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Video is linked from SA engineering article that SA engineering...

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    Video is linked from SA engineering article that SA engineering magazine media released




    https://www.engineeringnews.co.za/article/local-company-battling-industrial-power-challenges-with-flow-battery-system-2020-11-27/rep_id:4136

    Local company battling industrial power challenges with flow battery system



    https://hotcopper.com.au/data/attachments/2957/2957672-273f0a119688913f20127468a7d5c31a.jpg

    13th November 2020

    By: Schalk Burger
    Creamer Media Senior Contributing Editor


    Local electronic printed circuit board (PCB) manufacturer Bosco is using a flow battery energystoragesystem alongside a rooftop solarenergy and a battery management system (BMS) to keep a crucial production line and its engineering and sales departments free of disruptions caused by power outages that are common in South Africa.

    The main competitive advantage the company has over duty-free imported PCBs is its ability to serve its local clients quickly and accurately, which means it must prevent disruptions to its ability to engage with its clients, provide quotes and ensure its engineering and design department continues to operate, explains Bosco director Philip Verheul.

    The company has replaced its curing ovens with a conveyorised curing machine which comprises a combination of convection and infrared heaters that uses less electricity and shortens the process time from two hours to five minutes while providing consistent curing of PCBs produced. This is just one of many measures which Bosco has taken to reduce power consumption.

    Power Factor correction units have been installed to reduce the maximum demand charges. Energy efficient lights and a Building Control System (BCS) to manage the air conditioning and humidity have been installed to reduce energy consumption.

    "Our 1 200 solar panels - supported by networked inverters - provide about one-quarter of our energy requirements during the day. This is connected to the BMS, which automatically recharges the Redflow batteries or dispatches battery energy when needed, including in the event of a power outage."

    Bosco has placed its crucial plating production line on the Redflow battery system because a disruption in power on this line leads to all the materials in the line becoming unrecoverable and waste, which also impacts on the company's delivery times.

    Only the most crucial parts of the business are linked to energystoragesystem. Other production lines and equipment, such as the air compressors and vacuum plant, are not on the battery system and shut down during outages.

    The BMS enables Bosco to reduce energy consumption during peak tariff periods, such as between 6 am and 9 am by discharging stored energy from the Redflow batteries and feeding back into the electrical network. It also charges the batteries during the lowest tariff periods, between midnight and 6 am, as well as charging them from solarpower, although the factory typically uses the power produced by the solarsystem during its daily operations.

    The Redflow zinc-bromine flow batteries installed at Bosco can discharge 100% of their usable energy, allowing Bosco to use stored energy during peak periods although the BMS maintains the charge in the batteries above a minimum of 20% to provide power to the critical processes for three hours if an outage occurs. The Redflow batteries can be removed individually for maintenance without shutting down the energystoragesystem.

    Redflow batteries have a warranted life of 10 years, can be reconditioned and reused, have unlimited use cycles and allow for complete discharge (100% depth of discharge) without impacting on the performance of the batteries, he explains.

    However, Verheul adds that expanding its use of renewable and storagesystems is now a lower priority than diversifying its business to combat the effect of competition from markets such as Asia.

    Bosco produces PCBs for many local customers in the electronics industry such as electrical, automation, security and mining industries, as well as producing prototypes for local engineering research, development and innovation customers.

    The company considered producing multi-layer circuits boards to more effectively compete against imported products, but the capital outlay to achieve this is very high. The ability to afford to introduce new machines, capabilities and products competes against the need to meet increasing labour, raw materials and electricity costs.

    "We are a very capital intensive industry, and none of our high-precision machines is made in South Africa."

    The company also imports most of its raw materials, which cannot be sourced locally, of which one product attracts 20% import duties, but competing circuit board products from Asia are imported without duties.

    The 64-year-old Bosco has had to give ground and currently employs 43 people, down from 110 people employed 24/7 in 2006.

    Verheul says the local PCB industry has been battling against its own collapse, but has not been able to secure any concessions, relief or assistance from the Department of Trade, Industry and Competition to impose duties on imported circuit boards.

    "South Africa cannot reindustrialise and become an advanced manufacturing country unless it has at least a minimum number of companies working in the electronics sector to ensure that we can retain the necessary skills and productive capacity in the country."

    "We are striving to reduce our environmental impact, improve efficiencies, ensure we have reliable energy and serve our local clients, but we are not finding much support from government departments or industrialenergyefficiency organisations."

    Energystoragesystems are suitable for almost all businesses but the objective must be clearly defined. Businesses must be able to justify the capital outlay required, whether that is to prevent losses or support critical functions beyond only assessing the expected return on the investment horizon, concludes Verheul.




