A pioneering alternative to century-old lead-acid battery technology Sustainable ‘plug-and-play’ supercapacitors are set to revolutionise the trucking industry with benefits for fleet operators, human health and the environment. Energy © CHARGE2C-NEWCAP Trucks carry nearly 80 % of freight transported over land in the European Union. Almost all are powered by diesel and use two lead-acid batteries (starting, lighting and ignition, or SLI). SLI batteries provide peak power to start the engine but have relatively low energy capacity and short life cycles. Despite the myriad environmental and financial problems associated with lead-acid battery use, it has been accepted as a necessary evil given no suitable alternative. The Portuguese start-up C2C-NewCap (legal name CHARGE2C-NEWCAP) is changing that with GO-START, an eco-friendly supercapacitor module that could also usher in new lead regulation. Its EU-funded HYCAP project supported pilot production lines implementation, supply chain development and market release of the first commercial version. GO-START supercapacitor modules: the unparalleled solution Lead-acid batteries have persisted for more than a hundred years despite lead now being banned from fuels, paints, water pipes, and soldering material and recognised by the European Chemical Agency as damaging to fertility, unborn children, organs and aquatic life. Defenders cite high recyclability, but much of the recycling is done by unregulated operators, primarily in low- and middle-income countries, with grave consequences for people and the environment. Supercapacitors are sometimes used for engine start, but they require complex and expensive truck adaptations, and SLI lead-acid batteries are still used for all other battery-dependent systems. According to project coordinator André Mão de Ferro of C2C-NewCap, “C2C-NewCap developed a drop-in supercapacitor solution, removing the supercapacitor installation barriers. Our full pack solution includes a deep-cycle battery with a longer life cycle than standard SLI batteries to power vehicle electrical accessories. Although more expensive than lead-acid batteries, it pays for itself in the first year and can reduce operating costs up to EUR 112 000 over a vehicle’s lifetime.” This is because lead-acid batteries must be replaced every 3-18 months and their unreliability as they age can result in engine start failure, downtime and significant lost revenue . “We also supply a mobile app allowing customers to track their electric energy use,” adds Mão de Ferro. This will have an important impact on emissions and costs. Drivers often leave the engine idling while they rest or sleep to be sure they can roll when ready, resulting in up to 11 % more CO2 emissions and about EUR 7 000 in fuel annually. HYCAP’s app shows drivers how much energy is left in the battery, enabling them to turn off the engine and sleep stress free. Customers spoke, C2C-NewCap listened: reliable, plug-and-play design C2C-NewCap turned the COVID-19 pandemic restrictions into an opportunity to delve deep into the Portuguese market. “We learned first-hand what our clients need, what EU truck fleet owners have in common, and what characteristics are needed for product acceptance, immensely enhancing market fit. The plug-and-play design and the reliability of the full pack solution emerged from the pandemic setback. Our certified product is now helping trucks deliver goods throughout the EU,” explains Mão de Ferro. “What begins in the lab can have a massive impact on society and the environment with the necessary focus and funding. We now have an alternative to lead-acid batteries in the transport industry ready for large-scale adoption,” concludes Mão de Ferro. C2C-NewCap is also testing the first lead-free alternative for heavy vehicles, paving the way for new lead regulation. To top it all off, HYCAP has contributed to Europe’s high-tech energy storage ecosystem, keeping development and manufacturing in the EU. Keywords HYCAP, lead, lead-acid batteries, supercapacitor, plug-and-play, trucks, trucking industry
