John PetersenToday I'm going to begin with an
apology because I've done a terrible job
of describing the basics of hybrid electric vehicle (HEV) technology
for energy storage
investors. Many of my earlier articles dove straight into the
mind-numbing details of
battery technology without first providing an overview of what those
batteries will be used for. In other words I'm guilty of putting the
cart before the horse. It's time for me to make amends.
While the differences between HEV technologies have always been
important to automobile manufacturers, the public's understanding of
those differences is limited. That dynamic is about to change because
of
President
Obama's decision to accelerate the effective date of Federal fuel
economy standards that were first adopted during the Bush
administration. These accelerated standards will require
manufacturers to increase fuel efficiency by approximately 40% over the
next
seven years. They will also eliminate fleet-wide averaging and force
each class of vehicles to carry a fair share of the fuel economy
burden. I don't want to oversimplify a very complex topic, but I
believe the most cost-effective way to meet the new goals will be
the widespread adoption of HEV technology across all classes of cars
and light
trucks. The new rules are not an HEV mandate, but they have
put HEV technologies on a regulatory fast track that will rapidly drive
revenue growth across the entire spectrum of battery manufacturers.
There are four primary classes of HEVs
including the micro, mild and full hybrids that are available today and
the plug-in hybrids (PHEVs) that are scheduled for
next year. The following sections provide a simple overview of what the
various
classes of HEV technology do and what they're expected to cost. More
detailed information is available from the
Green
Car Congress, the
National
Alternative Fuels Training Consortium and the
Electric Drive Transport
Association.
Micro Hybrids do not use an
electric motor to propel the vehicle. Instead, they rely on hybrid
technology to:
- Use a small portion of the energy that is normally lost in
braking to recharge their batteries;
- Stop and start the internal combustion engine (ICE) when the
vehicle stops and starts; and
- Power accessories like heat and air conditioning while the ICE is
off.
The current cost of micro hybrid technology is roughly $500, plus
batteries. The main benefit of micro hybrid technology is fuel savings
of up
to 10% that arise from turning the ICE off when the vehicle isn't
moving.
Mild Hybrids use an electric
motor that is integrated into the ICE to boost power during
acceleration. They also rely on hybrid technology to:
- Use a larger portion of the energy that is normally lost in
braking to recharge their batteries;
- Stop and start the ICE when the vehicle stops and starts; and
- Power accessories like heat and air conditioning while the ICE is
off.
The current cost of mild hybrid technology is roughly $1,500, plus
batteries. The main benefit of mild hybrid technology is fuel
savings of up to 20% that arise from using a smaller ICE and turning
it off when the vehicle
isn't moving.
Full Hybrids use an electric
motor that's separate from the ICE and powerful enough to move the
vehicle on its own. Full hybrids typically launch from a stop in
electric
mode, start the ICE when needed and then use both the electric and ICE
systems
for acceleration. They also rely on hybrid technology to:
- Use most of the energy that is normally lost in braking to
recharge their batteries;
- Stop and start the ICE when the car stops and starts; and
- Power accessories like heat and air conditioning while the ICE is
off.
The current cost of full hybrid technology is roughly $2,000, plus
batteries. The main benefit of full hybrid technology is fuel
savings of up to 40% that arise from using battery
power in stop and go traffic, using a smaller ICE and turning it off
when the vehicle
isn't moving.
Plug-in Hybrids fall into one
of two sub-classes. A parallel hybrid is essentially a full hybrid with
a
larger battery pack that increases the EV range and
decreases reliance on the ICE. A series hybrid is essentially an
electric vehicle that runs on battery power for the first 10 to 40
miles and then uses a small ICE to generate electricity for the
powertrain.
Both sub-classes rely on hybrid technology to use most of the
energy that is normally lost in braking to recharge their batteries.
The estimated cost of plug-in hybrid technology is roughly $2,500, plus
batteries. While fuel economy estimates vary widely depending on
assumed driving patterns, most commonly quoted estimates fall in the
60%
range.
