Portfolio Management Energy from Smart Grid

Deliverable:
Report/white paper on
Ultracapacitor technology

Unlocking New Possibilities

through Innovative Energy Storage
The Role of Ultracapacitors in the Energy Transition

Date: October 2020

Version: Final

Website:
Status
X Final
☐In Progress. Please explain: ☐ Iterative Process – This year’s results have been 100% achieved.
☐ Delay – This year’s results were not fully achieved.

Tracking Changes

Level of Dissemination

X EIT and InnoEnergy

☐ Public

Author(s)

[Official Name KIC Partner] [Name and Surname]

Main Author InnoEnergy Scandinavia Subcontractor Frost & Sullivan
Contributor InnoEnergy Scandinavia Partners Skeleton and NAWA
Contributor InnoEnergy Scandinavia Johan Söderbom, Sofia Goncalves, Oguzhan Erim
Contributor
Unlocking New Possibilities
Through Innovative Energy Storage
The Role of Ultracapacitors in the Energy Transition

An EIT InnoEnergy White Paper

in collaboration with Frost & Sullivan
Contents

FOREWORD............................................................................................................... 3

INTRODUCTION........................................................................................................ 4

AN OVERVIEW OF THE TECHNOLOGY: PROS AND CONS................................. 6

KEY MARKET SEGMENTS....................................................................................... 10

Automotive Sector.................................................................................................................... 11

Transportation Sector.............................................................................................................. 15

Power Sector.............................................................................................................................. 18

Industrial Sector........................................................................................................................ 21

USE CASES................................................................................................................ 25

Lead-Acid Battery Hybridisation in Vehicles................................................................... 25

Frequency Control and Pitch Control for Wind Turbines............................................. 28

Elevators, Cranes and Power Tools in the Industry...................................................... 30

THE FINAL WORD.................................................................................................... 32

APPENDIX ................................................................................................................. 34
Foreword
The challenge is big, but our goal is simple: to achieve & Sullivan have jointly created a white paper on
a sustainable energy future for Europe. Innovation is ultracapacitors with a focus on unlocking new
the solution. New ideas, products and services that possibilities for storage for the energy transition.
make a real difference, new businesses, and new
people to deliver them to market. At EIT InnoEnergy The aim of this whitepaper is to provide a document
we support and invest in innovation at every stage of with an independent, accurate and balanced view to
the journey – from classroom to end-customer – and serve market development. The objective is to shed
covering eight key transformative areas, including light on the case for ultracapacitors and highlight
transport and mobility, renewable energy, circular the main areas of application. The automotive,
economy and energy storage. transportation and power grid sectors are given, but
industrial applications, such as cranes, elevators, data
The way we generate and distribute power is centres, connected IoT devices, etc make for an ever-
changing. Energy storage is vital in the transition widening perspective. Ultracapacitors can play an
to a sustainable energy system. EIT InnoEnergy essential role already today but perhaps even more
encourages innovation in large and small-scale so in the future to help build a more efficient and
storage that supports the integration of renewable sustainable energy system
energy into the electricity grid, enables a more
decentralised and responsive grid and creates This effort has benefited from the guidance
business opportunities for new actors in the energy and feedback of Skeleton Technologies, NAWA-
ecosystem. The industry’s attention regarding Technologies and C2C-NewCap that provided useful
storage technologies has mainly been focused insights and contributions for this work.
on batteries, and in particular Li-ion, but recent
breakthroughs have made ultracapacitors (also Our hope is that this whitepaper will be a clear and
known as supercapacitors) a viable, reliable, faster accessible step towards supporting all actors that
and potentially safer power storage. In some cases to want to have a better understanding on the role of
replace batteries but also in an efficient combination ultracapacitors.
with batteries

In line with an ever-increasing emphasis on climate

change and sustainability, EIT InnoEnergy recognises
a strong case for ultracapacitors to serve as a key
technology for both environmental and cost reasons.
Ultracapacitors can provide the short bursts of high
power at virtually endless number of cycles that
vehicles, industrial and grid applications require.
However, it is acknowledged that there is a general Johan Söderbom
lack of awareness, understanding and references Thematic Leader for Smart Grids and
around those use cases. EIT InnoEnergy and Frost Energy Storage at EIT InnoEnergy

3
 Introduction

Ultracapacitors are not new; they were invented in the late 1950s by
General Electric. The technology was eventually commercialised by NEC of
Japan in 1978, where it was used as a backup power device for computers.

Due to an increased focus on cleaner power sources

at the turn of this century, there have been several
attempts to commercialise the technology as an
energy storage device on a wider scale, but this has had
somewhat limited success. Early innovations included
cell-based ultracapacitors to power wristwatches and
other micro electric items, eventually graduating to
powering applications in hybrid electric vehicles (HEV).
Industry attention, however, has remained on existing
conventional technologies such as batteries and
innovations focusing on new battery chemistries such
as lithium-ion.

However, advances in new materials and

manufacturing technologies in the late 20th and
early 21st centuries have led to significant increases
in ultracapacitor performance and lower costs.
Coupled with an ever-increasing emphasis on climate
change and sustainability, there is a strong case for
ultracapacitors to serve as a key technology for both
environmental and cost reasons.

4
In particular, ultracapacitors potentially unlock and However, challenges exist in the industry, partly due
open a new horizon for the energy transition. As the to the lack of awareness of where ultracapacitors can
technology advances, it can move from specific, niche be used, especially when there is a strong case being
areas to more mainstream applications as a power put forward for batteries.
source, which can enhance the capability of existing
solutions, e.g. batteries, or replace these power This leads to a catch-22 situation wherein, with low
sources altogether. adoption, there is limited economies of scale, which
leads to ultracapacitors not being as competitive.
Organisations across the world are recognising This inevitably leads to a scenario where the overall
the need for innovative solutions to cater for ever- industry, and thus society, loses due to the benefits
increasing energy demands and are increasing the of the technology not being fully realised, especially
energy efficiency of their products and services, at a critical time defining our energy future.
subsequently lowering environmental footprints.
These innovations and breakthroughs push the This white paper is intended to shed new light on
boundaries of technology every day, leading to an the case for ultracapacitors and highlight the areas
increased demand for short-term, high-intensity where they can play an essential role to help build a
power; a case in point is in mobile devices, where more efficient and sustainable future.
ultracapacitors can be a game-changer. This has
driven companies to search for new and alternative
sources of energy that can fulfil these demands while
catering to customer needs, even as they adhere to
strict energy-efficiency and pollution norms.

5
 An Overview of the Technology:
Pros and Cons

Ultracapacitors are double-layer capacitors with higher capacitance than a

regular capacitor. They store energy using a static charge instead of an
electrochemical reaction compared to batteries and have an operational
voltage between 2-3 volts. They store energy via electrostatic double-layer
capacitance and electrochemical pseudo-capacitance.

There are three types of ultracapacitors:

1. Electrostatic double-layer capacitors (EDLCs)
2. Electrochemical pseudo-capacitors
3. Hybrid capacitors

Electrostatic double-layer capacitors (EDLCs):

EDLCs store energy in an electrical double layer called the is generated via a charge transfer achieved through redox
Helmholtz double layer that is created at the interface reactions, intercalation or electrosorption. They bridge
between an electrolyte and a conductive electrode. The the gap between EDLCs and batteries as they can store
conductive electrode is made of activated carbon and higher energy while operating faster. They can charge and
the space between the two electrodes is filled with an discharge between seconds to minutes. Electrochemical
electrolyte. Electricity is generated by the process of capacitors have a life cycle of 500,000 cycles.
adsorption and desorption of ions from the electrode
surfaces. The ultracapacitor does not have a solid Hybrid capacitors:
dielectric or have any chemical reactions, leading to a These capacitors use electrodes of different capacities,
lower impact on lifespan due to charging and discharging one with electrostatic capacitance and the other
time in seconds. In addition, the ultracapacitor does not exhibiting an electrochemical capacitance. They combine
need special circuits to control charging and discharging. the benefits of both EDLCs and pseudo-capacitors along
However, leakage of electrolyte is a concern as is high with a longer and pollution-free lifespan. They have
internal resistance, which makes it unusable for AC operating temperatures between -25 degrees Celsius and
circuits. EDLCs offer high cycle life in excess of a million +60 degrees Celsius and have 95% efficiency, compared
cycles with moderately higher operating voltage. to only 70% for batteries. This makes them suitable for
use in high-power applications in the automotive and
Electrochemical pseudo-capacitors: transportation space.
These ultracapacitors use conducting polymer or metal
oxides with high pseudo-capacitance as electrodes.
Electricity is stored in an electrochemical process, which

