Application Cases of Supercapacitor Modules & Systems
Supercapacitors, leveraging their core advantages of millisecond-level response speed, million-cycle service life, and wide temperature adaptability ranging from -40℃ to 85℃, have achieved large-scale deployment in six key application scenarios: energy storage, frequency regulation, backup power supply, energy recovery, voltage sag mitigation, and high-power startup.

Compared with traditional solutions such as lithium batteries, lead-acid batteries, and resistor-based energy dissipation, supercapacitors demonstrate distinct superiorities: their response speed can reach the millisecond level (≤0.4ms), far faster than the second-to-minute level of traditional alternatives; the cycle life is ≥500,000 times with a service life of 10–15 years, significantly outperforming lithium batteries (≤10,000 cycles) and lead-acid batteries (3–5 years of service life); they cover a wider operating temperature range without the need for additional thermal management equipment, while traditional solutions can only operate stably within the range of -20℃ to 60℃, are prone to failure in low-temperature environments, and require dedicated heating devices.
Meanwhile, this solution features low maintenance costs and supports hot-swapping, reducing annual maintenance expenses by 60%–80%. It eliminates the pain points of traditional solutions, such as the need for regular replacement and high risk of electrolyte leakage. In terms of safety, the supercapacitor solution is zero-pollution and free from combustion or explosion risks, whereas traditional solutions face potential hazards like lithium battery thermal runaway. Its low-temperature startup performance is also outstanding: the startup success rate is ≥99% at -35℃, far exceeding the ≤30% rate of lead-acid batteries and ≤50% rate of lithium batteries. Additionally, the return on investment (ROI) period is only 1.5–3 years, much shorter than the 5+ year ROI period of traditional alternatives.
I. Energy Storage Scenario: The "Stabilizer" for Renewable Energy Integration and Long-duration Power Supply

Core Requirement

Address the power fluctuation of wind and photovoltaic grid connection, replace traditional lead-acid batteries to achieve long-term reliable power supply, and reduce operation and maintenance costs.

Benchmark Case

A 50MW/100MWh wind-solar-storage hybrid project in a certain region

Application Background

This project is equipped with a 200MW photovoltaic power station and a 100MW wind farm, facing the pain points of large output fluctuation and high wind curtailment and photovoltaic curtailment rates. An energy storage system is required to smooth power fluctuation (within ±10%) and ensure grid stability.

Core Solution

Adopt a hybrid energy storage system combining dry-process supercapacitors and lithium batteries. Supercapacitors are responsible for instantaneous power regulation (0–1 second response), while lithium batteries undertake long-term energy storage. A domestically produced EMS (Energy Management System) is configured to realize coordinated control.

Key Data

Power fluctuation smoothing accuracy ≥ 95%, wind curtailment and photovoltaic curtailment rates reduced from 18% to 5%;Supercapacitor cycle life ≥ 500,000 times, the overall operation and maintenance cycle of the system extended to 8 years (only 3 years for traditional lead-acid batteries);Energy storage efficiency maintained at ≥ 88% under extreme low temperature (-25℃), without additional heating devices.
Value Highlights
Annually increase clean energy consumption by over 120 million kWh, reduce carbon emissions by 96,000 tons, and cut operation and maintenance costs by 60%.
II. Frequency Regulation Scenario: The "Ultra-Fast Responder" for Grid Frequency Stability

Core Requirement

Address the issues of slow response speed and low precision of traditional thermal power unit frequency regulation, improve the grid frequency qualification rate, and meet the demand for high-proportion grid connection of new energy sources.

Benchmark Case

A 16MW × 10-minute full supercapacitor energy storage frequency regulation system at a certain power plant

Application Background

As the world’s largest-capacity full supercapacitor frequency regulation project, it needs to be coupled with a 550MW thermal power unit to respond to grid AGC (Automatic Generation Control) commands, and solve the pain points of traditional frequency regulation, such as response time ≥ 1 second and insufficient regulation precision.

Core Solution

Adopt a domestically produced control system and dry-process supercapacitor modules, innovate the topology structure of string-type energy storage converters, and realize modular expansion and rapid deployment.

