SEABAT has generated a module design that was manufactured in a high energy and high power variant. The modules have been integrated into a system and performance tested. This validated design is based on market needs, requirements and a thorough concept study. Following list containes some of the concrete project results:
1) The research analysis has highlighted a future system-cost target of approximately 250-300 € / kWh with production volumes that should settle between 3 and 4 GWh per installation. Main bottlenecks for widespread implementation are: patents, certification for personnel, temperatures, humidity and the consequences of external fire. The main challenges are: the cost of onshore energy, battery cost, specific energy, ageing and related replacement costs.
2) The performance of 30 marine battery systems from 15 different suppliers has been studied and reported. SEABAT identified 33 different relevant battery properties, which were grouped to 9 topics: costs, energy, power, lifetime, thermal management, safety, ease of mechanical integration, ease of electrical integration and the capabilities of the battery management system.
3) Three topologies were explored, evaluated, and compared towards a baseline state-of-practice mono-type battery topology: (1) Converter integrated into the battery modules, (2) Switching between individual cells, (3) Partial power converter integrated into the battery modules. Topology 1 was deemed most performant and developed further in the project.
4) Each component has then been designed, procured and/or produced, including: module DC/DC converter & controller, string inductance & controller, casing, BMS slave & master, cooling plate, thermal management, and master controller. EMC analysis and performance validation was performed to confirm proper operation.
5) By using techniques from the automotive sector, SEABATs production line is capable of (in term) mass producing the battery modules. The current prototype line produced 3 modules per week, including validation. During the assembly preparation phase, an extensive analysis of the interfaces took place, covering mechanical, electronic, thermal, and communication aspects. The assembly process’ flow diagram and assembly steps were written out, along with the identification of de-risking measures for the module assembly process
6) A dedicated test setup was designed and a detailed testing sequence was followed. Some design challenges were identified, but the overall functionality including hybridization and modluarization have been proven to work. Finally, a roadmap for type approval was initiated.
The key exploitable results include
1) A validated hybrid and modular battery system model, that can be used to virtually design and benchmark SEABAT's solution to the state of practice
2) Three hybrid energy storage models, including a descrete battery system design, that offer alternatives to the selected hybrid battery systems
3) A validated battery mangement system design, that can be used to control and monitor a battery during its lifetime
4) A detailed cost and sizing optimization routine, to quantify potential cost savings. A limited version of this tool is publically available at battery.flandersmake.be
Plenty of the research results in SEABAT are openly available: 10 open-access and peer-reviewed papers were published. The final newsletter includes a summary of the takeaways of the project. All this information is available on the website.