6
Figure 1: The different types of ultracapacitors Source: Frost & Sullivan

EDLC PSEUDO-CAPACITORS HYBRID CAPACITORS

• Have carbon electrodes • Have metal oxide or • Electrodes can be

• Higher energy density conducting polymer composite or polymer
electrodes based
than low level capacitors
but not equal to batteries • Higher capacitance • High energy and
• High cycle stability and energy density power density
than EDLCs • Moderate cycle
• Lower cycle stability stability
• Lower power density
than EDLC

The advantages and challenges of ultracapacitors

compared to other technologies
Ultracapacitors have clear advantages over batteries; On the other hand, ultracapacitors have lower specific
they have a short charge and discharge time due to energy densities of 5-10 Wh/kg compared to 100-
minimal internal resistance (less than 2 minutes), 250 Wh/kg for batteries. Also, batteries offer a steady
whilst batteries take between 10-60 minutes. In voltage throughout their life, while ultracapacitor
addition, ultracapacitors have a charge/discharge voltage decreases with increasing discharge.
cycle of between 100,000 to a million, whilst Ultracapacitor voltage charge increases with increased
batteries have 500 to 10,000 cycles, so they hardly charging and the current starts dissipating once
need replacing and users save on operating costs. charging stops and the voltage level drops. Increased
voltage beyond a certain point may also damage
Critically, the specific power output of an ultracapacitor ultracapacitors with voltage dropping upon discharge.
is nearly 10 times as high as batteries, enabling a Finally, ultracapacitors currently cost significantly
high-power discharge in short periods. Storing energy more than batteries, with battery costs ranging from
in an electric field instead of chemicals also leads to $100 to $1,000 per kilowatt-hour (kWh) compared to
increased safety, lower fire hazard and explosion risk, $5,000 to $10,000 per kWh for ultracapacitors.
increasing the service life of the capacitor to between
10-15 years.

7
 Figure 2: The pros and cons of ultracapacitors Source: NREL

ADVANTAGES CHALLENGES
• Charge/Discharge time: • Cost: $5,000-10,000 per kWh,
1-10 seconds, minimum internal when compared to $180/kWh
resistance for Lithium-ion batteries and
• High Specific Power: $100/kWh for Lead Acid batteries.

10,000 W/kg • Cell Voltage: 2 to 3 volts

• Cycle life: 100,000 to 1 million • Low Specific Energy: 35 Wh/kg

• Service life: 10-15 years compared to 100-250 Wh/kg

for batteries.
• Charge/Discharge temperatures:
• High self-discharge
-40 degrees Celsius to
+65 degrees Celsius • Voltage drops with increasing

• Efficiency: > 95% discharge unlike batteries where

voltage is stable
• Low maintenance
• No chemical substances

Why will capacitors potentially be

a game-changing technology?
Given the differences between energy storage Two key elements are expected to change in
technologies, it is obvious that they are not always the coming years as research and investment
in direct competition. In other words, ultracapacitors into ultracapacitors gains momentum. The most
may replace batteries for those applications that important one is cost. The production cost of
require short-duration, high-specific power, e.g. ultracapacitors has dropped considerably in the
pitch control for a wind turbine, but not for those past 15 years - by 65% -75% as per analysis done
applications that require a steady stream of energy by various ultracapacitors manufacturers, such
over a long time, e.g. electric vehicles. However, in as Skeleton Technologies and IOXUS - and this is
the latter application, ultracapacitors will have a expected to decrease by another 30% from 2019 to
crucial role to play to support those devices in electric 2030. In comparison, battery costs are also expected
vehicles that need short-term power to take the load to decrease, especially Li-ion battery costs, as
off batteries and preserve their lifetimes. increased volume of production is expected to reduce
costs significantly over the decade, mirroring the
costs of lead-acid batteries.

8
Another important development will be the increasing However, a key argument for ultracapacitors is the
energy density of ultracapacitors in the coming high degree of flexibility that hybrid storage systems,
decade. The industry expects this to increase 10- which combine ultracapacitors and batteries, will
to 30-fold, which will make ultracapacitors more bring to various applications.
competitive with batteries as increased research leads
to the development of new types of ultracapacitors.

Figure 3: Cost forecast of ultracapacitors and Li-ion batteries Source: BloombergNEF and Frost & Sullivan

Cost of Ultracapacitors, 2005-2030 Cost of Li-ion batteries, 2005-2030

300002 1800
20,000- 1,700
1600
5000 30,000
1400
20000 1200
$/kWh
$/kWh

1000
15000
5,000- 800
10,000
10000 600
400
5000 1,500- 180
3,000 200
90
0 0
2005 2020 2030 2005 2020 2030

Figure 4: Energy density projections for ultracapacitors and Li-ion batteries Source: NASA

Ultracapacitor Energy Density, 2019 - 2030 Lithium-ion Energy Density, 2019 - 2030
160 100-200 700 650
140 600
120
500
Wh/Kg

Wh/Kg

100 400
400
80 50-100
300 250
60
200
40
20 100
6-10
0 0
2019 2025 2030 2019 2025 2030

9
 Key Market Segments
As energy storage devices become crucial to fulfil increased energy demand
more efficiently, there is a high opportunity for ultracapacitors across a
wide variety of industries, such as automotive, transportation, and power
generation and distribution, and industrial segments (such as cranes,
elevators, data centres, Internet of Things (IoT) devices, etc.).

The increasing electrification of automobiles and

other transportation infrastructure such as railways,
trams, trucks, and buses has increased the demand
on batteries for power while the emergence of
renewable energy has led to higher grid fluctuations,
which need balancing in short periods. Furthermore,
the increase in IoT devices and sensors that require
low downtime and rapid charging, and the expansion
of data centres that have critical power requirements,
all drive the need for ultracapacitors. Ultracapacitor cells from Skeleton Technologies

Figure 5: Key drivers by market sectors Source: Frost & Sullivan

AUTOMOTIVE TRANSPORTATION POWER GRID INDUSTRIAL

• Increased electrification • Increased need for • Higher Renewable • Increased power
and automation drives higher efficiency and Energy (RE) penetration requirements from
drive demand. lower emissions pushes and a decrease in industrial equipment

• Increased pressure on electrification of generation from such as cranes, and

railways, trucks and traditional fossil fuels elevators for heavy lifting
batteries leads to the
marine industry. leads to less grid stability. and for backup power.
need for alternative
and secondary sources • As loads increase • Need to compensate for • Penetration of IoT
of power. secondary power grid stability during peak devices leads demand
sources become demand times drives use for smaller power
• Energy savings seen as
mandatory to of alternative sources sources that have much
key to vehicle efficiency
supplement primary of power. longer cycle times.
and reduced fuel
batteries.
consumption.

10
Automotive Sector
Ultracapacitors can provide significant benefits and value to the automotive
sector, which includes commercial vehicles such as fossil-fuel-based
passenger cars, electric and hybrid vehicles and light utility vehicles.

