RayGen aim to making dispatchable solar a reality

‘When I first started in solar, way back in the 70s, solar was only one step away from witchcraft or alchemy.’
Raygen founder Dr John Lasich

An all-Australian hybrid solar energy and storage project promising cheap and dispatchable electricity is officially open for commercial-scale trials.

Combining incredibly efficient photovoltaic (PV) and low-cost thermal energy technologies, the new power plant will test Melbourne-based company RayGen’s unique approach to solar electricity generation and long-duration storage.

It’s the latest step, supported by ARENA, that has taken RayGen’s technology from a backyard shed to a 30-hectare site in Carwarp, north-western Victoria.

The test plant is designed to deliver 4 MW of solar PV generation and store 2.8 MW / 50 MWh (equivalent to 17 hours) of dispatchable energy.

If successful, RayGen plans to build a utility-scale power plant with 200 MW solar capacity and 115 MW / 1.2 GWh of storage. That would be enough, on average, to power around 45,000 homes for more than 10 hours.

To help achieve that, ARENA has also announced $10 million in funding to RayGen for a $32.7 million project. It aims to improve RayGen’s designs, achieve cost reductions and conduct a basic and detailed front-end engineering design (FEED) study of the planned utility-scale project.

ARENA CEO Darren Miller said at the Carwarp plant opening: “This project is the culmination of a 10-year journey.”

“ARENA has now supported RayGen through six different projects with over $38 million of funding. This sixth project is to help scale this technology up to even another level,” he said.

How does RayGen’s technology work?

Graphic schematic of RayGen's Carwarp plant — A field of mirrors, or heliostats focuses sunlight onto PV cells mounted on a tower

RayGen’s founder and now Executive Director Dr John Lasich has been interested in solar since the 1970s. Speaking on ARENA’s Rewired podcast, he said experimenting with solar cells in those days was regarded as akin to “witchcraft”.

“When I started looking at it in [Monash] university, people thought that was OK because it was research. But a lot of other people thought, ‘You know, this guy’s a bit crazy here.’”

“Back in about ‘75, we got some solar cells and did some initial tests. And we saw that by putting concentrated light onto those, we could actually increase the power by factors of hundreds of times.”

And that’s the basic concept. Mirrors, or heliostats track the sun and focus sunlight onto RayGen’s PV cells mounted on towers. The cells generate electricity up to 2000 times the power output of a conventional solar panel of the same size.

But that’s not the end of the story, because the concentrated rays also generate a lot of heat. In fact, roughly 60 per cent of the sun’s available energy at the PV cell ends up as heat.

Raygen’s design has transformed that challenge into an opportunity.

The Carwarp facility features two large, heat-insulated pools of water. Each pool is 15 to 20 metres deep and the size of a small farm dam. Together, they contain roughly the equivalent of nine Olympic-size pools of temperature-maintained water.

Heat energy from the solar towers’ cooling systems keeps one of the pools just below boiling at around 90 Celsius. Refrigerators use solar or off-peak electricity to maintain the other pool to near freezing.

That temperature difference can then be used to drive a heat-to-power engine, generating dispatchable base-load power to the grid.

Global implications

Cutting the ribbon at RayGen Carwarp plant — Senator Jenny McAllister (centre): ‘As innovators, we [Australians] punch above our weight.’

The fact that RayGen’s concentrated solar approach needs thousands fewer power PV cells than conventional solar panels has big implications.

In a world of challenging supply chains and China’s virtual monopoly on solar panel manufacturing, Dr Lasich says RayGen’s design offers an alternative.

“Our module manufacturing is governed by very different economic dynamics to those of solar panels,” he said.

“Our modules can be manufactured in Australia or any other place that is required. It’s a real change in the module manufacturing work.

“RayGen has developed the Goldilocks formula. We are bringing the right elements together to produce a high-performance solar generator and, at the same time, being low cost.”

The heat energy storage system also offers a simple solution, using established technologies and water.

Assistant Minister for Climate Change and Energy, Senator Jenny McAllister, speaking at the Carwarp plant opening event, said she believed the project “has real significance in terms of what’s going on globally”.

“We’ve got a role to play as a country because, as innovators, we punch above our weight.

“It’s true for our scientific organisations, but it’s also true for our government organisations, organisations like ARENA and the CEFC [Clean Energy Finance Corporation], which provide institutional support.

“Taking ideas out of the university into the commercial world and bringing you to a point where major investors can engage and get ready to take them to scale.”

ARENA has since 2012 supported more than 280 solar PV and solar thermal projects with total funding of over $1 billion.

In July 2023, ARENA announced a $541,640 grant to the Australian PV Institute to produce a Silicon to Solar study. ARENA also published a whitepaper, The Incredible ULCS: How Ultra Low-Cost Solar Can Unlock Australia’s Renewable Energy Superpower.

Born again: Can fossil fuel generators gain a second life?

Converting old fossil-fuel generators to perform a key role in a renewable energy electricity network is technically possible. It could also be quicker and cheaper than building alternative synchronous condensers.

An ARENA-commissioned report, Repurposing Existing Generators as Synchronous Condensers, estimates conversion costs could be up to 40 per cent cheaper than building from scratch an alternative device, known as a synchronous condenser.

Repurposing a gas-powered generator could cut installation lead times from a minimum of around 30 months for a new synchronous condenser, to as little as six months.

And although big, coal-fired steam generators could cost more to convert and take longer than the alternatives, the end product could deliver the equivalent effect of several synchronous condensers combined.

