International Wind – Diesel Workshop

Overview & DiscussionMarch 2011

Christopher Kuhl, Sales Application EngineerZBB Energy Corporation

Agenda

• ZBB Overview• Integrated Platforms • Flow Batteries• Operational Data - Savings• Design Considerations• Modular Architecture

The Leader in Renewable Energy IntegrationZBB is transforming intermittent renewable energy into a reliable power source through intelligent power-management platforms and advanced storage technologies• Leader in large format Zinc-Bromide flow batteries• Created the “Brain/Router” of renewable energy systems - the

Power and Energy Control Center (PECC)• Key installations of grid-connected and off-grid Storage

systems• Ramping penetration in multi-billion dollar distributed

renewable energy market

• Founded in 1995 / IPO in 2006

• Headquartered in Menomonee Falls (Milwaukee), WI, USA

• 75,000 Sq. Ft. ES & System Production Facility

• 10,000 Sq Ft. Power Electronics Facility (Tier Electronics – 2011)

• R&D group in Perth, Australia

• ISO-9001 Certified• +50 Full time employees• Traded on NYSE AMEX: ZBB

Quick Facts

“Conventional Architecture”Renewable Off Grid Non-Modular Power Plant

• Not a factory integrated and tested Energy Storage and Power Conversion System (PCS)

• Customer required to set up control dispatch or for load following

• Energy Storage suffers extra ‘round-trip’ across inverters (6 to 10% efficiency lost)

• Multiple inverters from various manufacturer’s

• Challenging to expand or change given typical microprocessor controls

kW

kVar

M

Control kW and/or kVAR to ZERO

Circuit Breakers & Meters

Each PV Array

Each Wind Turbine

Energy Storage

Energy Storage

Power Flows

“Micro” Grid & Loads480VAC, 3PH, 50/60 Hz

Master System

Controller

Always OnGen Set

ZBB ZESS POWR™Integrated Energy Storage and Renewable / Conventional Fuel

Generation

Customer Loads/Grid with Dedicated AC or DC Outputs- 1ph or 3ph- Various Voltages- 50Hz or 60Hz

ZESS POWR PECCPower & Energy Control Center

kW

kVar

• Factory Integrated and tested Energy Storage and Power Conversion System (PCS) with connections for multiple power inputs

• Fully managed energy and power between the generation and the load demand

• Energy Storage provides “after hours” power plant operation

• Complete Reactive and Active Power supply for the load and / or grid demand

• Can be equipped & configured to operate ‘independently’ of the grid (as an EPS) or even have the grid as a power input

ZESS POWR • ZBB control optimization• Optimal use of energy production• For Grid-Interactive or Grid-Independent Applications• Up to Multiple Megawatts (MW)/Megawatt Hour (MWH)• Load active/reactive power support• Load voltage regulation• Load frequency regulation• Single output as a “Firm” & regulated power plant• Built in protection• Local Display and Remote Monitoring

Scale & Flexibility• Modular• Multiple power

inputs• Multiple ZESS or alt

ES inputs

Platform Configurations:Grid Interactive (Synch-tied)Grid Independent (Off-grid / EPS)Grid Conversion (UPS with grid as an input)

Confidential

CONFIDENTIAL, ZBB Energy Corp - 2011

Power Flows

Segmented PV Array with MPPT per Section

Modular ES UnitsOne or More Gen Sets with Stop /

Start

Individual or Aggregated Wind Turbine

(VAC / VDC)

