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Making a Case for Flywheel Energy Storage

Drew Devitt, New Way Energy LLC
March 01, 2010  |  24 Comments

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Electricity is the ultimate in a perishable commodity. If it is not used or transformed as it is generated it will be lost. So the systems that supply electricity have been designed with flexibility in mind so that supply may be made to closely match whatever the demand happens to be.

Consumers take this balance for granted but our local electric company closely studies historical demand, accounting for the change in seasons, changes during the day, weather forecasts and even whether there is a baseball game at the stadium. When utilities turn to their supply side they may have hundreds of generator sets all varying in kilowatt rating size, cost efficiency and on/off flexibility. The electric company has taken its best bet as to which of the large inflexible turbines to have powered on. They would like to maximize the use of these turbines as they are generally the most efficient turbines to run and cleanest turbines for the environment. Due to the need to be able to follow demand they also need to have in the mix a spectrum of smaller turbines that may be turned on and off easily. this is the most expensive electricity and these are also the dirtiest turbines.

The electric company is more likely to own the larger capital intensive gensets and issue supply contracts with independent power producers for the smaller turbines (where there are deregulated markets). The contract prices are usually priced based on the kilowatts that can be provided and the speed at which they may be turned on or off. This spectrum of adjustability is referred to as "load following" on the broad scale and "frequency regulation" on the fine scale.

The need for frequency regulation is the main reason that power generators have to match supply to demand. It would sometimes be easier simply to create more electricity than is being demanded. But this is more dangerous than not supplying enough electricity. When there is more supply of electricity than is demanded the frequency of the alternating current goes above 60 Hz and when the supply is exceeded by demand the frequency drops below 60 Hz. (In Europe and other parts of the world this standard is 50 Hz.) Electric companies are mandated by federal laws to maintain 60 Hz on the grid. The bigger the disparity above or below 60 Hz the larger the fines that may be imposed on them.

Power companies are used to having a deterministic supply side. If they tell a supplier to fire up a turbine that is rated for 30 MW they can count on having 30 MW delivered within the contracted time with near certainty. With wind and solar energy, however, we are now asking the power company to deal with intermittency on their supply side and not just on their demand side. Although renewable energy sources (not counting hydroelectricity) account for less than 2 percent of the total energy generated in the United States, the popular press and politicians are talking about having 20 percent of our electricity generated by renewables within 10 years. Common sense suggests that load following and frequency regulation will become more difficult and expensive with this increase in supply side variability.

At the same time, however, a great degree of flexibility already is built into electricity supply. The classic demand curve in Figure 1 shows that within a particular regulation area with an average of 10,000 MW produced all the time, demand at any one time varies from 5,000 MW to 20,000 MW, which is a significant spread. It is sometimes insinuated that renewable energy sources will require a whole new fleet of turbines standing by when the wind dies or when clouds obscure the sun. This is simply not the case. Large utilities and control areas typically will have thousands of megawatts in reserve most of the time. And even at peak demand times they will be glad for the extra capacity.

The electric company though, has an obligation to supply the electricity that is being demanded. As the percentage of possible variability increases in their supply they will have to increase the value of contracts with deterministic generation sources. If the wind does stop blowing, the turbines they will have to turn on may not be as efficient or as clean as the turbines they might have selected in the absence of wind variability. This would have a negative impact on the value of wind energy, but new turbines and huge storage facilities will not be necessary.

The hope for renewables is aggregation. The idea is that as more renewables come on line their intermittency will average out, at least to some degree. The wind blowing harder at night will average with the sun shining bright in the day on a macro level. Likewise, as a gust of wind blows through a wind farm it won't much change the average output of the farm on a micro level. There is no doubt that there will be an averaging of renewable generated power, but on the macro side this averaging is limited by transmission constraints.

Energy storage technologies are often referred to as a way to shift time and smooth the delivery of renewable energy such as wind and solar. But the cost of energy storage infrastructure is not insignificant. Today's cost for advanced lithium batteries (one of the leading energy storage candidates) capable of storing 1 MWh of electricity is about $2 million, about the same capital cost per megawatt-hour as the wind turbine. So if a 1 MW-rated turbine has good wind and is able to produce its megawatt hour rating for 10 hours it will produce 10 MWh of energy. Storing this energy would require $20 million worth of batteries. This obviously is not an economic model.

