
Industrial-scale Lithium-ion Energy Storage Batteries for mining projects
Long-lasting and High-Performance Energy Storage
BlueNova is a manufacturer and supplier of a wide range of energy storage solutions for clients in different sectors. The company’s A-grade Lithium Iron Phosphate (LiFePO4) product offering is a perfect fit for addressing the demand for reliable energy storage in industries in the region. The chemistry has several advantages over lead acid energy storage batteries.
With increasing investment in power generation projects in Africa, there is a simultaneous need for industrial-scale energy storage solutions. To fill this gap, BlueNova has a wide selection of products divided into several product ranges bespoke for the different needs of clients.
Wide capacity range
BlueNova supplies A-grade Lithium Iron Phosphate (LiFePO4) batteries ranging in capacity from 104Wh (for powering gate motors and security systems) to 1.3MWh (for powering large office blocks or microgrids).
Besides batteries, BlueNova develops devices such as the BMAC (Battery Monitor and Control (BMAC). The BMAC not only facilitates serial (CAN) communication between its batteries and select inverters, but also enables remote monitoring of battery peripherals. This allows the company to provide unparalleled technical support in the industry.
The company’s medium to large solutions, as well as BMS electronics, are built at its facilities. Its smaller products are imported. However, BlueNova’s team tests and supports the products in terms of technical support and warranty.
Tailor-made turnkey solutions
BlueNova offers tailor-made turnkey solutions to meet the demand for industry-scale energy storage coverage. Its iESS (Intelligent Energy Storage Systems) are designed to meet the specific requirements of its owners. iESS systems typically include a battery bank, high voltage inverter(s), air conditioning, fire suppression, access control and remote monitoring electronics.
The battery pack includes a ten-year warranty supported by BlueNova and the inverter(s) and other components typically also include warranties from various suppliers. The battery pack includes its own BMS electronics. In general, BlueNova can provide delivery, commissioning and continuous technical support for the systems.
Delivering a suitable solution
BlueNova undertakes a thorough process to ensure that a client, for instance, a mining company in Africa, has a suitable lithium energy solution for its needs. Its technical sales representatives handle enquiries from customers.
The requirements that the representatives would normally need to confirm to provide a suitable solution include the following:
- Usable capacity requirements (including autonomy)
- Continuous & peak power requirements
- Application of the battery
- Inverters and/or chargers to be integrated with
- Additional charging sources (solar arrays, generators etc.) that would be included in the system
- Certain applications might require feedback on more than the above. Once requirements and expectations have been established, we propose one or more solutions that can then be discussed further if necessary.
Minimising downtime
BlueNova recognises that downtime to a battery storage system can be very costly to a mining company, leading to loss of productivity and revenue. For this reason, it has provisions firmly in place to minimise downtime.
BlueNova has established that the best countermeasure to possible downtime is for the battery/battery system to be remotely monitored. In this way, downtime can then be pre-empted and thus avoided. And so, the company offers several remote monitoring solutions that include functionalities that warn users and the technical support team automatically through SMS. For instance, these would be cases where power demand approaches higher than normal levels of capacity is discharged to levels beyond what was previously configured as “safe”.
Advantages of BlueNova LiFePO4 over lead acid
BlueNova assures customers that its A-grade Lithium Iron Phosphate (LiFePO4) medium to large batteries offer several advantages over conventional lead acid. Mainly, these include but are not isolated to:
- Longer Depth of Discharge (DOD)
A-grade Lithium Iron Phosphate (LiFePO4) cells fade with a maximum of 20% over the service life. The recommended maximum depth of discharge (DoD) of the batteries is 80%, which ensures a cycle life of 5000 cycles.
On the other hand, lead batteries can only be discharged to 40-50% DoD, and will then only yield a cycle life of 1800-2500 cycles for premium lead batteries. The BlueNova team states that performing a cost analysis based on these variables will illustrate that the running costs for LiFePO4 batteries is substantially lower than that of premium lead batteries.
- Less weight
LiFePO4 batteries are much lighter compared to lead acid batteries with equivalent capacities. Its weight is a quarter of a lead acid battery with the equivalent capacity, and the volume is a third of an equivalent lead acid battery. This not only translates to easier installation but also to financial savings associated with transportation fees. Such savings are further multiplied considering that LiFePO4 batteries last much longer than lead acid batteries and would therefore need to be replaced much less often.
