ZBB ENERGY CORPORATION

ZBB ENERGY CORPORATION
ZBB MAKES YOU MORE POWERFUL.
At ZBB, we store energy for you. And when you possess stored energy, you gain control. You’re better able to
manage how and when that energy gets used. That’s true power.
Consider the mounting challenges faced by utilities, industrial and commercial organizations, and renewable
energy generators. The need for power and the cost of power are increasing. Brownouts and blackouts occur
more frequently, raising likelihood of revenue losses and damage to infrastructure.
The solution? ZBB’s innovative, Zinc Energy Storage System (ZESS); a true Regenerative Fuel Cell type storage
product. Modular. Portable. Proven. It promises substantial operational advantages and cost savings without
significant capital investment.
For the advanced energy storage solution that increases energy efficiency, minimizes environmental impact and
enables renewable energy generators to maximize contributions, turn to ZBB.
ZESS.THE CLEAN, GREEN ENERGY SYSTEM.
ZESS technology represents a clean, green, environmentally friendly and cost-efficient alternative energy
storage system.
Scalable and mobile, ZESS is composed of a module or series of modules, each containing three cell stacks.
Each cell stack contains 60 cells in a series. Your application determines the number of modules required.
You can charge the ZESS from a variety of power generation sources at different charge rates and you can fully
discharge it repeatedly without damaging it.
Modules are fully self-contained, and a fully automated control system takes care of all the energy storage and
safety functions.
We manufacture the ZESS with cost-efficient, recyclable plastics, at low production costs, using techniques
allowing economical mass production.
BETTER TECHNOLOGY, BETTER ZESS.
The ZESS is an energy storage technology that converts real time electricity to on-demand
electricity. Very different in concept and design from more traditional batteries, such as
the lead/ acid battery, the ZESS is based on fuel cell technology and combines aspects
from both battery and fuel cell technologies. This energy storage system is more often
referred to as a Regenerative Fuel Cell (RFC) system.
The ZESS relies on a flowing electrolyte system:
• Chemical reaction takes place in the Cell Stack.
• Excess electrolyte is stored in external tanks.
• The predominantly aqueous electrolyte is composed of zinc bromide salt
dissolved in water.
• During charge, metallic zinc is plated from the electrolyte solution onto the negative electrode surfaces in the cell stacks.
• Bromide is converted to bromine at the positive electrode surface of the cell
stack and is immediately stored as a safe, chemically complexed organic phase
in the electrolyte tank.
• Each cell stack has 60 bi-polar electrodes between a pair of anode and cathode
end blocks.
• Operates quietly and at ambient temperature.
Unlike most batteries, ZESS electrodes don’t take part in the chemical reactions; they are simply substrates for the reactions.
That means no loss of performance from repeated cycling that causes electrode material deterioration.
When the ZESS discharges, the metallic zinc plated on the negative electrodes dissolves in the electrolyte and is available to
be plated again at the next charge cycle. In the fully discharged state, it can be left indefinitely.
CELL STACK ASSEMBLY
FLOWING ELECTROLYTE SYSTEM
CELL STACK
END BLOCK
ZINC
DEPOSIT
POROUS
SEPARATOR
BROMINE
ELECTRODE
SCREEN
PUMP
VALVE
BIPOLAR ELECTRODE
ANOLYTE
RESERVOIR
SEPARATOR
PUMP
TERMINAL ELECTRODE
END BLOCK
COMPLEX PHASE
WHERE ZESS WORKS BEST.
ZESS is ideally suited for a number of utility markets as well as remote area power and renewable energy
applications requiring deep cycle performance, long cycle life energy storage and where environmental/safety
aspects are important.
Energy providers realize more reliable delivery and alleviate system constraints. End users gain solutions to costly
power quality and reliability problems, and can better manage price volatility. Renewable energy generators harness
more clean energy.
Load management. Utilities possessing the cost-effective means to manage timing of electricity production and
consumption are able to:
• Implement peak shaving.
• Eliminate damage to power infrastructure during peak
demand periods.
• Defer capital expenditures required to serve increasing system loads.
• Manage the cost of energy.
• Replace peaking generation ($, CO2)
Power quality. Alleviate downtime caused by:
• Voltage sags.
• Voltage swells.
• Frequency fluctuations.
• It can also be combined with UPS systems to
eliminate outages.
Renewable energy. Convert the intermittent power generation patterns of solar and wind energy into predictable
power when you need it.
• Store and re-supply generated power during high-demand periods.
• Smooth power delivery from the generator to the grid.
NUMEROUS ADVANTAGES DEFINE THE ZESS.
• Delivers better cycling performance than lead-acid
batteries, particularly when deeply discharged on
each cycle.
• Suits multiple applications through modular
construction and portability.
• Reduces on site environmental and safety concerns
• Improves capacity and extends cycle life by allowing
complete system discharge.
and costs as well as future disposal issues.
• Environmentally designed using clean, low cost,
• Delivers higher energy density compared to
lead-acid batteries, making it smaller and lighter.
re-cycleable plastics.