Highlighted 3D plan of the synchronous condenser at the Ouyen Solar Farm — A synchronous condenser is, at its heart, a big spinning mass, ready to generate electricity

A generator is, essentially, a huge, powered, spinning mass with the main purpose of producing a steady supply of electricity. But because it is so big, its inertia can also help keep the electricity network stable.

Synchronous condensers are also huge spinning masses, albeit smaller than generators. Their only role, as old generators retire, is to help maintain network stability.

As more generators retire, replaced by renewable energy sources, their stabilising role disappears. One solution is to build more synchronous condensers.

But there are problems with that approach.

The whole world is looking for solutions to the same problem. As global demand for synchronous condensers accelerates, a supply shortage is emerging. That inevitably leads to rising costs and longer wait times.

For context, network operator Transgrid recently published initial estimates indicating a need for 20 synchronous condensers in NSW alone by 2025.

Which type of generators are the easiest to convert?

The report focusses on fossil fuel-powered generators, noting that many hydro generators can already operate as synchronous condensers.

The ease of converting existing generators varies with technology and local site conditions.

Examining three technologies, the report finds the order of ease, speed, and cost of conversion to be:

Open-cycle gas turbine, which van be converted by adding a clutch between the turbine and the generator. That would involve a lead time of six to eight months with only modest structural, cooling and lubrication modifications likely. Overall, the conversion cost could be around 60 per cent of building new synchronous condensers with the equivalent performance.

Combine-cycle gas turbines, which have both gas and steam turbines, would depend far more on the design and layout of the system. At its simplest, conversion could also just involve installing a clutch, with cost and lead-time savings to match.

Coal-fired steam generators are the most difficult to convert and most dependent on the design and condition of the system. Lead times could be as short as 12 months but more likely to range from18 months up to four years. Costs are also expected to be higher but, in favourable circumstances, could match those of gas generator conversions.

What are the report’s recommendations?

Although the report’s recommendations acknowledge “there are no precedents for the conversion of large fossil fuelled generators to synchronous condensers in Australia,” it strongly recommends urgent action.

Firstly, to build knowledge, the report highlights the need to support at least two, preferably three, site-specific investigations.

Secondly, to meet the challenge of ever-increasing system needs amid rapidly approaching deadlines, the report urges System Strength Services Providers to assess potential projects and seek regulatory approvals.

The report also makes recommendations around exploring the structure of relevant contracts and, separately, establishing data points for the value of inertia.

The final recommendation takes a sideways look at the repurposing question. It asks whether new synchronous condensers could be built from old generator spare parts.

Microgrids: Cheaper, cleaner, reliable energy for remote communities

Around 500,000 people, or two per cent of Australia’s population, live in remote areas without a connection to the electricity grid.

If you are in that situation, you are what is known as “off grid”.

For some, off grid is a term to describe a lifestyle choice to live self-sufficiently. But in many parts of regional and remote Australia, off grid is a fact of life.

In those areas, electricity supply is most often provided by expensive and unreliable diesel generators. Natural events, such as floods, can leave isolated communities without diesel fuel and spare parts for weeks or even months.

ARENA has opened a funding program of $75 million specifically for regional and remote First Nations communities.

The First Nations Community Microgrids Stream and the Regional Australia Microgrids Pilot Stream form the Regional Microgrids Program with a total funding pool of $125 million.

ARENA CEO Darren Miller said: “Remote communities relying on fossil fuels like diesel have unique challenges in transitioning to renewables. This new funding will help overcome barriers to broader deployment of microgrid solutions.”

The funding, Mr Miller said, will help First Nations communities access renewable energy and build on ARENA’s ongoing work in renewable energy microgrids.

What are microgrids?

Indra Monash Smart City — Monash University has installed a microgrid at its Clayton campus in Melbourne

The first thing to note is that microgrids are not a new idea. The first public electricity systems in Australia, starting with the regional NSW town of Tamworth in 1888, were all, effectively, microgrids.

The second thing is, not all microgrids are remote; some connect to bigger networks. For instance, essential services and military facilities often have their own diesel-powered emergency microgrids in case the main network goes down.

What is new, is the ready availability of renewable energy sources.

There is no internationally agreed definition of what a microgrid is, or even its size.

In general though, a microgrid must be capable of working in isolation from the main electricity grid. Nowadays, a microgrid should reliably integrate, coordinate and optimise various local energy resources, such as solar panels, diesel, batteries and other forms of storage.

In Western nations, microgrid power outputs range from hundreds of kilowatts to a few megawatts in power output. In developing nations, where energy use per household is much smaller, it’s more like tens of kilowatts.

Why use microgrids?

SETuP for life - enter now — Click the image to view a multimedia presentation of a past ARENA-supported microgrid project, Solar SETuP

ARENA backs the development of regional and remote microgrids because they offer a pathway to a renewable energy future.

Some of the advantages of renewable energy-powered microgrids for remote communities in Australia include:

coordinating local energy sources, such as multiple household rooftop solar panels;
increased resilience and reliability of supply;
cleaner energy supply;
mitigating the effects of natural disasters, such as bushfires, floods or cyclones.

ARENA has in the past supported several remote microgrid projects and programs. Projects have included Lord Howe Island in the Tasman Sea, and King Island and Flinders Island in Bass Strait.

What is the application process?

Applications to both Streams will be assessed in two stages, with initial Expressions of Interest followed by Full Applications.

