Periodic Reporting for period 2 - HEROES (Hybrid EneRgy stOragE Stations)
Reporting period: 2022-11-01 to 2024-10-31
The overall objective of the Hybrid Energy Storage Station (HEROES) project was to develop and demonstrate an innovative hybrid high-power stationary storage system for fast charging of electrical vehicles (EVs) (23 min for 75% of a state of the art 93 kWh EV) that can be connected to widespread low voltage grids without the need to invest in improving the grid infrastructure. The project has been funded under the Research and Innovation Action, developing a hybrid energy storage station from TRL4 to TRL6/7, from 01.05.2021-31.10.2024. The consortium includes 10 European partners, coordinated by Beyonder (Norway).
Core results:
• Designed and produced unique, innovative High Power Battery cells (HP-Batt) with 10 000 cycles, specific power of 5 kW/kg (up to 20C), and energy density of 90 Wh/kg. The HP-Batt cells were delivered to partners for cell testing and for development of HP-Batt modules. The HP-Batt cells were produced at Beyonder’s (BYO) facilities in Norway.
• Cell characterization of the HP-Batt cells throughout the project lifetime to understand the behaviour of the new cell to optimize utilization and estimate HP-Batt lifetime. Scope performed by Institute of Energy Technology (IFE) and Aalborg University (AAU)
• State of Health, State of Charge and State of function algorithms developed for the Battery Management System (BMS) for the HP-Batt modules
• Developed BMS for HP-Batt modules (Lithium Balance, LBA)
• Designed and produced 17 HP-Batt modules with a capacity of 2 kWh each for the demonstrator (ElringKlinger, EK)
• Developed new Energy Management System and DC/DC converter for the Hybrid Energy Storage Station, and integrated and tested the system at TRL5 (Siemens)
• Tested the Hybrid Energy Storage Station in operating environment demonstrating fast charging of cars with 400 V and 800 V platform (Fraunhofer ICT, FHG)
• Life Cycle Assessment showing that environmental impacts are >50% lower for categories related to human toxicity, and significant lower metal consumption for the HEROES charging solution compared to commercial chargers analysed
• Life Cycle Cost calculations show a cycle cost for the HEROES charging station of 0.037 €/kWh/cycle for power output of 300 kW and with a system lifetime of 12 years (ENSO)
• The project experienced great interest for the technology and project results that has been shared in different media and at different events (EASE).
• Market assessment (Sustainable Innovation, INNOVA)
• The technology was proven to be relevant for exploitation and commercialisation for fast charging solution of EV’s and heavy-duty vehicles
HEROES provide a solution for fast charging of EVs that will contribute to accelerate the electrification of the transport sector and thereby contribute to reduce CO2 emissions in Europe.
Core results:
• Designed and produced unique, innovative High Power Battery cells (HP-Batt) with 10 000 cycles, specific power of 5 kW/kg (up to 20C), and energy density of 90 Wh/kg. The HP-Batt cells were delivered to partners for cell testing and for development of HP-Batt modules. The HP-Batt cells were produced at Beyonder’s (BYO) facilities in Norway.
• Cell characterization of the HP-Batt cells throughout the project lifetime to understand the behaviour of the new cell to optimize utilization and estimate HP-Batt lifetime. Scope performed by Institute of Energy Technology (IFE) and Aalborg University (AAU)
• State of Health, State of Charge and State of function algorithms developed for the Battery Management System (BMS) for the HP-Batt modules
• Developed BMS for HP-Batt modules (Lithium Balance, LBA)
• Designed and produced 17 HP-Batt modules with a capacity of 2 kWh each for the demonstrator (ElringKlinger, EK)
• Developed new Energy Management System and DC/DC converter for the Hybrid Energy Storage Station, and integrated and tested the system at TRL5 (Siemens)
• Tested the Hybrid Energy Storage Station in operating environment demonstrating fast charging of cars with 400 V and 800 V platform (Fraunhofer ICT, FHG)
• Life Cycle Assessment showing that environmental impacts are >50% lower for categories related to human toxicity, and significant lower metal consumption for the HEROES charging solution compared to commercial chargers analysed
• Life Cycle Cost calculations show a cycle cost for the HEROES charging station of 0.037 €/kWh/cycle for power output of 300 kW and with a system lifetime of 12 years (ENSO)
• The project experienced great interest for the technology and project results that has been shared in different media and at different events (EASE).
