Firefly to Produce Truck Batteries

Firefly Energy Inc. the Peoria based developer of advanced lead acid batteries announced on October 3 that it is expanding into the trucking market with the commencement of a BCI Group 31 battery development program.

The Group 31 size battery is a broadly deployed battery type in trucks. The company said the Firefly Group 31 battery will be initially available next summer with full production scheduled for the fourth quarter of 2008.

The sealed, valve regulated Group 31 battery is similar to a battery Firefly Energy is developing for the U.S. Army to give combat vehicles enough onboard electrical storage to power equipment without significantly decreasing battery life.

“Conventional deepcycle lead acid batteries used in truck starting show sizeable performance dropoff after some 200 deep discharge cycles,” said Mil Ovan, senior vice president and cofounder of Firefly Energy.

He noted the Firefly Energy battery will deliver greater reliability and longer service life because it is capable of achieving more than triple the deep cycles while still maintaining over 90 percent of its initial capacity.

“In trucking, this means our battery can be expected to last three to five times longer than the best performing valve regulated lead acid batteries.”

He added that with the new antiidling laws, “drivers using our battery can keep cool during sleep periods without having to idle their engines. Substantial reductions in rest stop engine idling and diesel fuel use by heavy trucks are achievable because our battery powers accessories like air conditioners, TVs, VCRs, computers and refrigerators with 50 percent more runtime than top competitors.”

The company’s 3D battery will be valuable in trucking because it offers continuous power through the discharge process, a fast recharge to 100 percent capacity, excellent vibration resistance and greater cold starting capabilities.

The primary characteristic of  Firefly Energy's lead acid battery is the inclusion of a high surface area, noncorrodible and light weight carbon-graphite foam material. This technology, can deliver a unique combination of high performance, extremely low weight and low cost, all in a battery which utilizes the best aspects of lead acid chemistry while overcoming the corrosive drawbacks of this same chemistry. Not only is the lead content reduced making the batteries smaller and lighter, but additionally enables faster, deeper and more reliable discharges and recharges.This product technology delivers to battery markets a performance associated with advanced battery chemistries (Nickel Metal Hydride and Lithium), but for one fifth the cost, and can be both manufactured as well as recycled within the existing lead acid battery industry’s vast infrastructure

Typical battery life is extended since sulfation is reduced. When tested in cold weather extremes at minus 20°C, the batteries were capable of delivering above 65 percent of their rated “room temperature” capacity compared to 20 percent or less for standard Group 31 batteries. This can help minimize alternator damage incurred while attempting cold weather engine starts when batteries are low.

Additional characteristics of the Firefly Energy battery include:

• Energy Density – Because the Firefly design utilizes an efficient high surface area foam, more of the available chemistry can be engaged, leading to greater efficiencies in weight and size.
• Heat dissipation – Batteries with carbon graphite foam electrodes instead of heavy lead plates are able to transfer heat out of the battery as rapidly as it is generated. Operating heat of the battery is lower, is also generated more uniformly, and is dissipated more rapidly, resulting in longer battery life in many applications.
• Vibration resistance – The low mass of Firefly’s 3D cells along with the better retention of the chemistry within the pores of the foam help make its batteries more resistant to vibration.

Firefly Energy’s development program comes several months before landmark trucking related regulations take effect in the State of California. On January 1, 2008, diesel trucks operating in California face a five minute idling limit. Traditional batteries will now be challenged by the severe strain of trying to support a trucker’s various “hotel loads” (air conditioning, TVs, etc.) which were previously powered by diesel engine idling. The result will be premature battery failure since traditional lead acid batteries cannot easily withstand repeated deep discharging.

The California Air Resources Board’s antiidling rule is part of a wave of restrictions being introduced across the nation to help reduce emissions of greenhouse gases, toxics and pollutants. Additionally, the Environmental Protection Agency estimates that with a half million long haul trucks now operating nationwide, wasteful engine idling may consume as much as 840 million gallons of diesel fuel annually.

“Truckers historically have bought batteries based on cold cranking ratings and price,” said Edward F. Williams, chief executive officer. “The game is now changing, and battery performance will become much more important in its contribution to trucker safety, comfort, and productivity. This calls for game changing battery technology, which is why we are very excited to optimize our carbon graphite foam lead acid battery technology for the needs of truckers,”

This announcement comes closely on the heels of last week’s announcement whereby Firefly was honored by being named a cowinner of The Wall Street Journal’s 2007 Technology Innovation Award in the energy category.

It is now very clear to me what Firefly's strategy is: 1)The development of products that require the least development, IE, small batteries for lawn care equipment  2) Batteries for the military where high performance at a relatively high cost is allowed 3) Truck batteries where high performance at a lower price point is required and 4) (speculation) plug-in hybrid batteries where very good performance and the low costs of mass production are required, with delivery in 2010 at one fifth the cost of other advanced batteries.

Comments

[Engineer-Poet]

You're right.  This is another game-changer.

I checked the price of deep-cycle batteries at the auto store recently, and found them to be around $70 for something like the 105 AH unit I bought a few years ago.  This is about $56/kWh of capacity.  If 80% of this is usable and the battery can operate for 1000 cycles before replacement, the cost of putting energy through the battery is about 7¢/kWh.  Adding perhaps 8¢/kWh for off-peak charging and dividing by 80% battery efficiency, the total cost of energy at the terminals would be 17¢/kWh.

Put this into a PHEV consuming 300 WH/mile and the energy cost is 5.1¢/mile, including all depreciation (but not interest).  To beat that with $3.00/gallon gas, you'd need to get nearly 60 MPG.  Firefly Energy can bring the PHEV to the masses.

[Nick G]

E-P, I agree on the importance of this battery. Unfortunately, Firefly estimates the cost at $100-$150 per KWH, so the costs will be a bit higher than your estimate.

Still, 4x the performance at 2x the price is a big improvement. Plus, I suspect that PHEV's would get better cycle life than 1000 cycles, because of much better charge & temp management than in lawn tractors or trucks. Also, I thing 8 cents for off-peak is a bit high: check out www.thewattspot.com

[Wisen]

“In trucking, this means our battery can be expected to last three to five times longer than the best performing valve regulated lead acid batteries.”
---three to five times----
Do you test it? I am a R&D Engeneer of lead acid battery(VRLA-GEL,TUBLAR-TRACTION).I master the VRLA battery performance and design!!It's impossible!!!

[ManBearPig]

can be expected to last three to five times longer than the best performing valve regulated lead acid batteries

[Trucking Software]

I think this wil change somewway trucking business is done. Using more and moree new softeares really has helped these days. We have introduced MAsslogocs and trucking software that is really working for us. Get it at http://www.masslogics.com

[Trucking Software]

This battery seems to be a really great seeing the characteristics above. Its really different on an ordinary battery

[Trucking Gyan]

Good move from Firefly.
Nick, please go ahead and explain why is it impossible to give long life than other batteries?

[Truck Fleet Training]

Nick, Looking forward to hear from you as response for Trucking Dude's query.

[Truck Bed Covers]

Good information about producing this truck battery. I hope Firefly produces a similar battery for cars, too.

[Made in China]

Made in China

[7ah Battery]

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