Microgrid projects under the First Nations Community Microgrids Stream will progress in consultation with Aboriginal and Torres Strait Islander groups, First Nations renewable energy experts and state and territory governments across Australia.

A broad range of stakeholders, including the National Indigenous Australians Agency (NIAA) and other First Nations group representatives have helped develop the program guidelines.

Both Streams of the program will aim to resolve remaining barriers to final investment and full deployment of microgrid solutions.

Mr Miller said: “It’s vital we make sure Aboriginal and Torres Strait Islander people living in remote communities are able to participate in the electricity transition and share in the benefits of Australia’s renewable future.”

“ARENA’s strong track record in supporting the deployment of complex and emerging renewable energy projects means we are well placed to work with developers and First Nations communities to bring the energy transition to remote Australia,” he said.

Applications are now open. The program runs until December 2025 or funds are exhausted.

For more information about the Regional Microgrids Program, including eligibility and how to apply, please visit the ARENA funding page.

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Hysata to build next-generation hydrogen electrolyser

A pioneering, all-Australian hydrogen electrolyser technology is getting the chance to prove itself at a commercial scale.

If it works, the project has the potential to transform the economics of renewable hydrogen production.

ARENA’s support has helped develop this new technology since it was a concept in a University of Wollongong laboratory. That work saw a spin-off company, Hysata, established to commercialise the development.

Infographic: How Hysata's capillary-fed electrolysis cell works — Hysata says it has created the world’s most efficient electrolyser cell (Image: Hysata)

Now, Hysata will receive $20.9 million ARENA funding as part of a $47.5 million project. Hysata will build and test a 5 MW system at its new Port Kembla manufacturing facility.

The plan then is to move the entire system to Rockhampton in Queensland, for installation and trials next to the Stanwell Power Station.

Queensland government-owned power company Stanwell Corporation is providing the site and facilities, and also backing the project with $3 million.

ARENA CEO Darren Miller says the project is a crucial step to enabling purchase orders for the technology.

“Hysata’s electrolyser technology could be a game-changer for renewable hydrogen,” Mr Miller said.

“The demonstration at Stanwell’s site will be key to unlocking commercial demand for Hysata’s product by proving the technology works at scale.

Currently, the production cost of renewable hydrogen (using renewable energy) is at least twice that of hydrogen produced from fossil fuels. Hysata says its technology will slash costs and produce hydrogen “well below” a competitive target price of $2 per kilogram (approx. US$1.50/kg).

FYI, if there’s one number you should remember, it is that price of $2 per kilogram. That’s the key to competing with fossil fuel-derived hydrogen and fully unlocking renewable hydrogen’s industrial and energy future.

How does Hysata’s technology work?

It’s all in the bubbles.

All electrolysers work by passing an electric current from electrodes through H2O – water. The current splits the water into its two parts, hydrogen and oxygen. That process takes energy.

Now, if the entire process were 100 per cent efficient, all that energy would go into splitting the water. Nothing else.

But, until now, electrolysers have also produced a lot of heat. That’s because, just like an electric heater at home, they have electrical resistance.

The heat generated is not only wasted energy, but it must also be removed. Electrolysers need a lot of cooling and that uses even more energy.

So, if you can reduce resistance, a greater proportion of energy is available to split the water. Also, the system generates far less far less heat, which in turn requires less cooling.

Infographic showing the evolution of electrolysers — Evolution of electrolyser design (Image: Hysata)

Hysata has tackled the problem by completely redesigning their electrolyser to remove all the main sources of electrical resistance.

It turns out, that means eliminating hydrogen and oxygen bubbles. When bubbles form on the electrolyser’s electrodes, they reduce the surface area available for electrolysis and increase resistance.

In fact, Hysata says it has completely eliminated bubbles from its system and cut electrical resistance to virtually zero. As a result, Hysata says it expects a fully operational electrolyser will stay cool through good air ventilation alone.

The combined effect is what has raised the overall efficiency of a Hysata electrolyser to around 95 per cent. That’s a huge jump on current technologies, which operate with efficiencies closer to 75 per cent.

To put that in context, to make renewable hydrogen competitive with its fossil-fuel derived alternative, the International Renewable Energy Agency (IRENA) in 2020 set an electrolyser efficiency target of up to 85 per cent … by 2050.

‘Game-changing, homegrown innovation’

Minister Chris Bowen at launch of Hysata project — Minister for Climate Change and Energy Chris Bowen (second left) inspects a stack of Hysata electrolysis cells

Opening the new manufacturing facility, Minister for Climate Change and Energy Chris Bowen said: “We’re delighted to support game-changing, homegrown innovation that will power our future as a clean energy manufacturer and a renewable energy superpower.”

Hysata CEO Paul Barrett said this was a significant milestone.

“Green hydrogen is critical for decarbonisation of hard-to-abate sectors. We are committed to helping our customers deliver the world’s lowest cost green hydrogen,” he said.

“With exceptional 95% efficiency combined with cost-effective materials and reduced engineering, procurement and construction (EPC) costs, Hysata’s electrolyser will transform the economics of green hydrogen production.”

Stanwell CEO Michael O’Rourke said Hysata represented an important step in developing Queensland’s renewable hydrogen industry.

“The development of a renewable hydrogen industry is a key component of our energy transformation,” he said.

“The potential to utilise high efficiency Australian technology in large-scale hydrogen projects would be a real advantage.”