Cost-Benefit Table The
following table summarizes the relative costs and benefits of micro,
mild, full and plug-in hybrid technologies using lead-acid batteries
for lighting, accessory and related systems, and using NiMH or Li-ion
batteries for the electric powertrain. The price of $1,000 per kWh for
electric powertrain batteries represents a rough average of the current
cost of NiMH and Li-ion batteries published in a July 2008 Sandia
National Laboratories report on its
Solar
Energy Grid Integration Systems – Energy Storage program.
|
Lead-acid
|
Advanced |
Mechanical |
Incremental |
Fuel |
|
Batteries
|
Batteries |
Components |
Cost |
Savings |
| Micro Hybrid |
$200
|
|
$500
|
$700
|
10% |
Mild Hybrid
(1 kWh powertrain battery)
|
$100
|
$1,000
|
$1,500
|
$2,600
|
20% |
Full Hybrid
(2 kWh powertrain battery)
|
$100
|
$2,000
|
$2,000
|
$4,100
|
40% |
Plug-in Hybrid
(10 kWh powertrain battery)
|
|
$10,000
|
$2,500
|
$12,500
|
60% |
Cost-Benefit Graph To help
remind readers what matters to buyers, I've put together a simple
graph that superimposes the purchase price data from the Cost-Benefit
Table over a normal bell
shaped curve. In this particular graph there is no direct correlation
between the background curve and the price points in the foreground.
The curve does, however, help put the cost differences and fuel
savings into
the context of normal forces in a free market.
In combination, the table and the graph clearly show why I believe the
vast
majority of buyers will choose micro, mild and full hybrid
alternatives over their more expensive plug-in cousins. It's a
simple matter of economics. Cars with plugs simply do not work for
anyone other than the emotionally committed or the mathematically
challenged.
The following graph comes from the DOE’s
2009
Annual Energy Outlook and forecasts that sales of full and mild hybrids will grow
from 346,000 units in
2007 to 4.8 million units in 2030. Over the same time frame, sales of micro hybrids will grow from 13,000 units to 3.2 million units. Collectively HEVs will account for roughly 63% of unconventional vehicle sales and approximately 40% of all light car and truck sales by 2030.

The companion graph forecasts that less than 7% of the HEVs
sold in 2030 will be plug-ins. The other 93% of sales come from full, mild
and micro hybrids. Overall, the forecast corresponds well with
the distribution I would ordinarily expect under a normal bell shaped
curve.
While the
sex,
glitz, glamour and hype are clearly skewed toward the PHEV tail
of the normal bell shaped curve, the bulk of future sales will
almost certainly come from
the more affordable micro, mild and full hybrid alternatives.
Accordingly, I believe the question that investors need to ask
themselves is, "which battery technology is best suited to the
requirements of these lesser HEV technologies?" The following summary
paragraphs may help in that analysis.
Energy and Power The
distinction between energy and power is frequently blurred in
discussions of
HEV technology. In simple terms, energy measured in kilowatt-hours
(kWh) limits the distance of travel while power measured in
kilowatts (kW) limits acceleration and speed. In PHEV
applications that rely on the batteries for an extended travel range,
energy is the most important performance metric. For micro, mild and
full
hybrid
applications that use the batteries for short bursts, power is far more
important and there are many battery technologies including
lead-carbon, NiCd, NaNiCl, NiMH and Li-ion that can easily do the required work. In
other words, no technology has a clear performance advantage.
Size and Weight NiMH and Li-ion
battery
developers emphasize that they enjoy a substantial weight
advantage over lead-acid batteries. I'll be the
first to
concede that weight differences can be critical in the context of a
PHEV that needs to carry a 10 to 25 kWh battery pack to provide the
desired range. But the weight advantage is almost irrelevant in the
context of a micro, mild or full hybrid that only needs to carry a
couple kWh of battery capacity.
Cycle Life NiMH and Li-ion
battery
developers emphasize that they enjoy substantial cycle-life advantages
over the lead-acid batteries normally used for starting,
lighting and ignition. Those comparisons are inherently unreasonable
because they
use the best examples of their technology and the worst examples of
lead-acid technology. When
the
best NiMH and Li-ion technologies are compared
with the best lead-acid technologies, the cycle-life
advantages disappear.
