Case study 3

Demonstration of storage in the factory
Li-Ion battery installed in industrial zone
Navarra, Spain
Duration of demonstration:
April 2016 - May 2020

The target is to analyse and enhance the distributed power generation, so that the dependence of the distribution network would be reduced.

A further step in this process is the introduction of electric storage batteries, managing their programming to reduce customer energy costs (using battery power during the most expensive tariff periods of the network) and also reducing the peak power of the energy bill, covering these with energy accumulated in batteries.

Demonstration of storage in the factory

The target is to analyse and enhance the distributed power generation, so that the dependence of the distribution network would be reduced.

Navarra, Spain

Exkal demonstration in STORY is based on a storage system with Ion- Lithium battery, adapting an existing Photovoltaic Facility of 112,70 kWp installed on the roof of the factory for instant self-consumption, into a storage facility, focus on several targets:

  • Reduce peak power of the energy bill for industrial sector combining storage/batteries with PV integration.
  • Reduce energy factor of the energy bill by the consumption of energy stored on batteries during the most expensive tariff period of the day.

For the dimensioning of the storage system, we take as starting point for this demonstration:

  • A Power demand of around 280 kW per tariff period
  • Storage of 50 kW, 200 kWh with Ion- Lithium battery

Responsible partner: Exkal

"It's a great opportunity to show that the storage of energy is a reality that has already arrived, and will change our future."
Clemente López Gilardi, Exkal

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August 15, 2015
Download from meter data of consumption & download from EMS MANAGER (meter) data of PV Generation

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November 15, 2015
Overview of available data for demonstration

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February 1, 2016
Install of storage system and adapt it to the existing PV facility

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April 1, 2016
Launch of the purchasing of the store system (batteries and power electronic)

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April 1, 2016
Proofs of the storage system assembled at CINERGIA

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September 1, 2016
Transportation and installation of the Store system at EXKAL, in Marcilla (Navarra)

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PV Facility placed on the roof of the warehouse of EXKAL in Marcilla, Navarra

  • PV Installation of 112.70 kWp
  • The facility consists of 23 strings of 20 PV modules type LW245 of 245 watts each, for a total of 460 PV modules
  • Modules are fixed to the roof with galvanized structures of 25º tilt and an azimut

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PV Facility placed on the roof of the warehouse of EXKAL in Marcilla, Navarra

Main parts of the PV facility are:

  • 460 PV modules
  • 1 Inverter of 100 kWn
  • 1 MS Manager that prevents the discharge of energy to the distribution grid
  • PV installation saves 158.000 kWh/year to EXKAL, equivalent to the energy consumed by 72 households and CO2, that represents savings of 102.7 Tn/year

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Device that transforms direct energy into alternative current energy (DC to AC)

The electrical cabinet that you see on the left hand is the inverter. It is the device that transforms direct energy into alternative current energy (DC to AC), thus making it possible to return energy to the general grid  or to our internal grid, as it is in the case of self-consumption. I our case, this device is a model Ingecon Sun 100, manufactured by Ingeteam, of 100 kWn of power. On the right hand of the picture, you can see the electric board with all protections and control of the components, with DC components on the left hand and AC protections on the right hand.

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In principle, the charge of the batteries would be made with the energy generated by the PV facility, but the power electronic Equipment, MM60 of 60 kVA / 54kW, will have the flexibility to make the charge of the batteries from the Electrical Grid, in the future.

In this particular project, the decision of charging or consuming energy of the batteries will be taken by an external control system designed based on parameters as DOD, cost of energy, consumption… The MM controls the flow of energy to have these data always monitored within the limits fit by the battery manufacturer not to be exceeded. 

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By controlling the active and reactive power Microgrid Manager MM60 may have the following functions:

  • Storage of surpluses of renewable energy
  • Reduction peaks power (peak shaving)
  • Reducing energy consumption of the grid at peak hours
  • Compensation of reactive power (power factor)
  • Balanced consumption phase

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Operation and supervision of the equipment is done remotely from MODBUS / TCP over Ethernet. Also it has an LCD display on the front that allows a basic monitoring of the equipment status.

  • The equipment can be operated and monitored remotely via an Ethernet bus communications. A PC-embedded internally, allows the exchange of information between the internal CAN bus and the external Modbus TCP / IP (Ethernet). Thus, the Microgrid Manager acts as a server Modbus TCP /IP.

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