The technology can address two critical challenges to support batteries in a variety of other applications
in the industry - reducing the total cost of ownership across the vehicle, including power steering (where
and lowering the environmental impact of vehicles. 5% fuel savings are possible), electric catalyst heating
to purify exhaust gases, etc.
In addition, the industry is being deeply affected
by the transformation towards electrification Another key benefit of ultracapacitors in the
and automation. This is driving change in vehicle automotive industry is through energy recovery
architecture and the adoption of new energy storage systems where kinetic energy caused during braking
systems to reduce dependence on primary energy is stored and used in vehicle acceleration; this results
systems such as batteries. in fuel savings (and hence emissions reductions)
of 30%-40%. Car manufacturers such as Honda
Today, ultracapacitors can be used alongside began incorporating ultracapacitors at the start of
batteries, which results in a drastic improvement the century, but there was a slower adoption by US
in battery lifetimes (as ultracapacitors can replace manufacturers. Recently, Lamborghini introduced
batteries for high-discharge activities), leading to ultracapacitors in its latest hybrid vehicle, Sian, and
lower operating expenditure and environmental costs is collaborating with Massachusetts Institute of
(recycling costs and pollution). For example, they can Technology (MIT) to develop ultracapacitors to fulfil
be used in engine starting and stopping operations the power requirements of high-power vehicles.
(Start/Stop), where short bursts of energy are
needed, which eliminates the need for high load on All of these benefits drive considerable value for the
batteries and results in less frequent replacements. industry and can help overcome many challenges.
The energy stored by ultracapacitors can also be used

Figure 6: Use cases* and key value drivers for ultracapacitors in the automotive industry Source: Frost & Sullivan

APPLICATIONS AUTOMOTIVE

Engine Start-up/Engine Cranking HIGH

Hybrid and Electric Vehicles HIGH

Energy Storage/Backup Power Bridging HIGH

Power Steering MEDIUM

Ebrake/Kinetic Energy Recovery System (KERS) HIGH

Lead-acid Battery Hybridisation HIGH

Autonomous Driving MEDIUM

Electric Catalyst Heating LOW

Start/stop HIGH

*Relative Attractiveness Measure – see Appendix for Rating Rationale

11
 AUTOMOTIVE INDUSTRY VALUE DRIVERS

• Fast Charging/Start-Stop: 1 to 10 seconds

• Increased battery life (which can be as low as
12-24 months) and hence lower operating costs
• Fuel savings: 1% to 5%
• Lower maintenance: 10 to 15 years ultracapacitor life
• Lower pollution: 30-40% less emissions

However, challenges remain in the industry. Lead-acid existing fleets, especially in large commercial vehicles
batteries are still much cheaper than ultracapacitors such as trucks. Further, manufacturers need to reduce
and environmental legislation is not strong enough in the much longer starting times compared to batteries
many countries to push adoption. to incentivise customers to switch to the technology.

In addition, the technology needs to be improved to

enable easy plug-and-play installation for retrofitting

The Future - Electrification and Automation will Drive Value

Despite these challenges, the future looks bright for ultracapacitors in the
automotive industry. Electric vehicles will increasingly become common on our
roads with Frost & Sullivan forecasting that 125 million vehicles will be sold
by 2030. Ultracapacitors can be charged in seconds compared to hours with
batteries, which will help overcome the slow charging challenge in the industry.

Currently, the amount of power delivered by a applications for all types of vehicles. Japanese
charging station is designed for charging lithium-ion automakers led early adoption in the past decade,
batteries in electric vehicles. As automakers increase with North American automakers have been adopting
their focus on ultracapacitor technology, charging ultracapacitors for start/stop, energy recovery from
infrastructure is expected to be revamped to enable braking systems and engine starting applications
fast charging of ultracapacitors. By overcoming this over the past five years. This trend is expected to
constraint, the use of ultracapacitors will help drive continue over the first half of the next decade as
the roll-out of electric vehicles in the coming decade. automakers increase the scope of applications that
Ultracapacitors are seeing increased usage in engine can be powered using ultracapacitors.
starting, start/stop, energy recovery and storage

12
Figure 7: Electric vehicle sales forecast, 2018-2030 Source: IEA

Total Stock of Electric Vehicles, 2018 - 2030

300

250

200
Million Vehicles

150

100

50

0
2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
PHEV 2.0 4.0 6.0 10.0 13.0 18.0 25.0 31.0 36.0 44.0 52.0 61.0 74.0
BEV 3.0 10.0 15.0 23.0 31.0 41.0 54.0 68.0 83.0 101.0 122.0 148.0 179.0

As automation in automobiles increases through the and road signals, thereby drastically increasing power
middle of the next decade, more electronics such requirements. There is, therefore, a strong case for
as Wi-Fi, 5G, video streaming, and other automated automobile manufacturers to redesign the architecture
systems will become integrated. of existing vehicles and adopt ultracapacitors to cater
to these short-term, high-power uses. Ultracapacitors,
An increasing number of applications, such as power with their short-duration, high-discharge-intensity
steering and engine starting, will move completely power, are well-suited to fulfil these requirements, and
towards ultracapacitors and away from batteries. their light weight is also a benefit for manufacturers
Vehicles will increasingly become connected, leading that are trying to increasingly accommodate additional
to higher short-term power requirements driving the devices in vehicles.
appetite for more energy.
Increased electrification and hybridisation of vehicles
Furthermore, as autonomous vehicles gain ground, gives an impetus for the adoption of ultra capacitors as
more sensors and IoT devices are expected to be a secondary power source. The need to charge the main
incorporated into the vehicle architecture to read traffic power source while on the move, thereby providing

13
 12V ultracapacitor module for engine start
from Skeleton Technologies

a higher mileage to electric and hybrid vehicles, will shape with increased adoption towards the end of
drive the integration of ultracapacitors within these the decade as companies move towards increasing
vehicles. This will also lead to a change in the charging fuel efficiency and mileage and reducing pollution
infrastructure, which will accommodate the demands by increasing adoption of electric catalyst heating.
from ultracapacitors for fast charging. There will be increased collaboration between vehicle
manufacturers and ultracapacitor companies as vehicle
As vehicle architecture evolves, the systems that are architecture evolves; this is already beginning with the
expected to adopt ultracapacitors include safety and recent $100 million deal signed between ultracapacitor
powertrain, engine throttle, cooling fans, oil pumps, manufacturer Maxwell Technologies and Volvo
doors, seating, electrical windows, car heating and air automobiles to supply ultracapacitors for its electric
conditioning, and audio and video. Use of ultracapacitors and hybrid vehicles.
as a hybrid power source along with batteries will take

Figure 8: Anticipated impact of ultracapacitors in the automotive industry Source: Frost & Sullivan

2020- 2023- 2027-

2022 2026 2030

• Engine Starting • Hybrid and electric vehicles • Electric Catalyst Heating

• Start-Stop Applications • Power steering • Secondary Power source/
lead acid battery hybridisation
• KERS • Autonomous driving
• Energy Storage/
Backup power bridging

14
Transportation Sector
The transportation sector includes railways, trams, buses, trucks, marine vessels
and off-road equipment such as mining vehicles. These vehicles are involved
in the bulk transportation of goods and passengers. Rail includes urban and
regional rail networks, while trams include city-based tram systems. Similarly,
buses include both urban and rural buses, while trucks include heavy commercial
vehicles used for long-distance goods transportation. The marine sector
includes ships and offshore platforms, and off-road equipment refers to mining
vehicles such as large mining dump trucks, excavators, etc.

As urban populations increase, so does the need operation; this reduces the overall cost of operating
for clean and efficient transportation services. the buses and facilitates complete removal of CO2
Rising infrastructure spending by governments and emissions. Ultracapacitors also enable catenary-
the private sector has increased connectivity and free (electrical wire-free) operation for buses, trams
transport options, leading to an increase in rail and and electric rails, which can be charged during
tram networks, trucking, bus networks, and the stops at stations or while braking. This is especially
spread of other heavy equipment such as mining helpful in reducing overhead power lines in densely
equipment. Current transportation modes are mostly populated areas. In electric rails, ultracapacitors are
based on vehicles with combustion engines, which either located on the train or on the tracks, which is
cause pollution and congestion, and there will be known as way-side energy storage. This helps reduce
a shift towards more energy-efficient means of energy consumption from the grid, increases voltage
transport (such as trains) and electric-powered stabilisation for the train, and provides fuel efficiency
vehicles. These will lead to the adoption of alternative of 10% to 25% for various forms of transport. For
sources of energy, which increase engine efficiency example, several cities in China have adopted trams
and lower emissions. made by CRRC Corporation that run on ultracapacitors
and charge at stations.
The potential for ultracapacitors in the transportation
industry is high with rail expected to be the most
impacted. Ultracapacitors are used to capture and Ultracapacitors are usually combined with a primary
store energy generated from braking systems in rail, battery power source, which reduces the load on
buses, trucks and trams, which is then used for other the battery and the need to design heavy and large
applications such as engine starting or acceleration. batteries for transportation networks; again, this
This reduces the power requirement from the battery leads to lighter vehicles, which consume less energy
while also stabilising power output. This energy-saving and have a lower environmental impact.
measure leads to increased battery and engine life as
well as lower emissions. Ultracapacitors are usually
combined with a primary battery power source, which The marine industry has enacted stringent fuel-
reduces the load on the battery and the need to design efficiency norms that mandate a reduction in sulphur
heavy and large batteries for transportation networks; emissions, which will lead to increased electrification
again, this leads to lighter vehicles, which consume and hybridisation of systems. Ultracapacitors are used
less energy and have a lower environmental impact. as peak load-shaving applications that supply power,
allowing for the generators to operate at constant
A case in point is ultracapacitor-based buses, load and for absorption of excess generated power.
which are estimated to consume 2 kWh per mile of They are also used in active heave compensation,

