expanding the future of energy utilization · solar power generation railway gas turbine aa type :...
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Compact and High-performanceOffering Vast Possibilities for Energy Use.
Expanding the Future of Energy Utilization
Apr.2015GIGACELL® is a trademark of Kawasaki Heavy Industries, Ltd. in Japan and the U.S.A.
GIGACELL Battery Sales Section, Machinery & Parts Sales Dept.,Marketing & Sales Div., Rolling Stock Company
http://www.khi.co.jp/english/gigacell/
1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, JapanPhone: +81-3-3435-2572 Fax: +81-3-3435-2157
Tokyo Head Of�ce
Building 4, 29 Wells Avenue, Yonkers, New York, 10701, U.S.A.Phone: +1-914-376-4700 Fax: +1-914-376-4717 http://www.kawasakirailcar.com/
KAWASAKI RAIL CAR, INC.
GIGACELL® is a next-generation Ni-MH battery.Designed to be eco-friendly, GIGACELL® commits to the ef�cient use of energyand carbon footprint reduction.
HighScalability
FEATURE
Low internal resistance enables fast charging and discharging.
No welding used, enabling easy disassembly for recycling.
Designed to withstand frequent cycles of short, rapid charging and discharging.
No lead, mercury, cadmium or other toxic materials are used.
Low operating temperature; water-based electrolyte eliminates risk of �re.
Rapid Chargeand
Discharge
FEATURE
Easy toRecycle
FEATURE
ExcellentCycle
Durability
FEATURE
EnvironmentallyFriendly
FEATURE
Simpleand Safe
FEATURE
Conventional Battery
Wind power generation
Lead
Solar power generation Railway Gas turbine
AA Type : 2Ah 1.2V 2.4Wh
GIGACELL®
500A-running
3000A-50s
GIGACELL® NICKELdismantling
assembly
Lead oxide Cadmium Mercury Sulfuric acid
organic solvent metallic oxide Lithium hexa�uorophosphate
Received the Grand Prizefor the 19 th Global Environment Award
(Hosted by the Fuji Sankei Communications Group)
Received 2009 Japan Minister of theEnvironment Award for Achievements
in Reducing Global Warming
01 02
150Ah × 36V = 5,400Wh
× 2,250
No No No No No
No No No
0 20 40 60 80 100
50
48
46
44
42
40
38
36
34
32
30
1.0C discharge
3.0C discharge
5.0C discharge
5.0C charge
3.0C charge
1.0C charge
Volt
age
(V)
Charge / discharge capacity ratio (%)
03 0404
Innovative Design
Conventional cylindrical Ni-MH batteries consisting of rolled electrodes
and separators heat up during rapid charges and discharges. These
batteries also have limited scalability due to the energy loss created in
their connections. In addition, their welded structure complicates
recycling procedures.
In the GIGACELL®, cooling fans that send air through the structure
prevent overheating. The bipolar structure minimizes energy loss
between cells and actualizes greater capacity. GIGACELL® is highly
recyclable because of its non-welded structure.
Cooling Fan Powerful and ef�cient cooling enables charging / discharging at high amperages.
Non-welded With no welding processes during its production, disassembly and recycling processes are facilitated.
Fully Sealed The GIGACELL® is fully sealed, needing no mainte-nance.
Comparison of Conventional Ni-MH Battery and GIGACELL®
GIGACELL®
Conventional Ni-MH Cylindrical Battery
Negative electrode
Separator
Positive electrode
Bipolar enables GIGACELL®’s high capacity and rapid charging
GIGACELL® modules are composed of individual cells that are connected in series by their cell walls, with the front and rear surfaces becoming positive and negative electrodes, forming the bipolar structure. The thin cell walls provide a large cross-sectional area that minimizes energy loss, which occurs when the cells are connected. Therefore, the large capacities of modules can be accomplished by increasing the number of cells connected in the bipolar structure.
Bipolar
Press bolt
Fix plate
Single cell
Cooling fan
Detailed Drawing
Separator
Negative electrode
Positive electrode
Heat sink
Positive electrode
Nickel hydroxide/Substrate
Separator
Polyole�n non-woven material
Negative electrode
Hydrogen storage alloy/Substrate
Battery Monitoring System
Safty Tests
Overcharge Test Vibration Test
JIS Z-0200JIS Z 0200UN38.3 TestT.3Vivration(38.3.4.3.2)2.5.7 Vibration Test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO
Battery for power storage system(JEAC 5006-2010) table 3-6-2 in Articles 3 to 62.5.3 Overcharge test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO
Drop Test Water Immersion Test (fresh water and salt water)
2.5.9 Immersion Test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO
JIS C 8714 (Safty Tests for Portable Lithium-Ion Secondary Cells and Batteries For Use In Portable Electronic Applications)
* SOC: State of Charge, is the level of the charge in the battery
The Battery Monitoring System (BMS) that is installed on each module calculates the SOC* and uses this to determine if there are any abnormalities. BMS enhances the safety of GIGACELL®
Functions
Power supply line
Rail
Monitor slave unit(Capable of withstanding 1500 V)
Monitor master unit
IO SystemVarious typesof controllers
CAN:Control Area Network RS485/RS232C
GIGACELL®
GIGACELL®
GIGACELL®
Calculates SOC, takes measurements of cell voltage, battery temperature and battery internal pressure, and outputs warnings as necessary.
