Case Study: First use of the Revolution Battery
21 January 2025

Case Study: First use of the Revolution Battery

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Typical battery systems require large amounts of stored energy to generate high peak power. However, while many applications require high power, they only need this high power for a few seconds. As a result, comparatively little energy is used during operations. The required energy can often be supplied by the available mains connection or a small, efficient generator set. As a result, storing large amounts of energy in a battery system is not needed. Revolution Battery is an industrial battery energy storage system (BESS) which breaks the link between energy storage and output power. This innovative battery system incorporates a battery pack which can deliver high amounts of power from a comparatively small amount of energy storage. This results in a smaller battery system with much reduced use of battery cells, higher efficiency and lower embedded emissions. Dumarey Green Power produces its Revolution Battery in the UK, utilising local labour & suppliers as well as minimising transport emissions in the large UK construction market.

 

Fig 1: The Revolution Battery from Dumarey Green Power

Launch customer Falcon Tower Cranes immediately deployed their first Revolution Battery to a Bowmer + Kirkland construction site in Nottingham, where the system was set to work powering a Jaso J118pa and a Jaso J138A tower crane. Traditionally, these cranes would have been powered from a 200kVA generator. Such a large generator results in significant CO2 and other local emissions.

Instead of the large diesel genset, the Revolution Battery allows these cranes to be powered from only a 32A mains connection. As a result, Dumarey Green Power calculated that the Revolution Battery would save over 2T of CO2e per week.

The Revolution Battery can produce up to 300 kW of power and given the modest size of the two cranes the peaks of power were well within its capability. During the first week, the maximum load recorded was just over 60 kW (See figure 3).

Fig 2: 10 seconds of power data from crane operations

Daily energy throughput for the first week averaged 92 kWh per 10-hour day which corresponds with an average loading of just 4.6% on the proposed 200 kVA generator. This highlights the chronic underloading experienced when using diesel generators on cranes, and such low levels of loading are associated with a range of reliability issues. These issues are compounded when Stage V generators are deployed, as these can also suffer from particulate filter regeneration issues and problems with the SCR (AdBlue) systems.

Fig 3: 1.5 days of power data from crane operations

The Revolution Battery averted these issues, charging from the small 32A supply when needed. The data captured from the site validates the design concept of a high-power system with a small battery pack. Dumarey Green Power would like to thanks the teams from Falcon Tower Crane Services and Bowmer + Kirkland for their work on this case study.

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