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EESAT’02 Electricity Storage Conference

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The Electric Energy Storage Applications and Technologies Conference (EESAT 2002) was held in San Francisco April 15-17, 2002. Ever hopeful for the promise of storage, sponsors point to growth in markets, increased focus on reliability (supply crises and terrorism), and advances in technology. Evidence includes the increasing number of demonstration projects, and estimates that more than 100MW of advanced, distributed energy storage is being installed in North America this year, and another 100MW in Europe and Japan.

Session titles were:
– Overview of Electrical Energy Storage Applications & Technologies
– Multi-megawatt Applications
– Advanced Battery Applications
– Power Electronics and Conversion Systems
– Design and System Studies
– Flywheel Applications
– Capacitor and Super Capacitor Development and Applications
– High Speed Flywheel Development
– Battery Development and Applications

The website has the agenda with the complete list of papers.
http://www.sandia.gov/eesat/
It also provides the agenda from EESAT 2000*. I have the CD of the papers, if you want any of them. The 2002 papers should be available shortly to attendees, and I will supply them as well.
*(29 Oct 2000 UFTO Note – Travel Reports)

The ESA newsletter provides a helpful summary of the conference:
http://www.energystorage.org/archive/Newsletter_May_2002.pdf

And while we’re on the subject, have a look at this comprehensive technology overview:
http://www.re-focus.net/mar2002_4.html

Not on the agenda, but noteworthy: A new lobbying and educational group has formed; the Energy Storage Council promotes public policy that supports energy storage as a key dimension of the electricity value chain. This is the brainstorm of Jason Makansi, former editor-in-chief of McGraw-Hill’s Power magazine. Membership information and a white paper can be found on the website:
http://www.energystoragecouncil.org

Flow Batteries
Perhaps the biggest news is the progess that large scale “flow” batteries are making, both technically and commercially, for large scale systems (100 kw and up). Recall that there are several competing electrochemical schemes. A comparative assessment of flow batteries was provided in a paper by C. Lotspeich based on work done for an E-Source report.

– Regenesys- sodium bromide and sodium polysulphide (ufto note Sep’99)
– ZBB & Powercell – zinc bromine
– Vanteck & Sumitomo/Reliable Power – vanadium redox
– Plurion – cerium vanadium MSA

Except for the zinc bromine, they offer freedom to size a system’s power (kw) and capacity (kwh) separately (either aspect can be added to over time), by adding either cells or electrolyte storage.

Regensys is building their first N American installation at TVA. It will be 12 MW/120 MWH.
http://www.regenesys.com

ZBB’s demonstrations of a transportable system are proceeding well, in collaboration with Detroit Edison. This is 200kW/400kWh battery system, on a 40 ft trailer. The application is grid support. http://www.zbbenergy.com/

Powercell may be revived from bankruptcy. Too soon to tell. Word is that some of the former management team is trying to put it back together.
http://www.powercell.com/

Vanteck has resolved its corporate problems and has a field trial underway in S Africa for a 250 kw/520kWh system. The vanadium technology boasts very high power delivered over milliseconds or slower discharge over days. They’ve also announced a commercial order from Pacificorp. http://www.vanteckvrb.com/

Reliable Power is Sumitomo Electric Intl (SEI)’s presence in N America for SEI’s vanadium battery systems. (SEI is one of the original licensees of the patents.) Size range is 100kw-3MW. UPS *and* peakshaving. Peakshaving earns$ day in and day out, while the UPS sits and waits to deal with a power glitch. Very high power for 3 sec… 3 MW, or 1.5MW for an hour. Meanwhile, Sumitomo has a number of fully commercial systems in operation in Japan.

Plurion, a brand new arrival on the scene, made its public debut at the conference. Its chemistry is based on cerium and vanadium in a “mixed electrolyte” with methanesulfonic acid (MSA). They claim cheaper longer lasting electrodes and membranes, greater simplicity, and lower cost. The system requires neither nafion or precious metal catalysts. Electrolyte management is said to be simpler than in other systems, requiring no ongoing cleanup treatment. Remarkable in the current investment climate, the company raised $14 Million recently, and is on schedule with an ambitious development plan. The technology was developed by Electrochemical Design Associates, Inc (Berkeley CA), and EDA is doing most of the ongoing technical work. http://www.e-d-a.com/ [I have press releases and their powerpoint presentation that I can provide on request.]

Flywheels, Capacitors, Other Batteries

Progress continues on many fronts, with commercial or near commercial applications taking hold. Systems studies examined grid support and ancillary services, microgrids, and identifying best applications and key variables to cost effectiveness.

Travel Reports

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In September, I attended these three conferences. They were all different, but also had a great deal in common. This writeup attempts to capture major themes and to provide highlights of some of the more interesting developments that came to light. Please don’t hesitate to let me know if you’d like further details on anything discussed below (or anything you see on the agendas that I didn’t mention).

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EESAT Electric Energy Storage Applications and Technologies Conf.
Sept 18-20, 2000, Orlando, FL

Distributed Power Strategies and Business Opportunities
Sept 25-27,2000, Washington, DC

Clean Energy Roundtable
Sept 27-29, 2000, Aspen, CO

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One major common theme–

“Attack of the Killer Investment B’s”

Many investment banking firms are cranking up bigtime to get a piece of the action in high9s-clean-distributed energy technology. They’re starting to “get it” and don’t want to miss out, though there’s a lot they don’t know about it (and their in-house utility analysts aren’t much help). They’re attending these events in ever increasing force, and also putting on their own!

BofA Securities, CIBC World Markets, Robertson Stephens, First Albany, Deutsche Banc Alex Brown, Morgan Stanley, Goldman Sachs, Lehman … They’re issuing research reports, initiating coverage, and investing in and pushing services to companies in this industry. Not only are they coming to energy conferences, they’re putting on their own, usually invitation-only for clients and other investors.

– Goldman Sachs will be handling Powercell’s (zinc-bromine flow battery) next financing, following a recent $30 Million infusion from a variety of investors.

– Credit Suisse First Boston is acquiring DLJ, which is doing a private placement for ZBB (the other zinc-bromine flow battery).