Although energy storage does not play a significant factor in our current electrical distribution system it certainly seems like it should. One way to look into the future or see examples of how energy storage is used in smart grid applications is to have a look at what the U.S. Navy has been doing.

Navy ships historically have had mechanical, hydraulic and even steam-operated equipment on board. A Navy ship at sea has its own independent smart grid with multiple generation sources and a high requirement on the supply's reliability and capability. The ship needs to be able to go from economical cruising to full battle readiness within seconds. If there is an application where energy storage would be valuable, this is it.

One of the energy storage projects which the Navy is working on is the electromagnetic aircraft launch system (EMALS). Everyone has probably seen film footage with planes launched off aircraft carrier decks with the help of huge steam pistons located just below decks. This is still the way it's done today on modern aircraft carriers. But the Navy is planning to switch to a lighter, less maintenance-intensive linear motor that offers greater capability than current steam catapults.

The energy requirements of such electronic catapults are impressive. A 20-ton airplane needs to be accelerated to 200 miles an hour in about two seconds. This is equal to about 500,000 kWh or 0.5 MWh of energy. Remember that this energy is consumed in less than two seconds, so to maintain a constant acceleration much of that energy will be consumed in the last half second. Even if we spread the energy evenly across the two seconds the power required approaches 1,000 MW. This is equivalent to the power from larger utility steam turbines, which are obviously not practical to put onboard a Navy ship. So some type of energy storage is required.

There are multiple ways of storing energy: chemically, potentially or kinetically. A battery stores energy chemically, capacitors and pumped hydro store energy electrically and a flywheel stores energy kinetically. After evaluating the alternatives the Navy selected a flywheel system to provide kinetic energy storage for its EMALS project.

The principle behind the flywheel is that a relatively small generator can spin up or charge a flywheel over a period of, say, a minute and then take the power off the flywheel over a period of several seconds. Because it takes about a minute between aircraft launches on an aircraft carrier, the flywheel can be charged during this time. When called into action, utility-scale power can be delivered even if for only short periods of time.

Although energy storage may not be practical as a method for load following, there appears to be an application for energy storage on the finer side, frequency regulation. Earlier, we noted this is the most expensive electricity to the electric company, based on the general principle that the faster capacity can be supplied the more the utility will pay for it.

In Figure 2 the green line trending upward represents the electricity demanded and the blue line represents the supply and the utility's effort at load following. It can be seen the electric company increased the supply of electricity to meet increasing demand by about 400 MW between 7 a.m. and 9 a.m. Notice also that electricity demand is not a perfectly smooth line, but displays some randomness that cannot be predicted. The red line represents the difference between what is being instantaneously demanded and instantaneously supplied. When the red line is above zero as measured on the right-hand scale there is more electricity on the grid then is being demanded and the frequency is above 60 Hz. This is wasted energy. When the line is below zero there is not enough electricity on the grid and the frequency is below 60 Hz. In this example the supply line crosses the demand line about 10 times each hour.

This presents a huge opportunity for energy storage technologies as today this variability is dealt with by the electric company telling its contracted suppliers either to turn turbines on or off on a per-minute or per-second basis.

It can be seen in the example that a 1 MWh capacity energy storage device could have been completely charged and discharged five times in each hour meaning that 5 MWh of electricity could have been sold in a single hour. In contrast a 1 MW radiated wind turbine would require one hour to generate 1 MWh of electricity under the best wind conditions. The price for electricity in the regulation market is about 10 times what can be negotiated in a power purchase agreement for wind energy. This is not to disparage wind generated electricity; the object here is to point out the possibility of realizing healthy returns on investments in the energy storage sector and reducing carbon output from the dirtiest generators.