15
 which is a technique used to reduce the influence batteries to operate high-power requirements such
of waves lifting equipment in offshore vessels as engine starting and heavy load movement.
and platforms, and they absorb any excess power
generated by the cranes on ships and in ports. Challenges exist in the form of high cost of adoption
of ultracapacitors and redesign of existing systems
Ultracapacitors can also be used to store to accommodate the technology. Also, higher
renewable energy produced by solar or wind spending on research and development (R&D) of
energy onboard marine and offshore platforms, several battery types increases competition for
which helps reduce the demand on the primary ultracapacitors. The low cost of electricity and lower
power sources. Off-road equipment such as mining diesel prices also hinder alternative power source
equipment and heavy trucks require constant development as companies stick to tried-and-tested
operation as any downtime leads to losses; in such systems instead of moving to innovative ones.
cases, ultracapacitors can be placed alongside

Figure 9: Use cases* and value drivers for ultracapacitors in transportation Source: Frost & Sullivan

————————— TRANSPORTATION —————————

APPLICATIONS RAIL BUS TRUCK MARINE OFF-ROAD
EQUIPMENT

Engine Start-up/Engine Cranking HIGH HIGH HIGH MEDIUM HIGH

Generator Control Gradient LOW

Hybrid and Electric Vehicles HIGH HIGH HIGH MEDIUM MEDIUM

Energy Storage/Backup Power Bridging HIGH MEDIUM MEDIUM MEDIUM MEDIUM

Catenary-free Operation MEDIUM

Ebrake/Kinetic Energy Recovery System (KERS) HIGH MEDIUM MEDIUM HIGH

Lead-acid Battery Hybridisation MEDIUM LOW LOW

Start/Stop HIGH HIGH HIGH LOW

Heave Compensation MEDIUM

*Relative Attractiveness Measure – see Appendix for Rating Rationale

TRANSPORTATION VALUE DRIVERS

• Reduced emissions
• Lower operational costs for vehicles: ~20% cost reduction
• Fuel Efficiency: 10 to 20% in case of larger vehicles
• Reduced overhead power line for trains and trams
• Voltage stabilisation for trains: less than 20 milliseconds
• Heave Compensation in marine vessels

16
The Future - Increased Electrification and Emissions to Drive Adoption
As vehicles move towards increased electrification over the next decade, the
need for secondary power sources increases to reduce emissions and increase
efficiency. Along with the development of new technologies such as connected
trucks and machines and the spread of sensors and IoT devices, the demand for
power is expected to increase exponentially, putting a strain on existing power
sources. Subsequently, ultracapacitors will be deployed in various transport
applications to replace many of the current battery functions to extend system
life but also to reduce emissions coming from combustion engines.

Ultracapacitors are expected to increasingly play a and offshore renewable energy. The need for safe
role in applications such as start/stop and engine operations in such platforms is an added driver for
starting, and in energy recovery systems. Energy ultracapacitors as they have a lower risk of fires and
generated via braking systems is captured and stored improved safety compared to batteries.
in ultracapacitors using a Kinetic Energy Recovery
System (KERS) to be used when needed. The size of engines and batteries may decrease as
ultracapacitors become the norm with higher energy
Trains and trams are expected to move towards density and lower costs. New vehicle architecture
catenary-free operations as planners look for ways to is expected in off-road and heavy equipment as
reduce their dependence on overhead lines in urban the sector increasingly adopts electrification and
areas. Energy recovery from braking and charging hybridisation, incorporating ultracapacitors in their
using an overhead line at stations require fast- energy mix by the end of the decade. For example,
charging systems such as ultracapacitors. autonomous trucks used for mining, such as the
one launched by Volvo, will seek to increase energy
Marine and offshore platforms will also see increased efficiency by incorporating ultracapacitors.
ultracapacitor adoption to capture wave energy

Figure 10: Anticipated impact of ultracapacitors in transportation applications Source: Frost & Sullivan

2020- 2023- 2027-

2022 2026 2030

• Start/Stop application for • Increased penetration in • Used along with batteries in

buses, rail, truck and trams. off-road and mining electric buses, off-road and
equipment. mining vehicles and trains.
• KERS for rails, trams,
trucks and buses. • Increasing presence in marine • Increased adoption across
and off-shore platforms. marine systems and
offshore platforms as
• Increased usage in start/stop
energy storage and supply
applications in buses, trucks,
device.
rail and off-road vehicles.

17
 Power Sector - Generation, Transmission and Distribution (T&D)
The power industry is undergoing a seismic shift towards more efficiency
and less-polluting technologies. The power generation industry includes
sources such as fossil (power plants and standalone power sources used in
industries such as diesel gensets) and renewable energy (RE)-based sources,
including microgrids used in industries and communities. In addition to power
generation, the industry caters to the transmission and distribution grid
networks, which move electricity over long distances.

Climate change and sustainability are driving The increasing use of microgrids, which are
investments in renewable energy sources (wind, solar) interconnected power supplies that work
and replacing fossil fuels such as coal and oil. This has independent of the grid (mostly based on renewable
led to less centralised, large power plants and more energy sources) in industrial and commercial
decentralised systems feeding power to the grid. A establishments as well as remote communities, has
side effect of this change is reduced grid stability due led to grid stabilisation requirements. Ultracapacitors
to an increased, bidirectional electricity transmission. can fulfil the function of providing frequency and
Ultracapacitors serve a number of functions within this voltage stabilisation to such grids, thereby providing
context; they can be used to remove grid fluctuations high-power quality as well as an active energy
caused by the intermittency of renewable energy storage system. They are also incorporated with
production, thereby reducing the need for costly backup batteries in a hybrid system to take over high-
power sources or risking damage to the grid due to power applications of microgrids, which lessen the
high-power and voltage fluctuations. They can also load on batteries and enable longer battery life.
help absorb the excess power generated during high Ultracapacitor manufacturers such as Maxwell
availability of renewable energy. Technologies and Suneron Energy have introduced
cells, modules and storage systems that cater to the
At the same time, ultracapacitors can be used to energy requirements of grids.
provide smooth functioning of conventional backup
power generators by balancing the generator gradient
while ensuring smooth power supply. Backup power
generators are on standby to ramp-up or down power,
depending on demand and supply. With ultra-low
response time in milliseconds, ultracapacitors can
cater to these changing needs, thereby helping ramp-
up fossil fuel generators and extending engine life.
Ultracapacitors can also maintain the quality of power
supply by injecting high power at times of voltage
drops, reducing downtimes. At peak load, where the
demand on the grid is at its highest, there is a need 170V ultracapacitor module for power grids, transportation
and industrial applications from Skeleton Technologies
to have backup capacity - this is usually done through
large plants such as a gas plant - and ultracapacitors
are emerging as a key technology along with batteries to
provide short bursts of high-energy for ‘peak shaving’.

18
Pitch control for wind turbines is a key use case for damage due to unwanted power surges. For example,
ultracapacitors in power generation as it helps control SKELGRID ultracapacitors by Skeleton Technologies
the wind turbine and prevents damage during peak serve as energy storage systems, which improve
wind conditions; this will be discussed further in the power quality for industrial applications. Installed on
paper. Ultracapacitors are also used as energy storage the Scottish Island of Eigg, which is supplied with
devices in times of peak power production by RE power power from its own renewable energy-based microgrid
sources, to smooth generator gradients, and for peak system, SKELGRID enables fast-response backup
load-shaving applications, as deemed fit by various power to the microgrid, thereby helping the island
industries and power suppliers. The benefit is not only reduce its dependence on lead-acid batteries during
a reduction in overall costs but also less equipment peak power times.

