Technical Report: Impact of Kurb Kars Integration on Battery Energy Storage System (BESS) Requirements

This report analyzes how the integration of the Kurb Kars system, based on its public-facing focus on Digital Infrastructure, Electric Fleets, and Logistics[1][2], could reduce the Battery Energy Storage System (BESS) capacity required for the 210 tpd Plasma Gasification Plant.

Part 1: Operational Context and BESS Baseline

The plasma gasification plant has a continuous, non-interruptible operational load of 1.26 MW (including the critical 1.01 MW plasma torch system).

• Baseline BESS Requirement (Without STE): The initial BESS was sized at 45.4 MWh45.4 MWh to provide ∼36∼36 hours of autonomy, ensuring the continuous 1.26 MW1.26 MW load could be met when solar generation was zero.
• Revised BESS Requirement (With STE): As established in the previous analysis, integrating Syngas-to-Electricity (STE) generation shifts the plant to a net exporter, reducing the BESS need by >95%>95% to a small capacity (∼1−2 MWh∼1−2 MWh) for start-up and power quality.

This analysis focuses on the logistical and administrative loads associated with the plant and its feedstock supply, which is the most likely area for Kurb Kars’ impact.

Part 2: Role of Kurb Kars in Energy Optimization

Kurb Kars operates as a digital system focused on managing logistics and electric fleets[2]. When integrated with the plasma gasification plant’s microgrid, its primary function would be to apply intelligent load shifting and demand-side management (DSM) to the plant’s auxiliary (non-critical) loads.

The integration would affect two major electrical categories:

Electrical Category	Description	Kurb Kars’ Role in Load Management
I. Waste Collection/Logistics Fleet	The electric fleet (e.g., waste collection trucks, internal forklifts) that supplies the 210 tpd of feedstock.	Primary Impact. Kurb Kars manages the timing and rate of fleet battery charging to align with periods of Solar PV overproduction (mid-day) or Syngas-to-Electricity (STE) surplus (off-peak, low demand).
II. Balance of Plant (BOP) Auxiliary Load	Non-critical administrative, maintenance, and facility loads (e.g., lighting, HVAC, non-essential pumps).	Secondary Impact. The system schedules non-essential high-power tasks (e.g., air compressor charging, shredder maintenance) to avoid peak microgrid stress times.

Part 3: Mechanism for BESS Capacity Reduction

The integration of Kurb Kars reduces the BESS capacity need by minimizing the power demand during periods of low generation.

1. Optimization of Electric Fleet Charging (The “Base Load” Challenge)

In an unoptimized microgrid, an electric fleet returning to the plant might plug in at the end of a shift (e.g., 6 PM), requiring a large block of power during the most critical time: after the sun has set, when the BESS is discharging and the STE system may be operating near capacity.

• Unoptimized Scenario: Charging 1010 trucks at 100 kW100 kW each adds a 1 MW1 MW non-critical load exactly when BESS discharge is occurring, spiking the energy demand.
• Kurb Kars Optimized Scenario (Load Shifting): The Kurb Kars system communicates with the plant’s solar/BESS controller to:
  • Prioritize Mid-day Charging: Schedule fleet vehicles for opportunity charging during peak solar hours, effectively using “free” solar power that would otherwise be curtailed or stored unnecessarily.
  • Implement Variable Rate Charging: Charge batteries at a lower rate throughout the night, using excess STE power, rather than pulling a sharp, high-power load for a short period.

2. Reduction in BESS Power Output (kW) Sizing

By managing the fleet load effectively, Kurb Kars prevents instantaneous power spikes, which reduces the required Power Output (kW) capacity of the BESS (the rate at which it must be able to discharge).

If the BESS must handle a total of 

1.26 MW1.26 MW

 (Plant Load) 

+1.0 MW+1.0 MW

 (Fleet Load Spike), the BESS power size must be 

2.26 MW2.26 MW

. If Kurb Kars limits the fleet charging spike to 

0.2 MW0.2 MW

, the BESS only needs to deliver 

1.26 MW+0.2 MW=1.46 MW1.26 MW+0.2 MW=1.46 MW

.

Summary of Storage Reduction Impact

While Kurb Kars does not eliminate the fundamental energy storage required for the gasification process (which is largely mitigated by the STE system), its integration provides significant CapEx savings on BESS hardware by reducing the size required for non-critical, transient loads.

BESS Metric	Without Kurb Kars Optimization	With Kurb Kars Optimization	Reduction/Benefit
BESS Energy Capacity (MWh)	No change. Determined by autonomy/start-up need.	No change. Determined by autonomy/start-up need.	Focuses Savings on Power Output.
BESS Power Output (MW)	∼2.3 MW∼2.3 MW (To handle plant + simultaneous fleet charging spike)	∼1.5 MW∼1.5 MW (To handle plant + managed fleet charging)	Reduces Power Rating by ∼35%∼35% (Saving on inverter and battery cell instantaneous output costs).
Microgrid Stability	High volatility from charging spikes.	Low volatility from smoothed, scheduled charging.	Increased Microgrid Reliability.

Conclusion:

The Kurb Kars integration serves as a Demand-Side Management (DSM) Layer that intelligently controls the electric fleet and auxiliary loads. This prevents large, simultaneous electrical spikes from the plant’s supporting operations, allowing for a smaller, less expensive BESS Power Output (MW) rating. This reduction in peak demand power translates directly into a significant CapEx reduction on the BESS component of the overall microgrid.

Sourceshelp

1. kurbkars.com
2. kurbkars.com