    =========

    old links I had but not to different video


    https://redflow.com/wp-content/uploads/2017/09/Redflow_ZBM2_Bosco_Printed_Circuits_case_study_1710_FINAL.pdf

    From Simons blog

    https://simonhackett.com/2017/08/17/redflow-zbm2-at-bosco-printed-circuits/
    Posted on August 17, 2017

    Redflow ZBM2 deployment at Bosco Printed Circuits Posted on August 17, 2017
    A case study in complex energy system optimisationBosco Printed Circuits is the largest maker of Printed Circuit Boards (PCB’s) in South Africa. The production line at Bosco needs a lot of energy. The direct and indirect consequences of losing energy supply to the line are substantial.Johannesburg, where Bosco are based, has significant issues with energy supply – both in terms of reliability and also (as a consequence) in terms of energy cost.

    Like most businesses, Bosco already had an extensive solar array installation, which certainly helps with the economics of energy supply. The solar array is not sufficiently effective, is isolation, to address the complex challenges for the business in terms of supply cost and supply security.

    Energy supply to Bosco from the grid utility is time-of-day based. The energy supply cost is very high during distinct morning and evening peak periods, to discourage energy use in those times. These peak time bands are periods of high energy requirement for Bosco. The are the times when the potential for grid failure is greatest and are also the periods when the consequences of grid failure for Bosco are the most severe.

    Of course, these times (early morning, late afternoon) are also exactly the periods when the solar arrays can’t help, as they are outside of the solar peak generation periods.

    Grid outages are expensive for Bosco. Not only do they result in lost productivity, but they also have further economic consequences in terms of partially produced PCB’s having to be scrapped when the production machines are halted without warning.

    The Challenge

    Bosco had a variety of business aims and objectives across their daily operating cycle that their energy system had to address:

    • To ride over transient periods of grid loss seamlessly using battery energy
    • To support the operation of the production line for an extended period (hours, not merely minutes) in the face of longer periods of grid outage, so that the company can keep working, using battery energy augmented with any available solar energy, for as long as possible.
    • In cases of a very extended grid outage (several hours), to allow the production line to be closed down with plenty of warning (at least an hour) from the point at which the shutdown decision is made.
    • To time-shift energy obtained from the low cost overnight off-peak period into the morning peak period (0600-0800), prioritising battery energy usage at this time in order to minimise the use of very expensive grid energy.
    • To also minimise afternoon peak-period grid usage by again prioritising the use of battery energy in this second daily period
    • To use the residual battery energy, harvested from overnight off-peak charging and from any excess of daytime solar power, to supply the background energy needs of the building into the evening.
    • To recharge the battery array again using off-peak power from midnight to 6am ready to commence the next daily cycle.

    This need set required a battery energy system capable of consistent hard work and capable of daily 100% energy discharge, working in a hot environment, and without loss of output capacity over time.

    The Solution

    The solution uses 14 x Redflow ZBM2 batteries (140kWh) interfaced to a large array of Victron Energy inverter/chargers and a large solar array.

    The system orchestrates this complex daily cycle of energy optimisation using the Victron CCGX and the Redflow BMS, to achieve the aims and objectives noted above.

    Here’s a typical day in the life of this system, in terms of the sources of energy to run the plant:

    Bosco Daily Cycle Example

    Bosco Printed Circuits Energy Consumption

    You can see the periods where the battery system energy (blue) is prioritised in order to minimise the use of grid energy during peak times. You can see the battery being fully utilised to supply energy during the afternoon and evening as the solar consumption falls away, and you can see the system recharging using off-peak energy again from midnight, ready for the following day.

    You can use this Bosco Printed Circuits VRM Portal Link to see the live system running.

    Bosco ZBM storage array


    8888888888888

    https://redflow.com/resources/bosco-printed-circuits-zbm2-case-study-complex-energy-system-optimisation/?utm_source=Redflow+Mailing+List&utm_campaign=64023e84d9-EMAIL_CAMPAIGN_2018_01_31&utm_medium=email&utm_term=0_5e1bf20255-64023e84d9-116806977


    • Location: Johannesburg, South Africa
    • ZBM2 installation partner: Specialized Solar Systems http://www.specializedsolarsystems.co.za/
    • Storage: 14 x Redflow ZBM2 zinc-bromine flow batteries (total storage capacity of 140 kWh)

    South Africa’s largest manufacturer of printed circuits, Bosco Printed Circuits, has eliminated twice a week power cuts that had disrupted production, delayed deliveries and cost more than 100,000 rand a year by deploying Redflow ZBM2 zinc-bromine batteries. Bosco has also reduced its electricity costs by minimising grid use during peak demand periods in the morning and evening – when charges increase by 300-400 per cent – by running the production line on solar-generated energy and off-peak power stored in its 14 ZBM2 batteries.