– Bear Stearns, famous for their very popular 250 page research report, “Distributed Energy Services” back in April, is coming out with one on microturbines in the next couple of weeks, with more to follow.

– Beacon Group, recently acquired by Chase H&Q, has been actively doing energy technology investments alongside their extensive array of more traditional energy sector plays.

– Price Waterhouse Cooper is helping STM (stirling motor) to raise $4M each coming from a coalition of DTE, Delco Remy, Ricardo (engine consultants) and a group from Singapore, to be followed in the near future with a probable private offering.

The main drivers behind all this excitement include deregulation/competition, demand for premium power, environmental concerns (new regs, Kyoto, etc.), and technology advances (renewables, distributed resources, and the internet). Add to that the general supply crunch here and abroad. While there are some aspects of the investment “flavor of the month”, these trends are seen as real, irreversible, and significant.

Traditionally, development stage companies are financed by venture capital or corporate money. Now, however, companies are going public earlier and earlier (“pre-earnings” and even “pre-revenue”). This means that retail investors are engaging in “public venture capital” as it has been called, taking on the higher risk of early stage companies.

Speaking plainly, there’s a bubble in the pre-ipo and public company stocks that is similar to what’s been happening in the dot-com world and elsewhere. The players are piling on, and both good and bad can come of it. While this industry enjoys all the attention and increased capital (and valuations), there will be a continual shaking out, with big winners and losers–as we’ve seen very recently. One just hopes the losers won’t put a drag on the whole sector.

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Clean Energy Roundtable http://www.montreuxenergy.com

This is one in a series of invitation-only conferences, many in Europe, targeting senior executives. The “Aspen Clean Energy Roundtable” meeting was the 7th annual such event, with many repeat attendees. A number of major energy companies, bankers, and NGO’s were represented, plus a sizable contingent from the DOE National Labs, but just a few utility people. Speakers are strongly discouraged from doing sales pitches, but rather to shed light on big trends and issues.

The biggest trend and issue — a widely held view that is an absolute necessity to come up with a “low/no carbon” energy future, in light of global climate risks and population growth and economic development. Furthermore, hydrogen is the key, as the main energy carrier of the future. There were a few visionaries who began talking about the potential of a “hydrogen economy” in the mid 70’s (during the first oil crisis). Maybe their day is coming.

Another prominent theme was the evolving role of government, from “Nanny” to enabler. Bruce Stram of Enron Energy Services spoke about this historic role of government, intervening heavily to cope with market imperfections, as less necessary as telecommunications and information flow improve. Instead, government should avoid “command and control” and instead punish social externalities with penalties, and support a vigorous R&D program.

Swiss Re reviewed their outlook that global climate issues represent huge risks to the insurance industry, noting losses from hurricanes and other weather-related damages. They’ve been very active promoting Kyoto, emissions trading, and clean development mechanisms.
http://www.swissre.com/e/issues/environmental.html

Shell Hydrogen is a new independent business within the Shell group. CEO Don Huberts explained the parent company’s commitment to sustainable development (disposed of coal assets, and set up Shell Renewables and Shell Hydrogen). He described a 250 kW SOFC installation in Norway integrated with fish farming, use of an SOFC with injection of CO2 into depleted wells and deep aquifers, commercial and residential CHP with SOFC or PEM, and a proprietary natural gas processor to make hydrogen for residential fuel cells.
http://www.shell.com/hydrogen-en/

Valuing Renewables — Shimon Awerbuch of ICF Consulting reviewed his work on using a portfolio approach to valuing renewables. Traditional engineering-based approaches are completely inadequate–they ignore financial risk; they didn’t work in manufacturing (completely missed computers, robotics, and CAD); and they don’t work for high capital, low operating cost projects. Portfolio concepts are routinely applied in securities investment, where adding even a higher cost (lower return) investment to a portfolio can reduce the total risk, for an overall better result. See his articles Public Utilities Fortnightly, Feb 15, 2000, and Energy Policy (to be published) awerbuch@aol.com

Other presentations included:

CMS Energy is pursuing environmentally friendly technology solutions, including microturbines for gas field pumping operations, a methanol plant installed in Africa to eliminate a massive gas flare, and their own “virtual power plant” program they’re calling Elan (electric local area network).

Honeywell’s microturbine group sees their devices fitting into a seamless array of energy management systems, controlled over the internet in real time.

Stirling Energy Systems, in Phoenix, is gearing up to develop huge solar power farms using dish concentrators with the Swedish-made Kockums stirling engine.

H-Power is aggressively pursuing rural markets for their existing commercial small scale PEM fuel cell systems.

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Electric Energy Storage Applications and Technologies Conf.
EESAT http://www.cmcmtg.com/eesat

