Developing novel heat storage systems

Transcription

1 Developing novel heat storage systems Andrew Bissell, 2 July 2018, ECCI, Edinburgh andrew.bissell@sunamp.co.uk +44 (0)

2 Sunamp Globally ambitious company, based just east of Edinburgh: HQ, R&D, Factory, Sales Sunamp Ltd Edinburgh HQ & Factory Sunamp Switzerland GmbH Zurich Founded in 2005 in Edinburgh World leader in Heat Battery thermal energy storage First 4,000 heat batteries built and installed in 1000 homes: 2/3 in social housing, tackling fuel poverty since 2013 Hundreds of paying private customers Launched 3 rd generation UniQ heat battery range All market needs now met, including low cost Factory in place and starting serial production Ready to disrupt the incumbent tech (40m hot water cylinders/year) Ready to support the transition to a fully renewable grid & heat First OEMs and distributors signed for Global Markets Key materials R&D partnership with University of Edinburgh 28 people directly employed Raised 5M Equity & 5M Grants Raising 7M more this year for sales & manufacturing expansion Finalist: SHIFT Awards 2016 Winner: Solar Power Portal Awards 2016 Finalist Ashden Awards 2017 Winner: Regen Renewable Futures & Green Energy Awards 2017

3 Sunamp was started for global impact The challenge was climate change and its impacts Goal: enable the full transition to renewable energy for heat and cool Need: better, energy-efficient, ultra-compact energy storage for heat (and cool) at low cost The hot water cylinder has been declining, and the gas combi boiler advancing, just when we need more energy storage To give resilience and flexibility to electric grids containing more and more renewables To optimise self-consumption of home-generated electricity from PV (declining cost a huge driver), wind (commercial & industrial) To allow us to reduce fossil fuel consumption via the electrification of heat Thermal storage is much more needed To allow heat pumps and other renewables to compete on cost and performance with fossil fuels

4 The Basic Idea High Energy Density Melting and freezing a PCM (Phase Change Material) stores 3-4 times as much energy as heating and cooling hot water Hand warmer (melts at 58 C) High Power High power heat exchanger inside, so heat can be rapidly charged into the heat battery and equally quickly extracted high rate discharge Modular Cuboid and able to stack like Lego Cost-Effective Comparable price to Hot Water Tanks Lower Total Cost of Ownership 4

5 Electric Battery vs. Heat Battery BYD Lithium-ion battery 30.7dm dm 3 Sunamp Heat Battery 38kg 482.6mm 489.5mm 130mm 2.5kWh 2.5kW 6,000 cycle life (to 70% capacity) 2.5kWh 35kW >40,000 cycle life (to >95% capacity) 500mm 460mm 32Kg 115mm 16% final household energy consumption is electricity Appliances 12% Lights 4% Cooking 3% 81% final household energy consumption is heat Space heating 62% Hot water 19% % household final energy consumption in UK United Kingdom housing energy fact file,

6 Sunamp vs. Lithium-Ion Levelised Cost of Storage Battery Cost - per kwh stored (excl Installation costs, 15yrs expected life for all Li-Ion units) Li-Ion batteries PCM Batteries Akasol neeoqube Sunverge SIS Cost of Energy Stored (p/kwh) Sunamp UniQ edual 9 (@15yrs) Sunamp UniQ edual 9 (expected life) Sunamp UniQ ehw 9 (@15yrs) Sunamp UniQ ehw 9 (expected life) Tesla Powerwall 2 GCL E-KwBe 5.6 SunGrow SBP4K8 Ampetus "Super" Lithium BYD B-Box LV Residential Alpha-ESS ECO S5 Ampetus Energy Pod LG Chem Resu 10 Aquion Aspen 48S-2.2 Opal Storage Pylontech US2000B DCS PV 5.0 SolaX BOX Redflow Zcell Hybrid "Home" Plus Delta Hybrid E5 Hansol AIO 10.8 BMZ ESS3.0 Trinabess Powercube Sonnenbatterie ZEN Freedom Powerbank FPB16 SimpliPhi PHI3.4 Smart-Tech battery Fronius Solar Battery SolaX 3.3 Enphase AC Battery Leclanche Apollion Cube Fusion Power Systems Titan-3 Magellan HESS ELMOFO E-Cells ALB Senec.home Li 10 Based on data from SolarQuotes.com.au Note: for Sunamp = electric-in thermal-out Source: Sunamp Limited; SolarQuotes.com.au 6 SolarWatt MyReserve Matrix

