600kW/1290kWh Energy Storage System Case Study for Plastic Manufacturing Plant

600kW/1290kWh Energy Storage System Case Study for Plastic Manufacturing Plant

——Annual Savings: >$280K, ROI Period <3 Years

1. Project Overview

Customer : XX Plastic Products Co., Ltd. (Medium-sized manufacturer in Southern China)
Industry Pain Points :

• High electricity costs : Injection molding and extrusion machines operate 24/7, with monthly consumption exceeding 500,000 kWh (electricity accounts for 30%+ of total costs).
• Large peak-valley price gap : Peak tariff: $0.17/kWh (10:00–12:00, 18:00–22:00); off-peak: $0.04/kWh (00:00–8:00).
• Demand charge penalties : Frequent power fluctuations triggered monthly penalties up to $7,000 (transformer capacity: 1600kVA).

2. Solution

System Configuration :

• 600kW/1290kWh LiFePO4 battery storage (2-hour backup) + Smart Energy Management System (EMS) .
  Operational Strategy :

1. Peak-Valley Arbitrage :
   • Charge during off-peak (00:00–8:00), discharge during peak (10:00–12:00, 18:00–22:00).
   • Daily revenue : 1290kWh × $0.13 price gap = $167/day .
   
   
2. Demand Charge Management :
   • EMS reduces peak load to <85% of transformer capacity, avoiding penalties.
   
   
3. Backup Power :
   • Provides 30-minute emergency power during outages (prevents mold damage losses).

3. Economic Benefits