Australia’s first grid-scale battery manufacturing plant

[Sparty]

Australia's first grid-scale battery manufacturing plant is under accelerated construction in Maryborough, Queensland.

The $70 million facility is being built by Energy Storage Industries – Asia Pacific (ESI).
Funding includes a $25 million investment from the Queensland Government and $40 million from a British investment firm.

The project aims to establish a new battery manufacturing industry in Queensland, creating over 270 highly skilled jobs in the region.

ESI produces iron flow batteries that can store large-scale solar and wind power, providing electricity for up to 14 hours when renewable energy isn't being generated.

These batteries are non-flammable, non-toxic, recyclable, and suitable for use in sensitive environments.

ESI expects its activities to contribute $9.2 billion to Queensland's economy and create 500 jobs over 20 years.

The facility aims to produce Queensland-made grid-scale batteries by the end of 2025.
By 2029, ESI targets an annual energy storage production of 400 megawatts, enough to power a city the size of Toowoomba.

The project will source key battery components from throughout Queensland, supporting local businesses and creating skilled jobs in various communities.

https://press.esiap.com.au/releases/...ury-investment

https://www.youtube.com/watch?v=3VZc...siap.com.au%2F

[Sparty]

Iron flow batteries, also known as iron-salt flow batteries or iron redox flow batteries, are a type of rechargeable battery technology designed for large-scale energy storage. Here are some key points about them:

Working Principle:

They store energy using the redox reaction between iron in its ferrous (Fe2+) and ferric (Fe3+) states.

The electrolyte contains dissolved iron salts.
Iron flow batteries typically use an iron-based electrolyte. The most common type of iron flow battery uses an electrolyte solution containing iron in two oxidation states:

The negative electrolyte (anolyte) contains iron(II) chloride (FeCl2).
The positive electrolyte (catholyte) contains iron(III) chloride (FeCl3).

These electrolytes are usually dissolved in an aqueous hydrochloric acid (HCl) solution. The iron ions in the electrolyte undergo redox reactions during the charge and discharge cycles of the battery, allowing for the storage and release of electrical energy.


Components:

Two tanks of liquid electrolyte
A cell stack where the electrochemical reactions occur
Pumps to circulate the electrolyte


Advantages:

Long lifespan (potentially 20+ years)
Non-flammable and non-toxic materials
Environmentally friendly and recyclable
Can provide power for extended periods (up to 14 hours as mentioned in the article)
Scalable by increasing the size of electrolyte tanks


Applications:

Grid-scale energy storage
Balancing renewable energy sources like solar and wind
Providing power during peak demand periods


Cost-effectiveness:

Potentially lower cost compared to lithium-ion batteries for long-duration storage


Environmental Impact:

Use abundant and low-cost materials (primarily iron, salt, and water)
Lower environmental impact compared to batteries using rare earth elements


Challenges:

Lower energy density compared to some other battery technologies
Require more space due to the need for electrolyte tanks

[Sparty]

Iron flow batteries are indeed analogous to vanadium redox flow batteries (VRFBs) in many ways.

Similarities:

Operating principle: Both are redox flow batteries, meaning they store energy using reduction-oxidation (redox) reactions between two chemical components dissolved in liquids.

Structure: Both use two tanks of electrolyte, a cell stack for reactions, and pumps to circulate the electrolyte.

Scalability: Energy capacity can be increased in both by simply using larger electrolyte tanks.

Long duration: Both are suitable for long-duration energy storage applications.

Rechargeability: Both can be charged and discharged repeatedly without significant degradation

Grid-scale applications: Both are primarily designed for large-scale, stationary energy storage.

Key Differences:

Active material:

Iron flow batteries use iron salts (Fe2+/Fe3+)

VRFBs use vanadium ions in different oxidation states (V2+/V3+ and V4+/V5+)

VRFB electrolyte:

Composition: The electrolyte typically consists of vanadium ions dissolved in a sulfuric acid (H2SO4) solution.
Unique feature: VRFBs use the same element (vanadium) in both the positive and negative electrolytes, just in different oxidation states.
Oxidation states:

Negative electrolyte (anolyte): V2+ / V3+
Positive electrolyte (catholyte): V4+ / V5+


Specific compounds:

The V2+ and V3+ ions are usually present as sulfate complexes.
The V4+ is typically present as vanadyl sulfate (VOSO4).
The V5+ is usually in the form of vanadium pentoxide (V2O5) dissolved in sulfuric acid.


Concentration: The vanadium concentration is typically around 1.5 to 2 molar in the sulfuric acid solution.
Color: The different oxidation states of vanadium give the electrolytes distinct colors, which can be used as a visual indicator of the battery's state of charge.


Cost:

Iron is generally less expensive and more abundant than vanadium, potentially making iron flow batteries more cost-effective.


Energy density:

VRFBs typically have a higher energy density than iron flow batteries.