Cooling air
05 06
A Combination of Safe,Reliable Rail Transport and Ef�cient Use of Energy
* HSCB= High Speed Circuit Breaker
System Image System Outline
BPS
BPS can provide all functions simultaneously
Energy SavingReducing overall energy consumption by encouraging regenerative braking and then ”recycling” it.
No Regeneration CancellationStabilized line voltage prevents regenerative braking failure.
Peak ShavingPower discharged from the BPS reduces power demand at all times, including rush hours.
Emergency RunsBatteries will power trains to the nearest station during a power outage.
Line Voltage StabilizationCharging and discharging stabilizes line voltage.
Alternative to SubstationsThe BPS can serve as an alternative where substations are difficult to install.
Power line
HSCB
SubstationⅠ SubstationⅡ
Rail
BPS
HSCB
HSCB
HSCB
Battery
Direct Connection to System
Low Costs
No power controllers needed
High Efficiency
No loss through controllers
No Delays and Losses
Max. use of regenerative energy
No EMI
No adverse effects to signal systems
A large effect can be obtained by continuous operation
Fuse
DCCT
Batterymain
monitor
Disconnectswitch
Battery mainmonitor cubicle
Disconnect switchcubicle
Batterycubicle
GIGACELL(2 banks)
DCL
DC reactorcubicle
P-side HSBCcubicle
N-side HSBCcubicle
Hight-speedcircuit breaker
Hight-speedcircuit breaker
BPS System Diagram
Direct Connection to Feeder Line
No DC-DC converters Full range voltagecharge / discharge
900
850
800
750
700
650
600-1500 -1000 -500 0 500 1000 1500
Vo
ltag
e (V
)
Amperage I (A)
Power Supply Line Voltage > Vo Charge
Charge
Vo > Power Supply Line Voltage Discharge
Discharge
NEW APPL ICATIONS
07 08
Energy Saving
No Regeneration Cancellation,Line Voltage Stabilization
Peak Shaving Alternative to SubstationsEmergency Runs
625 V DC Third Rail Voltage & Battery Power Waveforms
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0
-2,000
-4,000
700
650
600
550
500
450
400
350
300
250
6000
5000
4000
3000
2000
1000
0
-1000
-2000
-3000
7:209:20 9:30 9:40 9:50 10:00 10:10 10:20
7:21 7:22 7:23 7:24 7:25
Po
wer
(kW
)
Th
ird
Rai
l V
olt
age[
V]
Bat
tery
Cu
rren
t[A
]
Time
Powered by the rectifier and the BPS
Powered by the rectifier
Powered by the BPS
Voltage Stabilization
3rd
Rai
l V
olt
age
(V)
Time
950
900
850
800
750
700
6504:00 8:00 12:00 16:00 20:00 0:00 4:00
Max. 939 V
Without BPS
Min. 703 V
Max. 854 V
Min. 718 V
Duration of BPS Connection
With BPS
Osaka Subway BPS Data
Location of BPS on Tokyo Monorail Line
Battery Current
3rd Rail Voltage (= Battery Voltage)
Rectifier Shutdown
9:38AM 10:08AMEmergency Power Supply
Transportable BPS
It is available as a temporary substation , in case of theconstruction, maintenance, or expansion of a substation.High tension electric work is not needed, and theconstruction period can be shortened.
All in two 20ft-containersContainer A : GIGACELL (forty modules) + Battery Monitering SystemContainer B : Circuit Braker Panel, Disconecting Switch Panel, etc
6,058 2,438
Tare weight : 2.2t Pay load : 21.8t Gross weight : 24t
2,8
96
(mm)
Disc
harg
e
Disc
harg
eCh
arge
Installed atShinagawa substation
in March 2013
Installed atTamagawa substation
in March 2014
Tokyo Monorail installedtwo BPS to allow strandedtrains on the entire 17.8 kmline to be moved to thenearest station during apower outage
0:00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 24:00
700
650
600
550
500
450
400
350
300
250
3rd
Rai
l V
olt
age
(V)
(= B
atte
ry V
olt
age
(V))
2500
2000
1500
1000
500
0
-500
-1000
-1500
-2000
Time
3rd Rail Voltage (V)
Battery Power (kW)
NYCT-BPS at Central Substation 3rd Rail Voltage & Battery Power Waveforms
Bat
tery
Po
wer
(k
W)
Dis
char
geC
har
ge
Data taken in July 2010
Char
ge
09 10
Grid Stabilization
System Image
A four-year joint development was conducted to study the usage of GIGACELL® for supply/demand control when more renewable energy is implemented in the grid. GIGACELL® was installed at a substation near a 10-megawatt PV generation plant.
