clean energy systems need clean...

Clean energy systems need clean batteries

NABCEP2016

Sustainable Energy Storage Solution for Off-grid and Microgrid Applications

Neal Roche

©Aquion Energy, Inc. Proprietary and Confidential2

Agenda+ Company

+ Technology

+ Products

+ Sizing

+ Transportation

+ Installation

+ Electrical Integration

+ Commissioning & Operation

+ Installation pictures


Company


Aquion Energy+ The world’s only manufacturer of clean and

sustainable Aqueous Hybrid Ion (AHI™) batteries

+ Products are optimal for stationary, long duration (4+ hr), daily cycling applications

+ Spun out of Carnegie Mellon

+ Headquartered in Pittsburgh, PA

+ Manufactured in Westmoreland, PA

Research into sodium ion rechargeable batteries begins

1980’s 2005

Research conducted at Carnegie Mellon University

Aquion Energy is founded and spun out of CMU

2008

Incremental progress made, but no significant advances

2011

First shipments to customers

Current generation of product launched

Q2 2014

15+ MWh (8K+ batteries) shipped to date

2015


Technology


Aqueous Hybrid Ion (AHI™) Battery

Aqueous Hybrid Ion

+ CARBON

+ SALTWATER

+ BASE OXIDE

+ COTTON

Carbon Titanium Phosphate Composite Anode

Synthetic Cotton Separator

Manganese Oxide Cathode

Neutral pH Alkali-ion Electrolyte

Stainless Steel Current Collector+ STAINLESS STEEL

Neutral pH water-based electrolyte

Poly-ionic system: Na+, Li +, and H+ ions all functional in the system


What is Intercalation?• A chemical reaction where ions are inserted into a compound with layered or spinel

structure

During charge, sodium ions intercalate into the anode, moving from the cathode.

In discharge, the sodium ions leave the anode and move intercalate into the cathode.

CathodeManganese Dioxide Spinel

AnodeSodium Titanium Phosphate and

Carbon

Note: Images are representative of the crystal structures used in the anode and cathode

How does it work?


Products


AHI™ BATTERIES

Products: Flexible, Scalable Energy Storage

* Stack and module capacities are for 8–battery stacks shipping today; these capacities will increase in Q4’15 and later quarters

M-Line Battery Modules+ ~ 24 kWh+ Nominal 48V output+ Designed for industry-

standard racking+ Forklift-ready

+ Compatibility, controls and system sizing

AQUION ENGINEERING SUPPORT

+ Monitors current, voltage, temperature, state of charge

BATTERY MONITORING SYSTEM

S-Line Battery Stacks+ ~ 2 kWh+ Nominal 48V output+ Smallest product

increment


CONTAINERIZED SYSTEMSHIGH-DENSITY RACKING

Bulk Energy Storage Configurations

+ Containerized systems available through integration partners

+ Accommodates modules, 2 rows high

+ Industry-standard racking accommodates M-Line Battery Modules

+ Scalable for wide range of interior configurations+ Simple interface + Available with several off-the-shelf grid capable

PCS Systems

~25 MWh system~38 x 30 x 5 m

16 modules~400 kWh system~5.3 x 2.4 x 2.5 m


AQUION GLOBAL PARTNERS

Integrated Energy Storage Systems

+ Partners provide sales, design, integration and installation of full systems including AHI batteries coupled with typical 3rd party equipment (inverters, controls, solar/wind, gensets, racking, enclosures)