Initial development of the system is currently underway, with the field pilot at Stanwell due to commence in 2025.

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Wanted: Supermarkets to check out flexible demand

Your local supermarket could soon contribute to a cool (there it is again) project aimed at helping Australia’s renewable energy transition.

If successful, the Unlocking Flexible Demand in the Commercial Refrigeration Sector project will help speed integration of renewable energy into electricity networks.

It would also change the way supermarkets operate their refrigerators. By allowing remote operators to control energy use, supermarkets could reap financial benefits and potentially pass them on to customers.

In simple terms, the flexible demand system will switch refrigerators on when renewable energy is plentiful, and off when energy demand exceeds supply.

That will help match electricity demand to available supply and maintain network stability.

ARENA has announced $3.7 million funding to Enel X to demonstrate flexible demand can work in the commercial and industrial refrigeration sector.

Enel X has already signed up a tier-one grocery chain to a 20-store pilot project. In total, it is seeking 440 supermarkets and 13 refrigerated warehouses across the National Electricity Market (NEM) to take part.

Participating supermarkets and warehouses will receive financial benefits through an innovative retailer tariff from Enel X’s virtual power plant (VPP).

Why refrigeration?

Renewable electricity sources are more variable than traditional fossil-fuel generators. One way to deal with variable supply is to control electricity demand to match.

Enel X with ARENA funding has previously conducted trials demonstrating that business users of electricity can respond in this way. But large-scale refrigeration operations are particularly attractive for flexible demand systems.

Pie Chart: Enel X 2019 demand response trial participants by industry — Enel X in 2019 aggregated 30 MW of electricity bill savings across its mix of residential and commercial energy users

Commercial refrigerators can quickly turn off and on, so they can respond to energy demands.

They also have what is called high thermal mass.

That means commercial refrigerators use a lot of electricity to cool down. It makes them an ideal tool for using up energy when supply is high.

But once cold they are slow to warm. They can turn off for lengthy periods and still maintain safe temperatures while the VPP prioritises energy demand elsewhere. And the combined effect of many individual refrigerators connected to the VPP could be substantial.

Around 500 MW of refrigeration-based flexible demand is potentially available across Australia’s supermarkets, grocery stores, beverage shops and warehouses.

On a much smaller scale, if you have ever listened to your kitchen fridge working … who hasn’t? … you will know that it switches on and off depending on the temperature inside. Now imagine, if as well as primarily responding to the thermostat, it also responds to the need of the network. It’s the same principle.

Demonstrating and proving the technology?

ARENA CEO Darren Miller said the project can pave the way for further investment in flexible demand.

“Our electricity grid is changing, and a more variable supply requires more flexible demand,” Mr Miller said.

“Commercial refrigeration can unlock this opportunity at a material scale,” he said.

“We want to see projects like this demonstrate the benefits of flexible demand to all users via a more efficient grid.

“By demonstrating and proving the technology, we’re hoping to see increased uptake as electricity users look to it as an attractive option.”

Jeff Renaud, Managing Director of Enel X APAC, said: “The energy market needs new ways to balance renewables and businesses need new ways to reduce energy costs.”

“With ARENA’s support, we will prove that small-scale refrigeration systems, when plugged into a virtual power plant, can make a large-scale contribution to the renewable energy transition.”

ARENA has previously supported Shell Energy Australia with a $9.1 million grant to trial flexible demand solutions across shopping centres, supermarkets and distribution centres.

The Unlocking Flexible Demand in the Commercial Refrigeration Sector project is due to be completed in 2027.

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Op-ed: How ultra low-cost solar will unlock Australia’s superpower vision

Darren Miller is CEO of the Australian Renewable Energy Agency (ARENA)

Forty years ago, Australian scientists invented the modern-day solar cell and kickstarted a global solar PV industry. So successful has solar become that the International Energy Agency has declared it as the cheapest form of energy generation the world has ever seen.

Current solar and wind technology is already mature enough to transform our electricity system, support the growth of electric vehicles and make the switch to all-electric homes and businesses. This is a worthy and important task. As such, it has considerable grassroots support and increasing investment from all levels of government.

However, it is clear the impressive renewable energy technologies currently at our disposal are not able to be produced and installed in the enormous volumes and at a sufficiently low cost to outcompete fossil fuels for many important end uses such as heavy industry, hydrogen production and long-distance transport.

Australia’s key assets include our vast land mass, low population density, and an abundance of sunshine. All of this points to ultra low-cost solar as the hero in our superpower vision.

What is ultra low-cost solar?

ARENA recently published a white paper, The Incredible ULCS: How Ultra Low-Cost Solar Can Unlock Australia’s Renewable Energy Superpower.

Ultra low-cost solar will more efficiently convert sunlight to energy. It will be manufactured from affordable, abundant, safe and stable materials. And finally, it will be deployed in the field at low cost and in a highly efficient, automated way.

Once operational ultra low-cost solar will require little ongoing maintenance and have a longer lifetime than today’s solar technology. Its low risk will attract financial backing from private investors and our financial institutions

Unless we make ultra low-cost solar a reality in Australia, we may never unlock our renewable superpower potential. We will limit the Australian economy’s options to adapt and thrive in the 21st century.

In the decades ahead, as the world decarbonises, our trading partners will seek low emissions sources of metals, chemicals and other materials that will be the backbone of the net zero global economy. Highly energy intensive commodities like lithium, steel and ammonia will need power from cheap renewable energy or low carbon sources.