7 Global Pespective on The Heat Opportunity World energy consumption x2.5 Electricity 17.5% Heat 46% Space Heat Hot Water Process Heat Cooling Transport 27.5% Others 9% Heating without global warming, IEA, Electrical storage: Over invested Overcrowded High entry barriers Materials questions Heat storage: Has not changed in centuries Ripe for improvement More heat storage needed Low cost, sustainable materials 7

8 Specific Focus on Heat Storage: Residential Example Renewable heat: need to time-shift from when energy is available to when it is needed CHP Solar Thermal Solar PV Heat Pumps Biomass Waste Heat Off-peak Elec... Intermittent input energy Heat storage time energy Controlled output hot water heating time 8

9 What is a Sunamp Heat Battery? A high-powered, high flow-rate heat exchanger is immersed in phase change material and encapsulated in a red moulded, polypropylene cell. (Cold batteries use a blue cell.) The red cell is surrounded by non-flammable vacuum insulation panels. These offer superior insulation, in minimal space. As a result the whole range is ErP A+, with regulatory and energy efficiency benefits. Finished in a cuboid, white powder-coated aluminium case, which offers pipework knockouts on any face for very easy installation. Our new factory enables us to ramp up production fast. Very reliable, safe. Non toxic, non flammable. 40,000 cycle life already proven (>50 years of use).

10 Modular, scalable, compact ErP A + UniQ 80 UniQ 12 UniQ *mm ( *in) UniQ *mm ( *in) UniQ *mm ( *in) *mm ( *in) 1,000mm (39.4in) 1,470mm (57.91in) 365mm (14.4in) 575mm (22.6in) 365mm (14.4in) 575mm (22.6in) 365mm (14.4in) 575mm (22.6in) 365mm (14.4in) 575mm (22.6in) 1,200mm (55.1in) *height for models including stand-by electric heaters Model Example Measured kwh Equivalent cylinder (L) Heat Loss (kwh/24h) Comments ErP Rating UniQ HW A+ UniQ Heat Stackable two high A+ UniQ HW for larger storage A+ UniQ Dual A+ UniQ Heat (provisional) Palletised, <1.5 Tonnes Non ErP

11 What is a Phase Change Material (PCM)? Energy density, Wh/L Ice (phase change at 0 C) Temperature, C Joseph Black s discovery of latent heat in 1761 at University of Edinburgh And this very phenomenon is partly the foundation of the opinion I have proposed; for if we examine what happens, we may perceive that a great quantity of heat enters the melting ice, to form the water into which it is changed, and that the length of time necessary for the collection of so much heat from the surrounding bodies, is the reason of the slowness with which the ice is liquefied. Hand warmer (melts at 58 C) Phase-change materials (PCMs) store heat and cool as latent heat: - absorbed on melting - released on freezing

12 Desirable Properties for PCMs include Reproducible performance over multiple (1,000-10,000's) of heating/cooling cycles Appropriate temperature range(s) Low volume leading to high energy density Efficient thermal conductivity Long term (i.e. years) chemical stability e.g. with respect to corrosion of construction materials and towards external factors such as variable relative humidity Low toxicity Non-flammable Low cost Reproducible performance often compromised crystallisation of other phases phase segregation to give anhydrous salts nucleation and crystal growth short-lived intermediate phases Sunamp found that most PCMs on the market fail some/all of these tests Search for an Academic partner Essential to map, understand, and control crystallisation processes

13 Interface found us the right academic partner CEO and Founder Andrew Bissell Professor Colin Pulham School of Chemistry University of Edinburgh From PhD Candidate at University of Edinburgh Dr David Oliver Materials Scientist at Sunamp Ltd