Figure 11: Use cases* and value drivers for ultracapacitors in the power industry Source: Frost & Sullivan

——————————— POWER ———————————

APPLICATIONS GENERATION T&D INDUSTRIAL

Engine Start-up/Engine Cranking HIGH HIGH

Pitch Control for Wind Turbine MEDIUM

Generator Control Gradient MEDIUM

Frequency Response/Synthetic Inertia MEDIUM

Energy Storage/Backup Power Bridging LOW LOW MEDIUM

Peak Load Shaving MEDIUM MEDIUM

Variable Speed Drive (VSD) Backup MEDIUM

*Relative Attractiveness Measure – see Appendix for Rating Rationale

GRID INDUSTRY VALUE DRIVERS

• Frequency Response and Voltage Stabilisation

• Generator Gradient Control: Response time in less
than 20 milliseconds
• Peak load shaving: 30 to 40% reduction in peak
demand energy
• They offer low costs for usage in pitch control for
wind turbines along with long life and simpler
monitoring systems
• Low operating temperatures: -40 degrees to
+65 degrees Celsius

19
 The Future - Intermittent Renewable Energy and Microgrids to Drive Adoption
The move towards renewable energy is expected to accelerate (especially
solar and wind) and there is higher risk for grid fluctuations due to the
intermittent nature of renewables. Hence, there will be a stronger need for
devices such as ultracapacitors in the coming years. According to Frost &
Sullivan, solar PV installations are expected to increase from 99 GW in 2019
to 128 GW in 2025, while wind power is expected to see annual additions
between 55-70 GW between 2021 and 2025. These large RE additions to
the global grid will lead to the increased need for power sources to address
the frequency and voltage fluctuations and peak power requirements.

Many wind turbine manufacturers and operators Smart cities will also drive the adoption of alternative
have already installed ultracapacitors in their wind sources of power as governments seek to reduce
turbines for pitch control functionality, and adoption energy consumption levels. Building energy
is expected to continue, leading to a complete management systems and increased energy controls
replacement of battery systems with ultracapacitors will drive the implementation of solutions such as
by the end of the decade. In such an application, batteries and ultracapacitors to increase overall
the ability to withstand temperature extremes energy efficiency.
and requirement for minimal service is an absolute
technological advantage over batteries. Cost remains a key issue as battery costs are
being reduced through recyclability, which leads
The proliferation of distributed power generation to higher adoption, creating direct competition for
and microgrids in industrial and remote communities ultracapacitors. However, the end of the decade will
provides a good opportunity for ultracapacitors as witness increased ultracapacitor and battery usage
they will have increasing power quality and energy as a hybrid power supply for grid networks, with
storage requirements. Additionally, the adoption of ultracapacitors used for several key functions, such
IoT devices, smart meters and sensors that monitor as voltage and frequency stabilisation, rather than
power quality will require prime power sources of batteries and generators.
their own that are long-lasting and do not need
frequent replacement.

Figure 12: Anticipated impact of ultracapacitors in the power industry Source: Frost & Sullivan

2020- 2023- 2027-

2022 2026 2030

• Engine Starting • Powering IoT devices in • Hybrid power source along

the grid with batteries
• Frequency Response
• Peak load shaving • Primary source of power for
• Generator gradient control
voltage and frequency
• VSD Backup
• Pitch control for wind stabilisation
turbines • Energy Storage/ Backup
20
Power bridging
Industrial Sector
Within industry, ultracapacitors can serve highly diverse applications, including
cranes (such as industrial, construction and port-based cranes), elevators
(used in offices, commercial buildings and residential apartments), logistics
equipment (e.g. forklifts and autonomous guided vehicles), medical devices
(e.g. CT scan machines, ECG machines), oil and gas facilities, power tools, data
centres of all sizes (including enterprise, colocation and cloud data centres) and
IoT devices (including sensors used in all industries and that require constant
power supply with minimal replacement).

Energy sources with fast response times and high- especially, when they are connected to an energy-
power density are key to fulfilling modern-day industrial generating source such as solar power. IoT devices
power requirements and providing back-up power are often located in hard-to-reach areas and cannot
bridging to expensive, sensitive equipment in case of be removed for charging and maintenance, often
power disruptions. As industries move towards higher leading to the need for permanent and long-life
levels of automation, this leads to an increase in power power sources, which batteries cannot provide but
requirements. Reductions in overall power demand which suit ultracapacitors. Faster charging also drives
during peak hours and the ability to store energy the use of ultracapacitors in power tools, which leads
generated on-site for future usage help with efficiency to the replacement of batteries and increases the
of operations and reduces operational costs; these are efficiency of equipment.
key value drivers for the industry.
Equipment used in medicine is critical and cannot
The shift towards automation has resulted in afford downtime; this requires the installation of
autonomous vehicles (e.g. autonomous guided several backup power sources for short-term power
vehicles) and IoT devices, which are used in industries loss. Ultracapacitors not only provide high power for
and warehouses. These vehicles and devices are the short term but also ensure delivery of quality
small, operate in relatively small and defined power to medical equipment, thus preventing
footprints, require continuous running power and damage during short-term power outages before the
need to avoid downtime. The use of batteries in main backup power comes online. The light weight
such systems leads to long charging time and heavy of ultracapacitors and long life also make sense for
discharge due to wireless communication of such replacing batteries in medical devices, leading to
devices, which may drain smaller batteries. This higher levels of adoptions in mobile medical units.
makes such applications ideal for ultracapacitors,

Ultracapacitors can provide exceptional benefits by capturing

energy generated by industrial equipment such as cranes or
elevators (during braking) and recycling it, leading to reduced
emissions and operating costs. This excess energy generated
from regenerative braking can be stored in ultracapacitors to be
used when required, resulting in reduced energy consumption.

21
 Data centres is another application that offers good proposition given the extreme operating environments.
opportunity as the industry moves backup power Here, ultracapacitors are used in drill heads for
supplies closer to the server level; smaller and micro communication, where extreme heat is commonplace.
ultracapacitors are installed at the source to take For example, an MIT-based start-up, FastCap, has
care of short-term power outages and minimises launched a new type of ultracapacitor which can
downtimes. As edge data centres (smaller facilities withstand temperatures within the range of -110 to
located close to the populations they serve that deliver 300 degrees Celsius, suitable for operation in high-
cloud computing resources and cached content to end pressure environments.
users) propagate, companies are looking for ways in
which they can employ alternative power sources to The increasing digitalisation of industries will lead to
reduce dependence on uninterruptible power supplies explosive growth in IoT devices and smart sensors
(UPS) for short-term power outages. The advent over the next few years that require power for periodic
of 5G technology will help increase the spread of pulses of high current to send back data; this makes
multi-edge access sites, which are micro data centres them an ideal use cases for ultracapacitors. IoT devices
with unique power requirements mandating smaller are often located remotely and require power sources
and modular power sources. The increased use of that can last a long time without frequent replacement.
advanced electronics, which have higher processing They also require light-weight power sources, which
power, also demands increased backup power sources cannot be provided by batteries. Ultracapacitors fulfil
at the server level, driving the need for ultracapacitor- these requirements by reducing the overall weight of
supplied backup power. IoT devices while ensuring continuous power supply in
harsh working environments. This increases the life of
An increase in horizontal drilling in the Oil & Gas the sensor and also increases the frequency of data
industry and the need for high-power drilling and transfer of IoT devices.
communications make ultracapacitors an attractive

Figure 13: Use cases* and value drivers for ultracapacitors in industrial applications Source: Frost & Sullivan

