Final East Penn Report

8/12/2019 Final East Penn Report

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The S-TeamEast Penn Sponsored Project

Penn State Berks

Edesign 100

By:

Tyler SimchesRobert Swahl

Bradley Schwenk

Evan Steigerwalt

Table of Contents

Introduction..................................................................................................................................3

Problem

Definition......................................................................................................................3

Methods.............................................................................................................................

............4

Research............................................................................................................................


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.....5-10

Generated Concepts

.....................................................................................................12-15

Concept

Evaluation..................................................................................................................17

Concept

Selection....................................................................................................................18

Applications......................................................................................................................

...19-22

Conclusion........................................................................................................................

.........22

Worldwide

Assessment..........................................................................................................22

Societal Impacts

...................................................................................................................22

References

............................................................................................................................23

Fig 1 House power flow

diagram........................................................................................... 8

Fig 2 Factory power flow

diagram......................................................................................... 8

Fig 3 Apartment power flow

diagram.....................................................................................8

Fig 4 Cruise Ship power flowdiagram..................................................................................9

Fig 5 Electric Load Profile for Average House

Consumption.........................................9

Fig 6 Electric Flow Diagram for all

Concepts....................................................................10

Fig 7 Concept

1.........................................................................................................................10

Fig 8 Concept #1 Assembly of

Module...............................................................................11

Fig 9 Concept

2.........................................................................................................................12

Fig 10 Concept #2 Assembly of

Modules...........................................................................13

Fig 11 Concept

3.......................................................................................................................14

Fig 12 Concept


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4.......................................................................................................................15

Fig 13 Baseline Application (House)

..............................................................................18

Fig 14 Factory Power flow

chart...........................................................................................19

Fig 15 Appartment Power Flow

Chart.................................................................................20

Fig 16 Cruise Ship Power Flow

Chart.................................................................................21

Table 1 Concept specifications for each generated

design..........................................16

Table 2 Decision

Matrix...........................................................................................................18

Introduction

East Penn Manufacturing is releasing a new product called the UltraBattery. This

revolution in the industry is a hybrid device that contains lead acid battery chemistry and

Ultra capacitor technology. It exhibits extraordinary endurance when in a partial state ofcharge, between 30-70%. The concept is applied to MW scale systems that support

solar, wind, and grid scenarios. The main importance of having energy available to

individual homes or businesses is being able to access the power when and where it is

needed. The majority of people rely on the grid however it is possible to set up

individual systems using renewable energy. The objective of this project is to design a

standardized energy storage module that can be used for a distributed energy storage

solution using the UltraBattery in the East Penn 24HR3000 package or AVR 95-7

package.

Problem DefinitionEnergy is needed in every home in order for humans to live their lives to the highest

standard of living. However, there is no efficient renewable energy systems set up that

can meet the needs of individual homes, communities, or any other application. Design

a power grid that can be used for many applications, that successfully exhibits all of the

criteria for success. In order to solve this issue, a power grid will be designed that can

generate a large amount of power which can also be stored for later use upon need.


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The limitations that affected the thought process and results of this project include: only

use the batteries provided, meet required power, easily accessible and maintainable,

and proper placement of modules.

Methods The first decision that needed to be made for each module was the selection of

the battery type

There were only two choices of battery types, the 2V or the 12V

Concepts one through three all used the 2V battery mainly for the reasons

that it is more adaptable and takes up less space.

Concept four used the 12V for the reason that it contains more volts and

amps per individual battery

All four concepts each used the sunny island inverter in the module

This inverter was selected due to its high efficiency and large range of

access in terms of connecting with other inverters, such as the sunny boy

and windy boy

The sunny boy and windy boy are inverters that take in solar power and

wind power respectively, and convert them to direct current power

All the concepts are adaptable to powering other applications because more

modules can be placed together in order to generate more power The 2V modules are more adaptable since they have a larger range of

output they can reach

The next decision to comes across the creative process was determining if the

modules were going to be connected to the grid or completely separate

The decision was made that all of the concepts are completely off the grid

using all of the power generated for their own needs

This shows that the modules are very productive and can be used in

isolated places resulting in wide adaptability to other applications

The main way to determine if the modules are a good decision for purchase is to

calculate the return of investment The return of investment is equal to ((annual savings - (first cost / life))/first