AHI™ INTEGRATED SYSTEMS

C&I or Microgrid ScaleResidential/Telco Scale Utility/IPP Scale


Battery Specifications

S-LINE STACK OPERATION & PERFORMANCE

Nominal Energy Up to 2.6 kWh at 20 hour discharge, 30° C

Operating Temp Range* -5 to 40° C

Round Trip DC Efficiency ~90% at 20 hour discharge, 30° C

Voltage Range 40 to 57.6 V

Charge/Discharge Modes CC, CP, CV, AC ripple tolerant

PHYSICAL CHARACTERISTICS

Height 935 mm 36.8 in

Width 330 mm 13.0 in

Depth 310 mm 12.2 in

Weight 118 kg 260 lbs

* 40° C average ambient over 24 hours

M-LINE MODULE OPERATION & PERFORMANCE

Nominal Energy Up to 30 kWh at 20 hour discharge, 30° C

Operating Temp Range* -5 to 40° C

Round Trip DC Efficiency ~90% at 20 hour discharge, 30° C

Voltage Range 40 to 57.6 V

Charge/Discharge Modes CC, CP, CV, AC ripple tolerant

PHYSICAL CHARACTERISTICS

Height 1,159 mm 45.6 in

Width 1,321 mm 52.0 in

Depth 1,016 mm 40.0 in

Weight 1,504 kg 3,309 lbs

M-LINE BATTERY MODULES

+ Twelve S-Line Battery Stacks in parallel

+ Voltage, current, temperature sensing optional

+ Optional BMS interface+ For systems up to 1,000 Vdc

S-LINE BATTERY STACKS

+ Smallest product increment+ Eight batteries in series, fused at the

stack level+ Nominal 48V output+ Designed for low cost, performance, and

modularity


Our batteries are different.

How We Stack Up

AHI batteries are a safe, environmentally friendly, long-lasting and easy-to-use alternative to lead acid and lithium ion.

They’ll give you and your customers a hassle-free experience, peace of mind, and pride in their new clean energy storage system.


Touch Safe

PSOC Cycling Tolerant

No Maintenance

Easy InstallationLow Voltage 48V

Non-FlammableNon-Explosive

Temperature Tolerant

+ The S-Line and M-Line products are touch-safe meaning they do not present electrical hazards as shipped

+ Aqueous Hybrid Ion chemistry can be operated at any state of charge and life is not reduced

+ S-Line and M-Line products are fully sealed and require no maintenance or special maintenance cycling

+ Standard connections and low voltage ensures these can be installed without high voltage safety equipment

+ No acid, heavy metals, or flammable organic electrolytes – AHI batteries are inherently safe and non-flammable

+ No safety concerns or life reductions at elevated temperatures

AQUION ADVANTAGEvs. PbA vs. Li-Ion

✓ ✓

✓

✓ ✓

✓

✓

✓

✓ ✓

Competition: Other Major Factors


Sizing


Sizing Example (1)

+ Energy: 9kWh consumption per day

+ Would like 3 days of autonomy

+ Energy needed: 9kWh/day x 3 days = 27kWh

+ Discharge duration: 72 hours

+ Charge duration: >20 hours

+ 27 kWh / 2.603 kWh = 10.37 11 stacks

+ Power: 4kW peak (inverter efficiency included)

+ 800W for S30

+ 4kW / 800W = 5 5 stacks

+ Since this power need is already covered by the stacks for energy, the number of stacks needed is 11

Size for Energy Size for Power

Embodied

Energy (Wh)

Charge Duration (h)

4 8 10 12 20

Dis

char

ge

Du

rati

on

(h)

4 1,264 1,520 1,600 1,647 1,803

8 1,335 1,672 1,780 1,848 2,055

12 1,389 1,775 1,900 1,982 2,217

20 1,569 2,046 2,200 2,307 2,603

Two bedroom home in Hawaii, low loads, grid defection, no generator


Sizing Example (2)

+ Energy: 150kWh consumption per day

+ Would like 2 days of autonomy

+ Energy needed:150kWh/day x 2 day = 300kWh

+ Discharge duration: 48 hours

+ Charge duration: >20 hours

+ 300 kWh / 2.603 kWh = 115.25 116 stacks


+ 800W for S30

+ 20kW /800 W = 25 25 stacks

+ Since this power need is already covered by the stacks for energy, the number of stacks needed is 116


Embodied

Energy (Wh)

Charge Duration (h)

4 8 10 12 20

Dis

char

ge

Du

rati

on

(h)

4 1,264 1,520 1,600 1,647 1,803

8 1,335 1,672 1,780 1,848 2,055

12 1,389 1,775 1,900 1,982 2,217

20 1,569 2,046 2,200 2,307 2,603

Micro-grid in the Caribbean with 50kW PV array


Sizing Example (3)

+ Energy: ~6kWh of average daily excess PV

+ Discharge duration: ~12 hours

+ Charge duration: ~8 hours

+ 6 kWh / 1.775 kWh = 3.38 4 stacks


+ 800W for S30

+ 4kW /800 W = 5 5 stacks

+ The number of stacks needed to cover the peak load AND the energy need is 5


Embodied

Energy (Wh)

Charge Duration (h)

4 8 10 12 20

Dis

char

ge

Du

rati

on

(h)

4 1,264 1,520 1,600 1,647 1,803

8 1,335 1,672 1,780 1,848 2,055

12 1,389 1,775 1,900 1,982 2,217

20 1,569 2,046 2,200 2,307 2,603

Grid-tied system in a home to maximize PV self-consumption


System configurations (1)