Battery Cost The one metric
NiMH and Li-ion battery developers never emphasize is cost, unless it's
in the
context of a happy-talk prediction that future economies of scale will
slash the cost of their products. The simple fact is that
the
best
NiMH and Li-ion batteries cost an average of three times as much as the
best lead-acid carbon batteries and there is no reason to believe
that the developers will ever be able to close the cost gap.
Revised Cost-Benefit Graph If one
assumes that advanced
lead-carbon batteries will be the technology of choice for micro, mild
and full hybrid applications, and that NiMH and Li-ion batteries will
be the technology of
choice for PHEVs, the revised cost-benefit graph looks like this:
Over the last couple years the media has fixated on the romantic notion
of PHEVs, which has drawn substantial investor attention to small
public companies like Ener1 (
HEV) and
Valence Technology (
VLNC)
that are generally perceived as leaders in the PHEV battery
market. As a result, the stock prices of both companies have risen to
levels that include
huge
premiums for intangible future potential.
While the market for PHEV batteries will undoubtedly be large, my
sense is that the market has not fully considered the business,
technical, operational, competitive, financial and ethical risks these
companies
are certain to face. That leads me to conclude that both companies have
far more downside risk than upside potential under current conditions.
While the media attention has been focused on the right hand tail of
the bell shaped curve, established lead-acid battery companies like
Exide (
XIDE),
Enersys (
ENS)
and C&D Technologies (
CHP),
along with technology driven newcomers like Axion Power International
(AXPW.OB),
have been quietly developing next generation technologies that will be
affordable for consumers in the middle of the
bell shaped curve who need HEV fuel savings but can't afford Li-ion or
NiMH batteries. These middle market solutions won't have the high per
vehicle value of Li-ion and NiMH solutions, but with far higher market
penetration rates, they should easily make up the difference in
volume. As I've discussed in earlier articles, the
lead-acid
sector has been treated like an orphan stepchild of alternative energy
for years. That leads me to conclude that these companies have far more
upside potential than downside risk under current conditions.
I believe the revised Federal fuel efficiency standards will drive the
implementation of micro hybrid, mild
hybrid and full hybrid technologies more rapidly than anyone could have
predicted and increase overall penetration rates. While the changes are bullish
for the energy storage sector in general, the biggest beneficiaries are
likely to be the undervalued lead-acid battery manufacturers that will
ultimately be the primary source of middle market HEV battery solutions.
In closing I would like each reader to take another look at the last
graph and consider a broader ethical issue that we all
need deal with. The resources required for micro, mild and full
hybrid technologies ramp up gradually as fuel savings climb from 10% to
40%. The incremental resources required for that last 20% in fuel savings one gets by upgrading from a full hybrid to a PHEV are immense. In effect, to save 100 gallons of gas per year by upgrading a single
full hybrid to a PHEV, we will have to forego using those batteries to build four additional full hybrids that could have collectively saved 800 gallons of gas per year. This is one of the most appalling
examples of selfish and wasteful arrogance I can imagine. It has no
place in a resource constrained world where 6 billion people have come
to understand how the other 500 million live and the primary challenge
for our species is finding relevant scale solutions to persistent
shortages of water, food, energy and virtually every commodity you can
imagine.
Disclosure: Author is a former
director and executive officer of Axion Power International (AXPW.OB)
and holds a large long position in its stock. He also holds small long
positions in Exide (XIDE)
and Enersys (ENS).
John L. Petersen, Esq. is a U.S. lawyer based in Switzerland who works
as a partner in the law firm of Fefer Petersen & Cie and represents
North American, European and Asian clients, principally in the energy
and alternative energy sectors. His international practice is limited
to corporate securities and small company finance, where he focuses on
guiding small growth-oriented companies through the corporate finance
process, beginning with seed stage private placements, continuing
through growth stage private financing and concluding with a reverse
merger or public offering. Mr. Petersen is a 1979 graduate of the Notre
Dame Law School and a 1976 graduate of Arizona State University. He was
admitted to the Texas Bar Association in 1980 and licensed to practice
as a CPA in 1981. From January 2004 through January 2008, he was
securities counsel for and a director of Axion Power International,
Inc. a small public company involved in advanced lead-carbon battery
research and development.