The possibility of HTS wind power generator Bus 190 for … 120 Jeju T/P Bus 130 Dongjeju Bus 140...
Transcript of The possibility of HTS wind power generator Bus 190 for … 120 Jeju T/P Bus 130 Dongjeju Bus 140...
1ALCA, 8th Mar. 2016, Minwon Park, Changwon, Korea
from HaenamHVDC #1 150MW
from JindoHVDC #2 250MW
Hanlim wind farm60MW
Bus 120Jeju T/P
Bus 130Dongjeju
Bus 140Sinjeju
Bus 150Hanlim
Bus 160Anduck
Bus 190HallaBus 180
Sinseogwi
Bus 200Sungsan
Bus 210Sanji
Bus 996Jhocheon
Bus 998Pyoseon
* Wind farms Hanlim CC : 42.7MW
Hanlim SS: 40Hanlim T/L 40MWSungsan : 103.2MWChocheon : 32.5Halla 15MW
Hanlim C/C : 42.7MWHanlim S/S 40MWHanlim T/L 40MW
Jhocheon : 32.5MW
Sungsan 103.2MW
Halla 15MW
The possibility of HTS wind power generator for the future of eco-friendly society
Minwon Park
Changwon National University
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1960’s 2010’s
Korean Power Network
Power System in 2005Power System in 1965
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How to prepare for the future.
100GW to 150GW society
• More power plants; nuclear, renewable, thermal, … .
• Smarter power network; super energy density line, no more pylon, … .
More power plants Smarter power network
no more pylon
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Korean Power Capacity (1960~)
Generation capacity ~90GW
by KEPCO
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1997~2013
Peak load ~80GW
by KEPCO
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-
200,000
400,000
600,000
800,000
De
ma
nd
(G
Wh
)
Increase rate of power demand: 3.4%/year
2015 2027
526,356 GWh
751,007 GWh
224,651 GWh
Power supply and demand
82 GW90 GW
100.6 GW
108 GW
120 GW124 GW
129 GW
140 GW144 GW
149 GW152 GW
153 GW154 GW
156 GW
157 GW
159 GW
2015 yr (%)
2027 yr (%)
0
50
100
150
Ma
x.
po
we
r (G
W)
2015 2027
Increase rate of Max. power: 3.5% per year
83.532 GW43.208
GW
126.74 GW
In 2027, 159 GW power supply in KOR.
Ref. 産業部
Power supply and demand
Now
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Component Ratio in Korea
by EIA
The current draft proposal of the country's long-term energy plan, submitted to the Korean parliament at the end of 2013, revised down the share of nuclear capacity to 29% of total generating capacity by 2035 from the prior 41% by 2030, specified in the previous plan.
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Nuclear
Coal
Hydro
LNG
Wind
Petrol
PV
g/kWh
CO2 emission, Coal 991g/kWh, Wind 14g/kWh
Coal; 27GWLNG; 22.5GW
CO2 emission
China >7,000MtonUSA >6,000MtonJapan >1,000Mton
Korea ~530Mton- coal 163Mton- LNG 75Mton
No more Hydro,Wind is alternative.
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Power from blade
𝑃𝑏=1
2𝜋𝑅2𝜌𝐶𝑝𝑉
3
Power of blade(Watt)
Radius of blade(m)
Air density1.225kg/𝑚3
Coefficient of blade(<0.48)
Wind velocity(m/s
)
1MW R=27m V=11.5m/s5MW R=60m V=11.5m/s10MW R=84m V=11.5m/s
Longer length of bladecan easily generate much higher power.
Good wind quality(offshore)can easily obtain much higher power.
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But, problem is the top head weight.
EESG
EESG
EESG
EESG
The heavy top head causes the high mechanical stress and high cost of foundation and tower.
1,000 ton
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BladeYaw system
Cooling system/Monitoring system
GeneratorMain frameSpinner
Hub
Pitch control
Converter Power system
Only one way to reduce the weight, it is generator.
Generator
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Best way to reduce the weight is to increase the field.
The high field of rotor makes small active volume and light generator.
𝑃𝐺=𝐵𝑟 ∙ 𝐾𝑠∙ 𝜋𝑟2𝑙 ∙
𝜔
𝑝
The high field of rotor makes small active volume and light generator.
Field of rotor(T)
Active volume(𝒎𝟑)
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If wind blows 5m/s in ground 100 m,Onshore : 72 m --> wind velocity : 5 m/sOffshore : 72 m --> wind velocity : 5.5 m/s
Offshore wind power system generates 30% higher rated power than onshore wind power system.