    Bosco beats power cuts with Redflow ZBM2s

    South African manufacturer Bosco Printed Circuits had a big problem. The company, located in the northern industrial city of Johannesburg, often had its production line stopped by sudden power cuts.

    While some power outages were scheduled in advance, others happened unannounced, which meant Bosco’s production line would stop mid-shift. As well as wasting unfinished raw materials, these stoppages disrupted Bosco’s tight delivery schedule, damaging the company’s brand.

    Power cuts caused by an unreliable electrical grid could happen as often as twice a week, imposing a heavy cost on Bosco in lost production. Tolerating this situation was untenable for Bosco, South Africa’s largest manufacturer of printed circuits, which serves many customers in the Mining, Security and Industrial electronic industries.

    In 2016, Redflow partner Specialized Solar Systems deployed an energy storage system using Redflow ZBM2 zinc-bromine flow batteries for Bosco. With 14 ZBM2s and six Victron Quattro 48/10000 battery inverters, the system stores grid power from off-peak periods as well as energy generated by 51 kilowatts peak (kWp) of dedicated solar panels. Bosco uses an additional 250 kWp of solar panels to power other areas of its operation.

    Bosco Printed Circuits Director Mr Philip Verheul said the company installed the Redflow batteries to avoid loss of production. “In our process, we have electroplating lines in which we plate copper in holes, so if there’s a power failure during the process. everything in the line is basically scrapped,” he said.

    “Stoppages could cost as much as 10,000 rand (A$1000) each. Even more of an issue was we lost our delivery time, which created inconvenience and concern for our customers, who depend on us.”

    Today, Bosco’s production line can continue working uninterrupted if mains power drops out as the ZBM2 batteries automatically supply energy to the production line. The company has also configured the system to provide energy to its front office, so power cuts do not disrupt Bosco’s commercial and head office activities.

    Even as the grid power supply has become more reliable, the Redflow-based energy storage system has continued to pay for itself by allowing Bosco to avoid buying mains-supplied electricity during peak demand periods. During these morning and afternoon peaks, electricity charges can increase by 300 to 400 per cent.

    Bosco avoids these punitive costs by charging its Redflow batteries from solar panels during the day and with low-cost power available from midnight to 6am. The company then runs its critical electroplating production lines primarily on battery power from 7-10am and from 6-8pm, saving more than 55,000 rand (A$5500) a year in electricity charges. “We are seeing savings because we use the batteries to supply power during the most expensive time of the day,” said Mr Verheul.

    The Bosco system orchestrates this complex daily cycle of energy optimisation using the Victron CCGX and the Redflow Battery Management System (BMS), which enables Redflow to monitor and manage the battery performance from Australia.

    Mr Verheul said Bosco had selected Redflow’s ZBM2 batteries because of their unique benefits. “When we looked at lead-acid and other batteries, their lifetimes were limited,” he said. “We decided to spend a bit more money to go the Redflow route. Its ZBM2 batteries are long-lasting, with a 10-year or 36,500kWh warranty, they work well even in hot weather, and they are easily recyclable.

    “We are very happy with these batteries, which keep getting better over time. I have to commend both Redflow and Specialized Solar Systems who have been fantastic.”

    Download a Redflow customer reference sheet about Bosco Printed Circuits from here or read Simon Hackett’s detailed examination of this ZBM2 deployment by clicking here.


    ====================================
    https://redflow.com/engineering-news-bosco-south-africa/
    November 16, 2020

    Video: Engineering News South Africa reports how Redflow batteries help PCB maker Bosco avoid power outages

    Engineering News South Africa has published a video story about how Johannesburg-based printed circuit board (PCB) manufacturer Bosco is using a Redflow battery energy storage system with rooftop solar PV to avoid disruptions caused by power outages that are common in South Africa.

    Engineering News reports that the company’s main competitive advantage over duty-free imported PCBs is its ability to serve its local clients quickly and accurately.

    Bosco director Philip Verheul said that meant Bosco must prevent disruptions to engage with its clients, provide quotes and ensure its engineering and design department continued to operate. Our 1 200 solar panels – supported by networked inverters – provide about one-quarter of our energy requirements during the day,” he said.

    “This is connected to the BMS, which automatically recharges the Redflow batteries or dispatches battery energy when needed, including in the event of a power outage.”