Ultra low-cost solar will fill that gap.

There is no question that cheap solar alone is not the whole answer. We also need other components such as cheap wind energy, low-cost firming, transmission and demand-side flexibility.

However, without cheap solar, the transition to net zero will be more expensive and carry significant risks to Australia’s resource dependent economy.

How will we realise ultra low-cost solar?

ARENA CEO Darren Miller at the Australian Clean Energy Summit — ARENA CEO Darren Miller launches the ultra low-cost solar white paper at the Australian Clean Energy Summit (Image: Dylan May)

We can make ultra low-cost solar a reality by focusing on three crucial endeavours.

Firstly, our scientists and researchers must keep innovating and improving solar cells and module design. We must find new materials and technology to turn more of the sunlight that hits the solar panel into electricity.

Current modules for rooftop and large-scale deployment convert about 22% of the available energy into electricity. We need to push this beyond 30%.

Secondly, our engineers and entrepreneurs need to find lower cost ways to install solar. Current methods would require hundreds of workers connecting solar modules to mounting systems by hand in far-flung locations across Australia.

If it sounds expensive, that’s because it is.

We must move into the digital age with factories pre-assembling modules and GPS-guided robots installing them in the field.

Thirdly, we must work with Australian communities, First Nations people and landowners to make available the amount of land required to host these facilities and the new high-capacity transmission lines we’ll need to connect these solar farms to the end users.

In addition, we need to take a serious look at opportunities to manufacture more of the components needed.

Currently, China dominates the global supply chain for solar. We must increase our resilience to future supply chain shocks by building local capabilities.

What is Solar 30 30 30?

Having led the way with the first competitive auctions for solar farms back in 2016, which kickstarted our large-scale solar industry, ARENA has set an ambitious ultra low-cost solar goal we call Solar 30 30 30. We want to achieve solar module efficiency of 30 per cent and an installed cost for solar farms of 30 cents per watt by 2030.

This goal is within reach if governments, private investors and society as a whole commit to solving this particular challenge.

With the right focus we can leverage Australia’s comparative advantages to achieve our ultra low-cost solar vision without sacrificing today’s urgent decarbonisation challenges.

Now is the time to invest in the technologies we need for future economic success in a net zero world.

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Silicon to Solar Plan: Australia’s manufacturing opportunities

One nation dominates manufacturing of solar photovoltaic (solar PV) panels and their components – China.

According to the International Energy Agency (IEA), China’s global share of all the stages of solar panels now exceeds 80 per cent.

Graphs showing China's dominance of solar PV — Click on the image above to view full size graphs (Source: IEA)

Why? China has invested heavily in solar PV over the past decade – around $US50 billion over the past decade, or 10 times total European investment over the same period. It has also leveraged access to cheap fossil fuels and labour.

Manufacturing costs in 2021 were 10 per cent lower in China than in India, 20 per cent lower than in the US, and 35 per cent lower than in Europe.

China’s low-cost production advantage has brought the world benefits, such as a massive fall in the price of solar panels.

But the concentration of both manufacturing and resulting global supply chains also carries huge risks. And that particularly affects Australia because solar contributes a growing share of Australia’s electricity mix.

Minister for Climate Change and Energy Chris Bowen said Australia will need to install at least 120 GW of solar generation capacity by 2050, which is a four-fold increase on current capacity.

“To achieve net zero, the world needs more reliable supply chains to meet surging demand for solar panels and Australia has what it takes to be a major supplier,” Minister Bowen said.

What can Australia do to reduce solar PV industry risks?

A new $1.12 million Silicon to Solar study will look at Australia’s options.

Backed by a $541,640 ARENA grant to the Australian PV Institute (APVI), the study will examine opportunities for domestic manufacturing, diversified supply chains, and the policy options needed to achieve them.

Australian solar PV research and development is already world leading. A key solar panel technology, the PERC solar cell, was invented and developed in the University of New South Wales. PERC technology is core to more than 80 per cent of solar PV cells manufactured today.

Australia researchers have held the world record for silicon solar cell efficiency for 30 of the past 40 years.

And in March 2023, an Australian National University research team backed by ARENA funding said it had surpassed a significant 30 per cent solar cell efficiency target. The team’s breakthrough technology offers potentially lower production and operational costs.

Australia also has reserves of many of the raw materials needed to make solar panels.

For instance, solar panels require very high-quality silicon, which starts with high-purity quartz. Currently, a single quartz deposit in North Carolina, US, supplies much of the world’s high-purity quartz. The supply risks of that situation are obvious.

But a recently published CSIRO Australian Silicon Action Plan identifies untapped high-quality quartz (silica) deposits in Western Australia, Queensland, Victoria and the Northern Territory. The report highlights the potential to develop regional silicon production, create jobs and reduce supply chain risks.

A path towards a more secure solar supply

SunDrive next generation solar cells — Testing SunDrive solar cells

The study brings together two strands of solar development: R&D and industry.

The Australian Centre for Advanced Photovoltaics (ACAP) has signed on as a study partner, bringing with it extensive expertise in solar PV research. Other industry partners involved in the study include 5B, AGL, Aspiradac, Energus, Siemens, SunDrive and Tindo Solar.

ARENA CEO Darren Miller said the study will provide a path forward to more secure solar supply chains as the industry scales up dramatically.

“Low-cost solar generation will be the foundation stone of Australia’s net zero economy, so it’s vital that we have reliable supply chains,” Mr Miller said.

