Development of Low-Cost 2G HTS Coated Conductors at STI

Transcription

1 Develpment f Lw-Cst 2G HTS Cated Cnductrs at STI Jeng-Uk Huh, Jian Ca, Jseph Chase, Xiafeng Qiu, Ken Pfeiffer EPRI 11 th Cnference n Supercnductivity Tuesday, Octber 29, f 18

2 Leading Supercnducting Innvatin Attacking large pprtunity with Cnductus wire strategic initiative 1987 High Temperature Supercnducting (HTS) Technlgy Develpment Key cmpetitive advantage HTS Prduct Release Only cmpany t successfully cmmercialize HTS prducts fr RF electrnics. Established leadership with best-inclass HTS prducts Technlgy Transfer and Partnerships HTS Manufacturing High Vlume Advanced prprietary HTS depsitin prcess in full scale manufacturing prductin. 6,000 systems deplyed with Verizn Wireless and AT&T Cnductus HTS Wire Prductin, New Manufacturing Facility in Austin, TX Manufacturing f secnd generatin (2G) HTS wire with industry leading perfrmance Wireless Prduct Business Crygenic Cler Business 2012 and Beynd 2 f 18 Tday

3 Delivering Supercnducting Wire Innvatin What fiber ptics is t telecm, supercnducting wire is t pwer N ther technlgy cmes clse Addressing large Smart Grid market pprtunity with a need fr game changing technlgy Our technlgical superirity prvides sustainable prductin advantages Prprietary expertise in supercnducting prductin technlgy Strng IP prtfli Histry f IP develpment with ver 100 patents issued and pending fr varius technlgies State f the art factry 20 years f HTS manufacturing expertise fcused n prviding large vlume f high-perfrmance Cnductus wire Pilt prductin equipment in Advanced Manufacturing Center f Excellence (AMCE) in Austin, TX nw peratinal Strng custmer demand - delivering ur slutin thrugh existing channels Receiving multiple rders frm large, multi-natinal industrial cmpanies fr certificatin testing Cmmitted t supercnducting cable demnstratin prject with majr prducer f supercnducting cables 3 f 18

4 Supercnducting Wire Changes the paradigm fr the future design f electrical devices Cnventinal Cpper Capacity Lw 100X mre Efficiency Pr Extremely high Size, Weight Large, heavy Cmpact, light weight Ecnmics Adequate fr tday Imprved fr future Design Limited Enabling new devices Replacing legacy cpper wire with ultra-high perfrmance supercnducting wire 4 f 18

5 Large Addressable Smart Grid Market Innvative supercnducting devices and industry participants Offers significant size reductin and increased perfrmance ver cnventinal technlgies Mtrs and generatrs utilize 10 s t 100 s f kilmeters f HTS wire per device 10X pwer capacity f cnventinal cable 100 s f kilmeter length HTS wire pieces used in a single cable Enhances the capacity and reliability f stability-cnstrained utility grids Superir prtectin; increases reliability, survivability, and minimizes pwer recvery time Shrt lengths f HTS wire are frmed int 100 s f cils stacked int a cnductr bank Enhances imaging perfrmance fr high field devices utilizing HTS wire Dentes Taking Orders 5 f 18

6 HTS Materials Cst Reductin Over Time 300% 140% 120% 3X Cst Estimate Metal-Organic Depsitin (MOD), Metal- Organic Chemical Vapr Depsitin (MOCVD) and Pulsed Laser Depsitin (PLD) implemented and studied befre being abandned in 2003 Transitin t RCE-CDR imprved yield t 99.5% HTS Materials Cst 100% 80% 60% 40% Over 80% cst reductin achieved with prcess imprvements 20% 0% MOD and MOCVD PLD RCE-CDR Mid 90 s f 18

7 Our Wire Superir depsitin technlgy and a simplified, layered wire architecture prvides sustainable prductin advantages: Significantly lwer cst Ultra high perfrmance Rbust and flexible design Optimized HTS manufacturing prcesses reduce runtime and increase yield and thrughput Validated perfrmance fr use in all majr HTS applicatins underway currently Custmizable fr all pwer requirements Reel f 10mm Cnductus wire Cnductus Wire Architecture 100mm Cnductus wire slit t 10mm 7 f 18

8 Lw-Cst HTS Cated Cnductr Requirements INPUTS STI s prcess allws fr lw cst f raw materials Elemental surce materials Inexpensive substrate material STEP PROCESS Lw number f template buffer layers Simple and repeatable 1 Lw number f prcess steps per layer High yield in each prcess High thrughput and large HTS grwth area EQUIPMENT Lw prductin equipment cap-ex Simplified structure inherently reduces cst and als increases yield 8 f 18

