Project Background
This energy storage project is deployed at a continuous-operation metal processing factory with no rooftop PV. The plant fully relies on utility grid power. Intermittent startup of melting furnaces and machine tools creates sharp load spikes, leading to expensive peak electricity bills and high monthly demand charges. The customer adopts 2 sets of 125kW/261kWh liquid-cooled PCS energy storage cabinets, total capacity 250kW/522kWh, AC-coupled topology connected to the factory's internal distribution bus. The key objectives include peak-valley arbitrage, peak demand limiting, no reverse power flow and remote intelligent monitoring.
Core Customer Pain Points
Frequent shock loads push up monthly peak demand, resulting in heavy demand charges.
Wide peak-valley tariff gap. High production load coincides with high-price peak hours, driving up overall power expenditure.
The outdoor installation area suffers high ambient temperature and heavy metal dust. Air-cooled ESS accumulates dust easily, causing poor heat dissipation and accelerated battery degradation with heavy maintenance.
Strict grid code: all discharged energy must be consumed on-site; reverse power back to the utility grid is forbidden.
Legacy power system lacks real-time load monitoring, making manual demand management ineffective.
System Configuration & Product Selection
2 × 125kW/261kWh liquid-cooled PCS energy storage cabinets, AC-coupled, no PV connection. Each cabinet integrates bi-directional PCS, LFP battery packs, liquid thermal management, BMS, aerosol fire suppression and local controller. Rated power:125kW, usable capacity:261kWh, IP55 protection. Auxiliary equipment: grid-connection switch cabinet, voltage/current sensors, cloud EMS platform.
Core Control Strategy
Demand limiting (priority strategy): EMS monitors total incoming grid power in real time. When load approaches the demand threshold, ESS discharges automatically to cap grid import and cut monthly demand charges.
Peak-valley arbitrage: Charge during low-tariff valley periods and discharge during high-price peak hours to replace expensive grid power.
Anti-reverse power flow: Real-time power direction detection at point of common coupling. Discharge power follows factory load strictly to guarantee zero reverse flow.
Intelligent O&M: Cloud EMS tracks SOC, battery temperature and PCS status, generates automated reports and fault alerts.
On-site Installation Challenges & Our Solutions
Challenge1: High temperature + heavy industrial dust, air-cooled ESS prone to overheating Solution: Fully enclosed IP55 liquid-cooled cabinet blocks dust. Liquid circulation delivers uniform temperature control across battery packs, eliminating hotspots and reducing routine cleaning work.
Challenge2: Fast fluctuating shock loads may cause demand control failure with slow ESS response Solution: The PCS provides millisecond power response. EMS predicts load surges and triggers pre-discharge to cap grid import within the preset demand limit and avoid penalties.
Challenge3: Narrow construction window; production shutdown is not allowed Solution: Cabinets are fully tested before delivery. On-site work only includes foundation mounting and cable connection. Phased commissioning by single unit keeps manufacturing uninterrupted.
Challenge4: Grid compliance risk of reverse power flow Solution: High-precision anti-reverse algorithm paired with grid-side power transmitters dynamically limits discharge power. 100% local consumption with zero backflow to meet grid interconnection requirements.
Project Outcomes & Benefits
Dual revenue streams: peak demand reduction plus peak-valley arbitrage, cutting both demand charges and peak energy bills, shortening ROI.
Liquid cooling suppresses battery degradation, delivering stable long-term operation under hot and dusty industrial conditions and lowering maintenance workload.
Millisecond response smooths shock loads from melting equipment and machine tools and improves on-site power quality.
Cloud EMS enables visualized system management, automatic saving-benefit calculation and remote early warning.
Liquid Cooling 125KW 261kWh Lithium Battery Energy Storage Cabinet
The IP55 Protected All-in-One Solar Energy Storage Cabinet is a high-performance, integrated energy solution engineered for outdoor commercial, industrial, and utility-scale solar applications. It integrates a 125kW Power Conversion System (PCS), a 261kWh lithium iron phosphate (LiFePO4) battery bank, an advanced liquid cooling system, and a intelligent Battery Management System (BMS) into a single cabinet with IP55 weatherproof protection. Designed to withstand harsh outdoor environments while delivering efficient energy conversion and storage, it supports solar energy absorption, peak shaving, load shifting, grid auxiliary services, and emergency backup power. Ideal for utility-scale solar farms, industrial parks, large commercial complexes, and remote microgrids, it provides a reliable, space-saving, and low-maintenance solution for large-scale renewable energy integration.