○Electrical Power Supply/ Demand System with GIGACELL®
Output signalCurrent output data
Charging and discharging will occur when frequency exceeds or becomes lower than the standard frequency of 60 Hz respectively. At high and low SOC levels, the system will prevent over-charging/discharging of the batteries.
Example of System Operation
GIGACELL® Bank
Ishizugawa Substation
Solar Sakai
Courtesy of KEPCO
Electrical Power Supply/Demand System
PV power
Wind power
GIGACELL®
Hydro-power
Fossil fuel power
Kansai Electric Power Co., Inc. (KEPCO)Nisshin Electric Co., Ltd.
JointDevelopment
Location KEPCO Ishizugawa Substation
GIGACELL® (12V-177Ah) × 48 modulesComposition
Rated Voltage 576 V
Rated Capacity 177 Ah
Battery Capacity 102 kWh
Battery Capacity 122 kWh
Start of Operation March 2013
Output 250 kW (System output with inverter connected.)
Freq
uen
cy (
Hz)
Inv
erte
r o
utp
ut (
kW)
Bias
con
trol
(kW
)
Dis
char
geC
har
geDi
scha
rge
Char
ge
Frequency increase Charge
Frequency decrease Discharge
Continuous lowfrequency
Continuousdischarge
Low SOC
Charge bias lowers output by 50 kWat SOC below 40% and preventsover-discharge.
Charge bias stops whenSOC recovers to 45%.
The charge bias lowers output by 50 kW in pink
compared to when there is no bias in blue .
20-ft container
20-ft containerNEDO project scope
Grid Stabilization
Installing renewable energy on remote islands with relatively small grid capacity can potentially increase frequency �uctuations. The GIGACELL® system can control these �uctuations, reducing the need for diesel generators to adjust their output.
○Remote Island Frequency Regulation
System Configuration
Wind turbine(OEPC)
Battery bank
20-ft containers for system (front: battery container)
6.6kV, 60Hz
Hzdata
Regulationsignal
Batterystatus
Monitoringsystem
Battery bank122 kWh
Batterystatus
Gridstatus
245kW×2
3640kW
Monitor slave unit
WT DE
TD
PLC
Transformer
Inverter300kVA
BMSLogger
Development of a Large-scale Energy StorageSystem with High-safety and Cost Competitiveness
NEDO*Subsidized Project
LocationMinamidaito, Okinawa PrefectureThe Okinawa Electric Power Co., Inc. (OEPC)Minamidaito C.S. & Internal-combustion Power Station
30-K5 GIGACELL® × 12 modules × 2 banksComposition
* New Energy and Industrial Technology Development Organization
SOC
(%)
2011/09/12 14:00-17:30
Frequency change &inverter output
Demonstration Data & Benefits
DE2 output
One out of twowind turbines
stopped
Battery output
Wind power output
14:30
600
500
400
300
200
100
0
-100
-200
-300
-400
0.30.20.1
0-0.1-0.2-0.3
14:40 14:50 15:00
Ou
tpu
t(k
W)
Fre
qu
en
cyd
evia
tio
n(H
z)
Operation ON Operation OFF
DE1 output
Reduce grid frequency�uctuations due tounstable wind power
Prevent frequency declinein the event of wind powerdrop
Provide alternative to dieselengine power (DE1 & DE2)governor adjustment
Dis
char
geC
har
ge
NEW APPL ICATIONS
11 12
Wind Power Generation
GIGACELL® can be applied for wind integration on the grid. Its smoothing and ramp control functions will reduce the adverse effects of unstable generation output. This leads to further implementation of renewable energy.
○Wind Power Smoothing
Example of Smoothing Wind Power Generation Output
Time
0:00 6:00 12:00 18:00 0:00 6:00 12:00 18:00 0:00
2011/1/10 2011/1/11
Bat
tery
po
wer
(kW
)
SOC
(%
)
Wind turbine output
Gen
erat
ion
ou
tpu
t (k
W)
Dis
char
geC
har
ge
Output after smoothing Actual GIGACELL® output × 8 SOC
GIGACELL®
Power converter
Location Yurihonjo City, Akita Prefecture (Fuji Green Power Co., Ltd.)