cost)100

The return of investment is a percentage that shows the amount of money

that is either gained or lost over the life of the module

All of the concepts are eco-friendly since all of them use renewable energy for

power


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All of the modules use steel as the base material and the terminal posts are

connected with copper wiring

These materials were selected since steel in a very strong material which

is also cheap

And copper wiring is very conductive and cheap, as well

After all of these factors were taken into place, the four concepts were made and

evaluated based upon the decision matrix

The decision matrix consisted of voltage, current, size, adaptability,

accessibility, safety, weight, cost, and cooling as the tools of evaluation

Each module received a score from one to ten, with ten being the highest

rating, for each factor based on the effectiveness of the module for that

factor

A total score was tallied up to determine the best overall rated module,

with concept one having the highest rating

Therefore, concept one was the recommendation for this project and aphysical model was built to represent it

Research

Grid Scale Energy StorageGrid scale energy storage is another wording for large scale energy storage. This is

where when there is a surplus of energy being created compared to the demand for

energy and the excess is stored until it is needed. This energy is then tapped into when

the demand for energy is greater than the amount being produced. By doing this it

allows power plants to run on a more constant level of production rather than fluctuatingup and down to meet the needs of power consumption. This allows them to run more

efficiently and operated easier

Currently the largest form of grid scale energy storage is pumped-storage

hydroelectricity. This is where during periods of low energy consumption water is

pumped from an low area to a higher one so that when a large amount of energy is

needed the water can be released and passed through turbines thus creating electricity.

Lead Acid Battery Types and Applications

There are three main types of lead acid batteries. They are wet cell, gel cell and AGM.The wet cell or flooded cell is a battery filled with an electrolyte solution and is prone to

hydrogen leaks and corrosion. The gel cell also has an electrolyte solution but it is

suspended near the plates and a silica additive is added to stiffen the solution so that

the possibility of leaks is much less than that of the flooded cells. The AGM or absorbed

glass mats is where the solution is suspended right next to the plates and this allows for

a much faster charge and discharge rate and a much more efficient one.


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Ultra Battery

The Ultra Battery is an AGM lead acid battery. The main difference between this battery

and other AGM batteries is that the ultra battery is a battery and a capacitor all rolled

into one. This means that it can give off high amounts of energy very fast and for a long

lasting period of time. Other impressive feats of the ultra battery include its ability to

power at a partial state of charge and its cycle life. This battery runs at optimal states of

charge between 30% and 70% charge. The cycle life of this battery is supreme reaching

about 194,000 to 200,100 cycles while remaining healthy.

East Penn 24HR3000 package

This is the 12V ultra batteries. These batteries are 259xmm167mmx209mm and the

battery weight is 56 lbs. These batteries have a capacity of 48.3 Ah for about one hour.

East Penn AVR 95-7 Package

This package can come in a multitude of possibilities. For the non-interlocking modulesyou can get them in a three cell or a six cell configuration. The interlocking modules can

come in a two cell, three cell, four cell, or six cells per module. All of these modules

have a capacity of 285 amps over an eight hour period. Each cell is one of the 2V ultra

cell batteries.

PV-Hybrid Cycle TestThis test shows that the Ultra battery keeps its capacity at 100% over a 40 day period of

160 cycles. Comparatively this is amazing since the other batteries in the test dropped

to 80% in under 30 cycles or one of them lasted to 70% in 60 cycles before they all

died. This stated that the ultra battery had a far superior cycle life and is capable of

holding its full charge for a much longer period of time than other lead acid batteries.

Deficit Charge/Partial State of Charge

Deficit charge and partial state of charge are what makes the ultra battery so amazing.

These batteries do not need to be at a full charge to give off their full amount of

capacity. These batteries run optimally at a partial state of charge in between 70% and

30% state of charge.

PNM NetworkThe PNM network is the network of high voltage lines in New Mexico that connects the

power plants to the homes. This grid is connected to the larger grid serving the entire

western United States so that power can be moved about quickly so that power can be

moved in case of an emergency.


