An initial investment cost estimation approach for the supercapacitor banks in electric vehicles

This study explores the use of supercapacitors in energy storage systems for electric vehicles, with a particular focus on the design and optimization of supercapacitor banks. Due to growing environmental concerns and the need to reduce dependence on fossil fuels, electric vehicles have emerged as a key component of sustainable transportation. However, the limitations of lithium-ion batteries—such as low power density, long charging times, and limited cycle life—make supercapacitors an appealing complementary technology. Their ability to charge and discharge rapidly, long lifespan, high power density, and wide temperature tolerance make them ideal for high-power-demand scenarios such as acceleration and regenerative braking. The thesis reviews the basic principles of supercapacitor technology, its types (EDLC, pseudocapacitors, hybrids), and various electrode materials (carbon-based, transition metal oxides, conductive polymers). It also evaluates the impact of electrolytes and separators on performance and highlights recent material advancements aimed at improving energy density. Applications of supercapacitors in electric vehicles—such as acceleration support, regenerative energy capture, cold-start assistance, and battery life extension—are examined. The advantages and configurations (passive, semi-active, active) of hybrid energy storage systems (HESS) combining batteries and supercapacitors are also analyzed. A key part of this research focuses on the sizing and cost estimation of supercapacitor banks. Design parameters such as voltage, capacitance, thermal management, weight, volume, and integration have been discussed in detail. The cost analysis includes cell cost, Battery Management System (BMS), cooling, packaging, and installation. While supercapacitors may have a higher initial cost, their long operational life can make them more cost-effective over the full life cycle. In the experimental and analytical section, multiple module configurations were analyzed under a fixed energy level (2304 J) and varying working voltages (16 V, 24 V, 32 V). It was observed that increasing the voltage decreases the overall capacitance, increases the number of series-connected cells, and raises the total ESR. As the number of parallel cells decreases, the system's current-handling capability also declines. A comparative analysis of various Maxwell BCAP cells showed that the BCAP3000 K2 cell is the most suitable for electric vehicle use, offering advantages such as reduced weight, fewer cells, high power density, and lower system complexity. In conclusion, this study provides a comprehensive evaluation of the technical and economic feasibility of integrating supercapacitors into electric vehicles. When combined with batteries in hybrid systems, supercapacitors have the potential to significantly enhance vehicle performance, reliability, and efficiency. The findings offer valuable insights for the future development of electric mobility technologies.