Returns on an energy storage investment targeted at frequency regulation are also more predictable than other renewable energy efforts as frequency regulation is a problem that needs to be addressed 24 hours a day, 365 days a year. It is also a safer and easier way to implement investment. In the case of flywheels they are sustainable, having no limitation on their cycle capability, no gearbox to wear out and no visible presence.

When you consider that almost 4 TWh of electricity were generated in the United States in 2008 a 1 percent regulation market would represent 40 GWh for profit opportunity. Energy storage for frequency regulation would also be one of the most cost-effective alternatives to carbon capture, or for earning carbon credits. Remember, eliminating the dirtiest 1 percent of turbines by definition means eliminating more than 1 percent of all the carbon generated.

Other significant advantages exist for grid reliability and safety. For example, the ability to distribute electric potential away from actual generators and close to demand centers or substations increases energy storage system effectiveness. This is especially true with other ancillary services like reactive power and voltage support, which are much more effective when implemented locally rather than trying to affect them through transmission lines. And last but not least, energy storage systems with the capacity to supply large power ratings for short periods of time (like our 1 MWh-capacity flywheel that could supply 30 MW of power for two minutes) are one way to make up for instantaneous outages and offer time to get other generators started.

So why don't we already have more energy storage built into our grid distribution system? There are multiple answers to this question. One is that energy storage technologies with the capacity to deal with utility-scale demand–including the Navy's recent accomplishments–are only just being developed. A second is that the cost of natural gas or even kerosene used in frequency regulation turbines has been relatively low and there is no additional cost penalty to the turbine for being dirty, in other words no carbon tax. A third is that frequency regulation has been perceived as a marginal issue and not as sexy as wind turbines or solar power to talk about. And probably the most significant reason is that electric companies typically are not inclined to pay what these services are actually worth. Rather antiquated rules currently govern much of the contracting of purchase agreements for providing the marginal power for frequency regulation.

Considerable opportunity exists for utility-scale energy storage. Just as the Department of Energy is making an effort to bring market forces to influence the use of electricity, it also should apply the same emphasis in using market forces to influence the way electric utilities procure electricity. This would be faster to deploy than demand response through smart meters and could be stimulated simply by changing rules and laws rather than throwing billions of dollars at it.

Drew Devitt is chief technical officer at New Way Energy LLC.

24 Comments

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k boers
k boers
October 10, 2012
Please keep track of your kW kWh MW and MWh, I know a lot of people confuse them. here is my 2c: 'This is equal to about 500,000 kWh or 0.5 MWh of energy' 500,000 kWh = 500 MWh = 0.5 GWh 'When you consider that almost 4 TWh of electricity were generated in the United States in 2008 a 1 percent regulation market would represent 40 GWh for profit opportunity.' http://en.wikipedia.org/wiki/Energy_in_the_United_States#Generation states that 4 thousand TWh or 4 PWh was produced in 2010 in the US. Interesting techniques, I am alwaysin search for latest developments in the area of flywheels
Stephen Davies
Stephen Davies
February 16, 2011
One very important thing to remember about flywheel cost is the life of the unit. A well designed flywheel should have a life of > 5 x 10^6 cycles (more than 20 years) with relatively minimal maintenance.

Regardless of the chemistry, batteries and other chemical storage devices have a finite life after which there is a replacement cost. Even if this is 5 years that is still four replacements compared to one flywheel unit.

ALSO there will be efficiency, power and capacity fade through the life of the battery or ultracapacitor, this is usually factored in by oversizing the unit therefore increasing costs again.