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Inverter Systems

SMA technologies offers a few inverters that would work very well with these concepts.

The have the sunny boy, sunny island, sunny towers and many others. The sunny

islands are capable of working on large scale systems and very efficiently converting

the energy with about an efficiency of 96%. The others are just as good but are for

smaller systems and work better with directly from solar panels to the grid.

Lead Acid Battery PackagingWhen shipping or storing batteries it is very important to keep a few things in mind. The

biggest thing to worry about is leaking battery acid. To avoid any problems with this

there are a few things that need to be done first is to set down some sort of absorbent

layer under the batteries. This can be anything from cat litter to paper towels. Another

thing to do is make sure that the batteries are placed face up so as to keep the chances

of leaking down. Another thing to keep in mind is to place something in between the

batteries to keep them from jostling around and bumping into each other such as asmall piece of cardboard. The final thing to do is keep them cool. Batteries at extreme

temperatures are prone to losing their ability to keep a charge and thus keeping them

stored at a temperature around 60 degrees is optimal.

Current Ultra Battery ApplicationsCurrently the Ultra Battery is being used in two big projects. The first is out in New

Mexico as they are being used in the PNM network. This is a megawatt system that is

used to lighten the load on the grid by shifting in solar power. The other project that is

going on is at Deka Batteries itself. Their System that is used to either hold excess

power from the grid when needed or can give off power to the plant when more is

needed. It can also give power back to the grid when power consumption is high and

production is low.

Existing SolutionsCurrently homes get their off grid energy one of two ways. They either take the

generated energy directly and use it or pump the excess into the grid or they store the

excess for later. As of now there is no storage system that works anywhere near as well

as the Ultra Battery will. Nothing has the cycle life or the ability to last as long at a partial

state of charge.

Currently this is how certain places deal with their off grid energy.


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Fig 1: House power flow diagram

Fig 2: Factory power flow diagram

Fig 3: Apartment power flow diagram


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Fig 4: Cruise Ship Power Flow Diagram

Fig 5: Electric Load Profile for Average House Consumption


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Fig 6: Electric Flow Diagram for all Concepts

Generated Concepts

Similar Concepts in all generations

Each Design will be using the same terminal connectors and terminal posts

The terminal posts will be screw in plugs into each module The terminal connectors will be the same ones currently used in East

Penns unigy II models

Fig 7: Concept 1

Uses the 2V batteries

It uses the Sunny Island Inverter

6v

1

142.5 Ah per hour for 8 hours

in mm 180x840x635


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The batteries will be connected with copper plates

The modules will be connected using high capacity copper wire

In each module there are 12 batteries 4 sets of 3 batteries in series and those 4

sets are paralleled together

There are 8 modules and they are in series they have 48V and 142.5 Ah

This module is made of steel and for racking has slots in the top for extruded

parts on the bottom of others to fit into so as to avoid sliding around

The ideal placement would be underground outside of the house or town and

kept cool using geothermal means

Fig 8: Concept #1 Assembly of Module


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Fig 9: Concept 2

Uses the 2V batteries

It uses the Sunny Island Inverter

Each module is 60V

Each has 35.625 Ah per hour for 8 hours

In mm 250x840x760

The batteries are all connected by copper plating

The modules are connected using high capacity copper wiring

In each module there are 15 batteries all in series

There are 2 sets of 2 modules each set has 120 V and 35.625 Ah with each set

using a sunny Island inverter

The module is built of steel and each one has feet on the bottom that fit into

holes in the top to keep the module from moving around

Placement for this module is varied such as underground or in a shed or other

enclosure outside of the house yet protected from the elements, while using

geothermal means to keep it cooled.


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Fig 10: Concept #2 Assembly of Modules


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Fig 11: Concept 3 Uses the 2V batteries

It uses the sunny island inverter

Each module is 8V

Each has 105Ah per hour for 8 hours In mm 235x675x635

The batteries will be connected using copper plates

The modules are going to be connected using high capacity copper wires

In each module there are 12 batteries with 3 sets of four batteries in series and

those three sets are in parallel

The module is made of steel and the modules would be welded together to keep

them from moving about.