32
2
1bladepbladeblade VCRP
72
Ref : Kim J.M. “Introduction of wind turbine generator”
OffshoreOnshore
5 (m/s) 5.5 (m/s)
Better wind quality in offshore (3)
Aerodynamic sound is related to tip-speed of blade.Noise level (A-weighted) ∝ log10 (Tip speed of blade)
To limit the generation of aerodynamic noise, large modern wind turbines limit the rotor rotation speeds to keep the tip speeds under about 80 m/s.
11 30windspeed
eedbladetipsp
V
NR
V
R R
Aerodynamic noise
Mechanical noise
Flickering shadow
Problems of onshore (2)
Why offshore wind power
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PartsRisøDTU
AMSC GESUPRAPOWER
AMLConverte
am
Rated power (MW) 10 10 10 10 10 8
Rotation speed (rpm) 10.4 10 10 8.1 10 12
Poles 16 24 36 - - -
Diameter (m) 4.7 5 4.9 - 5 5
Length (m) 1.15 - 2.7 - 2 2.2
Length of SC wire (km) 1450 - 720 - - -
Temperature (K) 20 30-40 6.08 - 20 30
Maximum field (T) 9.1 - 7.35 - - > 4
Field on stator (T) 3 - 2.2 - - -
Output voltage (kV) - 3.3 3.3 - - -
Voltage frequency (Hz) 1.33 2 3 - - -
Frequency converter O O O O O O
Drive-train DD DD DD DD DD DD
>10 MW wind power generators
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12 MW superconducting wind power generatorin CWNU
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Items Value
Rated output power PN (MW) 12
Shaft power PT (MW) 12.96
Rated ideal wind velocity VRI (m/s) 11.4
Tip speed ratio λ (VR ) 8.9
Blade length (m) 97.4
Tip speed VTIP (m/s) 85.6
Rotation speed ωR (rad/s) 1.047
Maximum power coefficient CPmax 0.48
Mass density of the air ρ (kg/m3) 1.225
• ρ : Air density, 1.225 kgm-3
• Cp : Max. power coefficient of rotor
• V : Rated ideal wind velocity
𝑅𝑏𝑙𝑎𝑑𝑒 =2𝑃𝑇
𝜌𝐶𝑝𝜋𝑉3 =
2(1 + 𝜀)𝑃𝑁
𝜌𝐶𝑝𝜋𝑉3
• PT : Mechanical power of the rotor shaft
• PN : Rated power of wind turbine
• PT = (1+ε)PN includes a loss factor of
the drive train (ε~8%)
The proposed 12MW class HTS generator
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3rd PhaseCommercial
Beta-type fabrication
2nd PhaseDown scale prototype
manufacturing
1st PhaseDesign in detail for 3 years
2015 2016 20192018 2020 20222021 2023 202520242017
Total 3 MW
Total 12 MW 12 MW design in detail
3 MW class proto-typemanufacturing
12 MN∙m torque test unit
3 MW class field test
12 MW real system fabrication
Blade 3 MW conventional 12 MW newly developed
Tower 3 MW conventional 7~8 MW conventional
Hub 3 MW conventional 12 MW newly developed
Generator 3 MW newly developed 12 MW newly developed
Converter 3 × 1 MW conventional 3 × 4 MW conventional
Foundation 3 MW conventional 7~8 MW conventional
VISION; 12 MW WPGS technology roadmap over the next 10 years
Plan of the technology application
Project about 12 MW Floating Offshore Wind Turbine
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Digit 1 Digit 2 Digit 3
Check the Design Objective Target of the generator Cost / Weight / Diameter / Efficiency
2D Generator Design
Rating of generator Output power / Output voltage
Set of generator parametersRotating speed / Number of poles / HTS field coil
/ Stator coil / etc.
Electromagnetic analysis Magnetic distribution / Output power
Force / Mechanical analysis
Lorentz force
Torque
HTS field coil loads
Generator Layout Drawingfor 3D Optimization Design
Drawing generator (3D CAD program)
Rotor part (Rotor body, HTS field coil, Cryostat)
Stator part(Stator body, Coil, Magnetic shield)
3D Generator Optimal Design Confirm the 2D Optimization ModelElectromagnetic analysis
Mechanical analysis
Detailed Analysis
Electromagnetic Analysis Magnetic flux density / Lorentz force
Mechanical Analysis Torque / Load / Max. stress
Thermal Analysis Cooling method / Cooling path / Temp.
