Case Study: Enclosure for Energy Storage and Power Grid ...

As a leading provider of custom deep drawn metal enclosures, cases, headers, and diaphragms, Hudson Technologies serves a diverse range of applications and industries. One of our most recent projects, for instance, involved energy storage and power grid management.

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The Problem

Ambri, an energy power grid management company recently approached Hudson with a request for an enclosure to be used in a new energy storage application.

This enclosure needed to be able to stand up to years of harsh exposure as it would be exposed to very high heat, thermal cycling, and corrosive chemicals.

Initially, we considered creating a catalog case, but ultimately decided this was not the best solution for the application; instead, we opted to build a customized enclosure.

The Solution

After carefully analyzing all application requirements and specifications, our team chose to work with stainless steel for its durability and longevity. We also had to ensure the new enclosure would fit within a predetermined footprint and would function well with stacked and packed storage cells.

Contact us to discuss your requirements of energy storage metal case. Our experienced sales team can help you identify the options that best suit your needs.

Our team worked with Ambri to develop a thick-walled custom stainless steel enclosure capable of withstanding severe environments and ensuring limited thermal expansion.

The Result

Hudson delivered the custom enclosure to Ambri and conducted testing to ensure high performance; the tests went smoothly and Ambri was satisfied with our unique solution.

They were also very impressed with our level of communication and collaboration throughout the entire process — namely, our weekly updates during the build, our flexibility in adjusting to changes in design requirements, and our commitment to on-time delivery.

This innovative, new power grid management technology is now in validation testing, and a second-generation enclosure is already in the prototyping and testing phase; our new model will allow for even greater capacity.

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Having a healthy respect for the type of batteries I use for my model airplane pursuits (LiPo, which have been known to energetically combust when not treated right), I am considering fabricating a metal cabinet for my built-up 24V, Wh Li-Ion battery. The cabinet would be vented to the outside to ensure any smoke/combustion is not released within my garage. For even more protection, I am even considering suspending a large plastic bag of sand over the battery -- in the event of a battery fire, the plastic will melt, dropping the sand onto the battery (another trick learned from charging LiPo's).

I am using one of the recommended BMS's from eBay, as well as carefully managing my charge controller settings.

Am I being overly paranoid or cautious? Is there a huge concern given that I have a BMS to protect from over-charge or -discharge? Or is this a prudent precaution?

One side benefit: an enclosed cabinet would make it easier to maintain battery temps above freezing, since it is located in my unheated garage.

Thanks!

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Having a healthy respect for the type of batteries I use for my model airplane pursuits (LiPo, which have been known to energetically combust when not treated right), I am considering fabricating a metal cabinet for my built-up 24V, Wh Li-Ion battery. The cabinet would be vented to the outside to ensure any smoke/combustion is not released within my garage. For even more protection, I am even considering suspending a large plastic bag of sand over the battery -- in the event of a battery fire, the plastic will melt, dropping the sand onto the battery (another trick learned from charging LiPo's).

I am using one of the recommended BMS's from eBay, as well as carefully managing my charge controller settings.

Am I being overly paranoid or cautious? Is there a huge concern given that I have a BMS to protect from over-charge or -discharge? Or is this a prudent precaution?

One side benefit: an enclosed cabinet would make it easier to maintain battery temps above freezing, since it is located in my unheated garage.

Thanks!

Those batteries will fit inside a 40mm ammo can. Hard to come up with a better enclosure for containing a battery fire than a can designed to carry high explosives around in during a battle.

I was going to use the same cells in my RV, but the thought of trying to sleep with those cells in the same room with me became too much for my piece of mind. I finally bought a set of the 280 AH LiFePO4 cells instead.

Idea behind the ammo can is if there is a fire, I would very much like it to stay inside the box. The box is made out of 11 gauge (1/8") thick steel and the lid is very solidly constructed and attached, plus there is a very heavy duty, high temperature, rubber gasket on the lid. If anything is able to stand up to a LiNMC fire it will be this box. I really wouldn't want to drop it on my toe.



I was planning on using a pair of bit-miner cold plates (one on each side of the cells) plus redundant water cooling systems so the battery enclosure could remain completely sealed (no air flow in or out).



Want to buy some water cooling parts that are a perfect fit for your cells?

Just kidding, I will probably build a portable power station with these next year after I am done with the van conversion. Burning metallic lithium can reach degrees C which is above the melting point of steel. If we get that far, I think I will be calling my insurance agent and asking about coverage for a total loss.

Throwing water on burning batteries can cause a hydrogen explosion so that doesn't sound like a great idea either.

Lithium-Ion Batteries and Electrical Fires | Envista Forensics

If a lithium-ion battery fails, it could burst into flame. Read more on how these fires start, and the advantages and disadvantages of lithium-ion batteries.
Sand, lots and lots of sand sounds like a good idea.

Glad I gave up on the idea of using LiNMC cells in my RV and switched to LiFePO4 cells.

I mean we all have to go sometime, but burning up in a completely preventable RV fire is not my idea of a good way to go.

Am I being overly paranoid or cautious? Is there a huge concern given that I have a BMS to protect from over-charge or -discharge? Or is this a prudent precaution?

One side benefit: an enclosed cabinet would make it easier to maintain battery temps above freezing, since it is located in my unheated garage.

Insufficiently paranoid or cautious. Unless the garage, its contents, and any attached structures are all expendable, I think you're better off making a detached bunker to hold the battery. Add whatever insulation and climate control necessary to keep battery happy.

Considering the Probability/Consequences matrix we use to evaluate risks, you should take steps to reduce worst possible consequences to an acceptable level.

It appears future building codes in the US will require a UL listed (in the case of lithium) battery, but make an exception for things like repurposed EV batteries if they are separated from buildings by 5'.

Insufficiently paranoid or cautious. Unless the garage, its contents, and any attached structures are all expendable, I think you're better off making a detached bunker to hold the battery. Add whatever insulation and climate control necessary to keep battery happy.

Considering the Probability/Consequences matrix we use to evaluate risks, you should take steps to reduce worst possible consequences to an acceptable level.

It appears future building codes in the US will require a UL listed (in the case of lithium) battery, but make an exception for things like repurposed EV batteries if they are separated from buildings by 5'.

I got an idea. How about a catapult held down by a very flammable rope. Battery pack catches fire, launches them in an arc aimed at the backyard pool.

This sounds like a product we should be able to buy from Acme.