Placement for this one is also varied and can be placed underground or outside

sheltered from the elements


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Fig 12: Concept 4

Uses the 12v batteries

Uses the sunny island inverter

Each module has 48V

Each has 108 Ah per hour for 1 hour

In mm 518x565x209

The batteries will be connected using copper plating

The modules are connected using high capacity copper wiring

In each module there are 8 batteries with 2 sets of 4 in series and the 2 sets are

in parallel The module is made of steel and the modules simply rest on or next to each

other


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Concept Chart for individual model

Table #1: Concept specifications for each generated design

Concept 1 Concept 2 Concept 3 Concept 4

Voltage 6 30 8 48

Current 142.5 35.625 106.675 96.6

Size (mm) 180x840x635 250x840x760 235x675x635 518x565x209

Inverter sunny island sunny island sunny island sunny island

Accessibility No backaccess, screw

on front panel

No back

access, units

can be stacked

for various

power needshas front

terminal posts

and front

removable lid

No back

access,

Stackable units

provide variable

stack heights,widths and

output

no back, only

front terminal

posts

Safety ie electrocution Front plate overthe batteries,

no back

access, and

units stack into

each other

Only access

from the lid and

must be

opened for that

and the

terminal posts

signs explaining

risk warning not

to touch or

electrocute

only front

access, air

holes small

enough where

nothing fits in to

them

Weight (lb) 578 750 590 475

cost $8,465.50 $5,311.50 $6,357.00 $1,008.75

Cooling Vents an inchand a half from

the sides and

every inch

down the

module. Two

holes on top of

module for

terminal posts

on top module.

And

Geothermally

placing of the

modules.

vents on sides

with

geothermal unit

on one side to

cool

Vents on sides,

tops, and

bottoms of each

single storage

container.

container legs

provide space

in between

units for air

flow.

vents on all

sides of the

module, space

between

modules for

natural odd

shape


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Explanation of Decision Matrix To power a house volts need to be 240.

All designs reach required voltage

The higher the amps the better.

Design 1 has the highest amps

Size and Adaptability are similar.

Smaller the Module better it can adapt

Design 1 is the smallest therefore the most adaptable

Weight also ties into size and adaptability.

Design 3 weighs the least and has a good adaptability rating

Able to access but still safe.

Design 3 is the most accessible but 1 is the safest

Batteries optimally need to be at 77 degrees.

Designs 3 and 4 have the most airflow therefore have the best cooling

Finally cost, high cost is bad the lower the cost the better.

All pretty cheap designs 1 and 3 are the cheapest

Because they have the same number of batteries

Table #2: Decision Matrix

Weight Concept 1 Concept 2 Concept 3 Concept 4

Voltage 10% 10

100

10

100

10

100

10

100

Current 10% 10

100

5

50

8

80

2

20


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Size 15% 9

135

6

90

8

120

6

90

Adaptability 10% 10

100

7

70

9

90

9

90

Accessibility 2% 7

14

7

14

8

16

5

10

Safety 8% 9

72

7

56

8

64

2

16

Weight 15% 9

135

7

105

9

135

10

150

Cost 20% 9

180

8

160

9

180

10

200

Cooling 10% 9

90

7

70

10

100

10

100

Total Score 100% 926 715 885 776

Application for Concept #1

Baseline Application (House)

Fig 13: Baseline Application (House)

The generation and load profile are about the same but over different periods oftime this Concept would generate about 30 Kwh per day and the house uses

around 27.5 Kwh per day

This Concept would use around 16 modules for a house

These would be set up in two groups of eight and each group would have oneinverter

Customers Without Solar Panels and Wind Turbines (in PA)

Only Solar would be a -5.6% Return on Investment (per year)

Half and half would be a -5.2% ROI (per year)


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Not Worth it

Customers With Solar Panels and/or Wind Turbines already installed

10.09% Return on Investment (per year)

Worth it

Investment turns positive when cost for solar panels and/or wind turbines is lessthan $20,000.

