John Petersen
A couple days ago Lux Research published a new report titled “
Every Last Drop: Micro‐ And Mild
Hybrids Drive a Huge Market for Fuel‐Efficient Vehicles”
that focuses on rapidly growing markets for micro-hybrid vehicles
and their battery systems.
During 2011, automakers sold an estimated 5,000,000 micro-hybrids
worldwide, mainly in Europe. By 2017, Lux forecasts global
micro-hybrid sales of 39,000,000 cars a year and a $6.3 billion
annual market for their battery systems, which represents an across
the board average of $161 per vehicle compared to an auto industry
average of less than $60 per vehicle in 2009. While most US
investors aren't even aware that micro-hybrid technology exists,
it's
already
crossed the chasm and become a mainstream automotive
technology.
To put the micro-hybrid phenomenon into perspective, most auto
industry observers believe combined global sales of HEVs, PHEVs and
EVs will be lucky to reach the 2,000,000-vehicle a year mark by
2017. Electric drive technologies may become mainstream
architectures for 2025 and beyond, but for the next six years
there's no doubt that cheap and easily implemented micro-hybrid
technologies for mass-market vehicles will be at the epicenter of
battery industry growth and profitability.
The term micro-hybrid is used to describe idle elimination systems
that reduce fuel consumption by turning the engine off when it's not
being used to power the wheels. They typically replace both the
starter motor and the alternator with a belt-driven
starter-generator, or BSG, upgrade to a better battery and add
required control electronics. No other changes are necessary. While
a BSG will offer a couple horsepower of cranking and generate a
couple kilowatts of electricity, BSG's are not robust enough to
drive a vehicle's wheels. Nevertheless, they're simple to combine
with existing engine architecture and very cheap to implement.
Because of their mechanical simplicity, micro-hybrids only cost $400
to $1,000 more than a conventional vehicle, but promise fuel savings
of 5 to 15 percent. Micro-hybrids are a baby step, but 39,000,000
baby steps a year can cover a lot of ground and save about 15
millions of barrels of oil per year.
In their latest report, Lux divides micro-hybrids into three
distinct classes that require different types of batteries.
Light
Micro-Hybrids are typically sub-compact and compact
cars that offer limited stop-start functionality and don't have
regenerative braking. The current batteries of choice for light
micro-hybrids are enhanced flooded lead acid batteries. The global
market for light micro-hybrids is expected to grow to 8.5 million
vehicles per year by 2017.
Medium
Micro-Hybrids range from sub-compact through full-size
cars that offer greater stop-start functionality and may offer
limited regenerative braking. The current batteries of choice for
medium micro-hybrids are enhanced flooded lead acid batteries and
advanced AGM batteries. The global market for medium micro-hybrids
is expected to grow to 22.2 million vehicles per year by 2017.
Heavy
Micro-Hybrids are typically mid-size and full-size cars
that offer the highest level of stop-start functionality, take full
advantage of regenerative braking and implement other fuel economy
innovations. Because of their extreme power demands, heavy
micro-hybrids need better performance than the best AGM
batteries can offer. The global market for heavy micro-hybrids is
expected to grow to 8 million vehicles per year by 2017.
The following graph from the latest Lux report shows how the market
is expected to evolve over the next six years.
On a regional basis, Lux is forecasting that:
- The European micro-hybrid market will grow from over 4 million
units in 2011 to 12.6 million units by 2017.
- The North American micro-hybrid market will grow from a
standstill in 2011 to over 8 million units by 2017.
- The Japanese micro-hybrid market will grow from about 400,000
units in 2011 to over 6 million units by 2017.
- The Chinese micro-hybrid market will grow from under 300,000
units in 2011 to 8.9 million units by 2017.
Last November I used the following table to highlight the
differences between the daily battery load in a normal car and the
daily battery load in a micro-hybrid for a typical city driving
commute with 15 engine-off opportunities per leg.
Power Event
|
Conventional |
Stop-Start |
| Initial engine start |
500 Amp Seconds |
500 Amp Seconds |
| Engine-off accessory loads |
|
45,000 Amp Seconds |
| Engine restart loads |
|
4,500 Amp Seconds |
| One-way battery load |
500 Amp Seconds |
50,000 Amp Seconds |
| Round-trip battery load |
1,000 Amp Seconds |
100,000 Amp Seconds |
We're all familiar with the flooded lead-acid batteries that have
been standard automotive equipment for decades and I don't think
anybody would suggest that they can do 100 times the work without
quickly failing. The automakers know that better batteries are
needed, but they all want to get by with the cheapest better battery
they can find because every dollar of cost matters in mass-market
products.