———————————— INDUSTRIAL ————————————

APPLICATIONS CRANE ELEVATOR LOGISTICS MEDICAL OIL & GAS DATA CENTERS POWER TOOLS IoT DEVICES

Engine StartUp/Engine Cranking HIGH MEDIUM

Powering Autonomous Guided Vehicles (AGVs) HIGH

Hybrid and Electric Vehicles MEDIUM MEDIUM

Energy Storage/Backup Power Bridging MEDIUM HIGH HIGH MEDIUM MEDIUM MEDIUM HIGH

Peak Load Shaving MEDIUM

Ebrake/Kinetic Energy Recovery System (KERS) HIGH HIGH HIGH

Lead-Acid Battery Hybridisation LOW

Start/Stop MEDIUM MEDIUM
Heave Compensation MEDIUM

Prime Power for IoT Devices & Tools HIGH HIGH

*Relative Attractiveness Measure – see Appendix for Rating Rationale

22
 INDUSTRIAL VALUE DRIVERS

• Energy Efficiency: 34% reduced energy consumption

for cranes and 70% in elevators
• No hazardous materials: reducing risk of fire
• Long lifetime: >10 years
• Fast charging/discharging: <10 seconds
• Ability to operate in extreme temperatures e.g. drill heads
in Oil and Gas
• Start/stop: 20% less starting time
• Higher power output improves communication range
(e.g. below earth surface)

The Future - Automation and Miniaturisation to Drive Power Needs

As industries move towards automation, the demand for sensors and IoT
devices is set to explode as they enable live tracking and control of industrial
equipment. The increased use of cloud computing and the advent of 5G
will lead to a higher use of sensors over the next decade, impacting energy
demand and leading to higher energy efficiency.

The increasing need to reduce pollution and emissions Heavy industrial equipment such as cranes and
will also result in higher RE penetration in industries, elevators will be first adopters for ultracapacitors in
which will require alternative power sources to the first half of the decade as they seek to reduce
balance the intermittency of RE power and also to fuel consumption and emissions and aim to recycle
act as an energy storage device. To increase the energy released during operations. IoT, autonomous
efficiency of existing systems, industries will move guided vehicles (AGVs) and other warehouse
towards capturing energy from their machines (energy equipment are expected to favour ultracapacitors to
harvesting), which will use ultracapacitors as they are reduce weight and shift away from heavy batteries.
easily integrated into systems of energy capture and New products catering to these industries are being
storage. Energy efficiency, extending the life of primary launched, which will ensure higher adoption.
power sources and reducing machine damage due to
high loads are all key factors driving industries to adopt
alternative sources of energy such as ultracapacitors.
With their higher power density, faster discharge cycles,
long life span and increased safety, ultracapacitors are
the ideal choice for industries looking to reduce costs,
lower the need for frequent maintenance, and provide
safe power supplies to industrial machines. Companies
like NAWATechnologies and CAP-XX are launching
ultracapacitors that help power IoT platforms. Ultracapacitor cells for a wide range of
applications from NAWATechnologies

23
 Horizontal drilling for shale oil and gas is expected Increased automation of Oil and Gas platforms and
to increase and spread from the US to other the need to reduce pollution in the industry have
countries, including Argentina. Horizontal drilling forced companies to develop innovative ways in
in the Oil and Gas industry results in the need for which energy storage using alternative sources of
a constant power supply for drilling equipment power can be incorporated to reduce overall pollution
and sensors in hard-to-reach places. These are and increase the efficiency of sites. Ultracapacitors
well-suited to move towards ultracapacitors as and renewables will replace polluting battery and
companies seek to adopt power sources that do generator technologies, which will reduce costs
not need constant replacement and reduce the risk and increase efficiency, even as oil companies are
of fire or other hazards. Horizontal drilling requires expected to battle low oil prices over the next decade.
communication networks to be robust and reach
deep into the earth, and ultracapacitors are well-
suited to provide the high-power requirement for
such communication networks.

Data centres are expected to reduce their use of UPS With their higher power density, faster discharge cycles,
and batteries for backup power and move towards long life span and increased safety, ultracapacitors are
ultracapacitor, as catering to short-term power the ideal choice for industries looking to reduce costs,
requirements increases the pressure on existing lower the need for frequent maintenance, and provide
systems, which can be alleviated by ultracapacitors. safe power supply to industrial machines.

Figure 14: Anticipated impact of ultracapacitors in industrial applications Source: Frost & Sullivan

2020- 2023- 2027-

2022 2026 2030

• Increased presence in cranes and • Higher adoption in Oil & Gas • Replace batteries in Oil & Gas
elevators. space due to increased horizontal drilling and increased presence in
drilling. offshore platforms.
• Introduction to IoT, medical
devices, data centers, fast • Replace batteries in autonomous • Data center usage as backup
charging for AGVs. vehicles and IoT devices. power replacing batteries and UPS.
• Hybrid structure along with
batteries in data centers.

24
Use Cases
Lead-Acid Battery Hybridisation in Vehicles

Key reasons for using lead-acid batteries 99% recyclable compared to only 5% for lithium-ion
batteries. Costs of lead-acid batteries vary from
Invented in the 19th century, the lead-acid battery
$130 to $250 per kWh compared to $250 to $1,000
is an energy storage device that generates electrical
per kWh for Li-ion batteries (Source: NREL). High
energy using a chemical process. In automobiles,
operating temperatures, ease of manufacture and
it is used to provide electrical charge for starting,
low self-discharge also make batteries an ideal
lighting and ignition systems. Apart from starting,
source of power for automobiles. They are used
the batteries also provide electrical power when
in hybrid and electric vehicles but only to support
the vehicle’s electrical requirements exceed the
primary Li-ion batteries. These benefits make
supply from the charging system and also act as a
lead-acid batteries well-suited for automobiles and
voltage stabiliser when voltage fluctuations take
especially difficult to displace from a technological
place in the automobile. There are two types of
standpoint.
lead-acid batteries, the flooded-cell type and the
sealed type, and they are used to supply 12V for
The case for ultracapacitors
passenger vehicles and 24V for heavy trucks and
mining equipment. Key benefits include low cost and Ultracapacitors can be used as a secondary power
high recyclability rate, with lead-acid batteries being source in tandem with batteries to cater to short-
term power requirements for various applications
in vehicles, which relieves the load on batteries and
extends battery life. Key benefits of ultracapacitors
include their ability to store energy generated
from braking systems, high-energy discharge,
fast charging and operations at low temperatures,
such as -40 degrees Celsius, which can be used for
applications such as engine starting, even in harsh
weather environments. By providing power for these
short-term requirements, they help balance the
load of the primary power source in an automobile.
For example, GM became the first US-based
manufacturer to adopt ultracapacitors for its Cadillac
range of automobiles in 2015 to power start-stop
systems.

Increasing performance expectations from automobiles

are pushing power requirements. To cater to these

25
 higher requirements, manufacturers deploy large replacement cycles reduce operating costs for vehicles
vehicle batteries, which increase costs and add to as they need not replace batteries for two years. This
the weight of the vehicle. This can be a drag on the is especially significant for large commercial vehicles,
vehicle performance and lowers overall fuel efficiency. such as trucks, that have an average of two batteries,
To meet these challenges, automobile companies which are often replaced more frequently and hence
have turned to incorporating alternative sources of have a better cost-saving potential.
power that can cater to peak electrical demands.
Ultracapacitors, with their high-energy discharge Policies from various governments on energy savings
and long life of 12-15 years, help lower maintenance also lead to the adoption of ultracapacitors to increase
costs while balancing the load on the batteries. Cost vehicle efficiency, and increased electrification drives
is a key challenge for ultracapacitors as initial costs the demand for fast-charging applications. New
vary between $2,000 and $6,000 per kWh (Source: forms of capacitors such as Li-ion or graphene-based
NREL) and the need to redesign vehicle architecture ultracapacitors have higher energy density and costs
to accommodate ultracapacitors can increase overall that are comparable with Li-ion batteries, which will
costs. Lower energy density compared to other drive higher adoption of this technology in the future.
battery types further hinders the increased adoption As older batteries are replaced, these new types of
as a vehicle power source. ultracapacitors will see higher adoption rates via the
battery aftermarket channel.
Lead-acid battery pollution provides further
reasons for the replacement of such batteries with Several Japanese manufacturers such as Toyota and
environmentally friendly power sources. Increased Honda have already incorporated ultracapacitors in
usage of lead and sulphur contaminates soil and their vehicles, while western manufacturers such
groundwater if not properly disposed or recycled. as GM and Tesla are also increasing their use of
Accidental leaks lead to poisoning and fires, including ultracapacitors. It is expected that more research will
explosions, which have led many manufacturers to go into ultracapacitors over the next decade, with
move towards alternative and safer sources of power vehicle manufacturers investing heavily in alternative
such as ultracapacitors. sources of power. This will lead to the development
of new products with costs and energy density
Unlocking the value potential comparable to batteries, driving higher adoption.