Grid Independent POWR™ PECC Operational Modes

08:1

9:33

08:5

2:33

09:2

5:33

09:5

8:33

10:3

1:33

11:0

4:33

11:3

7:33

12:1

0:33

12:4

3:33

13:1

6:33

13:4

9:33

14:2

2:33

14:5

5:33

15:2

8:33

16:0

1:33

16:3

4:33

17:0

7:33

17:4

0:33

18:1

3:33

18:4

6:33

19:1

9:33

19:5

2:33

20:2

5:33

20:5

8:33

21:3

1:33

22:0

4:33

22:3

7:33

23:1

0:33

23:4

3:33

00:1

6:33

00:4

9:33

01:2

2:33

01:5

5:33

02:2

8:33

03:0

1:33

03:3

4:33

04:0

7:33

04:4

0:33

05:1

3:33

05:4

6:33

06:1

9:33

06:5

2:33

07:2

5:33

-30

-20

-10

0

10

20

30

2x ZESS 50 Modules and 30kW PV Array 24 Hour Cycle

ZESS PowerPV PowerOutput Power

Time

Pow

er (k

W)Grid Independent ZESS POWR™ PECC

with PV, Storage & Gen Set

Grid Independent ZESS POWR™ PECC with PV, Wind, Storage & Gen Set

10:0

0:33

10:1

7:03

10:3

3:33

10:5

0:03

11:0

6:33

11:2

3:03

11:3

9:33

11:5

6:03

12:1

2:33

12:2

9:03

12:4

5:33

13:0

2:03

13:1

8:33

13:3

5:03

13:5

1:33

14:0

8:03

14:2

4:33

14:4

1:03

14:5

7:33

15:1

4:03

15:3

0:33

15:4

7:03

16:0

3:33

16:2

0:03

16:3

6:33

16:5

3:03

17:0

9:33

17:2

6:03

17:4

2:33

17:5

9:03

18:1

5:33

18:3

2:03

18:4

8:33

19:0

5:03

19:2

1:33

19:3

8:03

19:5

4:33

20:1

1:03

20:2

7:33

20:4

4:03

21:0

0:33

21:1

7:03

21:3

3:33

-30

-20

-10

0

10

20

30

40

2x ZESS 50 Modules / 30kW PV Array / 10kW Wind Turbine 18Hour Cycle

ZESS PWRPV PWRWind PowerOutput Power

Time

Pow

er (k

W)

ZESS POWR™ PECC Private Residence - State

College, PA System Parameters:

• Inverter Nameplate = 70kVA, 240V, 1-phase, 60Hz• Gen Set Nameplate = 75kVA, 240VAC, 1-phase (rectified)• Total Load ~ 500kWHr/Day• Average Load ~ 20kW/Hour – Peak Load ~40kW• Renewable Capacity (Including Storage) =

• Daytime ~100% • Nighttime ~ 50%

• Renewable Output Contribution (Daily Average)• Summer >70%• Winter ~40%

• Gen Set Runtime• Summer ~ 5 Hours / Night• Winter 2x Day @ 6 Hours per run

• ES & system losses have approximately a 70% round-trip efficiency when charged by Renewable or GS output;

• 100kWH / 0.70 ~ 142kWH required to fully charge

ZESS 50 Zn-Br Flow BatteryVersion 3 - ZESS 50 Zn – Br Flow Battery (50 kWH)

• Fully Front-accessible• 50 kWh of Storage per Module with a

25kW (max) Discharge Rate• Full Discharge Capability• 3x Expected Service vs. Life of Lead

Acid− Of one set of ZESS 50 cell stacks• Cheaper than Li-ion• 5x Energy Density of Vanadium Flow• Extended Operating Temp (-30° to

+50°C)• Modular & Transportable

CONFIDENTIAL, ZBB Energy Corp - 2011

ZESS 50V3 Module60”W x 25”D x 96”H

with integrated DC bus and internal heat exchanger,

controls and mechanicals

ZESS POWR™ 50 Expected “Service Lifetime Discharge”

Capacity

Discharge Capacity to Equivalent “Cycles”

Comparison

Maximum State – of - Charge10% 20% 40% 80% 100%

75MWH SLD Capacity of Cell Stacks per 50kWH Module

(Not an “End-of-Life” / Failure Mode Projection, but an Economic Operational Decision for Cell Stack Replacement)