Key Data

Response speed increased by 60%, compressed from 1 second of traditional thermal power units to 0.4 second, achieving millisecond-level response;Frequency regulation performance index Kp value ≥ 0.8 (industry average 0.5), and grid frequency qualification rate increased from 98.2% to 99.8%;Stable operation in extreme cold environment of -30℃, with construction completed in 4 months (comparable lithium battery projects require 10 months);Capacity retention rate ≥ 90% after 100,000 charge-discharge cycles, with service life exceeding 15 years.
Value Highlights
Annual frequency regulation revenue increased by over 30 million yuan, coal consumption of thermal power units reduced by 5g/kWh, and annual carbon emission reduction exceeded 20,000 tons.
III. Backup Power Supply Scenario: The "Uninterrupted Guardian" for Critical Equipment
Core Requirement
Replace UPS batteries to provide instantaneous power supply guarantee for data centers, medical equipment, and communication base stations, and solve the problems of low-temperature failure and frequent maintenance of traditional batteries.
Benchmark Case
Backup Power Supply System for a Certain Data Center
Application Background
Servers and storage devices in data centers have zero tolerance for power supply interruptions. Traditional lead-acid UPS batteries have their service life shortened to 2 years in high-temperature (40℃+) environments, and also face the risk of electrolyte leakage.
Core Solution
Adopt dry-process supercapacitor backup power modules, connect them in parallel with UPS host machines, and configure a voltage balancing management system to ensure 0ms seamless power supply switching after power failure.
Key Data
Power supply switching time ≤ 1ms, meeting the "zero-interruption" demand of servers;
Operating temperature range from -40℃ to 85℃, with a service life of up to 10 years even in the 45℃ environment of data center computer rooms;
Energy storage density of 12Wh/kg, single-module capacity of 25kWh, supporting hot-swappable replacement, and reducing maintenance time to 15 minutes per time.
Value Highlights
Annual maintenance costs reduced by 80%, electrolyte leakage safety hazards completely eliminated, and equipment failure rate decreased from 0.3% to 0.01%.
IV. Energy Recovery Scenarios: An "Energy-Saving Powerhouse" for Industrial and Transportation Sectors
Core Requirement
Recover regenerative energy generated during braking, start-stop operations and equipment running processes, reduce energy consumption and operational costs, and adapt to high-frequency cyclic working conditions. Case 1: Braking Energy Recovery System for Metro Line 11 in [XX City]
Core Solution
Deploy dry-process supercapacitor energy storage modules at metro stations to recover regenerative electric energy produced during train braking for subsequent train startup.
Key Data
Braking energy recovery efficiency reaches 85% (vs. only 40% for lithium batteries); annual power saving of 1.5 million kWh per line; 40% reduction in equipment wear and tear; 15dB decrease in noise level.
Value Proposition
Annual operational cost savings exceed 2 million yuan, with carbon emission reduction of 1,200 tons.
Case 2: Energy Recovery System for Container Cranes at [XX City]
PortCore Solution
Adopt an intelligent supercapacitor energy recovery system to recover gravitational potential energy released during crane lowering, which is then stored for lifting operations.
Key Data
Energy-saving efficiency exceeds 85%; 30% reduction in engine fuel consumption; 20% decrease in exhaust gas emissions; 5% shortening of crane operation cycle time.
Value Highlight
Annual fuel cost savings of over 800,000 yuan per crane, with an investment payback period of 1.5 years.
V. Voltage Sag Mitigation Scenarios: A "Voltage Stabilization Barrier" for Precision Manufacturing
Core Requirement
Resolve production line shutdowns and product scrap caused by grid voltage sags ("voltage flicker"), with particular suitability for precision manufacturing sectors such as semiconductors and automotive electronics. Benchmark Case
Voltage Sag Mitigation System for a 12-inch Wafer Fab
Application Background
During wafer fabrication, a grid voltage sag lasting ≥ 0.5 seconds will trigger shutdowns of lithography machines and etching machines, with a single fault incurring losses of up to several million yuan. Traditional voltage regulators fail to meet the required response speed.
Core Solution
Deploy supercapacitor instantaneous power support modules in the power supply circuits of critical equipment, equipped with voltage monitoring and fast-switching modules to achieve voltage compensation within 0.1ms upon the occurrence of "voltage flicker".
Key Data Can withstand grid fluctuations with voltage sag amplitude ≤ 30% and duration ≤ 3 seconds Zero-fault operation for over 3 years, avoiding downtime losses exceeding 200 million yuan Response time of 0.1ms, far outperforming the 5ms of traditional voltage regulators Value Highlights
Ensure a production line continuous operation rate ≥ 99.99%, eliminate the need for additional standby generators, and save space and energy consumption costs.
VI. High-Power Startup Scenarios: An "Instantaneous Power Source" for Heavy-Duty Equipment
Core Requirement
Resolve issues of difficult cold-start and battery degradation caused by high starting current in equipment such as diesel generators, heavy machinery and ships; improve startup success rate and extend equipment service life. Case 1: Startup System for a 300-ton Crawler Crane
Solution
Adopt a 48V supercapacitor startup module to replace traditional lead-acid starter batteries, meeting the instantaneous high-current demand of over 1000A during crane startup.
Key Data 100% cold-start success rate at -35℃ (vs. ≤30% for traditional lead-acid batteries) Peak starting current of 1200A, startup time ≤ 2 seconds, 10 consecutive startups with zero performance degradation 8-year service life, 4 times that of traditional starter batteries
Case 2: Main Engine Startup System for a Maritime Container Vessel
Solution
Equip dry-process supercapacitor modules to match the ship’s diesel main engine, addressing starter battery failure under low-temperature and high-humidity marine environments.
Key Data
99.9% startup success rate, maintenance cycle extended to 5 years, annual savings of over 150,000 yuan in spare parts replacement costs.
Value Highlight
Avoid delay losses caused by startup failures at sea and enhance ship navigation safety.
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