Design Scheme of Lithium Batteries for Industrial and Commercial Energy Storage Systems
I. Background of Industrial and Commercial Energy Storage Systems
Policy-driven
▲ The dual carbon goals lead the way: China has set the goals of peaking carbon emissions before 2030 and achieving carbon neutrality before 2060. Against this backdrop, industry and commerce, as a significant sector of carbon emissions, account for approximately 70% of the country's total carbon emissions. There is an urgent need to promote energy transformation through technologies such as energy storage to reduce carbon emissions.
▲ Electricity price mechanism reform: Since the state issued policies to improve the time-of-use electricity price mechanism on July 26, 2021, the price difference between peak and off-peak hours in various regions has gradually widened, creating conditions for industrial and commercial energy storage to obtain profits through "peak-valley arbitrage". On May 15, 2023, the provincial power grid transmission and distribution prices and reforms in the third regulatory cycle were implemented. The capacity (demand) price was generally raised, the electricity price was reduced, and users were encouraged to manage demand, bringing new revenue points to industrial and commercial energy storage.
The economic benefits are prominent.
▲ Reduce electricity costs: Industrial and commercial energy storage can take advantage of the price difference between peak and off-peak hours, charging during off-peak hours and discharging during peak hours, avoiding the need to purchase electricity at high prices. It can also participate in demand management, reducing electricity expenses based on demand. According to relevant research, industrial parks that combine industrial and commercial energy storage with photovoltaic power generation can achieve an energy self-sufficiency rate of over 30% and reduce annual energy costs by approximately 40%.
▲ Increase additional revenue: Industrial and commercial energy storage can participate in demand-side response. When the grid load is tight, it can adjust its power consumption behavior according to the grid dispatching requirements, thereby obtaining corresponding compensation revenue.
Energy security guarantee
▲ Dealing with emergencies: In the event of power outages caused by natural disasters, power grid failures, etc., industrial and commercial energy storage can serve as a backup power source to ensure the operation of key equipment in enterprises and prevent losses such as production interruptions and equipment damage due to power outages.
▲ Alleviating peak electricity consumption pressure: During peak electricity consumption periods such as summer, the power supply capacity of the power grid is tight. Local power grids will take power rationing measures for enterprises. Industrial and commercial energy storage can store electricity in advance and supply power to enterprises during the rationing period to ensure the continuity of production.
Technological progress support
▲ Improvement of energy storage technology: In recent years, energy storage technology has been continuously developing. The performance of energy storage technologies such as lithium-ion batteries and flow batteries has been constantly improving, costs have gradually decreased, and safety and reliability have been continuously enhanced, providing technical support for the large-scale application of industrial and commercial energy storage.
The development of smart grid: The advancement of smart grid technology has continuously enhanced the grid's ability to access and manage distributed energy, enabling it to better adapt to the interaction between industrial and commercial energy storage and the grid and achieve the optimal allocation of energy.
New energy lithium batteries, with their advantages of high energy density, long cycle life and environmental friendliness, have gradually become the preferred solution for industrial and commercial energy storage systems. This solution is designed to meet the application requirements of lithium batteries in industrial and commercial energy storage system equipment projects, ensuring that lithium batteries can provide safe, efficient and customized power solutions for their equipment in special fields.
II. Analysis of Equipment Demand Characteristics
1. Equipment application characteristics
▲ Equipment type: It is used in industrial and commercial enterprises, data centers, commercial complexes, etc. with high electricity consumption.
▲ Working environment: Temperature range, from -20℃ to +70℃, high temperature, extremely cold, high humidity environment, etc.
▲ Power demand: Large continuous/peak power and long battery life. The voltage platform generally adopts high-voltage platforms such as 12.8V or 48V.
2. Core requirements for lithium batteries
High security: Mature and standardized technology, with minimal environmental impact, etc.
▲ Long cycle life: ≥2000 times (80% capacity retention rate).
▲ Fast charging: Supports fast charging and is suitable for high-intensity work.
▲ High-power discharge: The battery supports continuous high-current discharge, meeting the high-current requirements of high-power devices and ensuring their continuous and stable operation.
▲ Intelligent management: The BMS (Battery Management System) is equipped with functions such as overcharge protection, overdischarge protection, overcurrent protection, short-circuit protection, temperature protection, and fault diagnosis, making the battery more intelligent.
▲ Discharge temperature range: -20℃ to +70℃. In a low-temperature environment of -20℃, the battery's discharge efficiency is over 70%. A wider range of ambient temperature adaptability.
▲ Charging temperature: -20 ℃ to +50℃ range, with a wider adaptability to environmental temperatures.