Redesign of the StructureChange the Structure
Based on the Detailed Analysis
Verify the analysis results
Drawing the modified model
Analysis of the modified model
Confirm the designed generator Confirm the design objective Cost / Weight / Diameter / Efficiency
Detailed Drawing Drawing based on designed generatorCheck the assembly process
Detail drawing of the generator
HTS generator design process
Ongoing
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Rotor support
Cryostat
Air gap
Superconducting field winding
Armature winding
Iron cored bobbin
Item Value
Rated power 12.3 MW
Rated L-L voltage 6.6 kV
Rated armature current 1.05 kA
Rated rotating speed 8 RPM
Rated torque 14.7 MNm
The num. of rotor poles 30
The num. of SC layers/pole 6
The length of air gap 30 mm
Thickness of vacuum vessel 15 mm
Number of stator coil /phase/pole 2
Current density of copper wire 3 A/mm2
Safety margin of operating current 30%
Parts Material Density (kg/m3)
Rotor wire (RE)BCO 11,000
Rotor body 304 stainless steel 8,190
Vacuum vessel 304 stainless steel 8,190
Stator wire Copper 8,940
Stator body M-27 24 Ga 7,650
1/30 model of 12 MW HTS generator
Materials of each part
Materials of the 12MW class HTS generator
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Specification and FEM analysis results
Parts Property Value
Rotor
The number of poles 30
Effective length 450mm
Rotation speed 8 rpm
Turns of SC coil/layer/pole 400
Field current of SC coil 352 A
Length of SC wire per pole 4.35 km
Total length of SC wire 130 km(12mm)
Parts Property Value
Stator
The number of slot 180
Copper coil winding type(Distributed Winding)
Short pitch
Cooling system Water cool
Current density of copper coil
3 A/mm2
Turns of copper coil 15
Diameter 6.7 m
Perpendicular magnetic field 5.42 T
Maximum magnetic filed 7 T
Active volume 25 m3
Active weight 107 ton
Total weight (incl. structure)
180 ton
Inductance per pole 4.84 H
100 mm
100 mm90 mm
For supporting structure space
12MW class HTS generator (Volume & Weight)
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PMSG362 ton
PMSG: 362 t
𝑦 = 𝑒(3.24253+0.38324𝑥−0.01354𝑥2)
SCSG: 180 t
SCSG 180 ton
Design results of the 12MW class HTS generator
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• No Power supply• No Slip-ring• No Current leads• Small volume of cryostat• High mechanical torque
on narrow & small space
The proposed idea of modularization.
Configuration of the modularized HTS wind power generator with the flux pump
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Rotor body
HTS one pole module
Flux pump exciter
Stator body
Stator teeth
Stator coil
Configuration of the module for the 12 MW HTS wind power generator
The modularization of the generator enables a smaller cryogenic volume, an easierrepair, assembly, and maintenance of the HTS field coil. Modularization will be suitablefor commercial mass production and will increase the operational availability of HTSgenerators in the wind turbine.
Cross section of the modularized generator
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254 mm
490 mm
390 mm
79 mm
128 mm
HTS coil & bobbin (Al)
Heat exchanger
(Cu)
Cryostat(SUS)
Coil supporter
(G10)
Bobbin supporter (SUS)
Heat exchanger(Cu)
But, there are two big problemshave to be solved.
• Heavy heat load capacity• Very high mechanical torque
Conceptual dimensions of the module(tentative)
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2 Conduction
Five principal heat sources
Heat load characteristics of the module
1 Excitation 3 Radiation
4 Eddy current
5 AC loss
• Gifford-McMahon (1-stage)
SRDK-500B
• Operating temperature of the HTS coils: 20 K
• Therefore, the total heat loss in the module should be lower than 50 W.
GM cryocooler power curve
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Heat load characteristics of the module(Conduction and radiation heat loads)
Coil supporters
-HTS field coils
-Pole type supporter
Diameter: 20 mm
79 mm
19.3 K
-HTS field coils
-Honeycomb type supporter
19.8 K
79 mm
131 mm419 mm
-HTS field coils
-Zigzag type supporter
390 mm840 mm
79 mm
16.6 K
Parts Pole type Honeycomb type Zigzag type
Max. temperature at the HTS coils 19.3 K 19.8 K 16.6 K
Conduction heat load 11.4 W 14.5 W 11 W
Radiation heat load 2.2 W 2 W 2.5 W
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<Eddy current distribution of the module structures>
Structures Value
SUS 4.6 W
Cu 7.5 W
Al 6.4 W
Total eddy current loss is 18.5 W.
