A modular range extended energy storage system combines battery storage, power conversion, and an auxiliary generator or range extender. It is designed for sites where grid power is absent or limited and where load changes over time. Instead of a single fixed unit, the system uses modules that can be added or removed. This supports construction, telecom, mining, rental, and event power. INJET HanCang develops such systems for temporary and off grid applications.
Load demand rarely stays constant. A site may start with 50 kW for offices and tools, then grow to 300 kW when cranes, pumps, and crushers arrive. A modular design allows capacity to follow demand. Battery modules may be 50 kWh, 100 kWh, or 215 kWh. Power conversion modules may be 50 kW, 100 kW, or 250 kW. Parallel operation can scale to several megawatt hours. This reduces oversizing and improves utilization across projects.
A range extender is not the main power source. It is an auxiliary generator that charges the battery or supports the load when state of charge falls below a set point. The battery supplies peaks and transient loads. The range extender runs at a stable output, often between 60% and 80% of its rated capacity. This is more efficient than a large generator following variable loads. Common range extenders use diesel, natural gas, propane, or biodiesel. Output may range from 20 kW to 300 kW depending on the battery size and site load.
A typical system includes battery modules, a battery management system, bidirectional inverters, a range extender, an energy management controller, and distribution panels. The controller decides when to discharge, charge, or start the range extender. It also manages parallel units and load priorities. Communication uses CAN, Modbus, or Ethernet. Remote monitoring can show state of charge, power flow, fuel level, and fault history. The architecture supports grid connection where available and island mode where no grid exists.
Sizing starts with a load profile. Engineers record average load, peak load, daily energy, and critical load duration. For a site with a 200 kW peak and 800 kWh daily energy, a 500 kWh to 800 kWh battery may be suitable if the range extender supplies average load. Inverter capacity must handle motor starting and welding surges. A 250 kW inverter may support a 200 kW continuous load with a short overload rating. Lithium iron phosphate batteries are common because they offer 4000 to 6000 cycles at 80% depth of discharge. Round trip efficiency is often 88% to 94% depending on conversion and thermal management.
The range extender should be sized to cover average load plus battery charging. If average load is 80 kW and charging adds 40 kW, a 120 kW to 150 kW range extender can keep the battery within its target state of charge. The controller can start the range extender at 30% state of charge and stop it at 80%. This reduces engine cycling. In many hybrid projects, generator running hours fall by 30% to 50% compared with a diesel only system. Fuel use can fall by 20% to 40% depending on load profile and solar input.
Battery modules and power electronics generate heat. Air cooling is common for smaller modules, while liquid cooling is used for higher power density. Operating temperature range may be -20°C to 50°C with appropriate HVAC or liquid cooling. Enclosures may be rated IP54, IP55, or IP66 for outdoor use. Containerized systems often use 10 ft, 20 ft, or 40 ft footprints. Noise levels for range extenders may be 65 dB to 75 dB at 7 meters, depending on enclosure and load.
The energy management system is the core of a modular range extended system. It can prioritize critical loads such as security, dewatering, and communications. It can shift noncritical loads to periods when the battery has charge. It can also manage solar inputs if available. Algorithms can use time of day, fuel price, and state of charge to decide when to run the range extender. Data logging supports reporting on fuel use, energy throughput, and equivalent operating hours.
Construction sites use these systems for offices, cranes, welding, concrete pumps, and lighting. Telecom sites use them for backup and off grid power. Mining camps use them for accommodation, pumps, and workshops. Rental companies use modular units because they can be moved between projects. Events and temporary facilities use them for quieter operation and reduced emissions. A modular system can be transported by truck, skid, or container.
Installation includes site preparation, cable routing, earthing, and protection coordination. The battery system should be placed on a level surface or pad. Clearance is needed for ventilation and service access. Commissioning checks voltage, frequency, phase rotation, insulation resistance, and protection settings. Load bank testing can confirm output at 50%, 75%, and 100% load. The energy management system is configured with site load priorities, state of charge limits, and range extender start stop points.
Maintenance includes visual inspection, cable torque checks, cooling system service, and firmware updates. The range extender requires oil, filter, and coolant service based on running hours. Battery state of health should be monitored over time. A well managed system can maintain 80% usable capacity after 4000 to 6000 cycles. Remote diagnostics can reduce site visits. Training for site electricians supports safe operation and correct switching.
The financial case depends on fuel cost, load profile, and project duration. A hybrid system may cost more upfront than a diesel generator, but it can reduce fuel and maintenance costs. If a site uses 100,000 liters of diesel per year, a 30% reduction saves 30,000 liters. At 1.2 USD per liter, that is 36,000 USD per year. Additional savings come from longer generator service intervals and lower noise compliance costs. Modular rental or lease models can improve cash flow.
INJET HanCang provides modular range extended energy storage systems for construction and off grid projects. The systems combine battery modules, bidirectional power conversion, range extender control, and remote monitoring. Configurations can be scaled from small mobile units to containerized systems. The design focuses on stable power, fuel reduction, and flexible deployment. Project teams can add capacity as load grows and redeploy equipment when the site changes.
A modular range extended energy storage system offers a flexible way to power sites without a fixed grid. It uses batteries for peaks and low load periods, and a range extender for sustained energy. With correct sizing and controls, it can reduce fuel use, engine hours, and noise. INJET HanCang supports this approach with scalable energy storage and range extension solutions.