14 Incongruent Melting Sodium acetate trihydrate melts to form a solution and anhydrous sodium actetate (NaOAc) The anhydrous sodium acetate sinks to the bottom of the heat battery It then doesn t re-enter solution So the capacity fades David Oliver solved this by using a novel polymer formulation (patented) Sodium acetate trihydrate solution The new formulation cycles without forming the anhydrous salt. Provided there is no loss of water, it will cycle forever. Solid sodium acetate trihydrate plus aqueous solution

15 Sodium acetate trihydrate hand-warmer NaOAc 3H 2 O is used in reusable heat pads excess water used to dissolve all anhydrous NaOAc a metal disk is used to initiate crystallisation Disks can be deactivated by boiling in water or flexing many times in molten NaOAc solution Solidification in heat packs, M. A. Rogerson, S. S. S. Cardodo, AIChE Journal, 2003, 49, 2,

16 Sub-cooling Salt hydrates generally sub-cool (supercool) This means they don t crystallise at their melting point For a heat battery this is a problem Though for a hand-warmer it is useful: Clicking disc allows control of when heat is released David Oliver solved this by using a novel nucleator formulation (patented) The new formulation cycles well, reliably crystallising and releasing heat whenever the PCM is dropped below 58ºC without requiring the clicking disc. Cooling Heating indefinite subcooling 6 subcooling Temperature ( )

17 Perfecting a Nucleator Disodium hydrogenphosphate, Na 2 HPO 4 (DSP) nucleates NaOAc 3H 2 O 1-2% is typical concentration used Four forms of Na 2 HPO 4 xh 2 O, x = 0, 2, 7, 12 but which form of DSP is the active nucleator and how does it operate? Added complexity that it deactivates in temperature range 70-90ºC Suggested that seed crystals of sodium acetate trihydrate are adsorbed onto the nucleator crystals and survive heating above melting point. Further heating desorbs seed crystallites and they melt. T. Wada, K. Matsunaga, Y. Matsuo, Bull. Chem. Soc. Jpn. 57, 557 (1984).

18 Problem studied using in situ powder X-ray diffraction Diamond Light Source, UK Exploits high flux of synchrotron radiation source and fast detectors Identification of active nucleator for NaOAc 3H 2 O Thermally induced dehydration is responsible for deactivation of efficacy of nucleation No obvious structural relationship between NaOAc 3H 2 O and nucleating agent Confirmation that formulation prevents phase segregation after multiple cycling Use of a facility like the Diamond Light Source to study a problem at this intense level would never have happened without a fantastic Academic Collaboration.

19 Gen 2 Heat Batteries: From Lab to Domestic Product SunampPV: Excess electrical energy from solar panels used to charge Sunamp heat battery Cold water entering heat battery emerges at ~55 C Problem solved: how to get the heat in and out fast Sunamp-developed heat exchanger Reduces heating demand from gas boiler: reduced CO 2 emissions and lower fuel bills No gas use at all over summer Sunamp Heat Battery containing new PCM formulation Early adopter testing at Prof Colin Pulham s house!

20 Sustainability Inorganic, non toxic salts Long Life Cycle Reuse or recycle at end of life There are many types of phase change materials Organic Paraffin & fatty Acids Inorganic Salts Hydrates & Metallics Eutectic Mixes of the above We use inorganic salt based PCM materials which are plentiful and easy to source No palm oil, no paraffin Mainstay 58C PCM is sodium acetate widely made and used as a food flavouring and runway de-icer Sodum acetate is made from by-products of chlorine production (NaOH) and oil industry (acetic acid can also be made biogenically vinegar) Non toxic Non flammable Long life: tested to 40,000 cycles with almost no degradation. At two cycles per day that s around 50 years. Can be reset to full capacity by simple process. We are able to fully re-use or re-cycle every component at end-of-life PCM reformulated to make new PCM or used as a de-icer Metal heat exchanger can be easily separated and recycled Plastic is easily separated and recycled (PP)