“With ARENA’s support, APVI will look at ways to secure our supply of the inputs into solar panels and find opportunities to reap the benefits of manufacturing at home.”

APVI project manager, Dr Muriel Watt, said “Australia has good working relationships with PV manufacturers across the world and is keen to develop diverse and sustainable supply chains as global and Australian demand increases.”

ARENA has also launched a white paper highlighting how ultra low-cost solar can unlock Australia’s potential to become a renewable energy superpower.

The key objectives of the paper are to elevate solar PV in Australia’s national priorities, and to identify and communicate key barriers and innovation priorities for ultra low-cost solar to government, industry and the Australian public.

ARENA has additionally committed $41.5 million to 13 solar PV research projects aimed at technological breakthroughs in ultra-low cost solar.

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Op-ed: When it comes to charging your EV, how fast is fast enough?

By 2030, there will be over 350 million EVs in the world but there is still a major factor that could put the brakes on this transition – the availability of sound charging infrastructure.

In Australia, big distances mean charging stations need not only to be readily accessible but also capable of charging vehicles quickly. So, EV drivers in Australia need to be confident of travelling long distances with timely recharging opportunities.

To meet this challenge, ARENA has over the years awarded funding to several fast charging network projects. Recipients have included Engie, Chargefox, Ampol and Evie.

In April 2023, ARENA, as part of the Government’s $500 million Driving the Nation Fund, announced $70 million in funding aimed at boosting the availability of charging stations across Australia. This pool of funding will initially support innovation in both public charging facilities and the management of charging.

But while the support is there, the question remains: what mix of public chargers will best suit Australia’s needs?

Down the memory lane: Trying to solve an old problem.

1996 Chevrolet EV1 electric vehicle — General Motor’s mass produced its EV1 from 1996 to 1999, making it the first purpose-designed electric vehicle of the modern era (Image courtesy of GM Heritage Archive)

By the end of the 1980s, EVs began to become a practical alternative to petrol and diesel fuelled vehicles. Car makers were already producing small vehicles using heavy lead-acid batteries, but one issue remained: Charging Standards.

In 1991, the US National Electric Transportation Infrastructure Working Council (NETIWC) was formed with members of the automotive Original Equipment Manufacturers (OEMs) and Distributed Network Service Providers (DNSPs). It defined three power charging levels: Level 1 (2 kW), Level 2 (7 kW) and Level 3 (330 kW). Incidentally, back then, it was thought if Level 3 was used, we would need to upgrade every transformer in the world, or “destroy the grid”.

Instead, for convenience, many EV manufacturers recommended users to install 7 kW charging stations at home.

Such was the case of the very first commercially available mass-adopted EV manufactured by General Motors – aptly named EV1. In the absence of clear guidelines, GM got creative and chose a wireless charging system as the way to go. Spoiler alert: it wasn’t very good.

Whilst wireless is great to charge your smart phone in 2023, it wasn’t the best way to charge a vehicle in 1999. Although the 7 kW charger dropped 132 km worth of range on the EV1 in under three hours and it was designed to be safe even when used in the rain, it wasted a lot of electricity doing so.

Please do not miss this YouTube video of the EV1 charging in 2002 before they were all destroyed.

Setting the standards

Electric vehicle charging station — EV chargers now operate to international standards

The Chevy Volt and the Nissan Leaf went cable instead of wireless and the Society of Automotive Engineers (SAE) developed the SAE J1772 charging standard that we still use today.

The International Electrotechnical Commission (IEC) adopted most of SAE’s standard for global implementation: 7 kW AC chargers for home use, and “faster” DC chargers for highway use with most cars in the market today able to take 50 kW.

In the absence of a physical definition and to avoid further confusion, in 2018, Electrify America introduced the following naming convention to settle this discussion:

Hyper-fast (green label) – Indicates power delivery up to 350 kW, providing approximately 20 miles of range per minute of charging (depending on a given EV’s charging capabilities).
Ultra-fast (teal label) – Indicates power delivery up to 150 kW, providing approximately 9 miles of range per minute of charging (depending on a given EV’s charging capabilities).

So, which type of chargers shall we prescribe for Australia’s National Ultrafast Charging Network?

The future of EV charging may be closer to 50 kW than 350 kW

Infographic: How fast can I charge my EV feature image — Click on the image above to view the full-size infographic

For people who can charge at low speed at home or at the workplace, that location should still be the number 1 choice for charging.

Indeed, the much-hated Level 1 charging, at 2 kW may often be the right choice for home and office. For instance, an employer might install five low-power chargers for the cost of one Level 2 charger. That might be the better choice since the average vehicle in Australia travels only 36 km daily.

A smaller number of 7-kW chargers could serve the subset of people who need a little more driving .

People who can’t charge at home or work, or people on road trips, need a different solution. Today that solution is generally the ultra-fast charger. Non-Tesla networks started by installing 50-kW stations, but as the Combined Charging System (CCS) charging system improved, new deployments, have settled around 150 kW.

So, to increase the coverage of the Australian network in the most economical way, the answer may be to increase the deployment of the 150 kW range. These chargers are currently expensive, but not nearly as expensive as the 350 kW ones.

Well… Who cares? Charging faster is always better, right? Isn’t it?

Electric vehicle connected to charger feature image — Depending on your situation, recharging convenience might outweigh speed

In theory yes. Each additional kW of power available adds about 6 km of range per hour of charging, so a 150-kW station, when going at full power, could add up to 900 km of range in an hour to a car.

