Faculty at the State University of New York at Binghamton are joining with the Raymond Corp. to build and demonstrate the multiple benefits a digitally networked, behind-the-meter solar-plus-energy storage system coupled with a lithium-ion battery-powered forklift charging system for warehouses.

Funded by the New York Energy State Energy Research and Development Authority (NYSERDA), the demonstration system is expected to deliver benefits to all stakeholders, the warehouse owner/operator Raymond Corp. and the utility grid, as well as the surrounding community and beyond, according to a university news report.

“We are honored to be selected by NYSERDA to support its clean energy initiative with research that includes a solar power system (photovoltaic), a stationary energy storage system, and several forklift battery chargers,” said principal investigator Ziang (John) Zhang and co-principal investigator Pritam Das, both of whom are assistant professors at Binghamton University's Thomas J. Watson School of Engineering and Applied Science. “We believe this partnership with Raymond can give the industry an example of what future warehouse energy systems look like and how it can benefit all parties involved.”

The lead-acid batteries traditionally used to charge the electric forklifts used in warehouses the world over are inefficent and hazardous, posing threats to human and environmental health and safety. One forklift in a high-use warehouse may carry and use two or three of them, one that's in use, another being recharged and another cooling down in storage, the research team highlights. In addition, they can take as many as eight hours to rechared.

Lithium-ion batteries are much more efficient, and pose less in the way of operational risk on balance, but warehouse operators' needs for fast-charging can cause spikes in electricity demand during peak hours, putting a severe strain on budgets. That's why the project is being developed, the researchers explained.

“Our partnership stemmed from the manufacturing industry’s growing need for more sustainable, more controllable resources,” said The Raymond Corp.'s CEO Michael Field. “By implementing lithium-ion batteries into more forklifts, our customers will see the same high-quality products but with overall energy consumption reduction due to the ability to charge at nearly 100 percent efficiency and reduced costs, on account of the batteries having a longer lifespan.”

The Raymond Corp. carried out an NYSERDA-funded, lithium-ion battery energy storage project in 2017. That project demonstrated the advantages of using lithium-ion batteries for energy storage on forklifts, according to the news report. Part and parcel of that project, methods were developed for "the battery, truck and charger to communicate temperatures, state of charge and other status information, as well as demonstrate improved performance while the forklifts were in use."

In order to suppor the utility grid, the project team will work with New York Electric & Gas (NYSEG) to estimate the net benefits and impacts of the demonstration system. A preliminary analysis estimates how the system would impact the local circuit, according to the news report.

“Controllable distributed energy resources, such as battery storage, will play a significant role in managing the electricity grid in the future. We are excited to be working with Binghamton University and The Raymond Corporation on this exciting project,” said NYSEG CEO Carl Taylor.

NYSERDA President and CEO Alicia Barton highlighted how the project will support New York achieving statewide clean energy and climate change goals and could improve the lives and livelihoods of New Yorkers.

“This is an excellent example of how companies are pushing beyond the status quo to bring clean energy technologies into their workplace while supporting Governor Cuomo’s nation-leading clean energy goals,” Barton stated. “Incorporating multiple clean energy technologies into one system, such as this project, will enable warehouses to become more energy efficient, save money and increase productivity, while making their buildings healthier for workers.”