21 Additional Impact on University of Edinburgh Strengthened links with Central Facilities: Diamond Light Source ISIS Neutron Facility Attracts very good students Incorporation into undergraduate teaching Public engagement activities Public Lectures Raised profile of University of Edinburgh Press coverage Better understanding of requirements of industry Costs IP generation and protection Enhanced international links IIT Bombay, HSLU, EPFL, UMD

22 Student Contribution: PhD, Year-in-Industry, MSc, Modern Apprentices

23 Accelerated Commercialisation Wide Range of Storage Temperatures Sunamp Heat and Cool Batteries can be filled with different PCMs to optimise each application { Freezing -18 (0) -14 (7) Cold storage Air conditioning -5 (23) 5 (42) 11 (52) Waste heat recovery Hot water pre-heat 18 (64) 32 (90) 43 (109) Hot water Space heating 58 (136) 73 (163) 81 (178) Industrial process heat Steam generation 118 (244) Waste Heat, Thermal Buffering (-15)(-13) (-6) -15 (5) -10 (14) Chiller 0 (32) 15 (59) 28 (82) Low temp heat pump Solar thermal High temp heat pump Boilers/Furnaces (biomass, gas, propane, oil) CHP/Co-Gen Sunamp PCMs are internally developed, and generally inorganic, non-flammable materials. Values indicate phase change temperature. Operating temperature range typically 40 >100 C (90 >200 F) around phase change temperature - consult Sunamp. Current commercial products (Space Heat & Hot Water) Near-term introduction (Q2 Q4 2018) 34 (93) Note: PCMs at different level of development and not all commercially available today 83 (181) 88 (190) 188 (370) 253 (487) T, C ( F) Electricity & Heat Co-Storage Thermoelectric, CAES, Organic Rankine Cycle, Steam Turbines, Storage Heaters

24 Expanding Universe of Collaborations

25 EastHeat: Large Scale Trials and Fuel Poverty Impact Large-scale installation programme Co-funded by Scottish Government Competitive Innovation funding Over 1000 social housing tenants positively impacted 766 Heat Battery Products installed in over 625 homes 4.4 MWh total storage in 2028 Heat Batteries 20% target reduction in cost of heat and/or hot water achieved

26 Retrofit Properties

27 Gen 3: UniQ: Mature, reliable, cost-effective Grid Electricity Natural Heat Fossil Fuel or Biomass Solar Energy Heat Pump Boiler PV or Solar Thermal Sunamp Controllers UniQ System Controller UniQ PV DC Controller Thermal Inputs Heat Battery Options Sizes: 3, 6, 9, 12, 80 * AC or DC elements * Mains AC Electricity Timer/Controller PV AC Controller PV AC Electricity PV DC Electricity Sunamp PV DC Controller Third Party HVAC Compatibility Boiler (Gas, Combi, Oil, Biomass, LPG) Heat Pump (Air, Ground, Water) * Controllers (Standard, Smart, Opentherm) Solar Panels (PV or Solar Thermal) PV AC Diversion Controller * * Consult Sunamp for compatible units and sizing Inverter Hot Water, Heat or Dual

28 Heating Systems Interacting with Sunamp Traditional (oil, gas, LPG) District Heating Heat Pumps Solar Thermal Sunamp TES CHP Solar PV Biomass RES Fossil fuel Sunamp focus Sunamp capability 28

29 Unvented Cylinder Replacement Linstone Housing Association Price competitive with equivalent direct hot water cylinder The most efficient heat storage, due to very low heat loss (ErP A+) Measured savings of 51 PA, single occupancy Ultra-compact: freed up storage space in cylinder cupboard Increased comfort, higher pressure Mains pressure hot water Not pressurised, no G3 regulation, no P&T pipework required Holds less <15 litres of water, Legionella risk & testing avoided Annual HW cylinder inspection avoided Sunamp expected to last 20 plus years Fully installed cost equal to a new hot water cylinder Tenant Comments Water pressure is unbelievably brilliant. Not noisy, More space freed up in the cupboard. Pressure has vastly improved things, notably in the kitchen sink, previously I could start the water running walk away and come back to it, now I get the hot water instantly which is great