Except it can’t. That’s the instantaneous rate and is only delivered at the start of the charge session. Once the battery gets over half-full (or even earlier) the charging rate drops. It might be closer to say it can add 100 km in 10 minutes, but only on a deeply discharged (empty) car. That is, it cannot add 200 km in 20 minutes.

The average rate in the Ultrafast Network is 60 kW. This is because only few cars on the road accept more than 100 kW charge rate. Most cars can’t charge at 150 kW, and even if they can, there are several factors capping charge rates, such as temperature.

350-kW charging is only an option in latest EV models (Hyundai Ioniq5, Kia EV6, and Genesis GV60). Porsche Taycan, Audi e-tron GT, GMC Hummer EV and Lucid Air all cap charge rates at 270 kW.

To complicate things even more -under a set of circumstances- a 350-kW EV could charge faster on a 150-kW charger. For instance, according to Hyundai, an Ioniq5 (77.4 kWh battery) takes 18 minutes to charge on a 150-kW station compared to 25 minutes on a 350-kW.

In reality, other factors dictate actual charging rates. It’s still worth reading this story of a guy who tested charging his Ioniq5 on 150 kW and 350 kW chargers to compare real charging rates. I’ll save you the clicking, he charged faster on the 150-kW station. Counter-intuitive, I know!

350 kW-charging belongs to a dated ‘petrol’ mindset

EV’s are introducing a refuelling paradigm shift.

Drivers are used to noticing their car is low on petrol and looking for the nearest station to quickly refuel. But EV’s are best charged whenever the vehicle is parked, rather than whenever it is approaching “empty”.

A very good reason might be that the EV is parked because the driver is sleeping. Or working. Or not using the car that day.

Instead of prioritising rapid, occasional refuelling, greater importance will be placed on regular, convenient and reliable topping up.

That’s not to say ultrafast charging is never useful. There are times where you have nothing else to do and you just want to get moving. There are places, like on a dark desert highway, where your only task is to get out of there as fast as possible.

And finally, consider the cost

However, all things are not equal. A 350 kW charger needs major juice and that means cost. Plus, the cost of delivering megawatts of electricity into remote stations or even existing commercial buildings is massive.

Most decent shopping centres are equipped to draw 50 kW of electrical power but 350kW is a major challenge. High voltage upgrades and wiring don’t come cheap and, inevitably, this cost must be paid back by the customer.

The important message is: stop thinking the way we do with petrol cars.

Consider where people will need energy, and how long will they stay.

Consider the costs of installing chargers. More slower chargers might make more sense in more places, while ultra-fast chargers are best in relatively few circumstances.

Adrian Salinas is ARENA’s Knowledge Sharing Manager overseeing the Electric Vehicle portfolio. He was previously the Electric Vehicles officer with the ACT Government and has worked for GM in the United States and run hydrogen bus trials in California. Adrian uses his global automotive sector experience to help Australia safely adopt new transport technologies and integrate more electric vehicles into the grid.

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Can hydrogen slash alumina refining emissions?

Australia is a global leader in alumina refining.

Not only a leader in terms of production – Australia is the world’s largest exporter of alumina, the mineral feedstock for aluminium production – but also in tackling emissions from the energy–intensive industry.

In November 2022, ARENA, in collaboration with Deloitte and in consultation with alumina refiners Rio Tinto, Alcoa and South 32, published A Roadmap for Decarbonising Australian Alumina Refining.

The report identified four key decarbonisation technologies: mechanical vapour recompression (MVR), electric boilers, electric calcination and hydrogen calcination.

Now, ARENA is helping a world-first trial to demonstrate renewable hydrogen calcination.

ARENA is providing funding of $32.1 million to Rio Tinto and global trading and business investment company Sumitomo Corporation to develop the $111.1 million Yarwun Hydrogen Calcination Pilot Demonstration Program.

The project will build a 2.5 MW on-site electrolyser to supply renewable hydrogen to the existing Yarwun Alumina Refinery in Gladstone, Queensland. It will also retrofit of one of the refinery’s four calciners to operate with a hydrogen burner.

Sumitomo Corporation will own and operate the electrolyser at Yarwun site and supply the hydrogen to Rio Tinto directly. The electrolyser will have a production capacity of more than 250 tonnes of hydrogen annually.

Potential ‘global impact’

Blog feature image: Rio Tinto Yarwun alumina refinery. Credit Thomas Bell — The Yarwun Hydrogen Calcination Pilot Demonstration Program is a world-first

If successful, the project will demonstrate an opportunity to reduce emissions from alumina refining by a whopping 30 per cent. And that is significant because the industry as a whole is responsible for about 3 per cent of Australia’s emissions.

ARENA CEO Darren Miller at the on-site launch of the trial said the Yarwun project could pave the way for adoption at scale across other alumina refineries.

“The six refineries in Australia, with 13 million tonnes or so of emissions, emit more than [the 10 million tonnes] we emit in all of our homes [in Australia],” Mr Miller said.

“You really have to look behind the scenes at refineries like this … to understand the sheer impacts and importance of decarbonising this kind of facility.

“This is the world’s first trial of this technology in a refinery, and if it works here it can work in other places. It can be deployed internationally.

“So not only are we making a difference to this refinery, we could also be making a global impact.”

What is hydrogen calcination and why is it important?