The message is similar to the June ESA meeting [See UFTO Note, 25 April, 2000]
–storage is coming into its own, as part of the boom in new energy technology, along with DG, renewables, premium power, etc. The complete proceedings will be published in hardcopy and on a CD, by early December.
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Keynoter Bill Parks, the lead for DOE’s new Distributed Power effort, [UFTO Note May 31] noted the convergence of many issues, including growth (economic, population and energy demand), price spikes, high oil imports, power quality needs, air and water quality, and climate change. New companies are entering, and everyone proclaims to be green. On top of that, average energy efficiency in the US hasn’t improved, capacity margins are below 10%, and power infrastructure is aging. DOE’s expanded efforts will go beyond the core technology R&D emphasis, to deal with systems, and to address institutional barriers. For example, the IRS is reviewing depreciation schedules for CHP and DG.
~~
Value of Storage – Tom Jenkin, Brattle Group, described an LP model they’ve developed to analyze in detail the arbitrage possibilities for a storage system. The model calculates the maximum net revenue over a one week period by optimizing the use of a generic storage device, hour by hour. At any given time, the device can do one of four things: charge (i.e. buy energy), sell energy, sell reserve capacity, or do nothing. Using price data for the California ISO, initial results suggest a capital cost of $250-$750/kW can be supported in this kind of application. tjenkin@brattle.com, 617-864-1576.
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At EA Technology (UK), they’ve developed a model to calculate net present value cost-benefit of various storage technologies in various applications. Alan Collinson, abc@eatl.co.uk
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Regenesys, the National Power spin off, has announced their first commercial scale project (120 MWH, 15 MW) at a power plant in the UK. This is one of the prominent “flow” battery technologies discussed several times before in UFTO Notes. Notably, they have qualified it to provide blackstart, in addition to energy management, arbitrage, and frequency and voltage regulation. They also have an initial agreement with TVA to the first N American installation.
http://www.innogytech.com
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Tokyo Electric is getting good results with their advanced sealed Sodium-Sulfur battery. A key to safety is an innovative self-shut down mechanism where an inner tube expands if heated (by the reactions that would result from a leak) and blocks the ceramic electrolyte. A 6 MW, 48 MWH system has been operating since mid 1999, for load leveling and ancillary services.
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AutoCap reported on the advantages of charging battery cells individually, greatly extending the expected life of batteries in large systems. When an entire string of cells are charged in series, due to variations some cells are overcharged and some undercharged. They’ve developed a system with an isolated charger, and a cell selector device that monitors and charges one cell at a time. This applies only to the maintenance charging, not the heavy recharging cycle after a discharge.
http://www.autocap.com/
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New Supercapacitor — there are countless stories around about ultracaps or supercaps. Many use low voltage aqueous electrolyte concepts, with extremely high surface area electrodes made of very porous materials, and utilizing the double layer effect. Though they can deliver unheard of capacitance in small packages (farads instead of microfarads), these cells have problems with high impedance and self-discharge. To reach any useful working voltage, cells must be put in series, and run into additional issues to do with voltage balance. According to tests of an 11,000 Farad unit at EPRI PEAC, a Russian company has a breakthrough concept involves an asymmetrical design, which solves these problems, and can deliver very high discharge rates over a wide temperature range, with high specific energy.
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From the website: http://www.esma-cap.com
“JSC ESMA electrochemical capacitors utilize a polar cell and aqueous electrolyte. The negative electrode is made of an activated carbon material having high surface area, where electric energy is accumulated at the electric double layer. The positive electrode is made of nickel hydroxide and designed for high charge/discharge rate. This combination of electrodes provides a 4-5 times increase in specific energy over capacitors designed with both electrodes made of a carbon material. The maximum operating voltage of the cells ranges from 1.3 to 1.6 V depending on the capacitor type and its operating mode. The capacitor is prismatic in shape, with a case made of plastic. It has a resealable safety valve in its cover to release gas during improper use when a certain value of excess pressure is reached. JSC ESMA capacitors have been designed to remain in service even if the operating voltage level is exceeded. Capacitor operating characteristics do not degrade if the capacitor is operated under an excessive voltage level over a short time. The capacitors can withstand a short circuit current caused by improper handling.”
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Emitter Turn-Off Thyristor (ETO) is a new solid state switch developed at Virginia Tech that promises great improvement over GTOs and IGBTs. It is a hybrid based on the GTO and MOSFET. It is much smaller and simpler, it uses less drive power, and it is 10 times faster — it can turn off 3000 amps in 2-3 microseconds, vs. 30 for present devices. This speed will enable switches that can react to faults in time to safely turn off rather than relying on fusing. Virginia Tech is actively looking for licensees to commercialize the ETO. (I have pdf copies of the full paper and the patent application.)
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Zinc Bromine Flow Batteries (ZBB & Powercell) Powercell’s standard unit is the PowerBlock, 100kW/100kWh, in one self contained package complete with power electronics, is in production. (http://www.powercell.com) ZBB Technologies Inc. in Wisconsin is developing a larger utility scale version, with DOE funding. Two 400 kWh demonstration units are being installed on Detroit Edison’s system this Fall. Though based on the same original work at Exxon years ago, the two programs have important design differences.
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Flywheels!
Active Power, following on their very successful IPO, has a deal with Caterpillar, who is selling systems under the name CAT 250. This is a 250 KVA, 12 sec system. A price of $250-325/KVA was mentioned. Active Power has also recently built active harmonic filtering into the package. Duke Power reported on a demo installation at one of their customer sites.

Magnet-Motor (Germany) reported on their use of 2KWH/150 KW flywheels on public buses, ever since 1988. Company website: http://www.magnet-motor.de/homeengl.htm

Several programs are working on flywheels using superconducting magnetic bearings: the Shikoku Research Institute, Chubu Electric with Mitsubishi, and Boeing Phantom Works. This last one appears to have some resemblance to the earlier work at Argonne that was supported in part by ComEd. It is funded under the DOE Superconductivity Initiative.

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Distributed Power Strategies and Business Opportunities
Sept 25-27,2000, Washington, DC

http://www.intertechusa.com/energy/distributedpower2000/introduction.html

One of dozens of conferences on distributed power, this one had some big names and a high level of international participation, but no big announcements or new insights. As usual, the networking opportunities were at least if not more valuable than the sessions.
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Ake Almgren, CEO of Capstone, was co-chair, with Mark Fallek of DTE Energy. In his opening remarks he noted that DG and central station plants are both needed, it’s not an either-or situation. DG can be thought of as another way to “distribute” power, not to “generate” it. Central station plants have a very long lead time, and difficult siting requirements. Also, T&D costs contribute as much as $4-500/KW to the price of power, which DG can avoid. Fallek cited some future global market estimates for DG of $38 billion/year. Premium power, now a $50 billion market, is growing at 30%/yr, suggesting $500 billion in 15 years.
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Bob Shaw, who single-handedly invented venture capital in new energy technology, and who helped start many of the notable companies now making headlines, gave a perspective that was extremely bullish on DG and renewables, but a bit alarmed about the “bubble” situation. He is convinced that DG really will take over from central station power, sooner rather than later. DG is a perfect case of a “disruptive technology”. The engines built by US automakers every year are equivalent to the capacity of the entire US generating system. So, an industry 1/10 the size of Detroit could replace that system in a mere 10 years. The fact that VCs and Wall Street see energy technology as the “next big thing” is making capital available to this sector as never before, but it is also leading to unsustainable valuations that could become problematic. The paper is available online: http://www.arete-microgen.com. I also have a copy of the powerpoint presentation, which provides some additional material.
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“First, Second, or Third Coming??”
Is DG just a replay of one or two previous episodes, or very different this time? Shaw clearly espoused the latter view, but others were less convinced. In the 60’s, a midwestern gas company pushed a “total energy” concept based on reciprocating engines; maintenance problems and the poor suitability of recips to baseload operation proved the undoing. In the 80’s, the PURPA QF provisions led to a swarm of packaged cogen installations; QF contracts have all but faded from the scene. Shaw maintains that today’s convergence of developments is really different. Robert Swanekamp, editor of Power Magazine, took an extreme contrarian position that DG is a non-event, and that 1/2 of the large CCGT’s on order will be cancelled as a power glut emerges. He said he had no knowledge of the disruptive technology argument, but that didn’t stop him from dismissing it. (He was probably the only person present who hadn’t heard about Clayton Christensen’s ideas and their relevance to DG. See UFTO Note 19 April 1999; or http://www.disruptivetechnologies.com/)
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Technologies — there were a dozen or more presentations by companies: makers of fuel cells, stirling engines, and microturbines; power electronics, internet-based controls and energy management; and O&M.
Barriers — reports on the EEI and IEEE interconnection efforts; an excellent overview of competitive, institutional, regulatory and financial obstacles by Nat Treadway, (for a similar presentation, see http://www.leeric.lsu.edu/deri/info/may2000/treadway.pdf)

