Top 10 Lithium-ION Myths

3. Lithium-ION batteries are prohibitively expensive.

It is important to take a long-term view of costs. Although the initial purchase price of Lithium-ION batteries is higher than lead-acid batteries, they have a lower cost per cycle due to their increased lifetime, making them the most cost-effective solution in the long run. 

Linde’s Lithium-ION batteries, in particular, have extremely low inner resistance and the most efficient technology, which means less grid energy is wasted, resulting in 30% savings (charging and CO2 emissions) when compared to lead-acid.

So, in the long run, Lithium-ION batteries can be significantly more economical.

4. We would need to replace our whole lead-acid fleet with Lithium-ION machines.

Certainly, it often makes sense to replace the entire fleet so that operators don’t have to switch between different charging regimes and operating procedures.  It also makes sense with an ageing fleet, where there is a decision to retire all existing machines and “start again”. 

Replacement is also advisable when there’s a corporate motivation for the switch, such as a commitment to reduce overall CO2 emissions or an operational wish to remove dangerous battery changes or reduce ongoing maintenance requirements.  

But a blended fleet is possible if some trucks are not utilised enough to warrant the investment in Lithium-ION batteries and we've assisted many customers with staged rollouts.  If you do choose to run a blended fleet, you need to be aware that different chargers are generally needed for lead-acid and Lithium-ION batteries, so there might need to be clearly marked charging areas and instructions to staff. 

5. Our power supply would have to be upgraded.

Yes, chargers for Lithium-ION batteries have a higher output, which means they require a higher input current compared to lead-acid chargers. However, Linde has various battery/charger combinations available depending on the utilisation, application intensity, and available charging windows.

A small or medium-sized charger may be used with existing power points, which means peak power draws may be only marginally above that of existing lead-acid chargers.

The Linde Lithium-ION range has the option of a “normal-sized charger” that may use a similar-sized outlet and current rate to charge the battery in half the time compared to the lead-acid charger it replaces.

Another ‘trick’ is to sequence charge trucks at any time throughout the day. Lithium-ION batteries do not necessarily need one charger per truck, unlike lead-acid batteries that need to be charged at the end of a shift – all at the same time.  Staggering the charging can limit the peak power draw to less than lead-acid chargers. However, where larger chargers are required, or if a business wants to add power points closer to the working area or break rooms, this might require some investment in power supply. 

6. Our drivers would have to be retrained and change their work habits.

Agreed, there will be a need for retraining, as standard AS2359:2 operations dictate that each user should have policies for safe systems of work with supervised practice, on-the-job training, and ongoing regular fresher training. So, there are requirements for records of ongoing training to be maintained by the user in all cases.

The good news is that Lithium-ION batteries are easy to use:

• The battery management system talks to the charger to prevent overcharging.
• It manages power delivery to prevent over-discharge.
• It requires no watering or equalise charging.
• Operator must simply know how to plug it into the charger when not in use.

Our customers have found that work habits need to be changed, but this is for the better. Ongoing battery maintenance tasks are all but eliminated, as are dangerous battery changes and the risk of damaging batteries through charging misuse. Unlike lead-acid batteries, Lithium-ION batteries thrive on opportunity charging, meaning operators can charge their forklifts during breaks. And the charging process will be quicker and easier since the bonnet no longer needs to be opened to connect the charger to the truck.

7. Lithium-ION batteries are not as stable as lead-acid and represent a safety threat.

This is a common myth, but in reality, lithium-ion batteries are much safer than conventional lead-acid batteries. Even though they have a higher energy density than lead-acid batteries, Linde Lithium-ION batteries have a multi-level safety system at cell, module, and housing levels, alongside a battery management system (BMS) with comprehensive protective functions. The BMS protects against overload, overcharge, deep discharge, excess current and short circuits. 

Linde Lithium-ION batteries are developed in-house, which means the trucks have intelligent vehicle control and battery management that are perfectly integrated and aligned.  The CANbus interface enables the battery, charger, and truck to communicate as one system, ensuring optimal performance and prolonging the battery life.

Furthermore, the truck and battery are tested as one system in the development stage – something not always done with lead-acid systems.

This short video shows the rigorous testing Linde does to ensure the safety of our batteries. 

Lithium-ION batteries have a longer cycle life, allowing them to be used effectively in applications with sufficient charging opportunities.  Because Lithium-ION electrochemistry has higher energy density and voltage stability, and less inner resistance, it leads to higher power output, increased efficiency, and fast charging capabilities.

Lithium-ION batteries are expected to last around 4,000 full cycles - in contrast to lead-acid’s 1,500 cycles.

9. Lithium-ION batteries are not suited to harsh environments.

Again this is not true. Through extensive testing, we’ve found that Lithium-ION batteries tend to outperform lead-acid batteries in rough surface environments, high-usage environments, low temperatures, and most other environments where lead-acid batteries would have struggled or not performed at all.

There are different types of Lithium-ION batteries available depending on the application and utilisation.  Because permissible operating and charging temperatures depend on each specific Lithium-ION battery group, Linde supplies datasheets and user manuals for each type, which specify the exact operating conditions.

As an idea of the maximum permissible operating environment, the Performance Plus group of Linde Lithium-ION batteries can generally operate as follows: