done and have multiple advantages that make them ideal for any application. The battery’s unique properties allow businesses to improve safety, efficiencies, and to significantly improve return of investment. Other benefits over lead-acid counterparts include faster re-charge times, opportunity charging, long cycle life, and full cloud data reporting for enhanced asset management. Lithium-ion batteries virtually eliminate hazardous off-gassing and spills, making them safer and “cleaner” than traditional alternatives. It’s reasons like these that are causing companies and investors to notice, and why some reports expect the industry to grow more than 30% annually now through 2030.

Effect on the Environment

So it is clear that the efficiency is there in lithium-ion batteries, but what exactly is the impact of this technology on the environment? Sulfate particles found in lead-acid batteries contribute to the acidification of water and soil on the surface. This leads to acid rain, and more damage to the ecosystem. Due to the light color of sulfates, energy from the sun is reflected back into space, meaning it has a cooling effect on our earth. The chemicals in the lead-acid battery also present a higher risk of discharging hazardous and toxic fumes or liquids. Lithium-ion batteries are without these heavy toxic metals, virtually eliminating hazardous off-gassing and spills. Further, most lithium-ion batteries are cased in aluminum, which is more easily recyclable than the lead metals found in traditional batteries. 

Where do Lithium-Ion Batteries Go from Here?

With the rapid evolution of technology and big data, leaders in the industry are looking for ways to get even more productivity and sustainability out of their products. Scalable, cloud-enabled telemetry technologies we can deploy today assure agility even if sustainability goals shift tomorrow. Fleet managers are eager to implement telematics to gain insight into performance and usage patterns. Detailed battery health and charging data, extreme temperature impact, and much more are becoming critical metrics for improving operational performance. The improved sustainability, cost-efficiency and positive global impact of lithium-ion batteries prove it to be a better overall product. Many Fortune 500 companies are migrating to lithium-ion products to meet demands of their large forklift fleets, disrupting the use cases for lead acid batteries.

Ron Dutt is CEO of Flux Power.

A positively charged anode, negatively charged cathode and electrolyte form the backbone of lithium ion batteries. Since the first lithium ion batteries were developed in the 1970s, the technology has become a mainstay in everyday life. Today, lithium ion batteries are used to power everything from smartphones to electric cars.

So, what makes lithium ion batteries attractive to product manufacturers? Below, we spotlight the benefits of lithium ion batteries. 

High energy density

When it comes to energy density, lithium ion batteries are top performers. This property describes the amount of energy a battery can hold, relative to its size. The more energy a battery can store, the higher its energy density. Compared to traditional lead-acid batteries which can hold between 50 to 100 wh/kg, lithium ion batteries boast an impressive range of between 260 and 270 wh/kg.

Lightweight

On average, lithium batteries weight between 50 and 60% less than traditional batteries. This makes them ideal for compact and handheld devices, including smartphones and e-readers.

Long lifespans

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As well as being rechargeable, lithium ion batteries boast exceptionally long lifespans. High-performance lithium batteries last up to 10 times longer than their lead-acid counterparts. Of course, lithium ion batteries eventually deteriorate. Though with the right recycling practices in place, materials can be salvaged and lithium batteries can find a place in the circular economy.  

Good long-term performance

Lithium or not, all batteries degrade over time. However, when it comes to long-term performance lithium batteries rate highly. The best lithium batteries continue to offer 80% of rated capacity after around 200 cycles.

Temperature tolerant

Unlike other batteries which don’t function well in extreme temperatures, lithium ion batteries are relatively tolerant.

Low self-discharge

Self-discharge is one of the biggest issued faced by battery engineers. Unlike other types of rechargeable batteries, lithium ion cells have a low self-discharge rate. Batteries will generally lose around 5% of charge in the first few hours, however this quickly drops to around 1 to 2% per month.  

Fast charge times

Fast charge times make lithium batteries the technology of choice for consumer products. This includes handheld devices like smartphones and tablets, as well as larger battery-powered products like electric cars.

Customisable technology 

Manufacturers don’t need to conform to a one-size-fits-all approach when developing lithium ion batteries. The potential to modify features like cathode chemistry and cell format makes it easy to customise lithium ion batteries. For example, Tesla uses a variety of cathodes to power its electric cars. These include lithium iron phosphate (LFP), lithium nickel-cobalt-aluminium (NCA) and nickel-cobalt-manganese (NCM).

Developing lithium ion batteries involves a huge amount of research and testing. Find out more about the anatomy of lithium ion batteries and some of the cutting-edge methods used to test different components in our complete guide, ‘Lithium Ion Batteries: Types, Testing & Uses’.

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