Energy Storage Assoc Meeting Notes

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Here are some notes from the recent meeting of the ESA, here in the SF
bay area. The ESA website will be posting additional information.
http://www.EnergyStorage.org/

Energy Storage Association
2000 Annual Meeting

“Cleaner, Greener Power through Energy Storage”
6-7 April 2000
Pleasanton, CA

OVERVIEW

Finally, energy storage appears to be breaking through, across a broad front. There are about 100 MW of pending purchases for systems in the US, and a comparable amount in Europe. This new success isn’t limited to one technology either, but is spread across many different ones, from flywheels to SMES to advanced Pb Acid to “flow” batteries. Applications range from small to large, from local UPS/power quality to grid support systems.

This meeting had as its theme the environmental implications of storage, noting the synergies with renewable power (e.g. to improve its dispatchability and application), and how storage also can improve the environmental performance of conventional plants.

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Flow Batteries

Flow batteries in particular are emerging strongly; four companies presented different chemistries and product niches.

In these systems, two electrolytes flow through a reactor, which is similar to a fuel cell, on either side of an separator membrane. When a voltage is applied across the reactor, the electrolytes change state and become “charged”. The “charged” electrolytes pass out of the reactor to be stored in tanks. Just like a conventional rechargeable battery, the process can be easily reversed. The “charged” electrolytes flow back through the reactor and electricity is produced. The technologies are environmentally benign, modular, comparatively easy to site, and separate the power rating from the energy storage capacity. They also appear to be free of the charge/discharge management issues that most battery chemistries suffer from, i.e. they can be fully discharged, and have no standby self-discharge losses (i.e. when the circulating pumps are turned off). Manufacturing and material costs are relatively low, and system costs will drop as the number of installations increases.

— Regenesys — Large Scale Utility Energy Storage — sodium bromide and sodium polysulphide electrolytes. An “electricity warehouse” reference design is based on 120 MWh with 10 hour discharge, max rated output 14.75 MW. Other configurations (5 – 500 MW) are possible. First plant at advanced stage of planning on a power station site in the UK. The first N. American “follow-on” installation is in advanced discussions. A transportable/containerised unit is suggested at 20 MWh, 2MW. (http://www.regenesys.com)

— Pinnacle VRB Ltd — Renewable and Remote Applications — vanadium (in various charge states). Invented at Univ of New South Wales, Australia. Licensed to Sumitomo and Mitshubishi in Japan. Sumitomo has developed collapsible storage tanks that can go through doors and manholes, enabling installation in existing structures. (High time-of-day rate differentials make diurnal peak shaving attractive.) Installation at SDGE as part of EPRI DR test program. A unit at a park hostel in Australia is 20 kw/120 kwh, part of a remote power system. Another on King Island is 100kw/1800 kwh supports a minigrid and drastically reduces diesel fuel and operating costs. (http://www.pinnaclevrb.com.au)

— Powercell — Zinc-Flow™ uses zinc bromide and polybromide solutions. Their standard unit is the PowerBlock, 100kW/100kWh, in one self contained package complete with power electronics. It is on the market, to date mostly through Williams Energy, and the company is ramping up production to meet the demand. (http://www.powercell.com)

— Cellennium — also uses vanadium. This Thailand based company is developing a wide range of applications, from small to large. (http://www.vanadiumbattery.com)

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Keynote Address: * Renewables, Distributed Generation and System Reliability in a Restructured Electric Supply Industry – Gregg Renkes, The Renkes Group, Ltd.

Renkes was staff to Senator Murkowski for many years, and directly involved in many of the congressional hearings on the energy industry. He gave a detailed view of how the players line up in Washington, particularly as to how the elections will impact restructuring legislation in the near future. Starting from a historical perspective (cold war, White House and Congress controlled by opposite parties), he uses various clues to how Gore and Bush’s views on energy will play out (in the closest race in recent history), and concludes they’re very similar. The current administration’s proposal, and what’s been done in Texas both point to restructuring, market mechanisms to deal with emissions, renewable standards, etc. In Congress, there’s also more agreement than disagreement, and the states’ speed on restructuring is pressuring Congress to do something sooner rather than later, regardless of election results. Grid reliability, and shortages expected this summer are high profile reasons for action. Overall, conditions are looking increasingly positive for distributed power, renewables, and storage application.

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* Energy Storage and Renewable Energy, BPA’s Perspectives
Mike Hoffman, Bonneville Power Administration

BPA is espousing an “EnergyWeb” concept, and see storage as an important element alongside distributed generation and renewables. In conjunction with wind, for example, storage can make it possible to dispatch wind power in the large flat blocks during peak demand, and displace carbon-based generation in the process. Wind power could also be bid into hour-ahead and week-ahead markets if the storage system has a high enough discharge rate. Customer side storage becomes relevant if there are demand charges–and retail access. Larger system configurations depend on local market structures. On the transmission system, storage presents many potential benefits, no one of which is enough by itself to justify the cost, but taken together could do it. Storage will be easier to site than new lines; it can help with congestion management, increase transfer capability, and replace contingencies. Transportable systems would overcome fears of stranded investment. Fast systems (e.g. SMES) can help with stability.

