When to recycle rechargeable cells?

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moldyoldy

Flashlight Enthusiast
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Sep 22, 2006
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Maybe Wisconsin, maybe near Nürnberg
This is the question that has kinda bothered me for years - rechargeable battery EOL. primarily the Ni-Mh cells.

I mentally eliminate the obvious failures - damaged case, will not accept a charge (shorted or open terminals), etc. I am also trying to ignore people like my older daughter who will attempt to use a laptop battery pack (Li-Ion) until it does not supply more than about 5 minutes of run time and then wonder about a replacement "this" week. I also acknowledge that Li-Ion cells seem to have a expectable lifetime after initial use (3 years?).

Soooooo, Depending on which battery reference book you review, Eveready and GE state that EOL is when the actual cell capacity has reached 80% of the stated cell capacity, the battery has reached End of Life. ummm, well, maybe. Other considerations are:

1. excessive self discharge. sure, but what is excessive? full discharge in a week? in a month?

2. inadequate capacity. meaning that the original capacity and run time was OK, but has since deteriorated to an inadequate run time _and_ any number of refresh cycles do not improve the situation.

3. too-low voltage under load even if the capacity is "acceptable". This is almost the same as too-low capacity, but not quite. The intention is that originally the cell voltage held up under the load, but no more, and the demonstrated capacity to a cut-off of 1.0 volts is still "ok".

Some of my tentative answers:

1. A recycle point for my uses is when the cell has self-discharged in a month. Why? I normally attempt to check/charge all cells once a month, unless I am testing them for self-discharge. An example of a recycle point is seeing a voltage of 1.1 on my BC-900 when I insert the unused cell for charging. Sometimes I fiddle with the BC-900 settings just to see how much capacity is left in the cell, but that requires that I be present before the cell begins recharging.

2. I tend to wait until I observe maybe a 50% decrease in capacity in use. If I am sufficiently irritated by an obvious way-too-short run time, I may actually run a test on the cell.

3. Too-low voltage under load. this is probably the most subjective evaluation as to why I recycle a cell. If the equivalent 'battery-low" indicator turns on, I think about the elapsed time since last charge and how much the cell was used. I may then run a test. FWIW, I do have a couple Ni-Mh cells that have test with a reasonable capacity, but simply do not hold an acceptable voltage under load. That is observable when running a discharge test on the BC-900. For much of the discharge time, the voltage for a Ni-Mh cell at maybe a 500ma load should be somewhere in the 1.2v range. These particular cells run most of their discharge time in the 1.1 and less range. This effect is also observable in a Fenix L1D-Q5 where there is no difference between "high" and "turbo" outputs, yet with most new'ish cells, the difference is obvious.

Thoughts?
 
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Hello Moldyoldy,

I have rather high standards and very little tolerance for "crap" cells in my inventory.

When I receive new cells, I do benchmark tests on them to determine if they are worth keeping or not. This gives me a benchmark based on actual performance to go from.

When the cell drops below about 80% of its benchmark capacity, it is recycled.

The voltage under load can be a variable when the load is small. I try to benchmark at a load that completely discharges the cell in about 1 hour. Under this load, a drop in voltage under load results in reduced capacity. Once again, when the capacity drops below 80% of its initial benchmark capacity, replace the cell.

Self discharge is interesting to study. The RC people have found that the high capacity sub C cells will self discharge in about a day, but hot off the charger, they still perform very well. I tend to ignore self discharge, until it becomes a hindrance to use. I don't have a set standard for self discharge.

I try to store NiMh and NiCd cells in a discharged condition, and do a charge/discharge cycle every 30 days. I have been storing the LSD cells at about 50% charged and basically ignore them until I need to use them. Li-Ion cells are stored at around 40 - 50% charged. There is no need to cycle Li-Ion cells, so I just check on them from time to time.