Smoothing and ramp control
Components GIGACELL® (12V-177Ah)× 48 modules
Battery Capacity 102 kWh
Start of Operation Above speci�cation completed in April 2010
Application
Fuji Green Power Co., Ltd.Joint Development ○PV + GIGACELL®
GIGACELL® connected to PV panels can store surplus energy for use during peak demand time. It can reduce peak demand, as well as provide power to essential loads during power outages.
Solar Power Generation
Location Yachiyo Shoin Gakuen
CompositionGIGACELL® (12V-182Ah) × 24 modules x 3 banks
Battery Capacity 148 kWh
Start of Operation August 2006
Peak shavingApplication Solar panels(100 kW)
Charge/discharge controller GIGACELL®Load
Mainload
DC-AC converter
Because the GIGACELL® offers stable battery voltage when charging and discharging, it can share the same DC-AC converter as the solar panels, and can be directly connected to the DC section, therefore reducing installation costs.
Solar panels
DC-AC converter
LoadLoadLoadLoad
GIGACELL®
DC-DC converterunnecessary
50
0
-50
Consumed Power
Received grid power
DC Output fromGIGACELL®
Discharge(Peak Shaving)
Charging(disconnected from power grid)
Output of 100 kWPower Controller
Output of 70 kW Power Controller
Command tobreak speci�c loads
TargetedPower Demand
500
400
300
200
100
0
En
ergy
(kW
)
Time (Hours)
GIG
AC
ELL
®D
isch
arge
Ou
tpu
t (k
W)
4 6 8 10 12 14 16 18 20
Example of Peak Shaving
NEW APPL ICATIONS
13 14
Distributed Energy (Gas Turbines & Engines) + GIGACELL®
Distributed Generation/Micro-grid
The Hybrid Power System forms a micro-grid system composed of installed wind turbine generator, PV panel and GIGACELL® batteries. The system controller sends optimal charge/discharge signals to the GIGACELL® through the power conditioner based on the generation data of renewable energies and the building’s power
consumption data and the power conditioner charges/discharges GIGACELL®. Therefore, the system not only stabilizes renewable energies, but also can reduce peak demand, level off power loads and provide emergency power during a blackout.
Kawasaki’s Kobe Works Office
Location Kawasaki’s Kobe Works Of�ce
CompositionGIGACELL® (12V-188Ah)12 modules × 2 banks
Battery Capacity 54kWh
Start of Operation April 2012
ApplicationPeak demand reduction, emergency power,renewable energy smoothing
○Kawasaki’s Kobe Works Of�ce Building Hybrid Power System
Office building
Power consumptiondata
Power input/output
Charge/dischargesignal
Charge/discharge
Generationdata
Generationoutput
PurchasedpowerGeneration data
Generationoutput
System controller
GridWind turbineGIGACELL®PV panels
Kawasaki Hybrid Power Conditioner
Hybrid Power System
Load InsideFacility
Gas Engine90 kW
Gas Engine350 kW
Charge/DischargeController
Charge/DischargePower Controller
100 kW
GIGACELL®81.2 kWh
Capacitor100 kW×2 sec.
Power SupplyControl System
A network of multiple power sources within a given area forms a micro-grid. The GIGACELL® has the ability to quickly respond to �uctuations in demand loads and generated power. It can ensure safe and dependable power for micro-grids isolated from the power grid.
Composition of Micro-grid
Location Shimizu Co. Ltd., Technical Research Center
Stabilization control to fix the amount of powerpurchased from power grid
Application
Components GIGACELL® (36V-141Ah) × 16 modules
Battery Capacity 81.2 kWh
Start of Operation February 2011
GIGACELL® can be combined with standby generators to provide stable power to �uctuating loads. This can reduce the capacity, cost, and space for emergency standby generators.
System Outline Example System Operation (Example)
Gas turbines/engines
Renewable energy
Lights Buildings Factories Gantry cranes
Small, stable loads Large, temporary loadsRegenerative machines
Electricity use / Battery charge Electricity generation / Battery discharge
6000
0
(Gen
erat
or
cap
acit
y)
(kVA) Disch
argefrom
GIGACELL®
Ch
arge toG
IGA
CE
LL®
Generator sup
ply
with
GIG
ACELL®
assistance
Regenerative energy
Load fluctuation GIGACELL® discharge GIGACELL® charge Generator output
Converter
GIGACELL®
Distributed Energy System
Kawasaki continues to develop and disseminate solutions for utilizing renewable energies such as PV, wind, and biomass.
Small hydro plant
Solar heat plant
Binary plant
Gas engineWoody biomassgassification power plant
Energy demand
Electric energy
Electricity & heat energy
Energy supplyGIGACELL®
Biomass methane plant
PV panel
Wind turbine
Power plant
Commercialfacilities
GIGACELL®
Gas turbinecogeneration system
Incineration plant
Schools
Homes Factories
NEW APPL ICATIONS
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