Electrolyte stability:

VRFBs can have issues with vanadium precipitation at high temperatures.
Iron flow batteries may be more stable across a wider temperature range.


Maturity:

VRFBs are a more mature technology with more commercial deployments.
Iron flow batteries are still emerging and in earlier stages of commercialization.


Crossover:

VRFBs can suffer from crossover of vanadium ions between half-cells, reducing efficiency.
Iron flow batteries may have less issues with crossover, but this can depend on the specific chemistry used.

Energy Density comparisons VRFB:FERB

a general comparison:

Vanadium Redox Flow Batteries (VRFBs):

Typical energy density: 15-50 Wh/L (watt-hours per liter)
Some advanced designs claim up to 70 Wh/L


Iron Flow Batteries: FeRB

Typical energy density: 10-50 Wh/L
Some newer designs claim up to 60 Wh/L



It's worth noting that:

These values are for the electrolyte only and don't include the full system volume (pumps, pipes, etc.).
Energy density can vary based on the concentration of active materials in the electrolyte and other design factors.
While VRFBs tend to have a slight edge in energy density, iron flow batteries often compensate with lower costs and potentially better stability.
Both technologies generally have lower energy densities compared to lithium-ion batteries (which can reach 200-300 Wh/L or higher), but they excel in other areas like scalability, lifespan, and safety for grid-scale applications.
Research is ongoing to improve the energy density of both technologies.

The relatively low energy density of flow batteries in general means they're more suited to stationary, large-scale energy storage where space is less of a constraint, rather than mobile applications like electric vehicles.

[Sparty]

comparing the energy densities of VRFBs and Iron Flow Batteries to other energy storage technologies and discuss how these differences impact their applications:

Comparison with other storage technologies:

Energy Density Comparison of Storage Technologies

Impact on applications:

a) Flow Batteries (VRFBs and Iron):

Best suited for stationary, large-scale energy storage
Ideal for grid stabilization, renewable energy integration, and long-duration storage
Can be easily scaled up by increasing tank size
Less suitable for mobile applications or where space is limited

b) Lithium-ion:

Dominate in portable electronics and electric vehicles due to high energy density
Also used in grid storage, especially for shorter duration needs (1-4 hours)

c) Lead-Acid:

Still widely used in automotive starting batteries and some backup power systems
Lower cost but shorter lifespan than newer technologies

d) Pumped Hydro and Compressed Air:

Very large scale, geographically dependent
Used for bulk energy storage and grid balancing


Key considerations beyond energy density:

a) Cycle life: Flow batteries often have longer cycle lives (10,000+ cycles) compared to lithium-ion (1,000-3,000 cycles).
b) Safety: Flow batteries are generally safer, with non-flammable electrolytes.
c) Scalability: Flow batteries can independently scale power (cell stacks) and energy (tank size).
d) Environmental impact: Iron flow batteries use more abundant, less toxic materials than some alternatives.
e) Cost: While upfront costs can be higher, the levelized cost of storage over the battery lifetime can be lower for flow batteries in long-duration applications.

Future trends:


Ongoing research aims to improve energy density of flow batteries
Hybrid systems combining different storage technologies are emerging
The choice of technology is increasingly application-specific, considering factors like duration of storage, cycle frequency, and location

In summary, while flow batteries have lower energy density compared to some alternatives, they offer unique advantages for large-scale, long-duration energy storage. Their lower energy density is often outweighed by benefits in scalability, lifespan, and safety for grid-scale applications.

Technology
|
Energy Density (Wh/L)


Vanadium Redox Flow Batteries
|
15-50
|

Iron Flow Batteries
|
10-50
|
|
Lead-Acid Batteries
|
50-80
|
|
Nickel-Metal Hydride Batteries
|
140-300
|
|
Lithium-ion Batteries
|
200-700
|
|
Sodium-Sulfur Batteries
|
150-300
|
|
Pumped Hydro Storage
|
0.2-2
|
|
Compressed Air Energy Storage
|
2-6

[Sparty]

How the specific energy values of different battery technologies impact their applications:

Flow Batteries (Vanadium and Iron:

Specific Energy: 10-50 Wh/kg
Applications:
a) Grid-scale energy storage
b) Renewable energy integration (solar and wind farms)
c) Industrial and commercial energy management
Impact:

Lower specific energy is less critical in stationary applications
Advantage in scalability and long duration storage (4-12+ hours)
Not suitable for mobile applications due to weight constraints




Lithium-ion Batteries:

Specific Energy: 100-265 Wh/kg
Applications:
a) Portable electronics (phones, laptops)
b) Electric vehicles
c) Residential and small-scale commercial energy storage
Impact:

High specific energy enables long-range electric vehicles
Allows for compact, lightweight designs in portable devices
Efficient for short-duration grid storage (1-4 hours)




Lead-Acid Batteries:

Specific Energy: 30-50 Wh/kg
Applications:
a) Automotive starting, lighting, and ignition
b) Uninterruptible power supplies (UPS)
c) Off-grid solar systems in developing countries
Impact:

Lower specific energy limits use in electric vehicles
Still viable where cost is a primary concern and energy density is less critical

Nickel-Metal Hydride (NiMH):

Specific Energy: 60-120 Wh/kg
Applications:
a) Hybrid electric vehicles
b) High-drain portable electronics
Impact:

Higher specific energy than lead-acid, but lower than Li-ion
Used in some hybrid vehicles as a balance between performance and cost




Sodium-Sulfur Batteries:

Specific Energy: 100-200 Wh/kg
Applications:
a) Large-scale grid energy storage
b) Renewable energy integration
Impact:

High temperature operation limits portability
Good for stationary applications where high energy density is needed

Key implications of specific energy on applications:

Mobile vs. Stationary:
High specific energy is crucial for mobile applications (EVs, portable devices) but less critical for stationary storage.

Duration of Storage:
High specific energy batteries (Li-ion) are often used for shorter duration storage (1-4 hours)
Lower specific energy batteries (flow batteries) can be more cost-effective for longer duration storage (8+ hours)


Space Constraints:
In urban or space-limited environments, higher specific energy can be advantageous even for stationary applications.

System Design:
Lower specific energy may require larger, heavier systems, impacting structural requirements and installation costs.

Transportation:
For large-scale projects, the weight of batteries affects transportation costs and logistics.

Hybridization:
Some systems combine high specific energy batteries (e.g., Li-ion) for rapid response with lower specific energy technologies (e.g., flow batteries) for long-duration storage.

Cost Considerations:
Often, there's a trade-off between specific energy and cost. Lower specific energy batteries can be more cost-effective for large-scale, stationary applications.

Lifecycle and Efficiency:
Some lower specific energy batteries (like flow batteries) can offer longer cycle life and better long-term efficiency, which can outweigh the energy density disadvantage in certain applications.

In summary, while specific energy is a crucial factor in battery selection, it's just one of many considerations. The choice of battery technology often involves balancing specific energy with other factors like cost, lifespan, safety, and specific application requirements.

Definition:
Specific energy is the amount of energy stored in a system per unit mass. It is typically measured in watt-hours per kilogram (Wh/kg).
In the context of batteries:

Specific energy refers to how much energy a battery can store relative to its weight.
It's a way to compare the energy storage capacity of different battery types or designs on a per-weight basis.

For example, when we say "lithium-ion batteries have a high specific energy," we mean that lithium-ion batteries can store a large amount of energy for their weight compared to other battery types.

To be more accurate, instead of saying "specific energy batteries," we should refer to:

"Batteries with high specific energy" (like lithium-ion)
"Batteries with low specific energy" (like lead-acid)

[Sparty]

A Vanadium Redox Flow Battery (VRFB) facility being set up in Gladstone, Queensland, Australia.

https://www.statedevelopment.qld.gov...sion-paper.pdf

Project:

Company: The project is being developed by Vecco Group, an Australian clean energy company.
Location: Gladstone, Queensland. This location is strategic due to its industrial infrastructure and potential for renewable energy development. See page 19 of queensland-batteries-discussion-paper.pdf

Scale: The planned VRFB facility is intended to be one of the largest of its kind in the world.

Purpose: The battery is designed to store and supply renewable energy, supporting the region's transition to clean energy and potentially supplying power for green hydrogen production.
Construction was expected to begin in the near future, but I don't have the exact start date or current status.

Significance: This project is considered important for Australia's renewable energy sector and could serve as a model for large-scale energy storage solutions.

For the most current information, I'd recommend checking recent news sources or the official websites of Vecco Group and the Queensland government.

https://www.statedevelopment.qld.gov...-hub-gladstone

https://www.statedevelopment.qld.gov...sion-paper.pdf

[Sparty]

Key points:

Local sourcing: There were plans to source vanadium locally, which aligns with Australia's goal to develop its critical minerals sector.

North Queensland: The primary source of vanadium was expected to be from North Queensland, where there are significant vanadium deposits.

Specific mine: The Julia Creek vanadium deposit in North Queensland was often mentioned in connection with this project. This deposit is part of the Vanadium rich oil shale deposits in the Toolebuc Formation.

Vecco Group's involvement: Vecco Group, the company behind the Gladstone VRFB project, also had interests in vanadium mining. They were developing the Saint Elmo Vanadium Project near Julia Creek.

Integrated supply chain: The plan was to create an integrated supply chain from vanadium mining to battery production and deployment, all within Queensland.

Processing: There were discussions about setting up vanadium processing facilities closer to Gladstone to complete the supply chain.

Economic benefits: Sourcing vanadium locally was seen as a way to boost the local economy and create jobs in both mining and advanced manufacturing.