• Market assessment (Sustainable Innovation, INNOVA)
• The technology was proven to be relevant for exploitation and commercialisation for fast charging solution of EV’s and heavy-duty vehicles
HEROES provide a solution for fast charging of EVs that will contribute to accelerate the electrification of the transport sector and thereby contribute to reduce CO2 emissions in Europe.
BYO successfully designed and produced innovative, unique HP-Batt with 10 000 cycles, specific power of 5 kW/kg (up to 20C), and energy density of 90 Wh/kg. More than 1000 HP-Batt cells were produced at BYO’s facilities in Norway and delivered to EK for HP-Batt module production and for cell testing by IFE, AAU and EK. BYO also developed and documented HP-Batt pre-lithiated cells with >10 000 cycles. BYO has developed and gained significant knowledge within battery technology development and manufacturing that has been a core for commercializing Beyonder’s first product, BePowered, spring 2024.
IFE and AAU completed cell characterization (capacity, cycle life, thermal and electrochemical properties). IFE also developed and delivered Si-material for development of some pre-lithiated HP-Batt that were produced by BYO. AAU developed SoX algorithms for the BMS for the HP-Batt modules.
EK designed and produced 17 HP-Batt modules of 2 kWh each for the demonstrator. The design process included cell testing, and need for compression pads and cooling system. Final HP-Batt module design was without housing that made some challenges with respect to safety. The issue was solved by a new site for the demonstrator provided by FHG and giving all installation and commissioning responsibility to FHG that could install the HP-Batt modules in a safe environment. LBA developed the BMS for the HP-batt modules in close cooperation with AAU, and delivered two high energy battery racks (LIB).
SIEMENS performed the system integration and developed the isolated DC/DC converter and the EMS. Siemens received all components from partners and tested each component individually before the whole system was tested at TRL5. Test results confirmed i) a possible maximum power of the system of 220 kW, ii) demonstrated a safe and reliable operation of the HEROES system and iii) the demonstration that the EMS automatically controlled the power flow, monitored the safety status of all components and guaranteed the communication between the system components.
FHG prepared the site for the demonstrator, and designed, installed, and commissioned the demonstrator at site. To evaluate the performance of the HEROES demonstrator, several extended charging procedures (approx. 20...80 % SOC) were carried out with different vehicles. Various cars were charged demonstrating fast charging of EV’s with 400 and 800 V platform. During the tests regarding the size of the energy storage units, a usable energy quantity of 105.6 kWh was determined for the high energy battery and 19.6 kWh for the HP-Batt (specifications: High Energy Battery 140 kWh, HP-Batt 26 kWh). The lower values compared to the design were because for safety reasons, both battery storage systems were operated within stricter voltage limits than it would have been technically possible.
INNOVA performed exploitation strategy and market assessment identifying the Key Exploitable Results that HEROES partners aimed to achieve through technical development. Results have also been added to the Horizon Result Booster. EASE has ensured communication and dissemination of the project and its results in different media and at different events. ENSO performed a LCA and LCC analysis by comping HEROES to two existing commercial charging solutions. The cycle cost for HEROES with power output of 300 kW and system lifetime of 12 years estimated to 0.037 €/kWh/cycle.
IFE and AAU completed cell characterization (capacity, cycle life, thermal and electrochemical properties). IFE also developed and delivered Si-material for development of some pre-lithiated HP-Batt that were produced by BYO. AAU developed SoX algorithms for the BMS for the HP-Batt modules.