    You can read the Engineering News story and view the video at https://www.engineeringnews.co.za/article/local-company-battling-industrial-power-challenges-with-flow-battery-system-2020-11-27



    -----====00
    https://www.engineeringnews.co.za/article/local-company-battling-industrial-power-challenges-with-flow-battery-system-2020-11-27/rep_id:4136

    Local company battling industrial power challenges with flow battery system



    https://hotcopper.com.au/data/attachments/2957/2957672-273f0a119688913f20127468a7d5c31a.jpg

    13th November 2020

    By: Schalk Burger
    Creamer Media Senior Contributing Editor


    Local electronic printed circuit board (PCB) manufacturer Bosco is using a flow battery energystoragesystem alongside a rooftop solarenergy and a battery management system (BMS) to keep a crucial production line and its engineering and sales departments free of disruptions caused by power outages that are common in South Africa.

    The main competitive advantage the company has over duty-free imported PCBs is its ability to serve its local clients quickly and accurately, which means it must prevent disruptions to its ability to engage with its clients, provide quotes and ensure its engineering and design department continues to operate, explains Bosco director Philip Verheul.

    The company has replaced its curing ovens with a conveyorised curing machine which comprises a combination of convection and infrared heaters that uses less electricity and shortens the process time from two hours to five minutes while providing consistent curing of PCBs produced. This is just one of many measures which Bosco has taken to reduce power consumption.

    Power Factor correction units have been installed to reduce the maximum demand charges. Energy efficient lights and a Building Control System (BCS) to manage the air conditioning and humidity have been installed to reduce energy consumption.

    "Our 1 200 solar panels - supported by networked inverters - provide about one-quarter of our energy requirements during the day. This is connected to the BMS, which automatically recharges the Redflow batteries or dispatches battery energy when needed, including in the event of a power outage."

    Bosco has placed its crucial plating production line on the Redflow battery system because a disruption in power on this line leads to all the materials in the line becoming unrecoverable and waste, which also impacts on the company's delivery times.

    Only the most crucial parts of the business are linked to energystoragesystem. Other production lines and equipment, such as the air compressors and vacuum plant, are not on the battery system and shut down during outages.

    The BMS enables Bosco to reduce energy consumption during peak tariff periods, such as between 6 am and 9 am by discharging stored energy from the Redflow batteries and feeding back into the electrical network. It also charges the batteries during the lowest tariff periods, between midnight and 6 am, as well as charging them from solarpower, although the factory typically uses the power produced by the solarsystem during its daily operations.

    The Redflow zinc-bromine flow batteries installed at Bosco can discharge 100% of their usable energy, allowing Bosco to use stored energy during peak periods although the BMS maintains the charge in the batteries above a minimum of 20% to provide power to the critical processes for three hours if an outage occurs. The Redflow batteries can be removed individually for maintenance without shutting down the energystoragesystem.

    Redflow batteries have a warranted life of 10 years, can be reconditioned and reused, have unlimited use cycles and allow for complete discharge (100% depth of discharge) without impacting on the performance of the batteries, he explains.

    However, Verheul adds that expanding its use of renewable and storagesystems is now a lower priority than diversifying its business to combat the effect of competition from markets such as Asia.

    Bosco produces PCBs for many local customers in the electronics industry such as electrical, automation, security and mining industries, as well as producing prototypes for local engineering research, development and innovation customers.

    The company considered producing multi-layer circuits boards to more effectively compete against imported products, but the capital outlay to achieve this is very high. The ability to afford to introduce new machines, capabilities and products competes against the need to meet increasing labour, raw materials and electricity costs.

    "We are a very capital intensive industry, and none of our high-precision machines is made in South Africa."

    The company also imports most of its raw materials, which cannot be sourced locally, of which one product attracts 20% import duties, but competing circuit board products from Asia are imported without duties.

    The 64-year-old Bosco has had to give ground and currently employs 43 people, down from 110 people employed 24/7 in 2006.

    Verheul says the local PCB industry has been battling against its own collapse, but has not been able to secure any concessions, relief or assistance from the Department of Trade, Industry and Competition to impose duties on imported circuit boards.

    "South Africa cannot reindustrialise and become an advanced manufacturing country unless it has at least a minimum number of companies working in the electronics sector to ensure that we can retain the necessary skills and productive capacity in the country."

    "We are striving to reduce our environmental impact, improve efficiencies, ensure we have reliable energy and serve our local clients, but we are not finding much support from government departments or industrialenergyefficiency organisations."

    Energystoragesystems are suitable for almost all businesses but the objective must be clearly defined. Businesses must be able to justify the capital outlay required, whether that is to prevent losses or support critical functions beyond only assessing the expected return on the investment horizon, concludes Verheul.

 
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