Project Honeycomb

Microgrid Life Cycle Research

Tyler Leighton, Alex Lozada, Jackson Roberts, Ty Cubley

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 Table of Contents
Introduction 3

Raw Materials 3

Transportation/Component Acquisition 4

Manufacturing (Installation) 5

Maintenance 5

Recycling 5

Wastes and Emissions 6

Citations: 7

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Introduction
In this research paper we will be exploring the product life cycle of a microgrid. A microgrid is a
large circuit that is typically integrated into commercial and private properties that can produce,
store, monitor, and export energy. They will consist of two or more distinct power sources as a
form of fault reliance, if one part fails the rest of the system will still function. A microgrid also
has the capability to connect to the main utility grid to export excess energy or import energy if
needed. However, a microgrid is not bound to the utility grid; it has the ability to go into “island
mode” where it uses its own power to function independently from the grid.

The main elements of a product life cycle are: raw materials, transportation/distribution,
manufacturing, use/re-use and maintenance, recycling, and waste/emissions. However, in our
case transportation/distribution and manufacturing will be changed to material acquisition and
installation. The reason for this change is because a microgrid is a product that can’t be
distributed due to it being integrated within a property. It is also unable to be manufactured due it
being made up of many complex small components that have been installed on a property to
make a functioning microgrid.

Raw Materials
There are many raw materials that would be used in this project. This project encompasses a
number of complex components such as lithium ion batteries, solar panels, electrical wires,
breakers, hydrogen fuel cells, and diesel generators. Lithium ion batteries are made of ​lithium,
cobalt, nickel, manganese, graphite, copper and aluminium. The components of a lithium ion
battery are the cathode, anode, electrolyte, and separator. ​Lithium is stored in the anode and
cathode.. Positively charged lithuim ions are carried by the electrolyte from the anode to the
cathode through the separator and vice versa. The movement of the lithium ions creates free
electrons in the anode which creates a charge at the positive current collector. The electrical
current then flows from the current collector through a device being powered to the negative
current collector. The separator blocks the flow of electrons inside the battery. ​Solar panels are
made of ​silica, cadmium, gallium, germanium, indium, selenium, tellurium, phosphorus boron,
polyvinyl fluoride film, ethylene vinyl acetate, silicon dioxide, quartzite gravel, iron, zinc,
alnium, nickel, steel, and copper. And its components are ​Solar Array Mounting Racks, Array
DC Disconnect, Inverter, Battery Pack, Power Meter, Utility Meter, Kilowatt Meter, Backup
Generator, and Charge Controller. Solar panels generate electricity by absorbing sunlight into
photovoltaic cells to create a direct current (DC)which can be turned into alternating current
(AC) with the help of an alternator. ​Electrical wires are much simpler than lithium ion batteries
and solar panels. These use copper and rubber. These are a vessel to carry an electrical current.
Breakers are also pretty simple. These use copper alloys to break the circuit if there is an
overload.

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The second main power source in our microgrid is a hydrogen fuel cell. Hydrogen fuel cells
work by combining oxygen with hydrogen, the chemical reaction produces energy which is then
converted into electricity. The parts that make up a hydrogen fuel cell are a membrane electrode
made of nafion, conducts hydrogen ions, catalyst layers made of a thin platinum sheet and
carbon paper, acts as a catalyst for the chemical reaction, electrodes that's made of platinum
coated carbon paper, telfon, and nafion, gas diffusion layers which is made of carbon paper that's
coated with teflon, moves reactants to catalyst layer and removes emissions (water), gaskets that
are made of silicone rubber, seal for the each fuel cell, bipolar plates graphite, stainless steel,
aluminum, titanium, connects fuel cells together into a stack.

Of the three power sources in a microgrid design, one of them will be a diesel generator. This
will act as backup power if needed. Diesel Generators work by using a combustion reaction to
create mechanical energy which is then converted into electricity through the alternator. The
components that make up a diesel generator are a diesel engine, source of mechanical energy,
alternator, converts mechanical energy to electrical energy, a radiator, helps disperse heat from
generator keeping it cool, exhaust system, expels exhaust fumes created by the generator, control
panel, allows control and management of generator, and frame with fuel tank provides structural
support and fuel. The raw materials that make up a diesel generator are as listed, aluminum alloy,
cast aluminum, Cast Iron, Copper, Epoxies, Ferromanganese (Fe-Mn), Ferrosilicon (Fe-Si),
Lead, Low Alloy Steel, Low Carbon Steel, Molybdenum, Nickel, PCB, Stainless Steel, Steel
Bars & Rods, Tin, Titanium Alloys, and Zinc

Transportation/Component Acquisition
To acquire all the needed components to meet our microgrids functions and subfunctions we will
incorperating pre-existing products recommended to us by our teams mentors or products we
found that could do better. The main components we use in our microgrid include, energy
storage systems, renewable power sources, backup power (fossil fuels), and energy monitoring.
For our energy storage systems, we would use lithium ion batteries from SimpliPhi or DC Tesla
Power packs. We might also incorporate sodium ion batteries from Aquion Energy. To meet our
power generation needs we will be using two types of renewable energy, solar panels and
hydrogen fuel cells. We will be specifically using LG 370 watt solar panels with 18.9%
efficiency and hydrogen generators fro, PowerPlug. As a backup power source we will be
incorporating a diesel generator from generac. The most logical way for us to acquire these
materials is through delivery trucks or overseas shipping. Fortunately, most of the components
that we are using are from companies based in the United States. Which cuts down on the use of
fossil fuels for transportations. However, the raw materials that are used to manufacture these
components may come from other countries and could be manufactured overseas.

