The recharge efficiency, I believe, is between only 15% - 20%.  But I don't
see it as much of an issue, since most people would be using the aluminum
battery only as a range extender, not in daily use.  The Phinergy test car
relies mostly on lithium cells for its primary mobility, employing the
Al-air battery  to recharge the lithium cells during extended trips.

When using the Phinergy cells, you need to stop and replace the electrolyte
every 200-to-300 miles.  The aluminum itself lasts longer.  Interesting, I
think the battery actually gains weight as you use it, since the atmospheric
oxygen that combines with the aluminum stays within the cell until you pump
it out and exchange it for fresh electrolyte at the above-mentioned 200-300
miles.

Bill

-----Original Message-----
From: EV [mailto:[email protected]] On Behalf Of EVDL Administrator
via EV
Sent: Wednesday, August 5, 2015 10:40 AM
To: Electric Vehicle Discussion List
Subject: Re: [EVDL] Aluminum-Air-Water Primary Battery Backup for LiIon Pack

Metal-air batteries seem to be pretty good for hearing aids.  For EVs, I'm
not so sure.  The main problem is that they're primary batteries - not
rechargeable.  When they're discharged, you have to rebuild them.  (Some
people call them metal fuel cells.) 

Alcan and Unique Mobility worked with Aluminum-Air batteries in the late
1980s.  They had a prototype system running in an Electrek EV (UM's
intriguing limited production purpose-built EV) but eventually concluded it
wasn't practical.  

In the 1990s, an Israeli company, Electric Fuel Corporation, developed Zn-
Air batteries with rebuildable zinc "cassettes."  They collaborated with the
German Post on a trial program of EVs using these batteries.  After several
years, the Post concluded that it wasn't a viable system. Electric Fuel
seems to have pretty much abandoned Zn-Air battery research and now
concentrates on conventional battery chemistries for industrial, medical,
and military uses.

http://www.efbpower.com/oem/

This isn't to say it's hopeless, just that there seem to be some substantial
hurdles for metal-air batteries in EVs.

David Roden - Akron, Ohio, USA
EVDL Administrator

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