Heat load characteristics of the module(Eddy current heat load)
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Heat load characteristics of the module(Total current heat load)
Excitation heat loss10.2 W
Conduction & Radiation heat losses<14 W
Eddy current heat loss18.5 W
GM cryocooler power curve • The cooling capacity of the GMcryocooler is 53 W at 20 K.
• However, the temperature of thecurve point at the HTS coils ishigher than 20 K.
• When the sum of the conductionand radiation heat losses is lessthan 7 W, the max. temperature ofthe HTS coil is achieved at 20 K.
• We should be reduce theconduction area of the supporter.
The sum of the heat losses is 43 W.
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Displacement
Lorentz force
Mechanical characteristics of the module
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Von Mises stress
Displacement
- Zigzag-type supporter
Max. stress: 468 MPaMax. displacement: 4.24 mm
- Honeycomb-type supporter
Max. stress: 282 MPaMax. displacement: 1.27 mm
- Pole-type supporter
Max. stress: 159 MPaMax. displacement: 0.05 mm
When the allowable stresses of GFRP and CFRP are considered,the pole type supporter is suitable at the allowable stress of CFRP.
Allowable stress of the GFRP= 93.3 MPaAllowable stress of the CFRP= 200 MPa
Mechanical characteristics of the module
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0.5 MN
0.15 MN
Von Mises stress
Displacement
Mechanical characteristics of the module
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p.32/40Characteristic evaluation device for HTS field coil
M
Cryostat & HTS coil
Ground
Stator & Transfer equipment
Accelerationmotor
Stator guide rail
Quick braking deviceCoil height control system
Ground
Load bank & Inverter system
Power supply
Cooling system & Pump
Compressor
Workbench
Cable rollerMotor inverter &
Monitoring system
Rail
HTS coil monitoring system
Clamp
Up & DownMove
Cryostat bottom
Thermal insulation pad
Radiationshield
Cryostat cover
Current lead
HTS coil
Cooling pad
Cooling pipe
Stator winding module
Motor
Wheel-2(Rail holder)
Stator holder
p.32/27
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Active parts Weight Material
Stator coil 48 ton Copper
Stator body 50 ton Silicon steel plate
Vacuum vessel 12 ton Stainless steel
Rotor body 11 ton Stainless steel
Total length of HTS wire
HTS wire 375 km
Material Cost
Copper 20.5 $/kg
Stainless steel 1.5 $/kg
Silicon steel plate 4.1 $/kg
HTS wire 23 $/m (100 A @ 77 K)
Parts Cost
Stator coil 985 k$
Stator body 206 k$
Vacuum vessel 18 k$
Rotor body 16 k$
HTS wire 18,616 k$
Structure 306 k$
Ref. Design of direct-driven permanent-magnet generator for wind turbines, Anders GrauersRef. SuperPower (4mm HTS wire)
Total cost of a 12 MW SCSG (Current price of HTS wire; 230 $/kA-m)
Total cost of the 12 MW SCSG=10,146,509 $=11,161,160,184 KRW (1$=1,100 KRW)
=112 억원
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HTS wire price-performance for commercialization
Ref. SuperPower
Today’s HTS wire price: $225/kA-m (100 A performance at 77 K, zero applied magnetic field)
Improving wire price-performance is key factor for commercialization
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Material Cost
Copper 20.5 $/kg
Stainless steel 1.5 $/kg
Silicon steel plate 4.1 $/kg
HTS wire 5 $/m (100 A @ 77 K)
Ref. Design of direct-driven permanent-magnet generator for wind turbines, Anders GrauersRef. SuperPower (4mm HTS wire)
Total cost of a 12 MW SCSG (Future price of HTS wire; 50 $/kA-m)
Active parts Weight Material
Stator coil 48 ton Copper
Stator body 50 ton Silicon steel plate
Vacuum vessel 12 ton Stainless steel
Rotor body 11 ton Stainless steel
Total length of HTS wire
HTS wire 375 km
Parts Cost
Stator coil 985 k$
Stator body 206 k$
Vacuum vessel 18 k$
Rotor body 16 k$
HTS wire 1,873 k$
Structure 306 k$
Total cost of the 12 MW SCSG=3,403,709 $=3,744,080,184 KRW (1$=1,100 KRW)
=37.44 억원
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BladeYaw system
Cooling system/Monitoring system
Generator
Main frameSpinner
Hub
Pitch control
Converter Power system
Drawing the whole shape of the 12 MW WPGS
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Thank you for your attention
in Changwon national university
20GW wind turbine (10MW HTS wind, 2,000 unit)We can reduce about 50Mton of CO2 emission per year.It is 1/10 of Korean CO2 total emission.