Integrating forklift batteries as a storage solution for photovoltaic systems is an innovative step toward sustainable energy solutions. These batteries, which in the past primarily supplied power to forklifts, now offer the possibility of storing excess solar power thanks to their high kWh capacity. Using a forklift battery in combination with a PV system allows you to collect solar power during peak solar radiation times and store it for times when the PV system is producing less or no power.
This allows you to optimize your own consumption of the energy you generate and reduce the need to feed excess power into the public grid. This is particularly interesting for photovoltaic systems that are no longer eligible for subsidies. Equipped with a solid capacity, our batteries, especially 48V forklift batteries , can absorb and release a significant amount of energy, making them an ideal choice for storing solar power. They are therefore a key pillar for anyone looking to supplement their PV systems in an efficient and environmentally friendly way. Please note that there are subsidies available from the German federal government (KfW subsidies) for expanding your solar system.
Forklift battery as battery storage in solar systems – The advantages
Forklift batteries can prove to be valuable resources for solar systems, serving as robust and cost-effective solar storage systems. By using them in a photovoltaic system, the directly generated solar power can be temporarily stored and used when needed. These battery storage systems have the advantage of being designed for the demanding use in industrial trucks and therefore offer high reliability and durability. Integrating forklift batteries as part of the photovoltaic infrastructure helps increase energy independence and maximize the use of solar power by storing energy for times of low sunlight or high electricity demand.
Forklift batteries are usually lead-acid batteries. These have several advantages over lithium batteries.
Reduced fire load, which you'll probably notice most in building fire insurance. As reported in the press, there are repeated cases of lithium-ion batteries catching fire or causing fires, requiring laborious extinguishing. Some even explode, releasing enormous amounts of energy that can even level entire buildings.
Lithium batteries are currently classified as hazardous waste! If a lithium battery needs to be disposed of, the costs can be considerable. Customers report disposal costs of €3,000 to €25,000 per ton. Lead forklift batteries, on the other hand, are even reimbursed. So, you'll still get paid even for your defective battery!
Forklift batteries consist of individual cells, which can be replaced individually if they become defective – even by you! Costly repairs by a qualified specialist company are not necessary. If they become defective, individual cells can be replaced with inexpensive used cells or even bridged to maintain the supply. Lithium batteries cannot be bridged or simply replaced. If there is a defect, the battery management system (BMS) usually switches off the cell blocks and even a reduced supply is no longer possible, resulting in total failure. This can be fatal, especially for critical systems such as cooling or oxygen supply.
Costs. A forklift battery, whether new or used, costs a fraction of a lithium battery.
Technical details: Capacity and compatibility of 24V, 48V or 80V batteries
The technical details of batteries are essential to understand their capacity and compatibility with photovoltaic systems. These batteries, whether made of lead or lithium, have different kWh values that define their storage capacity and influence how much energy they can absorb during charging and release during discharging. A 48-volt lead-acid battery, for example, can provide more stable voltages for consumers during discharging, making it more suitable for use in the home. Lithium-ion batteries allow for opportunity charging and offer better efficiency per kWh, but at a higher cost. The maximum power output is also important here, which can quickly lead to problems, especially with lithium batteries. Consult a trusted electrician and determine your needs before deciding on a battery system.
When feeding power into the home grid, compatibility with inverters and correct connection are crucial. New inverters also enable the use of 80V forklift batteries. High-quality inverters, such as those from Fronius, efficiently convert the direct current from the PV system into 230V alternating current, enabling seamless integration into the 230V grid. Depth of discharge and cycle stability also play a major role; while lead-acid batteries can be limited by gassing and the need for ventilation, modern lithium-ion batteries, particularly LiFePO4 types, offer a deeper depth of discharge without the risk of gassing, but with other disadvantages such as higher costs and a higher fire load in the event of defects and total failure.
KfW funding programs exist and could influence your decision. Storage systems, whether new or used, can be subsidized. Inquire so you can find a sustainable, affordable solution to reduce your electricity purchases from the grid operator and thus lower your electricity costs, especially if the surplus electricity generated by the photovoltaic system is intelligently managed and stored in a new or used battery storage system for periods of low production.
Lithium vs. Lead: Choose the right battery for your PV system
The decision between lithium and lead-acid batteries (accumulators) for your PV system depends on various factors, such as the desired service life, capacity, number of cycles, and behavior under load, type of application, and duration of use, but also, crucially, cost. Lead-acid batteries can be a more cost-effective alternative to lithium batteries and are usually the wiser choice.
Choosing the right battery not only influences the economic viability of your PV system, but also the stability of your power supply. A solar battery enables optimized power utilization and maximizes the feed-in tariff. When making your selection, you should also consider the nationwide electricity price and the potential reduction in electricity consumption. Lead-acid batteries are often the more economical and therefore better solution.
Integration into PV systems: inverters and BMS for optimal performance
Integrating forklift batteries into photovoltaic systems requires compatible inverters (INVs) and/or a battery management system (BMS) to ensure optimal performance. High-quality hybrid inverters are crucial because they not only feed solar power into the grid but can also efficiently charge the batteries.
For PV systems equipped with a Raspberry Pi or JavaScript-based system, a smart BMS combined with a hybrid inverter enables more precise control of charging and energy distribution. This helps reduce electricity consumption and more effectively utilize on-site power production, which can be monitored via the electricity meter. The use of forklift batteries in a PV system is therefore an innovative solution for increasing energy efficiency and ensuring a sustainable power supply.
At HK Handels GmbH you will find the right forklift battery that you can use as a PV power storage device in various capacities and voltages. Especially used, they are an unbeatable, economical and safe alternative to lithium batteries.
Build power storage from car batteries?
Building energy storage from car batteries is an innovative idea, but forklift batteries stand out as a superior alternative, especially in the context of sustainability and efficiency. Forklift batteries are designed for continuous use and high resilience, making them ideal for storing solar power.
Their robust construction enables a longer service life and lower maintenance requirements compared to conventional car batteries. In addition, forklift batteries offer greater cycle stability, resulting in more efficient and reliable energy input and output. The combination of durability, performance, and adaptability to changing load requirements makes forklift batteries a cost-effective and environmentally friendly solution for storing renewable energy.