+ DC-coupling

©DNV-KEMA NYSERDA Residential Solar-Storage report (Apr 2013)

Optional BMSSite Controller

or


System configurations (2)

+ AC-coupling

©DNV-KEMA NYSERDA Residential Solar-Storage report (Apr 2013)

Optional BMSSite Controller

or


Transportation


Shipping: Non-Hazardous Goods

+ Aquion classifies its products as non-hazardous goods

+ Products have no hazardous classifications and can be shipped as standard goods

+ Rules such as UN38.3 do not apply

+ Products have also undergone International Safe Transit Association testing for shock, vibration, thermal shock, and altitude


Installation/Transportation Angle

+ Do not install the batteries on a surface with greater than 15 degrees of tilt

+ Batteries can be tilted up to 45 degrees for one hour during installation

+ Battery “wells” (quadrants) are not sealed from the other wells within the battery

+ Electrolyte can leak between wells over time

+ Won’t leak out of the battery itself because the battery is sealed


Do Not Disassemble

+ Stacks should not be dissembled

+ Nut at the top of the stack should not be loosened

+ Stack is under pressure to maintain contact between electrodes and current collectors

+ Disassembly will greatly reduce battery performance and can permanently damage the stack


What’s in the box: Stacks

+ Stacks will arrive 12 or less to a pallet (depending on order size)

+ Each 6 stacks will come with one lifting eye for moving

+ Depending on type of transit, stacks may arrive wrapped on a pallet (top) or in a crate (bottom)

+ Summary:

• Stack

• Lifting Eye

• Ships up to 12 to pallet

• Installation guide


What’s in the box: Modules

+ Modules will arrive wrapped

+ Modules are on a steel pallet

+ Can be moved with a fork truck or pallet jack


Delivery Inspection

+ Upon receipt, check packaging and batteries for damage

• Document damage and immediately notify Aquionand the shipper

• Damage is not a safety concern

+ What to look for:• Scrapes or tears on packaging or products

• Tipped products

• Broken or missing components

• Leaking electrolyte

+ Salt residue

• White salt residue may be dried electrolyte

• Not hazardous, but may indicate a battery leak

• Provide photographs to Aquion and determine the source of the leak

• If no source is apparent, it is likely not a battery leak

Battery tilted >15 degrees

Battery case rupture


Installation


Site Requirements

+ IP Rating of Products: The S-line stacks are IP22 rated. Products are protected against:

• Objects greater than 12.5mm, such as fingers or similar objects

• Dripping water when tilted up to 15 degrees, for a duration of 10 minutes or less

+ Size and Weight: Position products on surfaces appropriately rated for their weight. Ensure that the installation location is large enough to contain the system

+ Ventilation: Per IBC and NFPA 1 guidelines, installations in enclosed spaces require ventilation equal to either: • Six (6) air changes per hour

• Ventilation at 1 cubic foot per minute (CFM) per square foot of room size.

IP22


Site Requirements (cont.)

+ Dryness: Install Battery Stacks in a dry environment only. Direct exposure to water may cause shorting. The unit may be installed in humid or coastal regions with atmospheric salt.

+ Sun Exposure: Install and operate Battery Stacks out of direct exposure to sunlight. Prolonged exposure to ultraviolet light may damage the polypropylene casing and reduce product lifetime.

+ Ambient Temperature: Battery Stacks must be operated in temperatures between -5°C and 40°C on a 24-hour average. Operation above or below these limits will cause advanced degradation of the battery chemistry.


Moving

+ Use the supplied safe lifting eye and equipment

+ Ensure products do not tip by more that 45 degrees for longer than one hour

+ S-Line:• Use either:

‒ Aquion supplied lifting eye with hoist or winch

‒ Hand truck or similar device

+ M-Line:• Use either:

‒ Pallet jack

‒ Fork truck


Placement

+ S-Line batteries do not need any particular amount of clearance between stacks or other architectural features.

+ Always follow local codes for aisle and access requirements

+ Do not stack Battery Stacks on top of each other.

