Application Scenario Differences Between Lead-Acid Batteries and Lithium-Ion Batteries in Electric Forklifts

The application scenarios of lead-acid batteries and lithium-ion batteries in electric forklifts differ significantly, with core distinctions reflected in cost structure, maintenance requirements, environmental adaptability, and operational efficiency. Below is a detailed analysis based on the latest industry practices:

I. Lead-Acid Batteries: Entry-Level Option with Low Cost and Low Maintenance Needs

Applicable Scenarios

1. Light-Load, Short-Distance Operations

• Typical Scenarios: Cargo handling in small warehouses and retail stores (single-load capacity ≤ 2 tons), with daily operation duration ≤ 6 hours.
• Advantages:
• Low initial cost (30%-50% lower than lithium-ion batteries). For example, a 48V/600Ah lead-acid battery pack costs approximately 8,000 RMB, while a lithium-ion battery pack ranges from 12,000 RMB to 15,000 RMB.
• Stable discharge characteristics, suitable for simple working conditions with constant-speed travel, such as pallet translation and short-distance transportation.

2. Low-Frequency Use and Temporary Leasing

• Typical Scenarios: Seasonal warehouses (e.g., agricultural product storage) and factory backup forklifts used occasionally.
• Economic Analysis:
• If annual usage time is < 500 hours, the annual depreciation cost of lead-acid batteries (approximately 2,000 RMB) is lower than that of lithium-ion batteries (approximately 3,000 RMB).
• In the leasing market, the daily rental cost of lead-acid forklifts is 20%-30% lower than that of lithium-ion forklifts, making them suitable for short-term projects.

3. High-Temperature and High-Humidity Environments

• Typical Scenarios: Outdoor construction sites and wood processing workshops (temperature > 35°C).
• Performance:
• Lead-acid batteries experience slower capacity degradation at high temperatures (10%-15% lower than lithium-ion batteries), and electrolyte evaporation can be compensated by adding water.
• The shell material (polypropylene) has strong corrosion resistance, making it suitable for environments with high dust and humidity.

Limitations

• Tedious Maintenance: It is necessary to check the electrolyte level and add distilled water weekly, perform equalizing charging quarterly, and replace the electrolyte annually. The annual maintenance cost accounts for approximately 10% of the battery price.
• Low Charging Efficiency: Standard charging takes 6-8 hours, which cannot support multi-shift operations. Moreover, fast charging accelerates plate sulfation and shortens the service life.
• Environmental Risks: Scrap batteries contain heavy metal lead and require professional recycling; otherwise, they are likely to cause soil pollution.

II. Lithium-Ion Batteries: High-End Option with High Efficiency, Intelligence, and Long Service Life

Applicable Scenarios

1. High-Frequency, Heavy-Load, and Multi-Shift Operations

• Typical Scenarios: Logistics hubs and port terminals (single-load capacity ≥ 3 tons), with daily operation duration of 16-24 hours.
• Efficiency Improvement:
• Support 2C-3C fast charging (e.g., a 48V/600Ah battery can be charged to 80% in 1.5 hours), enabling supplementary charging during lunch breaks without the need for backup batteries.
• The cycle life reaches 1,500-2,000 times (only 300-500 times for lead-acid batteries). With one cycle per day, lithium-ion batteries can last 5-7 years, while lead-acid batteries need to be replaced every 1.5-2 years.

2. Cold Chain and Low-Temperature Environments

• Typical Scenarios: Fresh food distribution centers and pharmaceutical cold storage (temperature ≤ -20°C).
• Performance Advantages:
• Lithium iron phosphate batteries can maintain over 80% of their capacity at -20°C, while lead-acid batteries experience more than 50% capacity degradation.
• The self-heating function (available in some high-end models) can raise the battery temperature from -20°C to 5°C within 1 hour, ensuring low-temperature startup.