III. Scheme Design
1. Battery selection
▲ Cell types: Ternary lithium batteries (ultra-low temperature, high energy density, high safety), lithium iron phosphate batteries (ultra-low temperature, high safety, long life), sodium-ion batteries (high safety, long life, good low-temperature performance). Different system cells are selected and matched according to different application scenarios.
▲ Battery combination configuration structure: Series and parallel schemes are designed based on the required voltage and capacity of the equipment to meet the requirements of different output voltage platforms.
▲ Structural design: IP65 to IP68 protection grade, shock-resistant structure, explosion-proof enclosure (suitable for extreme environments or flammable and explosive environments).
2. BMS Management System
Core functions:
▲ Real-time monitoring of the voltage, temperature, SOC (State of Charge), and SOH (State of Health) of individual battery cells.
▲ The battery charging active balancing technology enhances the consistency of usage among battery cells and extends the lifespan of the battery pack.
▲ The I2C/SMBUS/CAN/RS485 communication interface enables data interaction and communication with the main control system of the equipment.
▲ The Coulomb computing method makes the battery SOC more accurate and the battery smarter.
3. Charging solution
▲ Charging equipment: Customized intelligent solar photovoltaic panels, supporting constant current and constant voltage (CC-CV) charging.
▲ Charging strategy: Select fast charging or slow charging mode based on the working conditions to prevent battery overload.
▲ Intelligent control and management: Based on the technical performance characteristics of the battery, the battery charging process and fault diagnosis are intelligently controlled.
IV. Safety and Compliance
1. Safety protection
▲ Thermal management: By adopting a reasonable structural layout, thermal runaway is reduced. Air cooling/liquid cooling systems can be used (for high-power scenarios) to ensure temperature uniformity during battery use and effectively control battery thermal runaway.
▲ Fault protection: Multiple hardware protection mechanisms such as overcharge, overdischarge, short circuit, overcurrent, and over-temperature.
▲ Fault protection: Multiple hardware protection mechanisms such as short circuit, overcurrent, and over-temperature.
▲ Explosion-proof certification: The design can pass various safety regulations certifications.
2. Standard compliance
▲ It complies with national standards such as GB31241-2022 (Safety Technical Specification for Lithium-ion Batteries and Battery Packs for Portable Electronic Products), GB 17761-2024 (Safety Technical Specification for Electric Bicycles), GB/T 34131 (Lithium Batteries for Power Storage), GB 38031 (Safety Requirements for Batteries for Electric Vehicles), etc.
▲ How to obtain domestic and international certifications: GB certification, UN38.3 certification, UL certification, IEC certification, CE certification and other various certification requirements;
V. Project Implementation Plan
Number |
Progress stage |
Project content |
Periodic plan |
1 |
Demand research |
Equipment parameter and working condition data collection |
Within one week |
2 |
Scheme design |
Customized battery packs and BMS development |
2~3weeks |
3 |
Sample testing | Charging and discharging, high and low temperature, safety protection, structural performance verification testing, design compliance verification testing |
3~4weeks |
4 |
Small-batch trial production | Material preparation plan, production assembly, aging, and full inspection and testing |
2~3weeks |
5 |
Medium-batch trial production | Material preparation plan, production assembly, aging, and full inspection and testing |
2~3weeks |
6 |
Mass production | Material preparation plan, production assembly, aging, and full inspection and testing |
4~6weeks |
7 |
Delivery, transportation and maintenance | Installation and commissioning, operation training | Within one week |
VI. Economic Benefit Analysis
1.In terms of cost
▲ The initial investment in the early development stage is relatively large, which gives it an absolute advantage in terms of long-term usage costs.
2. Energy-saving benefits:
▲ It can increase the self-sufficiency rate of energy, balance peak and valley loads, optimize electricity charges, and reduce the pressure on the power grid.
3. Maintenance cost:
▲ The long service life of equipment leads to cost dilution, and intelligent operation and maintenance reduces labor costs.
VII. After-sales Service
1. Warranty period: 5 to 10 years of after-sales warranty, with a lifespan of over 2,000 to 5,000 cycles (whichever comes first).
2. Remote monitoring: According to the actual demand status, the cloud platform provides real-time monitoring of the battery status and early warning of potential faults.
3. Emergency Response: Respond within 4 hours, provide solutions within 8 hours, and offer on-site technical support within 24 to 48 hours.
Hint:
▲ The plan needs to be refined based on specific equipment parameters (such as voltage, capacity, and size limitations).
▲ If special environments are involved, corresponding protective designs need to be added.
▲ It is recommended to conduct joint debugging with the equipment manufacturer to ensure that the battery is compatible with the entire machine system