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* IBERDROLA’s Technology Demonstration Centre
Jesus Garcia Martin, IBERDROLA

This center supports the generation and other business units of Iderbola, one of the four large utilities in Spain. The only such facility in Spain, it evaluates and tests new technology, does technology transfer, and tries to reduce the time it takes to introduce new technology. In renewable energy, they have PV arrays, fuel cell demonstrations (one with Ansaldo in Italy is a molten carbonate), studies in biomass, thermal solar, wind and hybrid systems. There is also have a 2 MW battery storage system, operating for the last 4 years.

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* Power Quality Management as a Green Technology; Imre Gyuk, DOE

Storage is important for reliability and economic competitiveness, and it also plays a role as a green technology, by virtue of its ability to increase the potential of (intermittent) renewable energy sources by making them more dispatchable, and, for example, reducing/optimizing use of diesels in off grid or microgrid settings.

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* Flywheels for Renewable Energy and Power Quality Applications
Don Bender, Trinity Flywheel Power

(There was also a tour of Trinity’s plant nearby.) As lower tech flywheel (i.e. steel) systems are opening the market, high speed carbon composite systems are making steady progress, though they’re taking longer than anticipated. There’s been a lot of hype over the last 10 years, and only a small number of contenders are still around. Programs were underfunded, and had too much of a component, not system, focus. Also, requirements for vehicular applications were too severe for the first step.

Trinity’s “electromechanical battery,” as they like to call it, uses a 9 inch diameter rotor. Turning at 40,000 rpm, it will deliver 50 kW for 20 sec. Other configurations offer 100kW/15 sec to 250kW/3 sec, and 700kW/5 sec. Installed on a DC bus to add or remove power as needed, it can deliver energy, or power or both, from a compact package – power density (of the motor/generator and power electronics) starts at 5 kW/kg. The state of charge is always precisely known from the rotational speed. The balance of plant has turned out to be a bigger challenge than originally expected, and the power electronics have very special requirements. Flywheels should have an advantage for short duration power quality applications. Safety concerns have been addressed by a collaboration among most of the developers. You need either containment or rotor integrity, not both. Trinity has focused on rotor integrity, through extensive overspeed/burst testing.

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* Battery Energy Storage for Residential Photovoltaic Systems
Bill Brooks, Endecon Engineering

Over 75% of the 299 PV systems installed under CEC Emerging Renewables Buydown program in the first two years of the program include some amount of battery storage. (Even higher percentage among residential projects). The CEC Buydown does not apply to the battery portion of the systems. (even though several attempts were made to include batteries). Battery options are generally preferred and actually help sell the PV system by providing firm backup power capabilities. Batteries are here to stay in this market.

Most appropriate battery for this market is the Valve-Regulated Lead-Acid (VRLA) battery. Advantage—Low maintenance, good performance Disadvantage—Higher cost, intolerant of high temperatures or improper regulation voltages.

Enclosures need very little ventilation. Best if placed in garage or in an outdoor enclosure (in shade and/or conditioned to prevent high temperatures). Building inspectors are unfamiliar with reviewing battery installations; their requirements vary from plywood boxes to explosion-proof enclosures with four-hour fire ratings. Very few batteries or battery enclosures have listings or recognitions by testing labs. PV is blazing the way for a whole series of backup power options for residential and commercial customers.

The Trace 5548 Power Module has a5.5kW ac rating, 44-60V dc input, 120Vac output — Batteries and controls all in the same cabinet, up to 12 kWh in storage cabinet.

More Battery is ALWAYS better

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* Utility Evaluation and Demonstration of Dispersed Subsurface
Compressed Air Energy Storage, Dale Bradshaw, Tennessee Valley Authority

A 300 MW CAES site got pretty far in the planning stages in the early 90’s, but the plant was never built. Now TVA is considering a smaller scale system (10-20 MW; 6-10 hours) to be used close to the customer to help relieve transmission congestion. The compressed air field would consist of 3-4000 ft of 5-foot diameter gas pipe, laid out in any pattern convenient for the site, e.g. under a farmer’s field. The CT’s would always be available, even if the storage was exhausted, and while using the compressed air, plant output would not be sensitive to ambient air temperature, and would be a low cost source of spinning reserve, with rapid hot or cold start. Operating cost benefits compared with a CT become significant under higher gas prices.

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* Lithium Ion Batteries for Energy Storage Applications
Jim McDowall, SAFT America
Lithium Ion is not just one kind of battery, but refers to a whole family of battery materials and chemistries, with a wide range of characteristics. First proposed in 1990, and first shipped in 1993, they are now in 1/2 of all portable devices. Saft and others have been working on a large scale version for EV applications. Lithium is the lightest metal and offers the highest voltage. With no water present, there’s no problem with electrolysis during charging. SAFT’s battery has lithiated cobalt oxide as the positive electrode, lithium intercalated in graphite as the negative electrode, and the electrolyte consists of LiPF6 salt in an organic solvent. Lithium-Ion batteries must be protected from high temperature (they’ll burn over 150 deg C), overcharge, overdischarge, and over voltage. Therefore each cell must have its own built-in electronic monitoring and control. The batteries provide good cycling, high power, and deep discharge. They’re in pilot production and should be available commercially in 3 years. Though the initial cost is high, this will be very dependent on volume (as with so many new technologies). Life-cycle cost should eventually match Lead-Acid batteries.
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* Molten Salt as an Energy Storage Medium
Hugh Reilly, Sandia National Lab

The Solar II plant, closed down over a year ago, used molten salt to transport heat from the tower to heat exhangers, making steam for power generation. Adding 2 large storage tanks effectively decoupled the collection of energy from the generation of electricity, with 105 MWhr of storage, at 97% efficiency, and thus enabling anytime dispatch of solar electricity. The salts solidify at 430 deg F, so the “cold tank” must be kept above that temperature. A new plant using this approach, “Solar Tres”, is under construction in Spain by a consortium that includes Boeing and Bechtel.

