[Report] Materials for Large Size Batteries and Fuel Cells

INTRODUCTION

STUDY GOALS AND OBJECTIVES

Large batteries and fuel cells have long been used to provide backup electrical power, start automobiles and power industrial vehicles. More recently, they have been used for advanced military systems, electric automobiles and buses, and to generate power from clean fuels like hydrogen. This report defines "large" batteries as batteries approximately equal to or larger than automotive batteries. This definition includes most lead-acid batteries, most stationary fuel cell stacks, and many developmental systems such as high-temperature, redox and other flow cells.

This definition excludes most primary batteries and most portable product batteries. BCC discusses the market for small and portable battery and fuel cell materials in a related report, The U.S. Market for Small and Portable Battery & Fuel Cell Materials.

A battery has five components: two active elements (a cathode and an anode), a separator, an electrolyte medium for carrying ions between the reactants through the separator, and a case. One reactant, or electrode, has a net negative charge and is called the anode. The cathode usually is a metallic compound. The electrolyte usually is similar to the cathode to promote ion transfer.

Finally, the battery is contained in a structural support that provides dimensional stability and a positive and negative electrode or battery cap for discharging (or recharging) the cell. A number of separate electrochemical cells can be combined within the same case to create a battery.

Like batteries, fuel cells produce electrical energy through an electrochemical process. Fuel cells also typically have a pair of electrodes and electrolyte, as well as structural supports. Unlike batteries, fuel cells are "conversion" devices that change some kind of chemical fuel into electricity. Fuel cells can't directly store electrical energy, but they have a great deal of flexibility in fuels. Therefore, fuel generation and storage components must be used, each with its own unique material requirements. Fuel cells also typically require an electrocatalytic material to promote energy conversion. Like batteries, fuel cells can be combined into stacks with an effectively unlimited size.

In both cases, there are hundreds of combinations of possible electrode, electrolyte, separator, and electrocatalytic materials, and material selection plays an important (and often the most important) role in battery and fuel cell design.

With this in mind, this BCC Business Opportunity Report examines the U.S. Market for large battery and fuel cell materials. Each large battery and fuel cell material is profiled and analyzed. The report provides an overview of specific large battery and fuel cell technologies in terms of markets, value, number of units shipped, and types of materials used. Large battery and fuel cell consumption is discussed in terms of how they are used to create various components. An extensive set of large battery and fuel cell material supplier profiles is provided, along with a summary of contact information for the battery and fuel cell companies that use these materials.

REASONS FOR DOING THE STUDY

Both the electrochemical battery and fuel cell industries are enjoying unprecedented growth sparked by the need for reliable backup power, larger automotive batteries, and new ways to look at electrical power generation. Ultimately, the fortunes of batteries and fuel cells are tied to the materials used to create them. Battery and fuel cell demand have revitalized a number of raw material markets, and many material suppliers are counting on new battery and fuel cell markets to drive growth.

This study is intended to be the most complete technical, economic and business document of its type on this subject and is designed to provide information of a professional nature. The technical data depend on the accuracy of the manufacturers and technical sources that make up the BCC database. This report is not intended to constitute a legal or accounting document, nor is it an endorsement of any given product or process. The authors, and BCC Inc., as the publisher, assume no liability for loss or damage as a result of reliance on this material.

CONTRIBUTION OF THE STUDY AND FOR WHOM

This report is intended to provide a unique analysis of the U.S. market for large battery and fuel cell materials, and will be of interest to manufacturers of batteries and fuel cells, as well as battery and fuel cell powered stationary products, vehicles and power stations. This report also will be valuable to those involved in battery and fuel cell development and marketing, as well as those offering competing power sources.

Of course, existing and potential battery and fuel cell material providers, including miners, processors, refiners, chemical synthesizers and recyclers will find this report applies directly to their operations. BCC wishes to thank those companies, government agencies and university researchers who contributed information to this effort.

SCOPE AND FORMAT

This report begins with a technology summary and a discussion of industry structure and competitive aspects. Included are driving forces, trade practices, internationalization aspects, market segmentation, material supply chains, purchasing influences and prices, and material company market shares.

Next, the following specific battery and fuel cell materials are profiled and background, sources and suppliers, and developments and constraints are provided. Where appropriate, markets for specific battery and fuel cell materials within these major classifications are detailed. Historic, current and predicted battery and fuel cell markets by volume and value are provided.

Aluminum compounds
Antimony compounds
Arsenic compounds
Barium compounds
Bismuth compounds
Boron compounds
Cadmium compounds
Calcium compounds
Carbon
Chromium compounds
Cobalt compounds
Gallium compounds
Halogens
Indium compounds
Iron compounds
Lead
Lithium compounds
Magnesium compounds
Molybdenum compounds
Nickel compounds
Organic compounds
Platinum group
Rare earths
Selenium compounds
Silicon dioxides
Silver compounds
Sodium compounds
Potassium compounds
Strontium compounds
Sulfur compounds
Phosphorus compounds
Tantalum compounds
Tellurium compounds
Tin
Titanium compounds
Tungsten compounds
Vanadium compounds
Zinc compounds
Zirconium compounds.

Next, the markets for each of the following battery and fuel cell component groups are discussed:

battery electrodes
battery electrolytes
battery separators
fuel processing and storage
fuel cell electrodes and electrocatalysts
fuel cell electrolytes

Finally, the following large battery and fuel cell technologies are analyzed, including a background summary, materials used, comparison to small systems, companies, battery or fuel cell markets, and related material markets:

lead-based batteries
nickel-based batteries
lithium-based batteries
miscellaneous batteries
alkaline fuel cells
phosphoric acid fuel cells
solid oxide fuel cells
molten carbonate fuel cells
proton exchange membrane (PEM) fuel cells
aluminum-air fuel cells.

As appropriate, markets for specific battery and fuel cell technologies within these major classifications are detailed. Historic, current, and predicted markets in terms of units and value are summarized to define the materials market. In this context, the following battery and fuel cell applications are analyzed:

automotive and motive power
stationary products
specialty applications
developmental applications

METHODOLOGY

This report is based on a literature review, patent examination, and discussions with commercial and government sources. USGS mineral commodity data is evaluated and included where appropriate. The BCC monthly newsletter, Battery/EV Technology News, provides a valuable secondary source. Throughout the report, past market data is expressed in current dollars, and estimates and predictions in constant year 2001 dollars.

Estimated producer-level markets for 2000 and predicted 2001 and 2006 market figures are provided. Totals are rounded to the nearest million dollars. Volume is typically expressed in million units, tons, or in some cases, units appropriate to the particular kind of material. When appropriate, information from previously published sources is identified to allow a more detailed examination by clients.