Battery technology is constantly evolving and sweeping the globe, offering a multitude of possibilities for machines and devices, helping to keep our global infrastructure thriving. But with technological advancements and a plethora of choices, how do we choose between traditional lead-acid batteries and the newer lithium-ion batteries?
competitor
Lead-acid batteries have long held the largest market share among rechargeable batteries due to their low cost, high reliability, and lack of alternatives. They are popular in applications where weight and space are not a constraint. Lead-acid has a long history of successful use. However, lead-acid batteries also have the lowest energy-to-volume ratio and energy-to-weight ratio among rechargeable batteries. They also require a high level of routine preventative maintenance and a strict charging schedule. Neglecting this rigorous procedure can significantly shorten the lifespan of lead-acid batteries.
The main challenge with lithium-ion batteries is cost, as the initial purchase cost is typically much higher than that of lead-acid batteries. However, despite the higher cost, lithium-ion batteries have more than twice the cycle life of lead-acid batteries and boast the highest energy-to-volume ratio and energy-to-weight ratio among rechargeable batteries. This translates to more energy and less weight within a smaller space.
As long as lithium-ion batteries are more expensive than lead-acid batteries, the economics of switching battery types depend on their usage, and therefore on their downtime and maintenance requirements. Switching to lithium-ion can reduce total cost of ownership by 20% to 40%, including forklift fleets operating on multiple shifts.
In these types of companies, lithium-ion batteries require less time and space to charge and maintain than lead-acid batteries. Lithium-ion batteries offer better charging options, allowing forklifts to quickly resume charging, at least partially, during short breaks and downtime before returning to work.
A forklift company found it difficult to keep the areas where its lead-acid batteries were charged and maintained clean. Similarly, charging and cooling the lift offline for eight hours (as required for lead-acid batteries) incurred costs.
In contrast, lithium-ion batteries can be fully charged from zero in two hours and have no memory effect, so fast charging is recommended.
Lead-acid batteries will degrade significantly if charged frequently. Lithium-ion batteries, on the other hand, maintain their peak performance regardless of how often they are charged or how deep they are discharged.
In April 2019, with the help of Eastern Crane Trucks, Standard Distribution concluded that 12 forklifts running on lithium-ion batteries could do the same work as 17 forklifts powered by lead-acid batteries, thanks to the opportunity to recharge.
A major drawback of lead-acid batteries is that they require extensive daily maintenance, such as emptying water every shift. This increases labor costs. In contrast, lithium-ion batteries require no daily maintenance.
This saves maintenance time, allowing employees to focus on other tasks within the business. It eliminates routine maintenance, as well as the need for eight-hour charging and eight-hour cooling shifts, and also saves warehouse space. Lead-acid batteries require charging and storage in a dedicated room. During charging, they emit hazardous hydrogen and sulfuric acid gases, so the room must be well-ventilated and kept cool.
Lithium-ion battery chargers can be installed throughout the facility for short-term or long-term charging. By switching to lithium-ion batteries, Standards Corporation found that floor space previously used for lead-acid battery charging and maintenance could be reclaimed. Keeping the area clean (previously a challenge for the facility) is no longer an issue.
Density and capacity
A battery's capacity determines its runtime, which reflects the current it can provide until it needs to be recharged. On the other hand, power density defines the battery's maximum discharge rate. Some batteries require lower discharge rates, while those required to deliver bursts of energy require higher power densities.
A battery's lifespan durability is defined by its stability through repeated charge and discharge cycles. Some lithium-ion battery users have noticed that they can replace lead-acid batteries with lithium-ion batteries that have as little as 60% of the same capacity. This is because lead-acid batteries have a maximum discharge rate of 80%, while lithium-ion batteries have a maximum discharge rate of 100%. They can discharge to zero.
In addition to this difference, the harmless rapid or partial charging of lithium-ion batteries can quickly shorten the lifespan of lead-acid batteries.
Green Operations
Lithium-ion batteries offer a way to build more environmentally friendly warehouses. This is because lithium-ion batteries are 30% more energy efficient than lead-acid batteries, thus reducing costs and carbon footprint. Lithium-ion batteries do not contain toxic substances or release harmful gases, making them safer for the environment, warehouses, and their workers.
These considerations are crucial for standard rationing, where a clean and efficient warehouse is essential for both the beverages being processed and the company's green policy. This also means leaner overall operations, using only 12 forklifts instead of 17.
The company's new lithium-ion battery-powered forklifts also offer safer working conditions. Workers no longer need to unload heavy batteries; they can simply replace them with newly charged ones. Acid leaks are no longer a danger, and there is no longer the possibility of inhaling toxic fumes during charging.
Additionally, lithium-ion batteries in forklifts do not require frequent handling. For example, OneCharge collects lithium-ion batteries shipped to customers when they reach the end of their lifespan, disassembles them, recycles the metal casings, discards the electronics, and then sends the lithium batteries back to the manufacturer for reuse or proper disposal.
There are many analytical points to consider when choosing batteries for electric forklifts. However, in many cases, the clean, efficient operation offered by lithium-ion technology may be the answer for material handling companies, as it can improve forklift performance and increase profits.