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Manufacturing (Installation)
Polycrystalline solar panels are typically installed on roofs or on solar structures. Usually,
mounts are installed on the roof for the panels to sit on. Installation of the hydrogen fuel cells is
fairly straightforward since they’re already manufactured, although the complexity comes from
actually connecting them to the microgrid. The installation of diesel generators is also
straightforward as the generator is prebuilt and just has to be secured and connected to the
microgrid. Steps include: 1. Choose a location that is ideal, such as away from windows and
doors, near fueling and electricity hookup, and somewhere that is compliant with law. 2. Pour a
concrete pad. 3. Anchor the generator to that pad. Installation of the lithium ion batteries is basic
as they can be put anywhere as long as they have a connection and are indoors, just for
precaution. It is difficult to connect them to the grid though and requires experts. Installation of
underground wiring requires electricians to dig up and then bury the wiring. There’s a safety
inspection and basic steps which include: 1. dig up the trench where they’re to be installed, 2. lay
down the wired, 3. connect the wires to where you want them to be connected 4. bury the wires.
Wires typically need some sort of protection such as a metal case or burying the wire deep below
ground

Maintenance
Polycrystalline solar panels don’t require much maintenance since they have very little moving
parts and maintenance is limited to routine cleaning. The inverter may have to be replaced during
the solar panels’ lifetime. The panels have a lifespan of 25 years. Hydrogen fuel cells require
little maintenance and only need to be refilled. They also may need regular checks to insure
continued functionality. Diesel generators have moving parts, so they do need maintenance. A
maintenance schedule must be implemented and includes ​the timely removal of worn out parts or
upgrading the components, checking fluid levels, battery inspection and cleaning of connections,
load bank testing, verifying control panel readings and indicators, and the changing fuel and air
filters​. Lithium Ion batteries must be replaced after 2-3 years or 300 to 500 charge cycles,
whichever comes first. They must be kept inside to protect them from heat and water. Chemical
batteries have little moving parts, so they don't need that much maintenance. Underground
wiring has little moving parts, so it requires little maintenance. They have to be marked to
prevent accidental dig up.

Recycling
Lithium ion batteries
Often lithium ion batteries are very hard to be recycled and not many places recycle them. The
recycling rate is a little less than 5% because there is very little technology for recycling the
materials. The batteries that go to get recycled undergo a high temperature melt, and then
extraction, this is similar to the process used in the mining industry, but it is way too costly to do.

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Solar panels
Solar panels can be easily recycled since they are mostly aluminum and glass but it does come at
a cost
process
1. Removing the aluminum frame (100% reusable)
2. Separating the glass along a conveyor belt (95% reusable)
3. Thermal processing at 500 degrees Celsius
○ This allows for the evaporation of small plastic components and allows the cells to be
easier separated.
4. Etching away silicon wafers and smelting them into reusable slabs (85% reusable)

Electrical wires
The main materials in the electrical wires are plastic that covers the wires, and the aluminum and
copper wires, this is all recyclable. Just strip the wire with a utility knife or use a wire machine,
but these can cost up to 5000

Wastes and Emissions

Lithium Ion batteries
Toxic chemicals are needed to produce lithium, the extraction of lithium has lots of
environmental impacts. The production produces about 150-200 kilos of carbon dioxide per
kilowatt hour battery. ​An electric car with a 100kWh battery has thus emitted 15-20 tons of
carbon dioxide even before the vehicle ignition is turned on.”

Solar panel emissions

The solar panels them self are not producing greenhouse gases, however the process to create
solar panels have emissions. Produce 0.02 pounds of Co2 per kilowatt hour less

Hydrogen fuel cell

● Emit water vapor
● Does not emit any other gases
Diesel generator
Each gallon of ​diesel​ fuel ​produces​, on average, 10,084 g of ​CO2​, or about 22.2 lb. These.
Produce CO2, carbon monoxide, and nitrogen oxide

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Citations:
1. The Cost and Frequency of Solar Maintenance
2. How does a Hydrogen generator work?
3. Lithium-Ion Battery Maintenance Guidelines
4. How are Roof Solar Panels Installed? – Electric Choice
5. Generator Maintenance & Service: Tips on Maintaining Prime & Backup Power
Generators
6. Are lithium ion solar batteries the best energy storage option?
7. 6 Steps for Your Generator Installation Checklist
8. Technique for Installing Underground Cable
9. International Materials Reviews | RG Journal Impact Rankings 2018 and 2019
10. Fuel cell materials and components
11. Diesel Generator and its Major Components
12. A LIFE CYCLE ASSESSMENT OF A DIESEL GENERATOR SET
13. Electric Wire Recycling
14. ​PLATT ELECTRIC SUPPLY - Wholesale distributor of electrical, industrial, lighting,
tools, control and automation products for the electrical, construction, commercial,
industrial, utility and datacomm markets
15. ​It's time to get serious about recycling lithium-ion batteries
16. Can Solar Panels Be Recycled?
17. MYTH BUSTING: ‘ZERO EMISSIONS’ EVS ACTUALLY RUN ON NATURAL GAS
18. Towards a Just and Sustainable Solar Industry
19. Environmental Impacts of Solar Power
20. SimpliPhi Lithium-Ion Batteries
21. Aquion Battery Supply for Energy Storage
22. Solar Panels
23. Hydrogen Fuel Cell
24. Diesel Generator and its Major Components
25. A LIFE CYCLE ASSESSMENT OF A DIESEL GENERATOR SET
26. https://www.energy.gov/eere/articles/how-does-lithium-ion-battery-work