- High charge efficiency
The charge efficiency of LiFePO4 batteries is 96% (4% lost), if recharged over two hours. This efficiency improves to 98% (2% lost) if recharged over ten hours.
In comparison, the average charge efficiency of lead acid batteries is 67% (33% lost). Lead acid batteries can also not be recharged in two hours. The closer a lead acid battery gets to 100% state of charge (SoC), the slower it charges.
Additionally, over-charging a lead acid battery will inevitably shorten its lifespan dramatically and may result in toxic gases being vented from the battery. Lead acid batteries are dangerous under these circumstances and may result in thermal events and subsequent insurance claims.
- Safest battery
LiFePO4 batteries are the safest lithium-based batteries available (apart from lithium titanante). This is based on findings of rigorous tests conducted worldwide. LiFePO4 batteries have been punctured, crushed and incinerated in tests performed by several independent companies. Fascinatingly, this has never led to a thermal event taking place (unlike with the more dangerous chemistries in the lithium-ion family, such as lithium nickel cobalt oxide found in cell phone & laptop batteries).
LiFePO4‘s safety is further bolstered by the fact that LiFePO4 batteries include battery management system (BMS) electronics, which protect the batteries against over-charge, over-discharge and short-circuit complications.
- Warranty
One of the common concerns of end-users is the lack or limited warranty on critical components of products. Given this, on its part, Bluenova guarantees that most of its products include a 10-year warranty entailing local technical support on products that it has developed and supplied itself (incl. electronics). The company warrants that no other local supplier of LiFePO4 batteries can make this claim in its entirety.
BlueNova is keen to be involved in industrial projects where there is a need for medium to large-scale battery storage solutions.
Sidebar
BlueNova’s competitive
The battery storage arena has seen the entry of several players jostling to get a piece of the market pie, targetting the growing niche of renewables. BlueNova acknowledges that this is good for the end-user. However, it recognises that companies with a competitive edge will excel.
The company has always believed that, to remain competitive in the energy sector, it has to differentiate itself by means of continued innovation. This approach to doing business has led to the development and successful rollout over the years of the following:
High Current Product Range: Stainless steel enclosed and built with A-grade LiFePO4 cells with a characteristic maximum fade of 20% over a 10-year minimum service life. 10-year warranty included.
Battery Rack Series: Identical to the HC Range above except for the redesigned modular layout, specifically to simplify transportation to & installation at remote locations.
High Voltage Series: For deployment in high-performance demand environments. Developed for integration with ATESS® HPS inverters & subsequently officially approved by them.
iESS: Intelligent Energy Storage Systems. Its flagship products are each designed individually to meet exact requirements. Components typically consist of battery storage, inverter(s), local and remote monitoring, air conditioning, fire suppression and access control components which is built into 6m or 12m shipping containers. Noteworthy, BlueNova is currently in the final stages of production of the largest iESS system that it has supplied to date, with a rated continuous power output of 1.2MW and battery capacity of 1.3MWh. This is due to be delivered & installed in Australia.
Own BMS (battery management system) which is integrated into all four of the above product ranges.
Compact Power Stations: Wall-mounted systems that each include battery storage, inverter, output and distribution components. Preconfigured for UPS applications & designed for easy installation in residential and small commercial environments as solutions to load shedding.
BMAC (Battery Monitor and Control): This is a multi-purpose electronic module that can be installed for one or more of the following purposes:
- To facilitate serial (CAN) communication between its products and inverters, as well as other peripheral devices by ensuring that sent and received CAN data strings are translated correctly. The firmware of BMAC modules can be updated remotely by design. This is in instances where battery/inverter communication compatibility is suddenly lost because of an inverter firmware update.
- To enable in-depth remote monitoring functionality of battery performance and health variables from any internet-connected location worldwide (requires internet-connected Wi-Fi on site). Remote access to this data not only provides many clients with peace of mind regarding their investments but also enables the company to provide technical support of exceptional quality.
Auto Mode Change: A patented algorithm has been developed primarily to ensure that batteries will be charged to maximum capacity automatically in preparation for scheduled load shedding events and/or forecasted bad weather (backup mode). Then, it reverts automatically to standard operation (cycle mode) under favourable conditions to maximise investment returns.
Fascinatingly, BlueNova’s Research and Development (R&D) team is currently working on an algorithm for the BMAC that would monitor the load shedding schedule as well as weather forecasts. This will ensure that sufficient battery capacity is always available to our clients under less-than-ideal circumstances.