Supercapacitor Modeling
Theory: storing charge by lining up ions
Overview
Where are supercapacitors used instead of batteries?
Wherever large power must flow in or out over short times. An electric double-layer capacitor immerses porous carbon electrodes in electrolyte and stores charge by lining up ions on the electrode surface. With no chemical reaction, it charges or discharges in seconds and repeats hundreds of thousands of times. That suits buffering energy recovered by braking cranes or buses, or bridging the moment of a power cut. But stored energy is far below that of a battery of the same weight. Modelling looks at stored energy, losses and heat from internal resistance, whether pore depths can be used, and voltage spread in series strings.
Energy, power and time constant
R_ESR is the cell's internal (equivalent series) resistance. Here C = 3000 F, V = 2.7 V, R_ESR = 0.29 mΩ. P_max is maximum power with load resistance equal to internal resistance, at which efficiency is 50%.
Transmission-line pore model
R_s is electrolyte and current-collector resistance (0.19 mΩ) and R_p ionic resistance within pores (0.30 mΩ); at DC, R_s + R_p/3 equals the 0.29 mΩ internal resistance. The pore is a ladder of resistors and capacitors, the form de Levie derived for porous electrodes.
From Helmholtz's layer
Helmholtz proposed in 1853 that charge lines up in two layers at the electrode–electrolyte boundary. Becker of General Electric turned it into a storage component, patenting a porous-carbon capacitor in 1957. High-surface carbon offers over 1,000 m² per gram, giving capacitance orders of magnitude beyond ordinary capacitors. Starting as memory backup supplies, they are now used in vehicles and power systems.
Worked examples
Example 1: a 3000 F cell
| Item | Value |
|---|---|
| Stored energy | 10,935 J(3.04 Wh) |
| Energy used down to half voltage | 75% |
| Peak power | 6,284 W |
| Time constant | 0.87 s |
| 1 kW down to half voltage | 7.53 s (8.20 s if lossless) |
| Resistive loss in that discharge | 670 J |
At constant power, current rises as voltage falls, reaching 924 A at the end. Loss scales with current squared, so it concentrates at the end of discharge.
Example 2: frequency and usable capacitance
| Frequency | Usable capacitance | Fraction | Resistance |
|---|---|---|---|
| 0.01 Hz | 3,000 F | 100% | 0.290 mΩ |
| 0.1 Hz | 2,979 F | 99% | 0.290 mΩ |
| 1 Hz | 1,939 F | 65% | 0.275 mΩ |
| 10 Hz | 564 F | 19% | 0.218 mΩ |
Example 3: 18 cells in series with capacitance spread
| Item | Value |
|---|---|
| Module voltage | 48.6 V |
| Module capacitance | 167 F |
| Module energy | 54.7 Wh |
| Normal cell voltage | 2.683 V |
| Voltage of a cell 10% low in capacitance | 2.982 V |
If only one cell hits 2.98 V and the rest sit at 2.68 V with margin, isn't that fine?
Not so. The voltage limit of a double-layer capacitor is set by where the electrolyte starts to decompose; beyond it gas forms, internal pressure rises and ageing accelerates sharply. Ageing lowers capacitance, so that cell's voltage climbs even higher on the next charge. The weakest cell degrades fastest and grows weaker still — a vicious circle. Internal resistance also rises, increasing heat, and higher temperature speeds ageing further. Series modules therefore include balancing circuits that measure each cell and bleed the high ones. Design calculations include cell-to-cell capacitance and resistance spread and module temperature distribution to find which cell reaches the limit first.
Modelling workflow
- Fit internal and pore resistance to impedance measurements.
- Simulate discharge with the actual current waveform to confirm usable capacitance.
- Derive heat from resistive loss and solve module temperature distribution.
- Include cell spread to obtain voltage distribution in the string.
- Estimate life from temperature and voltage and size balancing and cooling.
“A regeneration unit that emptied faster than the datasheet said”
On one crane's regeneration unit, energy stored in the capacitor module ran out sooner than calculated, hitting the lower voltage limit. The calculation used the datasheet capacitance (measured at DC), but the real load swung strongly over about a second. Recomputing with the pore model and the actual current waveform showed about 20% less usable capacitance, matching measurements. Adding cells in series to gain voltage margin solved it.
Common mistakes
Mistakes and fixes
| Mistake | Effect | Fix |
|---|---|---|
| Using DC capacitance | Energy overestimated for fast loads | Pore model |
| Assuming use down to 0 V | Converter cannot operate | Use the minimum voltage |
| Ignoring spread in series | Some cells overvoltage | Balancing circuit |
| Heat from average current | Heat underestimated | Use RMS current |
| Constant temperature | Life overestimated | Couple with heat |
I'd like to learn related topics.
Related pages include battery degradation, lithium-ion battery simulation, battery thermal runaway, fuel cell modelling and corrosion simulation.