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* Annex XV: Energy Storage and Renewable Generation: The New Opportunity
John Boyes, Sandia National Lab
The International Energy Agency (IEA), which is an offshoot of the OECD, sponsors a series of research programs and working groups. For a complete list, see “Implementing Agreements” at http://www.iea.org/techno.htm

Annex XV is the successor to Annex IX, and both of these are under a broad category that covers all forms of storage for energy conservation.
For details, see http://cevre.cu.edu.tr/eces

An acrobat document gives an overview (http://cevre.cu.edu.tr/eces/ax15prop.PDF) The program scope will be determined at a meeting in October, with work to begin in November.

The objective is “to move storage systems towards commercial market implementation, via the mechanism of technology and applications demonstrators. Whilst it is beyond the scope of Annex 15 to implement an actual demonstration project, it is fully intended that much of the necessary groundwork will be covered within the project to make a demonstration project the next logical step in electrical energy storage system market development.”

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UPDATES:

Jon Hurwitch – His firm Switch Technology has merged with RK Sen to form Sentech

Evonyx – Ian Grant is new to ESA and a new employee of Evonyx, announced a major investment by Niagara Mohawk in their company. Evonyx has a new type of Zn-Air battery which can be recharged or physically refueled with solid plates or tapes. They forsee applications from AAA size to multi-MW. (http://www.evonyx.com)

Trace (Trace Technologies and Trace Engineering) announced their merger with Xantrex.

Brad Roberts explained that Omnion had been acquired by S&C Electric, and that they were filling commercial orders for the PQ2000.

Anthony Price and Joe Iannucci observed that lots of money has been spent on reducing the cost of storage technology, nothing has been spent on increasing its value, e.g., integrating it with renewables.

Steve Eckroad summarized recent developments at Golden Valley Electric, Fairbanks, where they’re in the last stage of bidding for a major BESS. There are 3 finalists- ABB, GE and Siemens, each teamed with a particular battery. An award is expected in September.

Technology Transfer Opportunities – Oak Ridge National Laboratory

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UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the Federal Laboratories

Oak Ridge National Laboratory

Oak Ridge, Tennessee

June 1998

Prepared for:

Utility Federal Technology Opportunities (UFTO)

By:

Edward Beardsworth

Consultant

Contents:
Summary
Overview & Organization
Technologies & Programs

This report is part of a series examining technology opportunities at National Laboratories of possible interest to electric utilities

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This report is proprietary and confidential. It is for internal use by personnel of companies that are subscribers in the UFTO multi-client program. It is not to be otherwise copied or distributed except as authorized in writing.

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Summary

This report details findings about technology and technology transfer opportunities at the Oak Ridge National Laboratory that might be of strategic interest to electric utilities. It is a major update and revision materials developed previously, and is based on a visit to the lab in April 1998, and also draws from various publications, collateral information and website content.

Acknowledgments:

A special note of thanks to Marilyn Brown for arranging the agenda and her gracious and tireless support, and to all the ORNL staff who gave generously of their time and attention.

Also to Mr. Scott Penfield of Technology Insights, who accompanied the visits (as a representative of one of the UFTO utilities) and kindly provided his written account of the meetings for use in the preparation this report.

ORNL — Overview & Organization

Oak Ridge National Laboratory (ORNL) is a “GOCO” lab (government-owned, contractor operated). Lockheed Martin Energy Research Corp. is the contractor that manages ORNL. (Lockheed Martin also manages the Y-12 Plant in Oak Ridge, Idaho National Engineering Lab and Sandia National Lab.)

ORNL has a matrix organizational structure, where “divisions” aligned primarily by discipline have the people, and “programs” have the projects and budgets. On some occasions, divisions do get funds and projects of their own. ORNL finds that matrix management can work well if there is a balance of power and the right incentives.

Both divisions and programs live in research “ALD’s” or Associate Laboratory Directorates, headed by Associate Lab Directors who along with other administrative and support groups report to the Laboratory Director (Alvin Trivelpiece).

ORNL’s four research ALD’s are:

=> Energy and Engineering Sciences — Gil Gilliland 423-574-9920

(Div: Engineering Technology, Fusion., Instrum & Control)

(Prog: Energy Effic/Renew Energy, Energy Technology, Fossil Energy, Nuc Technol)

=> Life Sciences and Environmental Technologies

(Div: Chemical Technol, Energy, Environmental Sci, Life Sciences)

=> Adv. Materials, Physical and Neutron Sciences

(Div: Metals & Ceramics, Physics, Solid State, Chemical/Analytical Sci . . .)

=> Computing, Robotics, and Education

(Div: Computer Science and Mathematics, Robotics and Process Systems…)

There is work in all four ALDs of potential interest to utilities. The point of contact for this study was established through the Energy Efficiency and Renewable Energy Program, which oversees activities involving 11 different research divisions. Contact was also made with the Fossil Energy Program, with a similarly broad scope. Divisions encountered include Engineering Technology, Instrumentation & Control, Metals & Ceramics, and others.

Staffing level is now at approximately 5000, of which 1500 are scientists, of which about 1/2 are PhDs. ORNL’s 1997 budget was about $550 million. Of this amount, the largest program areas were Energy Research (28%), Environmental Management (25%) and Energy Efficiency (16%). Nuclear programs, which were once the principal focus of the Laboratory, are identified at a level of 4% in the overall budget; however, when supporting research topics (e.g., High Flux Isotope Reactor (HFIR), materials, NRC Programs, etc.) are included, some $100 million can still be identified as nuclear related.

A major new initiative at ORNL is the Spallation Neutron Source facility. The 1999 budget year will constitute a major test for this project, as it will include a construction line item for the first time. If approved, construction is expected to take 6-7 years. A new ORNL directorate has been established to oversee the Spallation Neutron Source project.

