At Powerstar, we are proud of our ability to solve even the most complex of energy management and infrastructure challenges. The aim has always been to deliver functional, cost-effective solutions for our clients, however unique or challenging the issues they have encountered may be. With an innovative approach that treats each project as a unique challenge and delivers a bespoke solution from the ground up, we ensure that any solution we delivers works as expected across a broad range of different internal and external factors, contributing positively to a client’s energy cost management, carbon reduction and power resilience efforts.
Here, we outline some of the varying projects for which Powerstar found a solution to a major energy infrastructure challenge.
Racing Engine Manufacturer
The growing demand for high-performance electric racing vehicles prompted a UK-based racing engine manufacturer to invest in rigorous research and development to create new electric drivetrains. As motor racing shifts towards electric vehicles, this project became crucial for the company’s future.
However, the significant demand on the site’s grid connection led to the Distribution Network Operator (DNO) blocking the project. They were concerned it would exceed network fault current parameters, potentially jeopardizing the power resilience for other local energy users.
To overcome this challenge, Powerstar devised a solution enabling the R&D cell to operate independently of the grid. Using a digital twin to model the site and develop the solution, Powerstar installed two 500kW battery energy storage systems. This setup allowed one battery to power the R&D cell while the other charged from the grid, with the two batteries alternating roles
Parkinson Spencer Refractories
Located in West Yorkshire and shipping to 78 markets worldwide, Parkinson Spencer had been experiencing increasingly frequent blackouts due to disruptions on their grid supply. This had significant financial implications for the business. Each outage disrupted the firing cycles of the site’s seven kilns, leading to lengthy downtime and wasted raw materials. After experiencing six blackouts over a six-month period, Parkinson Spencer sought a solution from Powerstar, as each disruption resulted in losses ranging from £20,000 to £100,000.
Parkinson Spencer had already invested in on-site generation and other clean energy technologies, making the site ideally suited for Powerstar’s battery energy storage system (BESS). With the BESS able to keep the site operating for up to two hours during power disruption, the blackouts were eliminated. In addition, the battery delivered a 5% reduction in energy costs, as well as generating additional revenue through engaging with grid balancing services.
Rotherham General Hospital
With the NHS facing strict net zero deadlines and ongoing budgetary pressures, decarbonising without increasing costs is a major challenge. Rotherham General Hospital, as part of a broader energy performance contract, identified its existing emergency power provision—relying on traditional lead-acid UPS—as a significant source of unnecessary carbon emissions and inflated energy costs. The constant cycle of partial discharge and recharge in traditional UPS systems means that even when not actively providing emergency power, they contribute to energy costs and carbon emissions without any benefit.
To address this, Powerstar implemented a lithium-ion battery energy storage system. This innovation reduced energy losses from approximately 10% of total capacity to less than 1%, saving money and reducing Scope 2 emissions. Additionally, when not needed for emergency power, intelligent control software allows the BESS to enhance overall energy management. This includes generating revenue from grid services and storing energy generated on-site by rooftop solar panels.
Defence Sector
Ministry of Defence sites have substantial power resilience measures in place to prevent disruption, allowing them to continue to operate even if their grid connection is lost. For one site, they invested in Combined Heat and Power (CHP) to allow the site to operate independently.
However, the lengthy start-up period for CHP generation meant that the site risked losing power before the CHP cycle was able to fully kick in, resulting in blackouts. Powerstar devised a solution where a BESS was used to buffer the transition from mains electricity to CHP supply, giving the site time to shift safely into island mode and operate independently. In addition, the battery provided site-wide emergency power, protecting the site from brief power disruption events without the need to resort to the substantial running costs of the CHP system.