Just my 2c
Brad Will, AIA, LEED AP
Brad Will, AIA, LEED AP
April 10, 2010
For the article's author: I am interested in learning more about a "decentralized strategy," and the economic and practical viability of neighborhood micro utilities that could meet the needs of between 100-1,000 homes, specifically using flywheel storage technology. As architects and designers who want to design the most energy efficient AND affordable housing possible, the PV Solar approach has its flaws in terms of high embodied energy in its fabrication, and questionable "cradle to cradle" credentials. My second (and third) questions for flywheel technology are how it stacks up with both embodied fab. energy and site delivery, and its life cycle attributes, ie. recycled content and non-toxicity of materials, and ultimate recyclability at the end of its useful life (this sounds like 50+ years). And thank you for a most interesting and enlightening piece!
Chris Long
Chris Long
March 12, 2010
Decentralized energy strategy is fun to consider, like mainframes vs personal computers.
Combining functions and pay back is great when it works.
Some time ago Capstone Turbine offered the automotive industry a flywheel, propulsion system, well researched and engineered that could have provided energy storage and replaced the internal combustion engine.
The offer took the auto guys well out of their comfort zone, but that does not mean it was a bad idea, times have changed a lot of rethinking is going on, how about a grid connected, battery electric, flywheel hybrid.
The lithium battery technology is still evolving, prices expected to come down while battery electric vehicle energy storage capacity is increasing.
Forty kWh of storage per vehicle and one hundred thousand vehicles would provide four megawatt hours of storage.
The reversible fuel cell is another automotive energy storage opportunity, sending hydrogen to storage in electrolyzer mode and providing electricity to the grid in fuel cell mode.
The 300 million or so American auto fleet represents a capital investment of 4 1/2 billion dollars at a conservative 15 thousand per vehicle, what if we made those little monsters work for a living instead of sitting in the garage depreciating 96% of the time.
Automobiles as energy storage are well situated in high population density areas and include both invested capital and an earning opportunity for the owners that could help make the monthly car payment!
Edgar van Wingerden
Edgar van Wingerden
March 12, 2010
Minor point in excellent article: pumped hydro stores in gravitational field.
The porous media bearings and flywheels are another good example of the importance of combining compressed air/vacuum systems.
Learned something new from this article, thanks and good luck.
http://aquaculture1-energystorage.blogspot.com
Georges MOUGIN
Georges MOUGIN
March 8, 2010
To jamie-schlinkmann , comment 17
Discrepancy between our figures ( energy of 25 kwh instead of 30)
proceeds that metric tonnes were considered for the aircraft mass

Regarding the contribution of the aircraft during launch it could be
assumed that it takes care of the drag .
Georges MOUGIN
Georges MOUGIN
March 8, 2010
To Newway , comment 15
The utility cy will certainly ask more that $ 4.5 .
To deliver an energy of 30 kwh in 2 secondes , an instant power of 54,000 kw
is needed . the subscription for such a demand will inflate many many times
the unit cost of 1 kwh .
For a launch every minutre an appropriate storage system should release 30 kwh every minute from a permanent power of 1800 kw .Flywheel is probably the best ,if not the sole,solution for it .
Jamie Schlinkmann
Jamie Schlinkmann
March 6, 2010
@NewWay and georges mougin: This problem is interesting because it is easily related to the definition of a watt.
1Watt=1Newton*1meter/1second
By georges's assumptions:
50m/s² is about 5g
to accelerate the 20 ton aircraft (178,000N) at 5g is 890,000N of force
the distance required to reach 100m/s² is 100m at this acceleration and proposed time of 2 seconds (basic equation of motion)
therefore; 890,000N of force applied over 100m of travel divided by 2 seconds equals an average power of 44.5MW over the two seconds, which is indeed only about 25kWh.

One might question some of the assumptions because the deck of a carrier is longer than 100m and let's also not forget the aircraft is making its own contribution to the applied force.
ANONYMOUS
March 5, 2010
Regarding the authors respond in comment #14:

It was clear that flywheel storage can provide frequency regulation, but the arguments in the article seemed weak concerning why flywheels would be the best choice. In particular, pricing issues were not addressed effectively. Why should we believe flywheels will be competitive against standby methane generators or hydro power and other extant players in this market niche not to mention better demand management?
Steven
Drew Devitt
Drew Devitt
March 4, 2010
The author responds to georges-mougin-151491,
Thanks for your interest, I was following along with your math but your energy number seems low. Only 30 kWh? I pay about 15 cents to the electric company per kilowatt hour, by your calculations I could launch that 20 ton plane for about $4.50.
Drew Devitt
Drew Devitt
March 4, 2010
The author responds to Steven Anonymous;
I am sorry you missed my points regarding why flywheel energy storage is appropriate for frequency regulation.
Let me take this opportunity to review one or two reasons here.
In the regulation market there is a time value associated with how quickly energy can be delivered, the faster it can be delivered the more valuable it is. A 1 MWh flywheel can deliver that energy in 6 seconds at the power of 600 MW, no battery can do this. And batteries are all made from noxious elements, acids or chemicals. There is nothing green or sustainable about them, even if they do last the claimed 10 years imagine turning over the fleet of batteries that we would need every 10 years! That would dwarf the nuclear disposal issue. Flywheels have nothing to wear out and will likely work the same in their 50th year as they did in their first.
If you reread the article I bet that you will find a least two or three more good reasons.
Thanks for your comment.
DrewD
ddevitt@newwayairbearings.com
Drew Devitt
Drew Devitt
March 4, 2010
The author responds to; brian-julin-42934
I tried to write the article to be relatively generic with respect to all flywheel technology. You are right though, I do have plans for massive large diameter flywheel supported on air bearings. There are two squared functions in the kinetic energy equation; velosity and radius. Most flywheel manufactures are maximizing velosity, we are envisioning flywheels tens of meters across and weighing hundreds of tons. At 300 m per second there is relatively low stress and lots of real estate for flux field. Even with air bearings the rotor can be in a vacuum environment. The large rings would be located in circular trenches nearby substations and fabricated on-site. support bearings and motor/generator components are all at the perimiter, there is no center shaft. for more info write;
DrewD
ddevitt@newwayairbearings.com
William Dempster
William Dempster
March 3, 2010
Windfuels offers an effective solution for the problem of electrical energy storage. It is a 2-step process, electricity produces hydrogen by electrolysis of water. Then hydrogen + CO2 --> liquid fuels (gasoline, diesel, etc. whatever fuel you want). The fuel is then CO2 neutral, having consumed the same CO2 in its production as will be released when it burns. Both steps are already known, but Windfuels has made important efficiency improvements so that the fuel produced is competitive with oil-sourced fuel at current prices. The electrical storage trick is simple: the electrolyzers can be instantly turned on or off. So, let's say some wind farms are producing more power than the momentary electrical demand, the excess is taken by the electrolyzers to make valuable liquid fuel, needed for transportation. When electrical demand rises, or wind output falls, an appropriate number of electrolyzers are turned off, leaving just the right balance between wind output and electrical demand. This dance can be managed indefinitely. In other words, "storage" is achieved by giving up demand whenever necessary. Combined with some baseload conventional or nuclear power plant, all the wind energy which exceeds the electrical demand above baseload will produce valuable CO2-neutral liquid fuels at favorable prices, and the load-shedding feature of turning off the right number of electrolyzers whenever appropriate assures matching the combination of baseload + fluctuating windpower to the differently fluctuating electrical demand of cities & industry. Windfuels is scalable and offers a path for CO2 neutral liquid fuels and electric supply. Check out " Securing Our Energy Future by Efficiently Recycling CO2 into Transportation Fuels – and Driving the Off-peak Wind Market" on the science page of www.windfuels.com
Craig Howard
Craig Howard
March 3, 2010
You can say what you want about big government monopolies and not wanting to loose "control" by allowing small generation. But there are economic advantages to large scale electric generation. If you believe there is such a conspiracy you do not have to be tied into the electric grid, you can go to your local hardware store and buy a small scale generator fill it with gas and see how economic it is. You could also install solar and wind but don't plan on watching Monday night football or having cold beer in your fridge unless the sun is shining or the wind is blowing, but don't give me your line about government conspiracy. If you want to give me your address I could arrange to have your house disconnected from the big bad government run power companies and you can go back to the days of each small community having its own small unreliable inefficient generation plant. Or better yet you could use oil lamps and heat your house with buffalo chips in your stove. Get a life
Christopher Grieco
Christopher Grieco
March 3, 2010
Modular underground pumped hydro with fixed head and mass-produced power equipment. Siting and permitting easier and cheaper than PSH and CAES, quicker to revenue with a lot lower capital investment and if serves Regulation for the short term and time-shift/ramping issues in the longer term.