3. Cleanrooms and Environmentally Sensitive Industries

• Typical Scenarios: Electronics factories, food processing plants, and pharmaceutical workshops.
• Environmental Compliance:
• Lithium-ion batteries have no acid mist emissions, meeting the cleanliness requirements of GMP (Good Manufacturing Practice for Pharmaceuticals).
• The sealed design prevents electrolyte leakage, reducing the risk of equipment corrosion. The maintenance cost is 80% lower than that of lead-acid batteries.

4. Intelligence and IoT Integration

• Typical Scenarios: Automated warehouses and AGVs (Automated Guided Vehicles).
• Technological Synergy:
• The BMS (Battery Management System) communicates with the forklift controller in real time via the CAN bus, dynamically adjusting output power to achieve precise load control.
• The remote monitoring function can track the battery health status (SOH) in real time, predict faults, and optimize charging strategies, reducing downtime.

Limitations

• High Initial Investment: The price of lithium-ion batteries of the same specification is 30%-50% higher than that of lead-acid batteries, but the total cost of ownership (TCO) over 5 years is 20%-30% lower.
• High-Temperature Sensitivity: For environments with temperatures > 40°C, forced liquid cooling is required (increasing costs by 15%); otherwise, the service life will be shortened by 15%-20%.
• Imperfect Recycling System: Lithium-ion batteries have low recycling value (only 40% of that of lead-acid batteries), and improper disposal may easily cause lithium pollution.

III. Scenario Comparison and Selection Recommendations

Comparison Dimension	Applicable Scenarios for Lead-Acid Batteries	Applicable Scenarios for Lithium-Ion Batteries
Operational Intensity	Light load (≤ 2 tons), daily operation < 6 hours	Heavy load (≥ 3 tons), 24-hour continuous multi-shift operation
Ambient Temperature	High temperature (> 35°C), high-humidity environments	Low temperature (≤ -20°C), constant-temperature cleanrooms
Charging Conditions	Mainly charged at night, no need for fast supplementary charging	Shift-based charging or opportunistic charging (e.g., supplementary charging during lunch breaks)
Environmental Requirements	General industrial environments (e.g., construction sites, wood factories)	High-cleanliness industries such as food, pharmaceuticals, and electronics
Intelligence Needs	Basic handling, no data integration	Need for connection with WMS (Warehouse Management System) and IoT platforms
Budget	Limited initial budget, pursuing low-cost entry	Long-term operation, focusing on efficiency and cost optimization

IV. Comprehensive Evaluation of Economy and Environmental Friendliness

Cost Comparison (Taking a 48V/600Ah Battery as an Example)

• Lead-Acid Battery: Initial cost of 8,000 RMB, annual maintenance cost of 800 RMB, and 2 replacements over 5 years. Total investment is approximately 22,000 RMB.
• Lithium-Ion Battery: Initial cost of 12,000 RMB, maintenance-free, and total investment of 12,000 RMB over 5 years, saving 45%.

Environmental Benefits

• The full-life-cycle carbon emissions of lithium-ion batteries are 60% lower than those of lead-acid batteries, and they comply with the restrictions on hazardous substances in the EU RoHS Directive.
• Some regions provide subsidies for lithium-ion forklifts (e.g., China’s new energy vehicle purchase subsidies), further reducing the cost of use.

Conclusion

With their low-threshold advantage, lead-acid batteries still occupy a place in scenarios such as small and medium-sized enterprises and temporary operations. However, lithium-ion batteries, with their characteristics of high efficiency, intelligence, and environmental friendliness, have become the mainstream choice in fields such as large logistics hubs, cold chain storage, and high-end manufacturing.Enterprises need to make comprehensive decisions based on operational intensity, environmental conditions, budget cycles, and sustainable development goals. For long-term operations and efficiency pursuit, lithium-ion batteries have a significant TCO advantage; for short-term use or limited budgets, lead-acid batteries remain an economical option. In the future, as the cost of lithium-ion batteries decreases and the recycling system improves, their market share will further expand.