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

Using lithium-ion batteries in material handling equipment isn't a new concept, but it remains an underutilized market gaining significant traction today. Companies increasingly recognize that electrifying their industrial equipment is not only more sustainable for both operations and the environment, but it also enhances the performance of their machinery.

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Lithium-Ion Batteries Vs. Lead Acid Batteries

Lithium-ion batteries became commercially available in 1991 and have surpassed traditional lead-acid batteries to become the dominant rechargeable battery across numerous industries. A lithium-ion battery operates with a negative electrode (anode) and a positive electrode (cathode) through which lithium ions transfer. During discharge, lithium ions move from the anode to the cathode, depositing into the positive electrode comprised of lithium and other metals. This process reverses during charging. Conversely, lead-acid batteries generate electrical charge when sulfate in sulfuric acid bonds to lead, a process that induces more wear and tear and requires ongoing maintenance, unlike lithium-ion batteries. This lack of required maintenance equates to increased efficiency and a longer lifespan for lithium-ion batteries.

The Sustainable, Cost-Effective Solution

Todays sustainability is as crucial as operational efficiency. Lithium-ion technologies offer a pathway to 81% cost savings over five years compared to lead-acid systems for material handling equipment. While lithium-ion solutions might initially incur higher costs, they result in a considerably lower total cost of ownership, particularly in demanding forklift fleets. Lithium-ion cells provide longer run times, reduced operating costs, simplified operations, elimination of water maintenance, and notably lower emissions compared to lead-acid batteries and propane engines.

Efficiency and Safety

Industrial lithium-ion batteries have revolutionized modern business by providing advantages such as improved safety, efficiencies, and return on investment. They offer faster recharge times, long cycle life, opportunity charging, and full cloud data reporting for enhanced asset management. Moreover, they nearly eradicate hazardous off-gassing and spills, making them a safer and cleaner alternative to traditional batteries. Such benefits are propelling companies and investors to notice, with some forecasts projecting the industry will grow by more than 30% annually through 2030.

Environmental Impact

While efficiency is a considerable advantage, what about environmental impact? Sulfate particles in lead-acid batteries contribute to the acidification of water and soil, leading to acid rain and further ecosystem damage. In contrast, lithium-ion batteries lack heavy toxic metals, largely eliminating hazardous off-gassing and spills. Furthermore, their aluminum casings are more readily recyclable compared to the lead components in traditional batteries.

Where Do Lithium-Ion Batteries Go from Here?

With ongoing technological advancements, the focus is on increasing productivity and sustainability in lithium-ion batteries. Scalable, cloud-enabled telemetry technologies help ensure agility even if sustainability goals shift. Fleet managers are keen to leverage telematics for insights into performance and usage patterns. Detailed battery health, charging data, and temperature impacts are crucial for enhancing operational efficiency. The proven sustainability, cost-efficiency, and positive environmental impact of lithium-ion batteries render them the superior product, driving many Fortune 500 companies to adopt lithium-ion technologies for their extensive forklift fleets, thereby disrupting 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 their development in the 1970s, lithium-ion batteries have become pivotal in everyday life, powering devices from smartphones to electric cars.

So, what makes lithium-ion batteries so attractive to manufacturers? Below, we highlight the key benefits:

High Energy Density

Lithium-ion batteries excel in energy density, meaning they can store a significant amount of energy relative to their size. Compared to traditional lead-acid batteries, which hold between 50 to 100 Wh/kg, lithium-ion batteries offer an impressive 260 to 270 Wh/kg.

Lightweight

Lithium batteries typically weigh 50 to 60% less than traditional batteries, making them ideal for compact, handheld devices like smartphones and e-readers.

Long Lifespans

In addition to being rechargeable, lithium-ion batteries boast remarkably long lifespans, lasting up to 10 times longer than lead-acid counterparts. Though they eventually deteriorate, with proper recycling practices, materials can be salvaged, integrating lithium batteries into a circular economy.

Good Long-Term Performance

All batteries degrade over time, but lithium-ion batteries maintain commendable long-term performance. The best lithium batteries can still offer 80% of their rated capacity even after around 200 cycles.

Temperature Tolerant

Lithium-ion batteries perform relatively well in extreme temperatures, unlike other battery types.

Low Self-Discharge

One major issue for battery engineers is self-discharge. Lithium-ion batteries have a low self-discharge rate, losing around 5% of charge in the first few hours, which drops to around 1-2% per month.

Fast Charge Times

Quick charge times make lithium batteries a preferred choice for consumer products, from smartphones and tablets to electric cars.

Customizable Technology

Manufacturers can customize lithium-ion batteries by modifying features like cathode chemistry and cell format. For instance, Tesla uses various cathodes, including lithium iron phosphate (LFP), lithium nickel-cobalt-aluminum (NCA), and nickel-cobalt-manganese (NCM), to power its electric vehicles.

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