Look for us later this year in Texas.
Sore Bird
Sore Bird
March 3, 2010
This RMI plan of action is what utilities do not want to happen because they risk losing there monopoly on our power generation to many small providers. The government has no interest in small providers either because then the government loses all those big money utility lobbyist....like Southern Company one of the largest lobbyist in the US that just landed the big government loan for two nuclear power plants.

Keeping the Lights On While Transforming Electric Utilities
By Lena Hansen and Amory B. Lovins

http://www.rmi.org/rmi/Transforming+Electric+Utilities
"(((Also, windpower and photovoltaics, the fastest-growing renewables, are the only two renewable generators whose variability is at issue.)))
Half the world's electricity now made by renewables (other than big hydroelectric dams) is of other kinds—geothermal, small hydro, solar-thermal-electric with many hours of heat storage, biomass, and waste combustion, etc.—whose steady output utilities can "dispatch" just like thermal power plants."

Put simply, utilities must transition from operating a small portfolio of large power plants to more creatively operating a larger portfolio of small resources, while also incorporating additional flexibility from new advanced technologies.
Sore Bird
Sore Bird
March 3, 2010
Why should a utility always be in charge of either side, supply or demand, when we can create energy on site instead with microturbines, geo, and fuelcells. If we took the data centers, responsible for 3% of the USA total electrical use, and all the shopping malls, Walmarts, Costco, Grocery Stores, Convenient Stores, Post offices, service stations ect...off the grid then maybe the utilities wouldn't have so many "problems" to deal with.

The utilities are not the answer to our problems, they are the problem, along with a government that is really NOT interested in a private sector solution.
yuri ulianov lopez
yuri ulianov lopez
March 3, 2010
thanks for sharing that knodledge. As always, storage is a very interesting issue. Reading past comments I would invite anyone to prepare a research or technical report making a comparison between energy storage for grid, tecnologies. Thanks again and keep on wirting about it. YUL
Georges MOUGIN
Georges MOUGIN
March 3, 2010
I don't folow the arithmetics of the launch system :
To propulse a body at 100m/sec ( 220 miles/h )in 2 secondes require an
acceleration of 50 m/sec² and for 20 tons a force of 1000 kN ( kilo Newton )
1000 kN at 100 m/sec is a power of 100,000 kW .
Average power during 2 secondes is 50,000 kW which represents an energy of 30 kWh ( 50,000 x 2/3600 ) and not 500,000 !
Efficiency of the system could requires 2 or 3 times more .
According of a cycle of 2 secondes every minute net power is 1666 kW and
5000 or 5 MW with a global efficiency of 0,33 of the launch system and the
storage
ANONYMOUS
March 3, 2010
By the way, Beacon Power has already started building frequency regulation plants in New England.
Charles Toca
Charles Toca
March 2, 2010
Good article, good points. You point out that lithium ion is $2 million for one MWHr, however there are other systems available for less. We sell the vanadium redox battery, and a VRB-ESS would provide 1 MW for 4 hours for less than $4 million - and it could provide the same cycling as a flywheel or li-ion, plus unlimited full charge cycles of up to 4 hours for more than 10 years. That is a significant change in economics. www.utility-savings.com
ANONYMOUS
March 2, 2010
This article makes a fair case for the existence of a need for frequency regulation, but it does not do much to suggest that flywheels are an appropriate choice to achieve that goal....
Steven
ANONYMOUS
March 1, 2010
Drew, I applaude your writting skills. I appreciate everything you stated. Please check out my company @ www.energenicsgroup.com. I think your technology would fit into my EDPS system.
Brian Julin
Brian Julin
March 1, 2010
Your company has a very interesting product. I'm guessing you've done the math on its energy consumption and think it would be viable for flywheel applications? Would that be high speed low diameter systems or larger momentum-heavy systems?

You guys should see if you can get a pressure container and a jet into a table-hockey puck and have your sales reps give them out :-)

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