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Key Contacts:

Website: http://www.ornl.gov

Primary UFTO contact:

Energy Efficiency and Renewable Energy Program:

A.C.(Tony) Schaffhauser, Director, 423-574-4826, schaffhausac@ornl.gov

Marilyn Brown, Deputy Director, 423-576-8152, brownma@ornl.gov

Working with ORNL:

Technology Transfer: (Licensing and CRADAs)

Dean Waters, Acting Director, Office of Technology Transfer,

423-576-8368, watersda@ornl.gov

Sylvester Scott, Director, Licensing, 423-576-9673, scotts@ornl.gov

Partnerships: (CRADAs, User Program, Personnel Exchanges, Guest Research Assignments)

Louise B. Dunlap, Director, Office of Science and Technology Partnerships,

423-576-4221, dunlaplb@ornl.gov

Public Relations: Joe Culver, Director, Public Affairs,

423-576-0235, culverjw@ornl.gov

Partnership Mechanisms

ORNL makes use of an increasingly broad array of contracting mechanisms, including CRADAs, Work for others, User Facility Agreements, etc. Greater use of simpler standard formats makes the process much quicker than in the past.

They are seeing an increasing number of “100% funds-in CRADAs” (i.e. no cost sharing by the lab) from industry, as a cheaper alternative to work-for-others with essentially equivalent intellectual property rights. The Lab also will have as many as 4000 guest assignments per year, 1/4 of which are from industry, where visitors use the facilities or work with staff on CRADAs, etc.

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Energy Efficiency and Renewable Energy Program

Tony Schaffhauser, Director 423-574-4826 schaffhausac@ornl.gov

Marilyn Brown, Deputy Director 423-576-8152 brownma@ornl.gov

The EE/RE Program is a matrix organization that draws on several line divisions at ORNL for the majority of its personnel and technical facility resources, to set up multi disciplinary teams. DOE is the sponsor for most of the work, but they see industry and the public as the real customer.

ORNL budget expenditures controlled through the EE/RE Program office amount to some $80 million. The ORNL Energy Efficiency/Renewable Energy (EE/RE) budget was lower in 1996, but the level now appears to be stable.

Major Research and Development Areas

=> Transportation systems, including advanced automotive technologies, advanced materials, utilization of alternative fuels including biofuels, and transportation data.

=> Efficient building systems and for state and community programs, including heating, cooling, and refrigerating equipment; roofs, walls, and foundations; insulating materials; technology transfer; and retrofit of existing residential and commercial structures.

=> Industrial processes, such as bioprocessing, electric motor systems, advanced turbine systems, advanced materials, industrial heat pumps, and evaluations of energy-related inventions.

=> Utilities, including high-temperature superconductors (for transformers and transmission cables), power transmission and distribution systems, electric and magnetic field effects, biomass for power generation, and international programs (including IEA and APEC programs).

Technologies & Programs

Superconducting Technology Program for Electric Energy Systems

Fossil Energy Technologies

Real-Time Corrosion Monitoring

Hot Gas Filters

Materials R&D

Furnace Wall Corrosion with retrofit low-NOx burners

Effects of Coal impurities on fireside corrosion

Improved Stainless Steels

“Perfect Microstructures”

Nickel-Aluminide Alloys

Sulfidation Resistant Alloys

Building Technology Center

Frostless Heat Pump

High Efficiency Refrigerator (1 kwh/day)

Power Systems Technology Program

Energy Conservation Standards for Distribution Transformers

Flywheels and Energy Storage Technologies

Utility Restructuring and Electric Power Ancillary Services

Grid Reliability-Control Center Survey

Electric and Magnetic Fields Bioeffects

Research and Public Information Dissemination (RAPID) Program

Advanced Turbine Systems

Bioenergy Program

Motor, Steam, and Compressed Air Challenge Programs

Oak Ridge Centers for Manufacturing Technology (ORCMT)

Electric Machinery Center

Power Electronics Technology Center and Inverter Technology

Instrumentation & Controls

Machine Condition Monitoring and Diagnostics

Electrical Signature Analysis (ESA) for Utility Applications

Nonlinear data analysis–Component Failure Prediction

NRC/INPO plant database

Photonics and Hybrid Lighting

Superconducting Technology Program for Electric Energy Systems

Bob Hawsey 423-574-8057 hawseyra@ornl.gov

Web sites: http://www.ornl.gov/HTSC/htsc.html

http://www.eren.doe.gov/superconductivity/

(See special report and series of articles on “Superconductivity in Electric Power,”

pp 18-49, IEEE Spectrum, July 1997)

The discovery of high-temperature (i.e., above the boiling temperature of liquid nitrogen) superconductor materials dates to 1986. Since that time, the challenge has been to develop these brittle, ceramic-based materials into a form that can be produced and practically used. DOE research in this area has taken a major step increase, from $19 million in 1997 to $32 million in 1998. (By comparison, Japan is investing $100 million/year in superconductor research.)

DOE HTS Program

Contacts:

Jim Daley, Team Leader, 202-586-1165, james.daley@ee.doe.gov

or Joe Mulholland, Utility Liaison

202-586-1491, joseph.mullholland@hq.doe.gov

The DOE HTS program supports a balanced technology development effort. Wire and device technologies are developed through a large number of collaborative projects between U.S. national laboratories and industry, and systems technologies are supported through the SPI and other vertically integrated project teams.

DOE’s Superconducting Partnership Initiative (SPI) is a systems technology program designed to accelerate the development of HTS electric power systems. Begun in the fall of 1993, the SPI encourages the formation of vertically integrated teams comprised of partners who usually do not interact in the development cycle, involving close collaboration among system integrators, wire and device manufacturers, end-users (typically electric utilities)

Major projects include

– 5,000 hp high-temperature superconducting (HTS) motor

– 100 MVA HTS generator,

– 115 kV and 12.5 kV HTS transmission cable (2 projects)

– 5/10 MVA HTS transformers (2 projects)

– 15 kV HTS fault current limiter (2.4 kV successfully tested in 9/95 at a utility host site)

Fault Current Limiter

Later this year, pre-commercial (alpha) prototype will be tested by So Cal Edison and Lockheed Martin. Rating is 15-kV, normal 2 kA, intercepts/reduces by 80% a 20-kA peak symmetric or 45 kA peak assymmetric fault. Also functions as a 1/2 cycle circuit breaker. If demo successful, Edison will install it at a substation, and anticipates $1million in savings from avoiding need for a second bus. Next stage will be beta units.