75MWH / 100% / 50kWH > 1500 cycles

60%

75MWH / 80% / 50kWH> 1875 cycles

75MWH / 60% / 50kWH> 2500 cycles

75MWH / 40% / 50kWH> 3750 cycles

75MWH / 20% / 50kWH> 7500 cycles

75MWH / 10% / 50kWH> 15,000 cycles

ZESS POWR™ 50 Flow Battery Projected Efficiency Degradation of Cell

Stacks

1 2 3 4 50

10

20

30

40

50

60

70

80

50 50 50 50 50

67 68 69 71 72

15 15 15 15 15

20 20 21 21 22

kWh Out (Per 50kWH Module)

kWH In (Per 50kWH Module)

kWH Out (Annually x1000)

kWH In (Annually x1000)

Year (Cell Stacks)

kWH

Anticipated Annual Degrade Rate1.5% / Year

With 300 of 100% DoD Cycles or Equivalent partial discharges

Efficiency at DC TerminalsYear 1 = 75.0%Year 2 = 73.5%Year 3= 72.0%Year 4 = 70.5%Year 5 = 69.0%

ZESS POWR™ PECCDiesel Fuel Reduction Cost savings

Assumptions:

• CAPEX of systems + freight + install• $1000/kWH• $50,000 (ZESS 50V3)• +15% for install = $7500

• OPEX of systems (replace cell stacks)• 15% of CAPEX per 5 years• $7500 x 3 events = $22,500

• SLD Output = 2000 x 4 (sets) = • 8000 x 50kWH = 400,000kWH

• TCO Calculation = $80,000 / 400,000• = $0.20/kWH + cost of charging

energy• “Your results may vary”

Projected “Cost of Stored Energy” How Much Energy Storage Should We Have ?

What is the objective to using storage:

• Voltage & Frequency control• Seconds

• Ramp rate control• 1 to 5 minutes

• Provide ‘dis-patchable’ power • 15 minute increments

• Accumulate “off peak” wind• Hours

• Generator Shut down• >50% Reduction in diesel• Many hours of capacity ‘filling in gaps’ and

‘absorbing peaks’

ZESS POWR™ PECC Hybrid Output Operational Mode*

How long and often will the Gen Set run on these days?

12AM 6AM 12PM 6PM 12AM

‘Surplus’ Wind Output Charging

to ESGS is dispatched automatically by SoC, Output Provides for

Load & ES Charge

ES Discharge Automatically

Provides for LoadAny ‘dips’ in Wind Output are NOT

seen by loads

Any ‘spikes’ in Load are automatically

‘absorbed’ by Platform up to 100kw in total

System Max Output = 58kW; 60kW in Gen Set Bypass

(On @ 20% S-O-C; Off @ 80% S-O-C)

10kW

25kW

50kW

75kW

Load in kWES %S-O-C

80%S-O-C

20%S-O-C

50%S-O-C

Assumptions:

• ES & Renewable output = % of load average on a daily basis

• What are the SoC min / max points?• What happens at 100% SoC?

ZESS POWR™ PECCEquipment Packaging &

Configurations• Intelligent DC Bus

• Patented Design

• UL 1741 Qualified

• Configurable & scalable

• Hybridize multiple generation and storage sources

• Partnered with

• Multiple installations running now

ZESS POWR™ PECC DSP Control & Status Display

Typical “System-level” Home Screen with:

•Generation sources•Loads information•Battery SoC•System status

summary•Historical •Alarms / Faults

This web-based application is available both at a walk-up touch-screen and over a wide-area network

Existing Distribution; Possible New

Breaker

ZESS POWR™ PECC System Design & Operational Issues

Diesel Generator Auto / Manual By-pass

Each PV ArrayUp to 25kW;

120 to 300VDC

Each Wind TurbineUp to 125kW;

200VAC, 3-phasePersonal Renewable

Energy;<15% of Total System Load

1-phase loads imbalance;~ 25% Phase-Phase Imbalance

Existing Auto / Manual Transfer Switch

3-phase ‘start-up loads’;Max % Overload’ TBD

Summary

• ZBB Overview• Integrated Platforms • Flow Batteries• Operational Data & Savings• Design Consideration• Modular Architecture

Thank you !

Christopher KuhlSales Application Engineer

262-253-9800 ext. 124ckuhl@zbbenergy.com

www.zbbenergy.com