By incorporating ultracapacitors and batteries in a

hybrid set-up, manufacturers extend battery life while
allowing the vehicle to operate in wide temperature
ranges. The focus on emission reduction and fuel
efficiency drives the adoption of start-stop systems
within vehicles featuring ultracapacitors, which
increase fuel efficiency by 5% to 10%. Lower battery

26
Figure 15: Key value drivers in lead-acid battery hybridisation Source: Frost & Sullivan

LEAD ACID BATTERY HYBRIDISATION VALUE DRIVERS

• Long lifetime: > 10 years substantially reduces

operating costs due to frequent battery replacements
• Fast charging/discharging: < 10 seconds
• Higher efficiency: > 95%
• Lower weight helps reduce vehicle drag
• Lower operating temperatures: -40 degrees to +65
degrees Celsius
• Increases fuel efficiency in vehicles by 5% to 10%
• Carbon materials used by ultracapacitors offer low
pollution and good electrical conductivity thereby
increasing sustainability of power source

27
 Frequency Control and Pitch Control for Wind Turbines

Ultracapacitors are a critical reliability component of and costs. Further, batteries are unable to operate in
the turbine pitch control system, managing the pitch harsh weather conditions and have a narrow band of
for each blade individually and performing critical operating temperatures.
functions by ‘feathering’ the blades to enhance the
efficiency of wind energy conversion, as well as A low operating temperature can result in larger
shutting down the system by pitching the blades to battery systems, leading to extra weight, less
zero in case of high winds or a grid failure for fail- efficiency, higher costs and the inability to service such
safe operation. They adjust the blades to capture systems in offshore wind turbines, which will become
maximum power while maintaining high levels of a key growth area for renewable energy in the future.
safety and preventing the turbine from spinning
out of control. Traditional power systems for pitch
The case for ultracapacitors
control have depended on hydraulics or batteries to
supply power, both of which have their drawbacks, Ultracapacitors can store energy with a high-efficiency
including being complex systems that require output. They can operate in harsh weather conditions
frequent maintenance and replacement of parts, and have reaction time in milliseconds.
leading to downtimes. Manufacturers also have to
replace the batteries every two to three years and The lack of chemical substances leads to high levels
they have lower efficiency as the battery discharges. of safety and reduces the risk of fire, which is an
The large number of components in a battery also advantage in remote sites, where turbines are often
leads to increased complexity, adding to maintenance located. Ultracapacitors also have low maintenance

28
requirements compared to batteries and have a long spread the costs over a long time. Less maintenance
replacement time of 15 years; this is a key benefit and fewer replacements add to the lower costs for
since the wind turbine industry is highly focused on ultracapacitors, especially in remote and offshore
minimising operating costs to be competitive as a wind turbines, where maintenance is difficult and
technology. Operating temperatures for ultracapacitors infrequent. It is estimated that nearly 20% to 25% of
are between -40 degrees Celsius to +65 degrees all downtime in wind turbines is due to pitch system
Celsius, which can help wind turbines function failures, which is a significant cost for wind park
smoothly in low temperatures. This is valuable because operators. These failures can be reduced by using a
it allows wind park developers to potentially access less complex and highly efficient power source such
previously unfavourable sites. as ultracapacitors instead of batteries, which require
more components for operation.
The energy required for electrical pitch control systems
is low and the duration takes seconds, which is a good Ultracapacitors can offer efficiency in excess of 95%.
fit for ultracapacitors because they deliver high power It is estimated that nearly 30% of all wind turbines
in short periods. Ultracapacitors also require less of globally are installed with ultracapacitor systems
monitoring and maintenance systems compared to the first systems were installed by Enercon in 2006
batteries. They do not need heating or cooling systems, for pitch control and emergency power. According
resulting in lower hardware requirements and redesign to Maxwell Technologies, it is estimated that
costs for the manufacturer. ultracapacitors will be able to replace batteries and
hydraulic systems for pitch control by the end of
Unlocking the value potential the decade. Maxwell Technologies has introduced
Ultracapacitors have high initial costs but have reduced ultracapacitors in turbines in China and Europe, with
or equivalent total cost of ownership when compared retrofits introduced in North America.
to batteries over the lifetime of the system. This leads
to higher acceptance from manufacturers as they can

Figure 16: Key value drivers for pitch control in wind turbines Source: Frost & Sullivan

PITCH CONTROL VALUE DRIVERS

• Higher reliability resulting in reduced downtimes, which

are up to 25% with more complex battery operated
pitch control systems
• No chemical substances leading to lower fire hazard and
higher safety
• Lower operating temperatures: -40 degrees to +65
degrees Celsius able to operate in more hostile, offshore
environments
• Low maintenance requirement and long replacement
time reduces operating costs given the remote locations
of many wind farms

29
 Elevators, Cranes and Power Tools in the Industry

As mentioned, the potential applications of fluctuations is leading to a need for alternative power
ultracapacitors in industrial applications are diverse, but sources. Replacing batteries will increase penetration of
some of the most promising ones include elevators, ultracapacitors in power tools, which can benefit from
cranes, and power tools. lower maintenance and higher power density.

Elevators generate energy from their movement The case for ultracapacitors
and are grid-dependent for their primary power
Ultracapacitors serve as an energy storage and
requirements. Increasing building efficiency norms
supply device for industrial machines such as
drive energy storage requirements, which reduce
cranes and elevators. Energy can be recovered from
grid dependence and lead to lower costs. Similarly,
cranes during lowering and braking operations. It is
cranes also generate their own power and are in the
stored in ultracapacitors and can be used for lifting
process of incorporating RE power in their energy mix.
operations. This helps in reducing diesel engine size
As microgrids are enabled in ports, the need for peak
as peak power requirements are taken over by the
load shaving and to balance frequency and voltage
ultracapacitors. For example, the use of Skeleton
Technologies’ graphene-based ultracapacitor has
reduced power consumption by 34% in a crane in the
Baltic region. Expanding RE power and microgrids
in ports are creating demand for balancing grid and
voltage fluctuations where heavy cranes are deployed
for loading and unloading of goods. Ultracapacitors
provide quick bursts of power, which enable the rapid
starting of cranes without the need for power from
the grid or batteries. They also provide peak shaving,
which can balance loads and lead to the deployment
of RE power. This can lower loads on the primary
source of power to extend its life. With their long life
and low maintenance, ultracapacitors enable lower
operating costs for crane operators.

Elevators also are ideal candidates for ultracapacitors

to capture and store energy for their operations.
Elevators are capable of generating their own energy
upon descent or braking using a kinetic energy
recovery system (KERS), which stores the generated
kinetic energy in ultracapacitors for later use in lift
operations. The energy generated due to elevator

30
movement is less than the total power demands of Unlocking the value potential
elevators, so they depend on grid power or batteries
Ultracapacitors provide high-power efficiency of
as their prime source of power. Ultracapacitors can
more than 90% for use in industrial equipment. Their
be used in parallel with the prime power sources,
usage also reduces energy consumption by 70% in
reducing their load and extending their service life.
elevators as regenerated energy is used. Modern
Several ultracapacitors can be installed in parallel if
ultracapacitors such as graphene and lithium-ion-
there is an increase in stored energy, and because
based ultracapacitors can ensure cost reduction
they are lightweight, they do not add much weight to
of 50% for elevators. Nearly 40% of the power
the elevator.
requirement for crane systems comes from peak
power usage, and by reducing the peak power load,
The increasing use of hybrid power management in
ultracapacitors enable significant monthly savings on
power tools has led to ultracapacitors taking over
the power bill for crane operators.
several of the battery power functions. The absence
of any chemical substances leads to high charge Ultracapacitors face drawbacks in their cost as
and discharge currents, higher safety due to lower implementation in industrial equipment leads to high
incidences of fire or explosions, and simpler power initial costs and redesign of existing systems. These
control circuits for ultracapacitors compared to barriers are expected to be overcome by investments
batteries. As ultracapacitors have a charge/discharge in next generation ultracapacitors, which can bring
cycle of a million, this leads to longer life and a lower down costs equivalent to batteries by 2030.
replacement rate in power tools. This reduces costs,
ensures higher reliability, and lowers maintenance and
downtimes. The replacement of batteries also ensures
less pollution, and ultracapacitors enable power tool
operations at low temperatures of -40 degrees Celsius.
Ultracapacitor manufacturer IOXUS has introduced
lithium-ion ultracapacitors that can charge power tools
in less than a minute.