Contact: Eddie Leung, Lockheed Martin program manager

619-874-7945, ext. 4636, eddie.leung@lmco.com

ORNL is participating in two of these partnerships.

Transformers — There is a strong need for medium power transformers (10-150 MVA) that are smaller, more efficient and free of fire hazard, to meet the growth in urban power density. These transformers will go inside building and in multistory substations, and provide higher ratings from existing substations.

— Waukesha Electric Systems (WES), Waukesha, WI

For the Waukesha program, ORNL is responsible for the engineering, design and science of the cooling system, while Intermagnetic General is producing the HTSC coil. WES did the core, instrumentation tank, pumps and test rig. An initial 1 MVA prototype has been constructed and entered testing at WES in February 1998. Initial results are good–the first operational US HTSC transformer easily sustains 2X overloads. Rochester Gas & Electric (RG&E) and Rensselaer Polytechnic Institute (RPI) participated in this initial demonstration.

The next step will be a 5 MVA system, which will provide power to the WES plant beginning in 1999. A larger utility advisory group is participating in this second step (includes several UFTO members). The initial commercial target is a transformer in the range of 10-30 MVA.

Contact: Pat Sullivan, VP Marketing, Waukesha, 414-547-0121, x 1531.

There is a separate transformer development effort that involves ABB, EdF, Los Alamos National Lab (LANL) and American Superconductor.

Cable — HTSC Cables hold the promise of far greater capacity– 5X the power in the same 8″ diameter pipe of conventional buried cable, and without the losses, heat, oil and range limitations.

— Southwire,Carrolton, GA

The Southwire HTSC cable project is expected to culminate in an initial demonstration at Southwire in 1999. The planned 100 ft, 3-phase, 12.4 kV, 1250 Amp cable will provide power (30 MVA) to Southwire facilities. Southern Co, Georgia Transmission Co, and So Cal Edison are partners. DOE is providing half of the $14 million. Southwire has built a 200 ft clean room manufacturing facility, and recently delivered a 5 meter test cable to ORNL for testing.

Pirelli and Los Alamos are pursuing a parallel HTSC cable initiative, with participation by Detroit Edison. The initial objective is a 25 kV line.

Other HTSC development initiatives mentioned include motors/generators (including flywheel motors/generators under development at Boeing) and kaolin magnetic separation equipment being developed by Dupont for the paper industry.

NOTE- More uility participation is needed–to provide advice, and as partners, cofunders and beta test hosts. Any kind of innovative proposal is more than welcome.

RABiTS (TM) Process for Coated High-Temperature Superconductors

http://www.ornl.gov/~vhk/rabits.html

Oak Ridge researchers have produced a roll-textured, buffered metal, superconducting tape with a critical current density of 300,000 amperes per square centimeter in liquid nitrogen, which may pave the way for the future manufacture of practical yttrium- or thallium-based conductors for electric power applications.

To produce a superconducting wire sample, the ORNL researchers first developed a process called rolling-assisted biaxial textured substrates, or RABiTS(TM), which enables the superconducting materials to have a high degree of grain alignment in all directions, a necessary condition for more efficient current flow through the superconductor.

MicroCoating Technologies (MCT) in Atlanta and ORNL announced on April 16 that MCT has licensed key patents. “MCT scientists within a six-month period have successfully deposited both HTS coatings and oxide “buffer layers” on several single crystal oxide substrates. MCT also successfully deposited buffer layer on textured nickel. The epitaxy of some buffer layers is as good or better than with any other deposition technique to date. In addition, MCT’s open atmosphere process can meet or exceed industry-wide cost targets to enable commercial-scale production of superconductor technology.”

Other licensees include Midwest Superconductivity and Oxford Superconducting Technology, with two more pending.

Fossil Energy Technologies

Rod Judkins 423-574-4572 judkinsrr@ornl.gov

ORNL described some additional advancements in materials and technology for fossil and related applications that were not addressed in the ORNL survey of utilities (developed by Technology Insights and sent to UFTO members in mid 1997). Some examples are:

Real-Time Corrosion Monitoring: A flash of laser light is impinged on a fossil boiler wall. By observing the infrared response of the area, corrosion related effects, such as thinning, debonding and delamination can be inferred.

Hot Gas Filters: In partnership with manufacturers, ORNL has developed two distinct classes of hot gas clean up filters.

– A ceramic composite (SiC-based) filter developed with 3-M is primarily targeted to fluidized bed combustion applications. The filter has been tested in AEP’s Tidd Plant and a Studvik incinerator in S. Carolina. It is available through 3-M. Contact Ed Fisher, 612-736-1005

– A lower temperature (700 – 1000 deg C) iron-aluminide filter, with high resistance to sulfidation, has been developed in partnership with Pall Corp. (Portland NY) and is nearing commercial introduction. An alternative to ceramics, it can be made with standard manufacturing equipment. Tests at the University of Cinncinnati show excellent corrosion resistance. Coal gasification is the target application.

Materials R&D

Ron Bradley 423-574-6095 bradleyra@ornl.gov

Ian Wright, 423-574-4451 wrightig@ornl.gov

Furnace Wall Corrosion with retrofit low-NOx burners — root cause is flame licking walls, so that control of flame characteristics using sensor-feedback arrangements should be the best solution. Hence, there is a need to develop sensors to monitor flame condition as input to control mechanism. ORNL has approaches for this, using chaos theory to analyse the flame signatures, for instance (Stuart Daw, David Schoenwald). There will also be a continuing practical need for diagnostics, coatings, repair techniques, etc., since not all boilers will be amenable to combustion control, and the use of multiple and varying coal sources will lead to continuing corrosion problems in some parts of the furnace wall. Sulfidation-resistant ferritic alloys (ORNL’s iron aluminides) promising as overlay/cladding, but difficult to apply reproducibly. Development program with Lehigh Univ-utility boiler consortium (Prof. Arnie Marder) is showing good promise.

Effects of Coal impurities on fireside corrosion — Chlorine limits based on fundamental misunderstanding–only a problem when other combustion problems (flame impingement) present. Developing in situ probes to measure short-term corrosion.