9 STI s Three Step Apprach SDP Slutin depsitin planarizatin Atmspheric wet cating which prvides an amrphus ceramic verlayer Lw-cst slutin prcess Diffusin barrier and planarizatin layer N need t plish metal substrate tape Cmpatible with many allys IBAD + Epi MgO In beam assisted depsitin The thinnest, fastest template frmatin Requires nly 50 nm MgO layers fr crystallinity Fast prcess In-situ prcess in a 2 chamber depsitin system RCE-CDR Reactive cevapratin / cyclic depsitin and reactin STI has develped the RCE-CDR technique fr >15 years in wireless filters and shwn it t be a lw-cst & high-yield prductin technique fr HTS depsitin Enables grwth directly n MgO layer and can be used with ptinal buffer In-situ prcess in a single depsitin system Elemental raw materials lw csts Large-area depsitin 9 f 18

10 Slutin Depsitin Planarizatin 10X 1cm with slitting SDP Prductin System Operatinal High speed rll-t-rll prcess Up t 1000m length 10cm width capacity Manufacturing capacity >1000km/yr Slutin Depsitin Chemistry Optimizatin Base-line Yttria based SDP prcess has been transferred frm R&D stage t prductin scale Imprvements made in film quality by chemistry imprvements Eliminate cracking Minimize edge bead 10 f 18

11 In Beam Assisted Depsitin (200) Intensity (a.u.) IBAD + EPI MgO Prductin System - Meeting specificatins Omega (degree) Capable f handling up t 1000m lengths Capacity 1000km/yr RHEED Pattern Cnsistently getting Jc > 2.5 MA/cm 2 - Out f plane rientatin: 2.1 Perfrmed DOE with hundreds f cnditins t ptimize IBAD & EPI Jc 3.8 MA/cm 2 reached as a result f DOE 11 f 18

12 Reactive Cevapratin 100M System RCE 100M System installed Q and peratinal meeting custmer specificatin Batch system capable f depsiting ReBCO, ptinal buffer layer and silver Cyclic depsitin and reactin n rtating drum Uses thermal evapratin surces fr Rare earth, Barium, Cpper, buffer material and silver Ability t ptimize prcess fr different supercnducting applicatins: High Ic, High in-field 12 f 18

13 RCE 100M Results Successfully transferred RCE prcess frm wafer machine t 100M system Significant prgress made in last 5 mnths Thermal stability f heaters Reliability f evapratin surces Differential pumping between the heater and surce chamber imprved Imprved the depsitin rate 4X withut degrading HTS perfrmance higher thrughput Direct current measurement gives Ic > 450A/cm n meter length tapes Cmpsitinal unifrmity is within 0.5% frm alng entire 100m length Currently imprving scale up reliability, run-t-run cmpsitin cntrl and differential pressure cntrl 13 f 18

14 RCE 100M System Results n Tapestar TM I c (A/cm) 30m Sample : Avg Ic 350A Successfully transferred RCE prcess frm wafer machine t 100m system N significant drputs fr 30m lng tape Avg Ic 350A Mving quickly t meet 500A/cm perfrmance and lengths f 100m lengths / 4mm 3m sample: Avg I c 450Amps 14 f 18

15 STI 2014 Plans SDP and IBAD are prductin ready fr 1km lengths Fcused n ramping vlume as prductin RCE 1000M cmes n line RCE 1000M System is being built Capital t build new system was secured in August 2013 $2.5M in CAPEX System Operatinal in 1H 2014 RCE1000 System scale up frm existing pilt 100M system with same prcess: Lw risk Cnductus prductin specificatins: 1000m length (n splicing) f 500A-cm tape Prjected annual capacity f 750 km f 2G HTS wire 15 f 18

16 RCE 1000M System 16 f 18

17 Summary STI s Cated Cnductr is inexpensive, high-yield, and scalable Our apprach and HTS manufacturing experience can meet the demand fr cated cnductrs and beat the industry cst targets Achieved results n a simplified template prcess requiring SDP and IBAD layers Successfully shipping Cnductus wire t custmers utilizing 100m RCE system 250A t 450A/cm Piece lengths cntinue t increase frm 10 s f meters t 100m Tape shws great cmpsitinal unifrmity Cnductus wire prductin in 2014 Prject funded t capacity f 750,000m/yr SDP and IBAD prductin systems Cmplete 1000M RCE System is being built 1H/ f 18

18 Thank Yu 18 f 18