Alumina Roadmap infographic — Click on the image to view an infographic summary of “A Roadmap for Decarbonising Australian Alumina Refining”

Let’s start with the term “calcination”.

Alumina refineries take bauxite ore through two main processes:

the Bayer process extracts alumina hydrates, or alumina chemically attached to water molecules;
calcination drives off the water molecules at temperatures above 1000 degrees C to leave pure alumina.

The high temperatures required for calcination have been achieved by burning fossil fuels, most often natural gas.

So, the hunt is on for alternative, renewable fuels.

One option is to power the calcination furnaces with renewable electricity. Electric calcination is an efficient process, but it can’t easily be retrofitted to existing plant. That means installing expensive new equipment

Step up renewable hydrogen derived from electrolysis of water.

Producing and then burning hydrogen is less energy efficient than electric calcination. But replacing a natural gas burner with a hydrogen equivalent is both technically feasible and emissions free. Burning hydrogen burnt with oxygen means that the only byproduct is water in the form of steam.

If this steam is captured using MVR, it could potentially be recycled into the Bayer process. That would improve energy efficiency, reduce steam production and cut water consumption.

ARENA has also provided funding to Alcoa to investigate electric calcination and trial mechanical vapour recompression.

Real-world application

Minister for Climate Change and Energy Chris Bowen said innovative technology such as the Yarwun hydrogen project is critical for decarbonising heavy industry.

“This ground-breaking project could pave the way for hard-to-abate sectors to reduce their emissions and help make net zero a reality for Australia,” Minister Bowen said.

Rio Tinto Aluminium Pacific Operations Managing Director Armando Torres said: “This pilot plant is an important step in testing whether hydrogen can replace natural gas in Queensland alumina refineries.”

Sumitomo Corporation Energy Innovation Initiative Director, Seiji Kitajima said: “We are excited to be delivering this hydrogen project together with Rio Tinto as our long-term partner with the support of ARENA.”

“Demonstrating real-world applications of hydrogen in industrial settings with motivated partners is essential to reducing carbon emissions,” he said.

If the trial is successful, converting the whole Yarwun site to use green hydrogen could cut emissions by 500,000 tonnes per year. That is the equivalent of taking about 109,000 internal combustion engine cars off the road.

Construction will start in 2024 with operations at the hydrogen plant and calciner expected to begin by 2025.

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Green light for pioneering regional hydrogen project

A renewable hydrogen project, promising production on a scale so far not achieved in Australia, has passed an important milestone.

The 10MW Hydrogen Park Murray Valley development in Wodonga in north-eastern Victoria has now reached financial close.

As a result, ARENA is committing $36.1 million to what, when completed, will be the largest renewable hydrogen facility in the east of Australia.

The funding builds on ARENA’s leading role in renewable hydrogen which has seen more than $255 million committed since 2017.

The May Federal Budget also gave ARENA a key role in designing and supporting the $2 billion Hydrogen Headstart initiative. The program aims to position Australia as a renewable hydrogen early mover and global leader.

How will the renewable hydrogen be used?

ARENA initially awarded funding to Australian Gas Networks (AGIG) for its Wodonga development in May 2021. AGIG was a successful applicant to ARENA’s Renewable Hydrogen Deployment Funding Round.

This is the second project from that round to achieve financial close.

Another recipient, Engie Renewables Australia, achieved financial close in September 2022. Engie’s Yuri Project will use renewable electricity to produce hydrogen for renewable ammonia production. The ammonia will in turn feed to manufacture fertiliser. and supply it to the adjacent Yara Pilbara Fertiliser facility.

AGIG’s facility will initially supply renewable hydrogen for injection into the local natural gas distribution network. Up to 10 per cent hydrogen will be blended with natural gas to reduce local carbon emissions.

Network owner Australian Gas Networks, part of AGIG, estimates there are more than 40,000 gas connections, serving around 85,000 people in Victoria and across the border in NSW.

The 10 per cent hydrogen blend will cut approximately 4000 tonnes of CO₂ each year.

Growing Australia’s hydrogen industry

ARENA CEO Darren Miller said the project is exciting because it will reduce local emissions from day one of operation.

“It’s essential to scaling up Australia’s renewable hydrogen industry that we get these first-generation projects up and running,” he said.

“The lessons we learn here will help inform our hydrogen industry as it grows from its early stages to a pillar of the net zero economy.”

Mr Miller added that the project would have the potential to supply additional markets as they move towards net zero.

“Reliable supply of renewable hydrogen in places like Wodonga is going to be needed as hydrogen plays as growing role in road freight,” he said.

Additional financial backing

The Victorian Government is supporting the project with $12.315 million through the Department of Energy, Environment and Climate Action (DEECA). The Clean Energy Finance Corporation (CEFC) is providing additional financial backing.

Mars Petcare Australia will purchase Renewable Gas Guarantee of Origin certificates , generated by the project. Federal government accreditation program GreenPower will match the the energy use of Mars’ local pet food factory to the renewable hydrogen added to the local gas network.

AGIG CEO Craig de Laine said that AGIG is proud to work with both the Australian and Victorian Governments on this landmark project.

“The strong support received from both the Australian and Victorian Governments demonstrates the importance of renewable hydrogen to decarbonising energy across Australia. We thank all our project partners and key stakeholders, including the Albury-Wodonga community for their contribution to the project to date.”

Construction on the project is due to start in 2023, with the site operational by 2025.

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