Delhi NCR Factory Swaps Diesel Generator for Cleaner Lithium Battery Bank

Diesel generator sets burn diesel and emits carbon dioxide, carbon monoxide, nitrogen oxides (NOx), and particulate matter (PM 2.5 and PM 10)) besides causing noise pollution. DG sets release harmful particles into the atmosphere and substantially reduce air quality in the neighbourhood. Every litre of fuel burned in a DG set crates 0.73 kg of pure carbon and 2.6 kg of carbon dioxide. Lithium Battery Energy Storage System (BESS) is a rechargeable battery system that stores energy from the electric grid or any renewable energy source and returns that energy to the building. The first Indian factory in Delhi NCR to shift to the Lithium battery bank from the Diesel generator is Sun Food Tech in Bhiwadi, Rajasthan.

Su-vastika is a company that provides energy storage solutions for residential, commercial, and industrial applications. In 2022, the company replaced the diesel generators at its factory in Bhiwadi, Rajasthan, with a 70 KVA Lithium battery bank. This move is expected to save the company around Rs. 1 lakh monthly in fuel costs and the wastage of material savings during generator switching.

The Managing Director of this company, Mr Arun Bhardwaj, who has been running this business of making food colours for the last 40 years, stated that they were forced to change the Diesel Generator as they were given notices to change the Diesel generator to the Gas Generator and the cost of laying the pipes and minimum energy cost they had to pay yearly was very high compared to the Lithium battery bank with the Lithium inverter called Battery Energy Storage System. Somehow, he was not convinced initially that Lithium Inverter could run the factory as they have the 3 phase machines which work 24/7 to make the food colours, cosmetic colours and dies. They have machinery like Reaction Vessels, Mixers, Large Dryers, and Laboratory to make the new formulas and test the running product quality. Initially, Mr Arun Bhardwaj asked the company Su-vastika to give them a demonstration of the Lithium battery Inverter and installed a 20 KVA Lithium Inverter with a Lithium battery bank and to his utter surprise, this changed his expectations as the machines on which this 20 KVA was installed started working seamlessly as there was no switching time and the material which used to get wasted during the process of electricity coming and going was completely saved as there was no switching time. He never calculated the cost of material wastage. He waited three months before ordering the next Lithium Inverters. He then switched the complete plant on the Battery Energy Storage System, where his 125 KVA generator was replaced with 70 KVA BESS only. The first 20 KVA BESS were installed in April 2023, and the rest system was installed in July 2023. Now, his factory is working on the lithium battery storage system without help from the diesel generator.

He realized the benefits like no person was required to bring the Diesel, which was a major challenge and then the storage of Diesel, which used to take up a lot of space. Then, whenever the power failure happened, one person was dedicated to switching the generator to On and OFF and after the installation of BESS, the staff of the factory does not know about the power cuts anymore as the power back up had been shifted to the Lithium bank uninterrupted power System. This system is completely noiseless and maintenance-free, and the space taken is one-sixth of that of diesel generators.

There is already a study done on the replacement of Generators with Lithium battery Energy Storage Systems to reduce pollution.https://indiasmartgrid.org/isgf/public/banner_img/1667378855RE8IO4g4X4hTzy3vLoGuQkSRkHFUXZdMHWWIopId.pdf

The Diesel Generator service used to be another challenge as after every 300 units, a man used to come and do the servicing of the Diesel Generator timing. If the power went down, then there was no way powering the factory was possible. They needed to shut down the plant for the Diesel generator maintenance. Now that it is past, it is a major relief, and the plant can be run 24/7 without any shutdown.

The life of the Lithium Inverter is more than 50 years, and the life of the Lithium bank is approximately 7 to 10 years, depending upon the usage at the site, the frequency of power cuts and the time for which the battery is being used. The life of the diesel generator is also ten years, but people run the old diesel generators with higher maintenance costs and increased wear and tear.

Monitoring these battery Energy Storage Systems is done through the IOT system, which is built into the product and can be seen by the customer from anywhere. This is Wi-FI driven, and the factory’s Wi-FI monitors the system on the central server.

The cost and savings are approximately more than 1 lakh a month, which will be summarized after the use of one year as the maintenance cost will be compared, which has reduced substantially as there is no replacement of motors and other parts which were used to replace when the DG set used to run them as the quality of power coming from the Diesel Generator and lithium Battery Storage System can not be compared. The Pure Sinewave and the frequency stability compared to Dg is very high. The major advantage is uninterrupted power, which saves the cost of wear and tear of machinery as the starting current of any machinery is very high. While power is coming and going, that plays a major role in the wear and tear of machinery. The location of the plant ishttps://www.google.co.in/maps/dir/28.4621234,77.0909804/SUN+FOOD+TECH,+SUN+FOOD+TECH+F,+37+F%26G,+Khushkhera,+Bhiwadi,+Rajasthan+301707/@28.2997812,76.6194649,10z/data=!3m1!4b1!4m18!1m8!3m7!1s0x390d4907b39f56f9:0x551addcef34f8b8f!2sSUN+FOOD+TECH!8m2!3d28.1245006!4d76.7926506!15sChVTdW4gRm9vZCBUZWNoIEJoaXdhZGmSAQxtYW51ZmFjdHVyZXLgAQA!16s%2Fg%2F11v43r3lt2!4m8!1m1!4e1!1m5!1m1!1s0x390d4907b39f56f9:0x551addcef34f8b8f!2m2!1d76.7926657!2d28.1245597?entry=ttu

The video was also made on the running of the plant on the Lithium battery Storage System: https://www.youtube.com/watch?v=t8_3fSIczTA.

The use of Lithium battery banks has several advantages over diesel generators, including:

  • No environmental impact: Lithium batteries are more environmentally friendly than diesel generators because they do not emit greenhouse gases or other pollutants. The wear and tear of machinery has been reduced, which further helps the environment remain clean and green.

  • No Noise Pollution: Lithium batteries are much quieter than diesel generators, which can be a major advantage for businesses as the pollution is created outside and inside the vicinity of the factory, which affects the health of the workers and the general public.

  • Vibration: The diesel generator creates vibrations all around, which reduces the building’s life. Installing it inside is impossible, so keeping it outside or in the building is the only solution.
  • No maintenance costs: Lithium batteries require less maintenance than diesel generators, saving businesses money in the long run.

  • Improved efficiency: Lithium batteries are more efficient than diesel generators, storing more energy and providing more backup power. The wastage of material during the switching time is a big saving along with the savings in the workforce involved in running DG and bringing the Diesel.https://suvastika.com/indian-factories-ditch-generators-for-lithium-batteries/

The shift to Lithium battery banks is a trend that is likely to continue in the coming years as businesses increasingly look for ways to reduce their environmental impact and save money.

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  1. […] While quantifying the exact emissions reduction from individual battery swaps is challenging, studies have shown significant positive impacts. A 2021 study by the International Renewable Energy Agency (IRENA) found that widespread adoption of lithium-ion batteries for stationary storage could reduce global CO2 emissions by 1.5 gigatons annually by 2050. Considering Delhi NCR’s population density and reliance on inverters, the collective impact of switching to lithium batteries could be substantial. https://suvastika.com/delhi-ncr-factory-swaps-diesel-generator-for-cleaner-lithium-battery-bank/ […]

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