30 ASHP + Heat Battery + Time-of-Use Electricity Trial in 7 homes funded by DECC since 2013 all still running, with measured bill savings 45-57% Off-peak Economy 10 electricity Air source heat pump (2.5-3x COP efficiency) Heat Battery compact storage provides time-shift: run heat pump when its cheap, use heat/hw at any time, radiators heat up fast (familiar gas boiler style heating modes) Easy retrofit installation In service for 5 winters (some still with Gen-1 heat batteries, some upgraded to Gen-2) Replicated at ONGO homes in 2016/2017, installing in old coal cellars Now many private customers too Central Heating Heat Pump SunampStack Hot Water

31 Trial Results Running successfully since 2013 Running costs savings 45% to 57%, carbon emission reductions 17% to 36% Replicated at ONGO homes in 2016/2017, installing in old coal cellars CASE A CASE B CASE C CASE D This is a 2-bedroomed house with 2 working occupants. They are heavy hot water users having 2 deep baths in the morning and 2 deep baths in the evenings This is a 3 bedroomed house lived in by a young working couple, their heat and hot water usage is normal. This household had night storage heater. Comfort has improved. This is a one-bedroom house, semi detached bungalow. The occupier is an retired man who looks after his grandchildren in the early evening so the house must be warm - Achieved This is a 5-bedroomed house with 2 working occupants and 1 teenager child and 1 visiting young adult Annual Savings on Heat and Hot Water Energy saving Bill saving CO 2 Saving 59% 56% 29.1% 8,404 KWh KgCO 2 Annual Savings on Heat and Hot Water Energy saving Bill saving CO 2 Saving 40% 45% 36% 4,921KWh KgCO 2 Annual Savings on Heat and Hot Water Energy saving Bill saving CO 2 Saving 49% 57% Not 3,291 KWh Available Not Available Annual Savings on Heat and Hot Water Energy CO Bill saving 2 saving Saving 77% 50% 46% 28, KWh KgCO 2

32 Modular Build Can be factory fitted and delivered to site Quick to install Long lifecycle Very low maintenance Moving away from Gas dependence to Renewable Technology e.g. ASHP (+ Solar PV if specified) and Sunamp UniQ delivering low energy bills Highly sustainable, small compact units A UniQ 9 store can be fitted under stairs replacing the need for a cylinder cupboard to house a 210 L cylinder Helps to meet national and local space, energy and zero carbon homes standards Cutting edge heating systems Superior comfort and control Delivering lower energy bills for tenants Significant carbon reductions

33 Sunamp PV / UniQ epv 3 PV panel Meter Grid connection DC Inverter AC Consumer unit Appliances Electricity consumption by PV on roof Gas consumption reduced by SunampPV 101 SAVED 74 SAVED Self- Consumption Diverter Gas combi boiler Hot water Cold water John and Jayne It gets a bit to getting used to, switching on the hot tap normally you would hear the sound of the gas boiler that doesn t happen any more Alec & Joan In comparison to the old system, the new system performs to a much higher standard, providing a larger quantity of hot water for a much cheaper price.

34 Solar PV & Sunamp DC storage PV panel Meter Consumer unit Grid connection Inverter Appliances DC Self- Consumption Diverter Separating the PV panels from the grid deals with some connection issues and costs for developers. Gas combi boiler Hot water supply Cold water supply Also provides solar-thermal type performance for lower cost, complexity and maintenance.