If you have less demanding usage, you can adjust things a little and still enjoy good performance from your cells. Discharging at a rate that discharges the cell in one hour will drive the voltage down. If your application is less dependent on voltage under load, you can extend the discharge time to two hours. Another thing you can do is to set the bottom at 60%.

Some people, who consider a cell good as long as it can hold any charge at all and deliver it at any voltage above 0 volts, will relax these criteria and keep a cell in service longer... :)

Tom
 
Need to find that link about voltage suppression and the link to large crystal formations in nickel chemistry cells, which is often mis-labeled/interpreted as "memory effect..." If I don't find it, maybe Tom could post a quick blerp or a link... The more important component being, that there are various methods of "reviving/repairing" this condition that nickel chemistry cells can suffer from (sometimes it works sometimes it doesn't).... breaking down those large crystal formations in the electrolyte (is that right Tom?) can be done.... But I can't remember if the method was a few cycles of slow slow discharge and slow trickle charge... (0.1C charge rate for 16 hours IIRC), or exactly what it was.... I use LSD cells almost exclusively, so I don't dedicate any particular sector of my biological hard drive to the details anymore, lol.... Unlike Li-Ion tech, where I think I have devoted most of sections I-28 through Q-51 :)

Eric
 
Thanks for your input SilverFox!!

I appreciate your humor about "as long as it can hold any charge at all and deliver it at any voltage above 0 volts". almost like my one daughter... :) in any case, I no longer have access to an active load device capable of discharging a cell at a 1C rate other than maybe a flashlight - and that is not very consistent or steady-state depending on LED vs incandescent. Which active/passive load device do you use?

As for the 50% vs the spec'd 80% EOL condition? well, I may have been a bit more extreme than even 80% when it counted. In a "hobby" diversion of some 15 years of sports photography and some 100 weddings with my daughters, I would simply replace all Ni-Mh cells used every couple years. Between a lot of photography and a normal EE job, I had no time left to test much of anything. Now I do not even own a camera - sold my Nikon gear (F100 cameras and the best lenses Nikon sold at the time) a couple years back when I balked at the price tag for digital conversion... Since I re-discovered the advances of LEDs in flashlights, I relaxed the EOL to maybe 50%. I do notice any capacity below about 2000mah in an AA cell and tend to look for a recycle bin at work.

By far my worst problem was with self-discharge, not the (tested) capacity. Drove me crazy with teachers and maintenance personnel until I gave up and switched them all to LSD cells. So far the Maha Imedion LSD cells have served well. no offense against the Sanyo Eneloops - tried those too. I simply stayed with the AA cell brand that in its original formal did not demonstrate self-discharge to any objectionable level - the Maha Powerizer brand.

Hi mdocod,

I appreciate your "biological hard drive" storage system. what happens when the tracks start spreading....... ? :naughty:

as for dendrite growth, that was most noticeable in the Ni-Cd system. We learned to deal with that in the military by a judicious jolt of serious current - in essence we "flashed" the dendrite. Unfortunately that left a hole in the separator as well, thru which another dendrite eventually grew. in the long term I gave up on trying to save Ni-Cd cells like that and just ordered/purchased a replacement. I left off with NiCd cells at 1000mah - long time ago!
 
Hello Moldyoldy,

I have a lot of "mission critical" equipment that run on batteries. I have spent a lot of time and effort developing test methods and benchmarking standards to make sure that when I grab the equipment, it works, and works very well.

In order to do this, I have invested in test equipment that goes a little beyond the average hobby user.

Most of my discharging is done with the CBA II, and I am getting ready to add the CC-400 for higher wattage discharge rates. The CC-400 is an add on module (a little over $400) that couples with the CBA to allow for 400 watt discharges. It can be pushed to around 700 watts if you aren't interested in the warranty. If higher discharge rates are needed, several CC-400 units can be daisy chained together.

Now that I have my NiMh and NiCd packs working well, it is time to move on to the 12 volt gel cell batteries...

Tom
 
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