Secondary-Use Battery Energy
Storage Systems
Michael Starke, PhD
Power and Energy Systems
Oak Ridge National Laboratory
ORNL Team:
Phil Irminger, Ben Ollis, Brandon Johnson, Omer Onar, George Andrews
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I would like to thank Dr. Imre Gyuk, Program Manager of the Electrical Energy Storage Program for DOE’s Office of
Electricity for his support and funding.
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Project Overview
• Supporting the industry investigation into vehicle battery secondary-use through testing, demonstration, and modeling.
– Potentially a cost competitive energy storage technology
– Validate reliability and safety – working with industry to troubleshoot and test systems under operational conditions
– Examining regulatory environment – investigating hurdles that are institutional
– Industry acceptance – build confidence in this technology.
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Current Activities
HARDWARE
SYSTEMS INTEGRATION
SOFTWARE
• Energy Storage – Used EV Batteries
• Energy Management System
• Electric Grid
An effective partnership that merges
equipment, technical know-how, and
infrastructure:
ORNL is testing and demonstrating the technology as a
third party.
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GM/ABB Quote
" The collaboration between ORNL, GM, and ABB has been instrumental in confirming the opportunity to utilize automotive second use batteries in a grid based application. The high quality of the extended ORNL testing gave us a deeper understanding of design, installation, and operation of energy storage devices. The team used the sophisticated lab environment to examine a wide range of performance scenarios not possible at a single production installation site.“ – General Motors
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The Technology
Grid Application (25kW/50kWhr)
• Expected capacity for 10 Years
of Operation
• 5 Volt Battery Packs
• 5 kW per Volt Battery
• Air Cooled/Heated
Automotive Application
– Capacity for 10 Years in Automotive Application
– Power 111kW
– Liquid Cooled / Heated
GM Chevy Volt Battery
Re-Packaged
ABB Enclosure
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Testing Setup at ORNL
• ORNL objective for testing: Provide real world examination systems integration and applications with the flexibility to capture many different case scenarios.
ORNL Distribution
System
750kVA, 13.8kV/2.4kV
Circuit #22.4kV System
750kVA, 2.4kV/480V
480V, 3 Phase, 60Hz
2.4kV, 3 Phase, 60Hz
13.8kV, 3 Phase, 60Hz 480V Distribution
Panel
Disconnect Switch
37.5kVA, 120V-240V/480V
Programmable Load Bank (240V,
Split Phase, 24kW)
Community Energy Storage (240V, Split
Phase, 25kW)
Disconnect Switch
480V, 3 Phase, 60Hz
240V, Split Phase, 60Hz
480V/2.4kV
50kW PV
50kVA inverter
15kW PV
1 Hardware
2 Communications
3 Controls
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Hard/Soft: Communication and Control
Communications
and Control
and Measure &
Validate
Communications
and control done
through Serial,
Modbus over Serial,
and TCP/IP
- All integrated
through
Matlab/Labview
DECC Facility
Communications Cable, RS232/RS485
over Modbus
Communications Cable, RS232
ORNL/Distribution
CT/VT
CT/VT
CES
ROOFTOP PV
CONTROL/COMPUTING
GRID
M&V
CT/VT
LOAD
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Hardware: Equipment Inside DECC
480V/240V(split-phase)
Transformer
Islanding
Contactor/Relay
Programmable
Load Bank
Emergency
Disconnect
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Battery
Enclosure Inverter
Hardware: Equipment Outside DECC
Emergency
Disconnects
PV Array
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Interface
Set of pre-programmed controls
CES Alarms
Manual Control
State display
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Controls and Programs
PV Forecast
Load Factor Control Points
SOC Estimate
text message
Cloud Cover
Solar Irradiance/PV output
Residential Model Consumption
% Cloud Cover Temperature (C)
Temperature
solarirradiance
GA Optimization
kW load
kW PV
Measured Data
Main ControlEmergency Monitoring
Data Acquistion
Load Bank
Shutoff
Data Processing
Data
Historian
Data
Load Bank Temp
Temperature (C)
Control Mode, P, Q
Storage
• Auto-runs at 12:00AM
• Controls depend on selected settings.
