Why are lead acid batteries still being used to start engines on mine sites? There is a better way.

When selecting power sources for starting large diesel engines on mine sites the preferred solution for the last 100 years have been lead acid batteries. However is now the option of using capacitors for starting. So why make the change?

Ultra-capacitors and batteries each offer distinct advantages. Here's a detailed comparison of their benefits:

1. Capacitors

Ultra-Capacitors are emerging as an alternative to traditional batteries for engine starting applications. They store and release energy through electrostatic fields rather than chemical reactions, delivering several benefits:

·????? High Power Density: Ultra capacitors can deliver a substantial amount of power over a short period. This characteristic is particularly useful for starting large diesel engines that require a high burst of current for ignition. Capacitors provide a stable system voltage and high current to crank the engine. Ultra capacitors are consequently significantly lighter for the same cranking power.

·????? Durability and Longevity: Ultra capacitors have a longer lifecycle compared to batteries. They are resistant to wear and degradation from frequent charge-discharge cycles, making them a more durable option in harsh mining environments. They can withstand extreme temperatures and vibration, reducing maintenance and replacement costs.

·????? Fast Charging: Ultra capacitors can be charged rapidly compared to batteries. This capability means they can be quickly recharged between engine starts, ensuring readiness for the next operation with minimal downtime.

·????? Maintenance-Free: Unlike batteries, ultra capacitors require less maintenance. They do not suffer from issues like sulfation, which affects lead-acid batteries, nor do they need periodic topping up of electrolyte fluids.

2. Batteries

Batteries, particularly lead-acid chemistry, are the traditional choice for engine starting and have advantages:

·????? Energy Storage: Batteries can store a larger amount of energy compared to capacitors, making them suitable for applications where a sustained power supply is needed. For starting large diesel engines, this means they can handle the energy demands over a longer duration if required.

·????? Cost-Effectiveness: Lead-acid batteries are relatively inexpensive compared to ultra capacitors to purchase. They are well-established in the industry with a broad range of options available, which explains their use for many mining operations. However regular replacement of banks of batteries means the shorter life will make them higher cost over the vehicle life.

·????? Established Technology: Batteries are a well-understood technology with extensive infrastructure for support, including charging systems and maintenance protocols. Their reliability in engine starting applications is well-documented.

·????? Availability: Batteries are readily available and come in various sizes and specifications to meet different power needs. This availability can be crucial in remote mining sites where quick replacements and repairs are needed.

Comparison and Context

·????? Performance Needs: Ultra capacitors are advantageous for their ability to deliver high bursts of power instantly, which is ideal for starting engines that require a quick and strong cranking current. However, their energy storage capacity is limited compared to batteries, so they are typically paired with batteries or other systems for continuous operation.

·????? Operational Environment: In the harsh conditions of a mine site, capacitors’ resilience to temperature extremes and physical stress makes them a robust choice. Conversely, batteries, especially lead-acid types, can be susceptible to performance degradation under mine operating conditions.

·????? Lifecycle Costs: While ultra capacitors offer long-term savings due to their longevity and low maintenance requirements, the initial investment might be higher than for batteries. Ultra capacitors are also lighter than batteries, reducing handling costs.

In conclusion, the benefits of using ultra capacitors for starting depend on specific operational needs and conditions. Capacitors excel in delivering high power bursts and enduring harsh environments with minimal maintenance. For starting diesel equipment on mine sites ultra capacitors can safely reduce maintenance, increase reliability and increase productivity.

Contact Duncan Scott Benavente or Chris Henderson to discuss how to improve productivity and reduce cost with a new starting solution for your fleet.

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