Drivetrains Direct Drive Generators High Temperature Superconductor Based Machines Daniel McGahn Senior Vice President
AGENDA Wind turbine power conversion Drivetrain evolution Market Driver: Cost of Electricity Superconductor Generators 2
Wind Turbines: Wind Energy Converters Classical Turbine Hub Pitch System, to optimally capture the wind energy Gearbox Varying speed, high speed shaft Generator Varying speed, low speed shaft Blades Drivetrain Tower From Variable Wind Power to Mechanical Varying Speed to Fixed Frequency Electrical Power to the Grid 3
Drive Train Comparison Doubly Fed Induction (Geared) Full Conversion PM (Geared or no Gear) Full Conversion HTS (Direct Drive) History: ~1990 ~2000 ~2010 Usage: 1.5 to 3MW 2 to 4MW 5 to +10MW Benefits: Drawback: Low Cost Mature Technology Poor Power Quality, Gear Failures Good Power Quality, possibility of no gear Large/Heavy difficult to transport Great power quality, efficient at all loads, small, light, no gear In Development Cost Energy*: 1.0.9.8 *relative; onshore about 5 /kwh, offshore about 10 /kwh HTS Enables OffShore and Scaling Enables Lowest Cost of Energy 4
Offshore: Lowered Cost of Energy Reduction through Technology: Large HTS Direct Drive Global market begins HTS Based Direct Drive Turbines Needed to Reach Low Cost of Energy 5
The Growth in Turbine Size is Predictable 160 8MW +10MW 140 5MW 120 2.5MW 100 1.5MW 80 50 40 20 50kW 300kW 500kW 650kW >5M Ft Lbs 1980 1985 1990 1995 2000 2005 2010 2015 Drive Train Induction DFIG DFIG DFIG Full Conv. PM FC HTS Tower Height (m) 60 70 75 80 100 120 140 Torque Produced (ft lb) 19k 124K 218K 754K 353K 2932K 5118K Top Weight (Metric Tons) 50 100 200 400 450 HTS Enables Large Turbines, Nothing 6 else can Convert the Torque to Power
Performance and Profitability Solution: Direct Drive Superconductor Wind Turbines HTS Direct Drive Generator Superconductor wind generators are a key enabler of 10 MW-class wind turbines 7
10 MW Class, Direct Drive HTS Wind Turbine Size Comparison Conventional Geared with DFIG (Repower) Dr=129m Direct Drive, Sync, CU (Enercon) Dr=126m Direct Drive, Sync, HTS (AMSC) 140t Generator P = 5 MW P = 4.5/6MW Gearbox 13m 13m 13m 480t Shaft Hub 5m 12m 6m Blade Nacelle Tower 100m >55m 138m P = 8/10MW 135m Mass of Nacelle + Hub + Blades Extrapolated for 8 MW m Top ~410t m Top ~750t m Top ~500t m Top ~800t m Top ~480t Power density of HTS generators allows for 8/10MW in a 5MW top head weight 8 8
AMSC s HTS Machine Development History Feasibility Prototype Systems Pre-Production 10000000 Wind 1000000 100000 10000 Maritime 5MW 230 rpm 8MVAR 1800 rpm 40MW 10MW Class 11 rpm 35.3MW 120 rpm Motor Torque, ft-lbs 1000 100 10 1 0.1 2 hp 5 hp 100 hp 1000 hp 4MW 1800 rpm Today EPRI DOE AMSC/TVA 0.01 U.S. Navy AMSC 0.001 DC Motors AC Synchronous Motors and Generators 1990 1995 2000 2005 2010 2015 Over 18 years of HTS machine development has validated HTS benefits New opportunity emerging with large scale 9 wind generation
Partners for The Development of the HTS Wind Generator PARTNERS 10
Superconductor Facts: Wind Turbine Generators Zero DC electrical resistance Metallic superconductors were discovered in 1911 Require cooling to 4K; Hospital MRIs are the best example Ceramic High temperature Superconductors (HTS) were discovered by IBM in 1986 Much higher temperature Less cooling required, enables ultra low speed (10rpm), power dense, synchronous generators Over 100 times more power than copper wire of the same dimensions Power density allows efficient, maintenance free, direct drive generators Revolutionizing the wind turbine generator industry 11
Superconductor Synchronous Machines: HTS Compared to Copper Less than half the size Less than a third the weight High Efficiency Controllable field Low noise HTS enables slow speed machines with very high field synchronous rotor without iron 12
5MW, 230RPM HTS POD Motor, Powered by AMSC 5 MW Motor Testing at Center for Advanced Power Systems (CAPS) 2.5M Long, 1.9M High 23T The Florida State University and the FAMU-FSU College of Engineering in cooperation with the National High Magnetic Field Laboratory have established the Center for Advanced Power Systems (CAPS). Also in association with CAPS is the Electric Ship Research and Development Consortium. 13
36.5MW, 120rpm, Superconductor Motor This synchronous motor is equivalent to a 3.6MW, 12rpm wind turbine generator More than $150 million invested in slow-speed HTS machines at AMSC 14
AMSC Windtec Approach to the Wind Energy Market Design and license wind turbines Develop customized wind turbines Sell turbine electrical systems Localization and supply chain support Develop superconductor wind generators Fully engaged in all aspects of the wind value chain 15
AMSC Windtec Customer Timelines CY (Germany) (China) 2006 2007 2008 2009 2010 2011 600 kw 1.5 MW 1.5 MW 3 MW 5 MW (Czech Republic) 2 MWsg (Korea) 3 MW (China) (China) (Canada) (India) (Taiwan) (Turkey) 1.65 MW 2.5 MW 1.5 MW/1.65 MW 2 MWsg 1.65 MW 1.65 MW 2 MW (China) (Korea) (China) 2 MW 1.65 MW 2 MW 2 MW Customer prototype Volume production 16 16
10MW Class Direct Drive Superconductor Wind Turbine Benefits In a multi-turbine windfarm the lowest Cost of Energy of any solution - High revenue and profit Lowest installed cost: 10MW vs Multiple 5MWs or 3.6MWs or 2MWs Lowest operating cost: Highest efficiency of any turbine Availability exceeding 98% Maintenance interval >2 years 10MW Direct Drive Superconductor Wind Turbines promise highly profitable wind energy generation 17
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