Figure 17: Key value drivers for industrial equipment Source: Frost & Sullivan

ELEVATORS AND CRANES VALUE DRIVERS

• Energy Efficiency – 34% efficiency in case of cranes and

70% in case of elevators
• No hazardous materials – reducing risk of fire
• High power efficiency of 90%
• Long lifetime: > 10 years
• Fuel efficiency: 5 to 10% for cranes
• Fast charging/discharging: < 10 seconds
• Start/Stop: 20% less starting time
• Enable power tool operations at very low temperatures
of -40 degrees Celsius

31
 The Final Word

Ultracapacitors have been relatively under-explored compared to other

established energy storage technologies, such as batteries. Although the
technology is already being implemented in some applications, there is great
potential to develop it further to overcome some of its limitations.

As highlighted in this paper, some features of have the potential to play a significant role and allow
ultracapacitors are far superior to those of batteries; the industry to generate value in innovative ways.
for example, they have much longer life cycles, the Indeed, in many respects, ultracapacitors cannot
ability to withstand extremes, high-power discharge, compete directly with batteries, e.g. lead-acid batteries
etc. However, some key challenges remain, most in overall cost versus performance. However, this is not
notably the cost of the technology and its energy the argument for the increased role of ultracapacitors
density. Although great strides are expected in the in this application - the ‘sweet spot’ of the technology
coming decade to address these weaknesses, which lies in the value that it will unlock when combined with
will help with adoption, these need not be deal- batteries to form hybrid systems. For example, using
breakers for the technology. ultracapacitors with lead-acid batteries in vehicles
significantly increases battery lifetimes and eliminates
As the energy transition towards cleaner and more the need for additional batteries in trucks, which greatly
efficient systems gains momentum, ultracapacitors reduces the total cost of ownership for the end user.

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In this instance, ultracapacitors do the heavy lifting for It is therefore critical that the industry does not look
batteries (e.g. engine start) and allow the batteries to only at cost, but rather considers the holistic benefits
be optimised and used in other increasingly important the technology would bring to a use case. In this
functions, such as powering an increasing number of respect, the potential to unlock new value streams from
devices due to automation and electrification. ultracapacitors across industries is considerable and
equipment manufacturers should investigate how they
On the other hand, ultracapacitors may compete with could leverage this technology to the fullest extent.
batteries in applications where cost is not the main
value driver. For example, in pitch control systems for
wind turbines, ultracapacitors are preferred, given the
low requirement for maintenance and ability to operate
in more extreme temperatures. This allows wind farm
operators to exploit sites that may have been previously
too harsh for batteries and also enables them to reduce
the costs of maintenance, which can be considerable in
remote sites – 25% of current downtimes associated
with wind turbines have to do with failures of pitch
control systems. Along similar lines, ultracapacitors also
enable industries to unlock new value opportunities
that would have otherwise not been possible with
batteries. For example, horizontal drilling applications in
Oil and Gas require constant communication between
the drill head and the surface for positioning; given
the extremes of high temperatures and high power
requirement to transmit the communication signal, this
would not be possible with batteries.

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 Appendix

1. Rationale for Ratings in the Frequency Response/Synthetic Inertia: Rising RE

penetration increases the load imbalance on the grid,
Matrix
leading to blackouts and load shedding. Ultracapacitors
The ratings provided in the tables refer to the degree with high-energy discharge help stabilize the grid
of relative attractiveness of ultracapacitors for by providing a quick burst of high power, which
various applications. This is a qualitative assessment compensates for the variations in grid power.
based on the current usage profile in the industries
Fast Charging: Ultracapacitors can charge quickly,
along with the future potential for the technology,
provided the right amount of power is available.
depending on cost, reliability and the availability
Charging time is between 10 seconds to 10 minutes,
of competing power sources/existing technology.
compared to 2-12 hours for batteries.
Interviews with key industry participants were
conducted to gain external perspectives of the Hybrid/Electrification: Ultracapacitors offer short
potential for the technology. bursts of high-power applications and can be used
along with batteries in hybrid and electric vehicles,
helping automakers increase the electrification of
automobiles to improve fuel efficiency and reduce
2. Definitions of Applications emissions in electric vehicles.

Engine Start-up/Engine Cranking: Ultracapacitors Energy Storage/Back-up Power Bridging:

are used to start engines in automobiles and other Ultracapacitors are used to store excess energy
transport equipment such as trucks, trams, rail, generated from various sources, which can then be
buses, etc., by providing a short burst of high power. released when needed. Ultracapacitors act as energy
They are especially useful for starting engines at low storage devices that can provide backup power.
temperatures.
Catenary-free Operation: Applicable for urban rail
Pitch Control for Wind Turbines: Pitch control and tram networks, ultracapacitors reduce the need
systems adjust the blade of the wind turbine during for overhead power lines in urban areas because they
high winds to ensure increased efficiency and less absorb the power generated while braking quickly and
damage to the turbines. Ultracapacitors are used also in power lines located only at stations, which is
to provide power to help run pitch control systems then used to power the rail from station to station.
instead of hydraulic or electric pitch control systems.
Peak Load Shaving: Ultracapacitors are enabled to
Generator Control Gradient: Ultracapacitors help handle peak load situations in which they act as a
generators balance the high load variations by secondary power source, supplementing prime power
delivering the power needed to compensate for the applications. This reduces the need to scale down
high load variations. This helps maintain the stability of operations as well as reduces the load on electrical
the power generation. equipment.

34
Power Steering: Ultracapacitors provide a large Heave Compensation: Heave compensation systems
amount of power to steering systems for short are used in the marine industry to lift equipment.
periods, thereby reducing the load on batteries. Ultracapacitors are used to store energy during
heave-up movements, which is then discharged when
Ebrake/Kinetic Energy Recovery System (KERS):
needed. This helps reduce the peak energy load on
Braking systems in vehicles, rails, trams, etc., release
ships’ main power systems and increase efficiency of
energy that can be stored by ultracapacitors due
the system.
to their fast-charging nature to be used for further
applications, such as engine starting or vehicle VSD Backup: Voltage drops affect the operation of
acceleration. variable speed drives (VSDs) of electrical motors,
leading to production shutdowns. Ultracapacitors are
Lead-acid Battery Hybridisation: With higher
used as backup power for short-term outages and
efficiency and lower charging times, ultracapacitors
voltage drops, thereby ensuring power quality.
are being considered for use in parallel with batteries.
They last for more than 10 years and require low Prime Power in IoT Devices & Tools: Smaller devices
maintenance compared to lead-acid batteries. such as sensors, which require constant discharging
of power without frequent replacement of the
Autonomous Driving: Autonomous vehicles
power source, employ ultracapacitors to power their
require high power and lower load on batteries.
operations, including sending data in periodic high-
Ultracapacitors tied to batteries are increasingly
power bursts. Power tools can also use ultracapacitors
adopted in such vehicles as they provide a secondary
for their key power requirements.
source of power, reducing the load on batteries while
increasing fuel efficiency and reducing emissions.

Electric Catalyst Heating: Ultracapacitors can operate

in temperatures between -40 degrees Celsius and +65
degrees Celsius. They can be used to heat automobile
catalysts to purify exhaust gases.

Start/Stop: Automobile engines are automatically

switched off when the vehicle comes to a stop and
restarted when the brake is removed. This system
requires restarting the engine several times in heavy
traffic conditions, which drains batteries. The use of
ultracapacitors enables adequate power for start/stop
systems without putting a burden on batteries.

35
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