Payback Period

7.83 years 8 years

To power a house with solar power it becomes much cheaper in areas with moresunlight

The cost for solar panels with low sunlight is about $200,000

In areas with medium amounts of sunlight the cost is around $150,000

Areas with the highest amounts of sunlight will cost about $80,000

Alternate Applications

Factory

Fig 14: Factory Power flow chart

One system produces about 30 Kwh per day and this concept would need at

least 60 Kwh per day, therefore the systems would need to be doubled from the

baseline

Since the system is doubled in order to meet the requirements of this application,

32 modules would be needed and they would be split into groups of eight with

four inverters

Customers Without Solar Panels and WInd Turbines (in PA)


Half and Half would be -7.8 ROI (per year)

Not Worth It

Customers with Solar Panels and/or Wind Turbines already installed

15.1% Return on Investment (per year) Worth It


Payback Period

11.7 years 12 years

To power a house with solar power it becomes much cheaper in areas with more


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sunlight




Apartment

Fig 15: Appartment Power Flow Chart

This application is very similar to a house where it uses about 27 Kwh per day

and one system would produce about 30 Kwh per day so that would be all that is

needed

A system consists of 16 modules which would be all that is needed The 16 modules would be split into two groups of eight with two different

inverters




Not Worth it



Worth it Investment turns positive when cost for solar panels and/or wind turbines is less

than $20,000.

Payback Period

7.83 years 8 years





Cruise Ship


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Fig 16: Cruise Ship Power Flow Chart

This application has a wide range of Kwh per day but this range seems to

centralize around 30 Kwh per day and one system produces 30 Kwh per day

On average one system would be enough to power a cruise ship, so 16 modules

would be needed however some can may need to added or taken away

depending on the size of the cruise ship

Recommendation for Cruise Ship

The 16 modules would be split into two groups of eight with two inverters, one for

each group




Not Worth it



Worth it


Payback Period

7.83 years 8 years


The cost for solar panels with low sunlight is about $200,000 In areas with medium amounts of sunlight the cost is around $150,000


Conclusion

Concept #1 provides the ideal amount of batteries to properly power a house completely

off grid. To do this it uses 16 battery modules. These are split into 2 groups of 8 with

one inverter for each group. Each of the modules uses twelve 2V batteries. These

batteries are in the configuration of 4 sets of 3. The 4 sets are in parallel and then the 3

batteries in each set are in series.

The terminal connections can be error proofed for the DIY community by painting the

connectors certain colors. For example one could paint the outgoing connector brown

and the ingoing yellow. These colors would be good because people who are color blind

are most likely red-green color blind so the chances of not being able to see yellow and

brown is greatly reduced. On top of that one can write in and out on the connectors to

erase any confusion.


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Worldwide Assessment

This recommended concept has the possibility to be used very well in other parts of the

world. If this concept is used in PA it will not be very profitable or worthwhile, yet if it is

placed in areas with greater amounts of sunlight it has the possibility to be fantastic.

Placing this in an area such as the Sahara Desert would be ideal. The amount of

insulation hours for solar panels there is much higher than in PA. The insulation hours

are about 6.9 hours of sunlight in the Sahara compared to the 2.9 in PA. With this

higher insulation rate the amount of solar panels needed to support the system drops

and the ROI and Payback period is much shorter as well.

Societal ImpactsThe societal Impacts for the recommended battery module are not that great. For the

module itself and the connectors they are all made of steel and copper. Once that

module breaks or is out of date the steel would all be melted down and the copper

would be reused in other parts of the home because copper is a very expensive metal.

As of the batteries they will be recycled and used to create new batteries. There will beno great impacts on the society.

References

http://arpa-e.energy.gov/LinkClick.aspx?fileticket=k-81ITzfv34%3D&tabid=259

http://www.batterystuff.com/kb/articles/battery-articles/battery-basics.html http://www.pnm.com/systems/lines.htm http://itep68.itep.nau.edu/itep_downloads/Anchorage_11SWM_Haz/Day2/Backhaul/TRI

%20Lead%20Acid%20Battery%20Instructions.pdf

http://www.sandia.gov/ess/docs/pr_conferences/2010/hund_snl.pdf

http://www.furukawadenchi.co.jp/english/research/new/ultra.htm

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