EK designed and produced 17 HP-Batt modules of 2 kWh each for the demonstrator. The design process included cell testing, and need for compression pads and cooling system. Final HP-Batt module design was without housing that made some challenges with respect to safety. The issue was solved by a new site for the demonstrator provided by FHG and giving all installation and commissioning responsibility to FHG that could install the HP-Batt modules in a safe environment. LBA developed the BMS for the HP-batt modules in close cooperation with AAU, and delivered two high energy battery racks (LIB).
SIEMENS performed the system integration and developed the isolated DC/DC converter and the EMS. Siemens received all components from partners and tested each component individually before the whole system was tested at TRL5. Test results confirmed i) a possible maximum power of the system of 220 kW, ii) demonstrated a safe and reliable operation of the HEROES system and iii) the demonstration that the EMS automatically controlled the power flow, monitored the safety status of all components and guaranteed the communication between the system components.
FHG prepared the site for the demonstrator, and designed, installed, and commissioned the demonstrator at site. To evaluate the performance of the HEROES demonstrator, several extended charging procedures (approx. 20...80 % SOC) were carried out with different vehicles. Various cars were charged demonstrating fast charging of EV’s with 400 and 800 V platform. During the tests regarding the size of the energy storage units, a usable energy quantity of 105.6 kWh was determined for the high energy battery and 19.6 kWh for the HP-Batt (specifications: High Energy Battery 140 kWh, HP-Batt 26 kWh). The lower values compared to the design were because for safety reasons, both battery storage systems were operated within stricter voltage limits than it would have been technically possible.
INNOVA performed exploitation strategy and market assessment identifying the Key Exploitable Results that HEROES partners aimed to achieve through technical development. Results have also been added to the Horizon Result Booster. EASE has ensured communication and dissemination of the project and its results in different media and at different events. ENSO performed a LCA and LCC analysis by comping HEROES to two existing commercial charging solutions. The cycle cost for HEROES with power output of 300 kW and system lifetime of 12 years estimated to 0.037 €/kWh/cycle.
Innovations:
1. Developed an unique, innovative, high-power, fast charging/discharging battery cell (HP-Batt) with 10 000 cycles, power density of 5 kW/kg (up to 20C), and with energy density of 90 Wh/kg
2. HP-Batt modules.
3. BMS for the new, innovative HP-Batt modules.
4. Isolated DC/DC converter to charge electric vehicles. A wide range of possible output voltages is enabled for flexibility. Furthermore, its power density is beyond the state of the art.
5. EMS for the Hybrid Energy Storage Station.
6. Hybrid demonstrator for fast charging of cars without the need for grid upgrade.
Other benefits: ramp up of significant, highly valuable and unique expertise within battery technology development, cell testing, battery module production, battery system, system integration, and testing of hybrid, innovative charging infrastructure. Also, cooperation with new partners and increased knowledge about EU funded projects that has resulted in partner cooperating on new project applications (BYO and FHG, application submitted together with 15 other European partners but failed to be granted) and projects (EASE and BYO).
1. Developed an unique, innovative, high-power, fast charging/discharging battery cell (HP-Batt) with 10 000 cycles, power density of 5 kW/kg (up to 20C), and with energy density of 90 Wh/kg
2. HP-Batt modules.
3. BMS for the new, innovative HP-Batt modules.
4. Isolated DC/DC converter to charge electric vehicles. A wide range of possible output voltages is enabled for flexibility. Furthermore, its power density is beyond the state of the art.
5. EMS for the Hybrid Energy Storage Station.
6. Hybrid demonstrator for fast charging of cars without the need for grid upgrade.
Other benefits: ramp up of significant, highly valuable and unique expertise within battery technology development, cell testing, battery module production, battery system, system integration, and testing of hybrid, innovative charging infrastructure. Also, cooperation with new partners and increased knowledge about EU funded projects that has resulted in partner cooperating on new project applications (BYO and FHG, application submitted together with 15 other European partners but failed to be granted) and projects (EASE and BYO).