35 Grand Designs All Electric House Channel 4, 25 th Oct 2017 Passiv Standard Heat load 800 watts per day All electric No Solar PV or Heat Pump Three Gen-2 stores in basement (one for heating, two for hot water) One store in kitchen (hidden in corner unit) for point-of-use hot water Gen-3 would reduce this to two: UniQ edual9 UniQ ehw3

36 Commercial Retrofit Village Hall Brief was to remove gas They wanted to be the greenest village hall Installation 12kWp Solar PV Array was already installed We retrofitted 2 Daikin Heat Pumps & 1 Stack Removed gas boiler Replaced the old inefficient radiators Have now added EV Charging for community Savings and Payback The committee have been monitoring their savings and estimate they will save over 3000 PA which is over 50% of their fuel costs Payback in 10 years Have not switched to off peak tariff yet, which could increase savings Benefits Very easy to control & sets back automatically Can heat the 2000 Sq Ft room very quickly Radiators replaced with no redecoration required Better water pressure

37 Products: HVAC C&I 3 D W H Palletised Up to 80 kwh in <2 Tonnes Easy to transport, deliver, install (Palletways, pallet truck, forklift) First orders delivered Q Containerised Up to 15 MWh in 20-foot ISO Container (using new materials in development by Sunamp/UoE) Easy to transport, deliver, install Scale-up pathway defined Multiple temperatures (refrigeration, cooling, hot water, space heat, process heat) Meets key needs in upgrading existing plant (no increase in system water, minimum space, more energy efficiency, waste heat re-use) New system designs possible ( e.g. artificial stratification in minimal height impossible with water, district heating optimisation) Transportable heat (also known as MTES Mobile Thermal Energy Storage) at multiple scales and distances, rail, road, barge, ship

38 HVAC: District Heating Current DH Approach UniQ Heat Interface Unit (HIU) with Storage (heat &/or HW) Size central plant and Network to average, not peak (lower CapEx) Satisfy even higher peak hot water loads (local storage) Mix DH flexibly and dynamically with DSR/local renewables (e.g. PV) Low temperature storage (SU32 & SU43) optimised for DHW pre-heat, UFH and 4th generation DH 5 th Generation DH Concept Storage at every level of the network Ability to recover waste heat (from cooling plant) and inject to return network Heat pump/storage Combination for HW preparation allows main network to run at very low flow/return e.g. 35/25

39 Automotive Solutions Separate Business Unit since 01/01/18 (Bob Austin as Head) Leverages underlying PCM science & heat battery engineering; sector-specific system engineering (environmental, cost ) Addresses vehicle thermal management system (VTMS) segment Solutions (currently) for: Passenger Vehicle & Commercial Vehicle (bus, taxi, mobile home) EV (range consistency 90% cost reduction vs. EB) & ICE (fast-engine warm-up 80% time reduction) Retrofit (near-/medium-term) & OEM business (medium-/long-term) Several trials completed & prototype development orders stage with 2 leading global Tier-1s Truck refrigeration Cold storage Air conditioning Battery Thermal Conditioning Cabin HVAC Engine and oil warm-up Catalytic converter light off T, C

40 Market Development Sunamp is a well proven, low risk solution Future Innovation Overseas Markets Vertical Markets, eg automotive, cooling DECC Project Eastheat Project 2018 Huge growth expected, with key drivers in building standards

41 Sunamp Highlights Sunamp Heat Batteries are probably the world's most energy efficient Thermal Stores Certainly the most compact, three to four times higher Energy Density than hot water High power (>30 kw per cell) means high flow rate hot water and heating on demand is assured Very reliable and safe. Non toxic, non flammable, >40,000 cycles proven so far with no degradation, 10 year warranty. Disruptive to hot water tanks (cost parity, performance superiority) Complementary to HVAC equipment, electric batteries, renewable energy & intermittent grids Much lower cost per MWh and cost per MW than lithium-ion batteries (for grid balancing) Gigafactory manufacturing capacity coming online for Gen-3 CapEx intensity 50 times smaller than Tesla Gigafactory for each GWh/year production capacity Priced to compete head-to-head with like-for-like hot water tank solutions Differentiated by higher efficiency and much smaller physical size (70% smaller) Unique applications in high temperature and cooling 23 patents granted, 74 in pipeline across all key geographies materials, heat battery, system, applications DECC funded trial of Gen-1 Heat Battery systems in 2013 (still in use today) Over 1000 systems installed using Gen-2 Heat Batteries (trial and private sale)