• State of the art manufacturing techniques.
ZESS 50 DEEP DISCHARGE ENERGY STORAGE SYSTEM.
ZESS 500 DEEP DISCHARGE ENERGY STORAGE SYSTEM.
The ZESS 50 consists of one 50kWh module, a Power Conversion
The ZESS 500 consists of 10 – 50kWh modules, a Power Conversion
System(PCS) and an overall system control package.
System(PCS) and an overall system control package.
• Each cell stack contains 60 cells in series arranged in
bi-polar configuration
• Each module contains 3 cell stacks having an open cell voltage
of 108V.
• All stacks supplied with electrolyte from a flow system consisting
of tanks and electrolyte circulation pumps.
• Discharge capacity of 50kWh.
• Chargeable from a variety of power generation sources
at differing charge rates, enabling fast re-charge time
(3-4 hours).
• Discharge can be sustained at continuous rates up to 300A.
• Can be equipped to be totally self-contained and can run
independently from the grid.
• Fully automated control system manages all storage system
controls and safety functions.
TURNKEY AND READY TO ROLL.
The ZESS 500, 500kWh energy storage system arrives on the back
of a trailer and plugs directly into the grid . This fully grid-interactive
system is ready to perform in peak shaving or renewable energy
applications upon arrival and ready to move when you are.
• Each module is the same as that used in the ZESS 50.
• Modules connected in two separate strings, five modules per
string, offering maximum operating flexibility.
• Total open cell voltage of 540 V.
• Nominal string current is 150A and achieves a full-charge cycle
in 4.5 hours.
• Achieve complete continuous discharge at twice the 150A rate
(600A for total DC system).
• Achieve maximum continuous power (250kW) and sustain it for
two hours (500kWh) with 200% peaking capability.
• Both strings connected to the PCS, with AC side of the PCS
connected to the utility grid and/or the customer load.
EQUIPMENT SPECIFICATIONS
ZESS - 50 ENERGY STORAGE SYSTEM
ZESS - 500 TRANSPORTABLE/ENERGY STORAGE SYSTEM
PHYSICAL
Weights:
Module Enclosure (empty)
Modules (1)
PCS (incl enclosure)
500 lbs
3,200 lbs
1,000 lbs
PHYSICAL
Weights:
Trailer (empty)
Shipping Container (empty)
Modules (10)
PCS
10,000 lbs
10,000 lbs
30,000 lbs
10,000 lbs
Dimensions:
Module Enclosure
PCS Enclosure
84” H x 48” W x 48” D
92” H x 36” W x 36” D
ELECTRICAL
Mdules / PCS Interface:
Maximum Voltage
Voltage Range
Current (Discharge)
Current Range (Discharge)
Current (Charge)
Input Current Ripple
Dimensions:
Trailer
Shipping Container
Module (each)
PCS
4.5ft H x 8ft W x 45ft D
8ft H x8ft W x 20ft D
73” H x 44” W x 42” D
96” H x 96” W x 54” D
120 VDC
0 VDC - 120 VDC
300 ADC
0ADC - 300 ADC
150 ADC
<2% RMS
ELECTRICAL
Mdules / PCS Interface:
Maximum Voltage
Voltage Range
Current (Discharge)
Current Range (Discharge)
Current (Charge)
Input Current Ripple
625 VDC
0 VDC - 625 VDC
300ADC per Module String
0ADC - 300 ADC
150 ADC
<2% RMS
*PCS /Utility Grid Interface:
Phases
Voltage
Frequency
Output power
3
480 VAC, +/- 10%
(MV avail w/set-up transf)
60 Hz, +/- .5 Hz
25.0 kW / 35.7K VA
(0.8 PF lead or lage)
• Overload capability: 110% continuous (required trip level
for UL 1741)
• Enclosure: NEMA 3R
• Operator interface display (OIT)
*PCS /Utility Grid Interface:
Phases
Voltage
Frequency
Output power
3
480 VAC, +/- 10%
(MV avail w/set-up transf)
60 Hz, +/- .5 Hz
250 kW / 357K VA (0.8 PF lead
or lage)
• Overload capability: 110% continuous (required trip level
for UL 1741)
• Enclosure: NEMA 3R
• Operator interface display (OIT)
ELECTRICAL SAFETY FEATURES
Enclosure door interlock switches
E-Stop
AC disconnect switch
Anti-islanding protection
System protection: o/u voltage, o/u frequency
Completely Self Protected: Over Current, Surge Suppression, and +/- fuses
UL1741 Compliant
IEEE 519 Compliant
*For alternate configurations and/or complete MV systems, contact the factory.
Manufacturing
Menomonee Falls, Wisconsin
For more information, contact ZBB Energy Corporation in Wisconsin at 1 (262) 253-9800.
Research
Perth, Australia
For more information, contact ZBB Energy Corporation in Bibra
Lake, Western Australia: 61 (8) 9494 2055.
www.zbbenergy.com