Project Background
This project is deployed for a high-energy-consumption manufacturing factory with no PV installation. The factory fully relies on utility grid power and suffers from high electricity expenditure due to significant peak-valley tariff differentials. To cut operational costs and realize refined power management, the customer adopted grid-tied energy storage system for pure peak-valley arbitrage, with strict operation requirements: no over-charging, no reverse power flow; all stored energy is consumed onsite.
Core Pain Points
- High industrial power consumption leads to expensive peak-period electricity bills.
- No PV or backup power resources to adjust power consumption structure.
- Traditional grid power mode results in rigid high-cost power expenditure.
- Strict grid compliance prohibits reverse electricity transmission and invalid over-load charging.
System Configuration & Solution
The project is equipped with 2 sets of 125kW/261kWh liquid-cooled PCS energy storage cabinets, forming a total capacity of 250kW/522kWh. The system adopts an AC-coupled grid-only topology without PV connection, connecting to the factory internal power distribution bus.
Supported by intelligent EMS energy management system, the ESS performs fully automatic peak shaving and valley filling. With professional liquid cooling thermal management, the system features low noise, low attenuation, high safety and minimal maintenance, perfectly adapting to long-term industrial operation scenarios.
Key Control Strategy (Compliance Guaranteed)
Valley-time On-demand Charging: The system charges intelligently during low-tariff periods according to actual factory load, avoiding over-charging and capacity waste.
Peak-time On-site Discharging (No Reverse Flow): During high-tariff peak hours, the ESS discharges to offset factory load demand. The anti-reverse algorithm strictly ensures all electricity is consumed locally without any power backflow to the public grid.
Intelligent Arbitrage & Peak Shaving: Transfer power consumption from high-price peak periods to low-price valley periods to reduce overall electricity costs.
Full Remote Monitoring & O&M: Real-time data monitoring, early fault warning and automatic data statistics realize unattended and refined operation management.
Installation Challenges & Our Professional Solutions
Retrofitting energy storage systems into operational industrial factories faces many common on-site construction, grid connection and operational restrictions. During this project implementation, we solved typical industry pain points with customized technical and construction solutions, ensuring safe, compliant and fast deployment.
Challenge 1: Limited On-site Installation Space & No Civil Engineering Conditions
Most running manufacturing factories have compact plant layouts, dense production equipment and reserved no extra space for large civil construction, foundation pouring and cable transformation. Traditional split ESS occupies large area and requires complicated on-site assembly, which affects normal factory production.
Our Solution: We adopt integrated liquid-cooled all-in-one cabinet design. The 125kW/261kWh cabinet features highly integrated structure, compact footprint and plug-and-play deployment. No complicated civil engineering and no extra cooling system construction are required. The whole system only needs simple foundation fixation and cable access, greatly saving factory space and avoiding production interruption during construction.
Challenge 2: Harsh Industrial Environment Causes High Equipment Maintenance Pressure
Factory workshops and outdoor areas feature high dust, long-term high-load operation and fluctuating ambient temperature. Traditional air-cooled energy storage systems are easily affected by dust accumulation, resulting in poor heat dissipation, high failure rate and frequent manual cleaning, bringing heavy maintenance workload for factory management.
Our Solution: Adopt full liquid-cooled temperature control system and IP55 high-level protection. The fully enclosed cabinet structure isolates dust, moisture and industrial debris. The liquid cooling system achieves uniform temperature control inside the battery cluster, eliminating local overheating and reducing battery attenuation. No regular dust cleaning is needed, realizing low-maintenance and long-cycle stable operation.
Challenge 3: Difficult System Debugging & Compatibility with Old Factory Power Distribution
Old factory power distribution systems have aging circuits and complex load types. New energy storage systems may have compatibility problems such as voltage fluctuation and harmonic interference during grid-tied operation, bringing hidden dangers to original production equipment.
Our Solution: Our PCS adopts high-precision power factor correction and harmonic suppression technology. Before formal grid connection, we complete overall power quality testing and parameter matching debugging. The system realizes smooth grid connection without impacting the original factory power supply, ensuring zero influence on production equipment operation.
Project Achievements & Value
Effective Cost Reduction: Realize precise peak shaving and valley filling, greatly reduce factory peak electricity expenditure and create stable arbitrage benefits.
Full Compliance: Zero reverse power flow and zero invalid over-charging, fully meeting industrial grid access standards.
Low O&M Pressure: Liquid-cooled cabinet design reduces daily maintenance work, and cloud platform realizes intelligent visualized management.
High Industrial Adaptability: Stable temperature control, low failure rate and long service life support long-cycle and high-intensity factory operation.
Related Products
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.