+ Ensure the products are installed in an upright position with less than fifteen (15) degrees of tilt


Electrical Integration


Electrical Integration

+ The following contains recommendations on how to connect your system

+ Should not be taken as the only method

+ Always follow all local codes and regulations

+ Perform proper FMEA analysis to determine where safety precautions such as external fusing or breakers are necessary


Connectors: Stacks

+ Stack Connectors:

• Negative (Black): Female Amphenol Helios H4 Connector (H4CFC4DI)

• Positive (Red): Male Amphenol Helios H4 Connector (H4CMC4DI)

+ Mating connectors:• Not supplied by Aquion

• Recommend using Amphenol brand mating connectors

• Connectors can be ordered as a mated pair, part no. H4CPC4DI

+ Replacement connectors:• Custom 12 AWG connectors on the

stack, can be re-ordered from Aquion

• Aquion offers certain connectors as replacement parts

Negative: Female Amphenol H4

Connector

Positive: Male Amphenol H4 Connector


Connectors: Modules

+ The following parts are required to make connections to the M100 Battery module

• 1 Amphenol Radlock Tubular Connector Black RL0100150BK

• 1 Amphenol Radlock Tubular Connector Red RL0100150RE

Negative: Amphenol Radlok RL9100103Positive: Amphenol Radlok RL9100103


Connectors: Tools Required

+ S-Line• Amphenol H4 Solar Connector

• Disconnect tool

• Wiring

‒ If crimping cables yourself

• H4 Crimp tool

• Male and female H4 connectors (one pair per stack)

• 10 AWG or larger wire based on current (A) and codes

‒ If purchasing pre-crimped wires

• Available from various online distributors

+ M-Line• Amphenol Radlok Connector

• Greenlee Crimping tool

• 2/0 cable or larger based on current (A) and codes


Wiring and Fuses

+ The following is one way to wire together several S-Line products in parallel

+ Always consult local code and regulations when wiring an electrical system

+ Bussing in parallel (48 V system):

• One common method is to use a standard solar combiner box

• Example: MNPV12 from Midnite Solar would allow you to combine stacks in parallel and provide fusing/breakers

+ Fusing and breakers: Systems should be protected in accordance with local codes and regulations• Follow the rated current of the stacks and

wires, which is 17A/stack

FuseCombinerBox


Grounding

+ Low voltage (<60V) systems do not necessarily require grounding

+ Stacks:

• If grounding is required or desired, the following parts can be used:

‒ Ring Terminal (Morris Products 11072)

‒ Nut (McMaster 93839A835)

‒ 12 AWG wire

‒ Standard wire crimper

• Attach the ring terminals to the battery stacks, then ground the battery stacks.

+ Modules• The Battery Module is equipped with a ⅜”-‐16 grounding lug. A 6 AWG wire

should be connected from this grounding lug directly to the system DC ground.


Commissioning & Operation


Inverters & Chargers

+ Aquion batteries follow a typical three-stage (bulk/absorption/float) charge profile, similar to lead-acid batteries.

+ Aquion batteries are compatible with most inverters and chargers on the market: SMA, Studer, Schneider, OutBack, MidNite Solar, etc.

+ Recommended settings are provided in the battery Operations Manual


Determining State of Charge

+ State of charge of an Aquion battery can be estimated by using the Open Circuit Voltage (OCV)

+ To measure the OCV, first disconnect the stack or stacks from the DC bus by either unplugging the H4 connectors or powering down the system

+ Let the stacks sit unpowered for at least 3 hours and then measure the voltage between the positive and negative terminals


Storage

+ If the batteries are to be stored for an extended period of time, remove all signal and power connections to prevent unintended self-discharge and undetected ground faults. Keep any grounding in place.

+ Standing at a partial state of charge does not harm AHI batteries.

+ Batteries stacks must be stored indoors or protected from sun and water, in temperatures between -10C and 40C.


Recycling

+ AHI batteries are non-toxic, non-corrosive, and can be disposed of as ordinary trash or through proper recycling channels. Follow all local laws and regulations regarding disposal.


Record Keeping

+ Aquion Energy recommends maintaining proper system documentation records:

+ Aquion Energy also recommends maintaining proper and regular operating records which include. For module based systems that include the optional Aquion Energy BMS, this data is logged automatically.

Record Description Frequency

Single line system diagram complete AC and DC system diagram at installation or upon change

System component settings charge voltage and current settings at installation or upon change

Measurement Description Frequency

Average Battery Temperature daily average temperature logged every 24 hrs

Minimum Battery Voltage daily minimum voltage logged every 24 hrs

Maximum Battery Voltage daily maximum voltage logged every 24 hrs

Maximum Battery Current daily maximum current logged every 24 hrs


Installation Pictures


Installation #1


Installation #2


Installation #3


Installation #4


Installation #5


Installation #6


Installation #7


Thank You+1 [email protected]

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