Some automakers are using enhanced flooded batteries for their light
and medium micro-hybrids solely because of cost considerations. They
reason that enhanced flooded batteries offer twice the lifetime
energy throughput of their simpler siblings and twice the throughput
is always a good thing. The problem, of course, is that the numbers
don't balance if you double the throughput of the battery and expect
it to do 100 times the work.
A similar, albeit less dramatic, dynamic exists for the automakers
who are upgrading medium micro-hybrids to AGM batteries that cost
twice as much as their more primitive cousins but offer ten times
the lifetime energy throughput. After all, improving performance by
an order of magnitude is huge – until you understand that they're
increasing the required work by two orders of magnitude. The bottom
line is that AGM batteries will be the best available technology for
micro-hybrids until a significantly better solution emerges, proves
its merit and becomes available at relevant scale. Once a better
solution is widely available, the market must gravitate to better
performance unless the incremental cost exceeds the value of the
incremental fuel savings.
I follow two companies that will be the first big beneficiaries of
the rapid global adoption of micro-hybrid technologies. Johnson
Controls (
JCI)
and Exide Technologies (
XIDE)
both manufacture enhanced flooded batteries for micro-hybrids and
are rapidly expanding their AGM battery manufacturing capacity in
North America and Europe. They will clearly be preferred suppliers
for light and medium micro-hybrids from American and European
automakers for the foreseeable future. While enhanced flooded
batteries won't have a huge impact on either revenues or profits,
their rapidly expanding AGM battery sales will double their per
vehicle revenue and triple their per vehicle margins. It truly is a
manufacturer's dream scenario. As micro-hybrid production numbers
ramp rapidly over the next few years I expect both companies to
outperform the market's expectations by a wide margin.
From my perspective the most interesting segment is heavy
micro-hybrids that demand more performance than AGM batteries can
hope to deliver. These next generation systems will push the
frontiers of micro-hybrid technology by maximizing regenerative
braking and adding other nuanced features like passive boost, which
disables the BSG during acceleration, opportunity charging, which
increases power to the BSG when the vehicle is decelerating, and
engine-off sailing, which turns the engine off while the vehicle is
rolling to a stop. The heavy micro-hybrid market is the prime target
for two advanced technology systems that are working their way
through the development and commercialization process, and
stand a good chance of becoming industry leaders over the next few
years.
In the fall of 2010, Maxwell Technologies (
MXWL)
and Continental AG introduced a dual device system that matches a
supercapacitor module from Maxwell with an AGM battery and control
electronics from Continental. The first design win for the
Maxwell-Continental system is diesel powered micro-hybrids from
Peugeot-Citroën. A comparable system will be used by Mazda in
it's iELOOP heavy micro-hybrid. Other automakers will almost certainly follow
their lead in adopting dual device systems for heavy micro-hybrids.
A second advanced energy storage system for heavy micro-hybrids is
the PbC battery from Axion Power International (
AXPW.OB).
The PbC is an integrated battery-supercapacitor hybrid that combines
lead-based positive electrodes from a battery with carbon based
negative electrodes from a supercapacitor in a single cell. While
the PbC is not yet available as a commercial product for heavy
micro-hybrids, it is two and a half years into evaluation by BMW and
other leading automakers, and offers a performance profile that
simply can't be matched by anything short of a
lithium-ion battery pack. If Axion can clear the last testing and
manufacturing hurdles, the PbC has the potential to be a game
changer in the heavy micro-hybrid space because it offers 5X the
capacitance of dual device systems and 5X to 20X times the dynamic
charge acceptance after a few months in service.
Last week I spent some time with a former Enersys engineer who noted
that there are only two components in a car that automakers refuse
to put their brand on. The first is the tires and the second is the
battery. If a consumer has problems with either of those components,
the automakers say, "Take it up with the manufacturer" who
frequently says, "You abused our product by pushing it beyond design
limits."
While the traditional blame game has a long and storied history, it
can't continue indefinitely because micro-hybrids are being sold by
the automakers as fuel efficiency and emissions control systems.
Over the short term, the automakers will continue to play the game
of using cheap batteries that can't stand up to the duty cycle. Over
the longer term, applicable regulations will change to require that
the OEM battery installed in a micro-hybrid be designed to satisfy
the requirements of the vehicle's electric load profile.
For investors who want to benefit from the micro-hybrid vehicle
trend but don’t have the time or inclination to study the various
energy storage technologies in depth, a balanced portfolio weighted
in favor of the large established battery manufacturers makes the
most sense. While I have a personal favorite, I expect all four
companies to outperform over the next three to five years.
Disclosure. Author is a
former director of Axion Power International (
AXPW.OB)
and holds a substantial long position in its common stock.