Big iron flow battery powering energy storage solutions in Qld

Researchers at the Queensland University of Technology-operated National Battery Testing Centre (NBTC) in Queensland have commissioned a large-scale iron flow battery to meet the state’s renewable energy targets. The Queensland University of Technology is collaborating with Energy Storage Industries – Asia Pacific (ESI) and the Future Battery Industries Cooperative Research Centre (FBICRC) to enable large-scale energy storage solutions to help meet clean energy targets set by state and federal governments.

The Queensland Government’s Energy and Jobs Plan sets a target of 70% renewables in the energy grid by 2032. Deputy Premier Steven Miles said the Queensland Energy and Jobs Plan is creating new jobs in new industries, like battery manufacturing.

“Large-scale iron flow batteries are the cutting edge of the energy revolution, and that innovation is happening right here in Queensland thanks to the support of the Palaszczuk government. As we invest in more solar and more wind, the demand for large-scale batteries and storage will increase to ensure Queensland’s energy is reliable and affordable, these new batteries are perfect to support our energy grid. Testing the biggest large-scale iron flow battery at QUT’s Banyo facility is another step toward meeting our renewable energy targets,” Miles said.

Construction is also underway in Maryborough for a large-scale iron flow battery manufacturing facility, being developed by ESI. NBTC Project Lead Dr Joshua Watts from the QUT Faculty of Science said effective long-duration energy storage — such as flow batteries — is necessary to support the intermittency of renewable energy such as wind and solar. A flow battery contains two chemical solutions, separated by a membrane, with electricity stored and released through changes in the oxidation state of metal ions dissolved in solution.

According to Watts, this particular battery shows potential in providing large-scale long-duration energy storage solutions to store energy for distribution when the wind is not blowing and the sun is not shining. “It’s not the type of battery you would buy for the backyard, but more targeted toward large-scale solar and wind farms, or new community developments where they’re looking to build in more localised energy generation and distribution networks,” Watts said.

Image caption: The working components of the large-scale iron flow battery. Image credit: Queensland University of Technology.

The ‘Energy Warehouse’ iron flow battery being commissioned and tested at the NBTC is a 12-metre-long containerised system, designed to be used for large-scale energy generation and distribution support for the electricity grid. Watts said Energy Warehouse systems could store solar energy generated by residential solar arrays to assist with the management of excess energy that the current electricity transmission infrastructure can’t handle. Watts said lithium batteries are more compact, but the cost of scaling them for long-duration storage applications could potentially be an issue for large-scale applications.

Iron flow batteries are better suited for large-scale applications, offering ease of scalability for long-duration energy storage applications. Iron flow batteries are also environmentally benign, fully recyclable and offer a potential lower cost per kWh for long-duration storage applications.

“Iron flow batteries are well suited for long-duration applications due to the nature of the energy storage mechanism, which is achieved through dissolved metal salts in aqueous solution. So, you just increase the electrolyte volume, and you increase the capacity. You only need to make the tank bigger,” Watts said.

The potential for local manufacturability of the iron flow systems is high because they use simplified componentry. They mainly comprise PVC pipes, water pumps and fibreglass tanks assembled in a 12-metre container. “There’s potential then to reskill workers moving out of the coal-fired power station industry who have similar skill sets in maintaining plant equipment,” Watts said.

According to Watts, iron flow batteries have an advantage when it comes to enlarging, repurposing or recycling, as they utilise a weakly acidic iron chloride solution which is non-toxic, which simplifies the refurbishment and recycling process for these systems. The NBTC, at Banyo on Brisbane’s north side, is one of the flagship projects funded by the FBICRC grant program — it is one example of QUT’s efforts in accelerating new energy storage solutions in support of Australia’s decarbonisation efforts. Watts said the NBTC will reduce costs by allowing local battery system manufacturers to test and certify their products to Australian and international standards.

“Previously companies would rely on overseas testing facilities in the US, Japan and Europe. Activating that local support will enable local manufacturers and industry to get their products to market quicker and at reduced cost. We’re also working with partners to develop safer systems, safer materials that go into cells and safer control methodologies,” Watts said.

Watts said his team has been demonstrating the iron flow battery’s features to a range of government sponsored enterprises (GSEs) and private energy companies at the NBTC. “And we'll be going through — over the next three months or so — a rigorous testing regime in collaboration with potential off takers to test the battery under different use conditions to get these batteries out into the wild supporting the energy grid as soon as possible. The next step is to support ESI in pilot manufacturing efforts to establish onshore large-scale manufacturing of the systems to meet local supply,” Watts said.

Top image caption: The large-scale iron flow battery at the NBTC in Banyo. Image credit: Queensland University of Technology.