REDFLOW ZINC-BROMIDE MODULE (ZBM )FOR DC APPLICATIONS Energy Storage for Communities, Mining and Telecommunications – Case studies Mike Giulianini, PhD CTO, Redflow Limited
Redflow Product Source: Google search ‘Flow Batteries’ Option: Photo Redox Flow Battery replacement for existing lead acid systems • 48V and 170Ah, 200Ah or 200Ah (@53V) • 100% DoD • Up to 50°C with no ageing effect • Water based and inherently safe • BMS integrated • CE approved
Recent Timeline (related to DC applications) 01/2014 04/2014 12/2014 New electrode shows First ‘full - DC’ ZBM DC ZBM CE compliant and unprecedented life equipped with Module declared inherently safe by estimation in advanced Management System independent body. degradation test assembled Results available for the Hibernation Mode 03/2014 06/2014 04/2014 First ZBMs built with the ZBM production ZBM2, ZBM3 products new electrode for successfully outsourced to launched with 2,000 cycles characterisation in the Flextronics 100% DoD warranty long time test facility All the ZBMs in test since 3/2014 are cycling daily with no sign of degradation (several MWh processed per ZBM) Test of the Module @48V not the single cell!
ZBM Key aspects • 3/5 kW, up to 11kWh energy out; • Long shelf life either charged or discharged; • Designed for long life applications; • At the end of life the battery can be 100% regenerated at a fraction of the price; • Almost entirely made of plastic; • Large-scale production is expected to drive the price reduction constantly over the coming years;
Redflow in the World
Base Telecommunication Station Site • Telco site, approximately 1.8kW load; • Frequent grid blackouts 3-5h; • Backup needed 4h; • Existing LA capacity 400Ah Nom (20kWh Nom); • Replacement period 1 or 2 years;
Results • A total of 29 blackout events were recorded in the last 143 days (one every 5 days approximately); • The ZBMs provided a total of 2807Ah or more than 140kWh (and 100Ah or 5kWh per event on average); • 6 events were longer than 4h 30m or 270m which accounts for more than 160Ah per event • Several events featured temperatures above 40 degrees and ended with the ZBM fully discharged. The same events with the existing batteries would have resulted in a fast aging processes;
Results Projecting the experimental data back to the beginning of the trial brings the following: • A total of 37 blackout events would have happened in the last 183 days (one every 5 days); • The ZBMs would have provided a total of 3592Ah or 180kWh; • The total usage of the ZBM up to date is 37 cycles which corresponds to 74 cycles per year; • Therefore the ZBM life expectancy in this application is well over 20 years.
Added value The ZBM solution eliminates the following costs related to the existing solution (LA): • Elimination of the existing cost to replace lead acid batteries every year which includes: • Battery costs; • Installation costs; • Disposal costs; • Eliminates service down costs and loss of revenues; • Payback period expected to be very short; • Creates an advantage over the competitors; • Customer service and perception is improved as communications are available during blackouts and possible emergency situations; • Potential marketing opportunity.
110V DC system in Power plant The customer contacted Redflow about a backup application with the following specification: • DC bus nominal voltage 110V DC; • Normally floating voltage 125V DC; • Load current 12A ; • Backup time 5 hours; • Needed backup time 12 hours; • 8.5 m 2 ; Available space Redflow solution: • Deployment of 3 ZBM for a total of 510 Ah ; • Resulting footprint of less than 3 m 2 ; • Resulting backup time of more than 12 hours ;
Results The system @48V guarantees same performance as in the lab
Hibernation Mode • Designed for UPS and backup applications targeting extremely long life; • Charge (up to 120%) – Prepare – Stop (pumps off); • When a loss of power occurs the battery wakes up and perform a full cycle (in the worst case scenario); • The main advantage is that the battery is OFF most of the time without any degradation (pumps or electrodes); • If the site experiences 100 blackouts a year, the battery projected life exceeds 20 years (2,000 cycles)
Hibernation Mode • The hibernation consumption is a few mA; • The ZBM charge is inhibited but the battery is able to supply instantaneously up to 10Ah (@50V and available for months); • To improve reliability and response time we coupled the ZBM with a Supercapacitor (120F / 64V);
Hibernation Mode Test • Even if the ZBM is at 0V it restarts in 20/25s; • The Supercap can supply 1.5kW for over a minute (3kW for 30s); • The system will be always able to tackle a blackout and backup the site for over 6h per ZBM; • There is no limit to the number of ZBMs that can be connected in parallel;
Hibernation Mode Business Case • Valid alternative tho the existing system (LA + DG) considering: – DG restart issues; – DG maintenance; – LA maintenance (assessment, replacement, disposal); – Non-modular solution; – Non ideal for intermediate duration blackouts; • Supercaps have certified 1M cycles and guaranteed no-loss of Capacitance over 10 years @V R ; • Both devices (ZBM and Supercaps) are tolerant to high temperatures up to 50°C so no need for environment conditioning.
Other ZBM applications • Large scale and microgrids; • AC application: Residential and Industrial; • Integration with Renewables; Please Enquire Us!
Thank you!
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