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Testing Procedure (Systems Tests)
• Objectives:
– Obtain standard metrics (round-trip efficiency/ensure within bounds of standards)
– Demonstrate application examples
• Standard Metrics:
– Round-trip efficiency
– Harmonics, etc.
• Applications
– Load factor,
– Power factor,
– Renewable Integration,
– Islanding
Start
Charge Battery at Requested Power Level to 70% SOC
Rest Battery for 30 Minutes
Discharge Battery at Requested Power
Level for 30 minutes
Rest Battery for 30 Minutes
Time Since Last Power Level Change > 24 Hours?
At Maximum Power Level?
Increase Requested Power Level
No
Yes
No
Yes
Stop
Requested Power: 5
kW
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Multiple Value Streams: Stacking Benefits (Load
Factor/Power Factor, Renewable Integration)
Grid (nearly flat)
Power (W)
Time (hr)
Power (Var)
SOC (%)
Time (hr)
Time (hr) Time (hr)
Histogram power factor
Target Set to 0.97
SOC target to return to 50%
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Other Applications: Off-grid and PV Smoothing
Grid power
Battery-supplying
entire load
Power (kW)
Power (kW)
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Initial Economic Approach
(Mixed Integer) Linear
Optimization Grid
Services
Battery Model
Data
Optimal Battery
Dispatch
Cost/Savings
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• Arizona Public Service Company residential rate structures
• Year-long simulated load for 3 homes
• Dispatch the battery to minimize the homeowners’ cost
• Utilized efficiencies of real system, 10year/3000 cycle battery
Initial Economic Results
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Initial Economic Results
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ORNL Summary/Conclusions
• Developed controls and applications ES testing
• Demonstrated and tested ABB/GM secondary-use battery storage.
• Drafted a report on initial testing procedures (currently in review.)
• Obtained and evaluated PNNL optimization toolbox for ES.
• Developing models for distributed control of energy storage.
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Future Tasks
• Continued testing of ABB/GM.
• Modeling and economics assessment for DES.
• Optimization of DES dispatch
• Development of refurbished secondary use ES with ATC New Technologies partners.
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L1
L2
L3
S11
S12
S21
S22
S31
S32
C3
C2
C1
S1 S2 S3
S4 S5 S6
BMS
BMS
BMS
V1
I1
V2
V3
I3
Va
Vb
Vc
G12
G11
G21
G22
G31
G32
G1
G2 G3
G6G5G4
G11, G12
G1, G2, G3, G4, G5, G6
Estop1, SOC1, kWh1, kW1
Estop1, SOC1, kWh1, kW1
DC/DC Converter 1
V1, I1
Va, Vb, Vc
Ia, Ib, Ic
Inverter Control System
Preq, Qreq, Mode
DC/AC Inverter/Grid Connection
G1
La
Lb
Lc
Battery
I2
Battery
Battery
Ia
Ib
Ic
3ϕ 480VAC
600VDC
<500VDC,
25kW
L4
S41
S42
BMS
V4
I4
G41
G42Battery
L5
S51
S52
BMS
V5
I5
G51
G52Battery
<500VDC,
25kW
<500VDC,
25kW
<500VDC,
25kW
<500VDC,
25kW
C4
C5
100kW
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Special thanks to Dr. Imre Gyuk for his dedication and support to ORNL and ES industry.
Questions?
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PI : Michael R. Starke, PhD
Oak Ridge National Laboratory
Power and Energy Systems
Energy & Transportation Science Division
(865) 241-2573 office One Bethel Valley Road
(865) 574-9329 fax P.O. Box 2008, MS-6070
Oak Ridge, TN 37831
