SINEXCEL deploys 107.12 MW PCS converter-backed BESS for aluminium smelting cost optimisation in China

SINEXCEL, a developer of high-efficiency power modules and reliable charging systems, has wrapped up the grid connection of a 107.12 MW, 428.48 MWh energy storage system to the grid in Guangyuan, Sichuan Province, which is deemed to be one of China’s flagship commercial-industrial energy storage projects. For the aluminium producer Zhongfu Industrial, this project has been developed, which has been designed with the aim of cutting down electricity costs by facilitating peak shaving during the energy-heavy electrolytic aluminium production process.

Addressing the energy challenge of the industry

The primary aluminium smelting process is highly energy-intensive, requiring between 13 and 15 MWh for every tonne produced, with electricity making up as much as 40 per cent of the overall cost. Here, a sudden power outage may lead to huge financial losses, which, at times, can be in millions of yuan, due to the electrolyte freezing. This marks the primary reason why a reliable PCS converter is crucial for avoiding such issues.

Based Energy Storage System (BESS) aids in addressing this challenge. How? By providing a way to store cheap energy during off-peak times and releasing it when demand is high. With this strategy, the firm will be able to save 140 yuan (USD 20.5) for every tonne of aluminium produced, which, if added, may go up to 60 million yuan (USD 8.79 million) in annual savings and not the mentioned reduction of 52 thousand tonnes in CO2 emissions.

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Technology that operates in extreme conditions

The project features 104 PCS SINEXCEL converters, where each of them will boost power output worth 1725 kW, while successfully integrating with 5 MWh battery containers in a smart DC-coupled setup. These new converters are designed to aid the operations at lower power ratings, which, in return, will expand their prolonged lifespan and have a rigorous industrial setting.

The converters are said to respond in milliseconds, which ensures the start of the backup power is smooth if any grid hiccups are encountered and eliminates any possible costly production downtimes.

With a maximum efficiency of 98.5 per cent, these converters assure substantial energy savings over time. Additionally, the IP54 protection keeps the devices safe from the high dust levels often found in steel mills, reducing the wear and tear that traditional systems face.

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The 1725 kW PCS converters come with CE, VDE 4110/4120 and EN 50549 certifications for the European market, along with grid compliance certifications for the US, Australia, Japan and Thailand. In the present situation, the total global installed capacity has now surpassed 1 GW.

Nudging higher sustainability in the industry

The 1725 kW PCS converters adaptation aids in multiple global projects, starting from powering Latvia’s largest integrated wind farm with energy storage to the commercial and industrial setups.

The firm's solution can aid nearly 60+ countries by boosting a total installed capacity, which may exceed 17 GW/50 GWh. This perfectly aligns with the firm's commitment towards delivering reliable, high-performing hardware solutions for the industrial initiatives and energy across the globe.

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