Hochdynamische Schwungmassenspeicher für Industrie- und ...€¦ · Flywheel Storage Systems and...

Hochdynamische Schwungmassenspeicher

für Industrie- und NetzanwendungenDr. Wolfgang Walter | ZIEHL V

Babcock Noell GmbH

15.03.2016

Outline

▪ Introduction: Babcock Noell GmbH

▪ Flywheel Storage Systems and Applications

▪ Advantages of HTS (High-Temperature Superconductors)

▪ The ENERSPHERE project

▪ Goals

▪ Development Status

▪ Summary

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Babcock Noell

Site and Location

Page 3

Office

2. Workshop: 1.000m²

1. Workshop: 2.100m²

Babcock Noell GmbH

Magnet Technology at Babcock Noell

Experienced to Apply Superconductivity

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• Physicists, Engineers and

Technicians work hand-in-

hand

• More than 30 years magnet

technology and

superconductivity experience

• Cooperation with research

institutions and industry

Background

Advance Superconductivity from the Research World to Industry

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BNG is well known as a manufacturer of superconducting magnets for science

Extend this know-how to applications beyond science

Develop superconducting flywheel for multiple applications

Wendelstein 7-X - First Hydrogen Plasma

February 3rd, 2016

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courtesy of IPPCourtesy of IPP: Picture: IPP, Norbert Fellechner

1G

Roller bearings

Steel rotor

1.5 G

Active bearings

Steel rotor

2 G

Active bearings

Composite rotor

3G

Passive SC bearing

Composite rotor

Flywheel Generations

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Source Enercon GmbH

Source Calnetix

Source Powerthru

high storage

density (kW/kg)

long lifetime

(>20 years)

large number of

cycles

Flywheel the „Power Storage“

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Flywheel

• Input and output of energy in short

time ´power storage`

• Short term storage (hours)

• Low energy (kWh), high power (kVA)

Energy storage systems by energy density and power density

Source: TU Braunschweig, Prof. Canders

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ApplicationsStorage of Energy a Growth Market

Technological solutions are required for increasing problems

• Rapidly transforming energy markets

New challenges for stable grid operation

• Decentralized generation from renewable sources

Imbalances of generation and demand of electric power

• Unstable network levels: hazard to electrical equipment and grid infrastructure

Risk of large scale black-outs

Source: Bilfinger Construction GmbH

Measures

Global approach:

• DC-Transmission

• Power highways

• Large scale electricity storage

Local approach on low- to medium voltage

distribution level:

• Smooth feed-in of fluctuating renewable

sources

• Regulate voltage levels at local nodes

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ApplicationsPower Quality Market

Parameters

• Performance: 500 kW per unit

• Capacity: 5-10 kWh

• Smoothing/buffering of renewable energy feed-in (PV and Wind)

• Grid stabilization and support at local nodes

• Power management in industry and public transport

• Peak shaving in industrial processes

• High cycle application

Applications and benefits

• Renewable energy producers: Meet feed-in requirements of utilities

• Grid operators: Installation of Flywheels avoid costly line upgrades

• Industry/transport: Reduce peak power consumption, enhance power quality

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ApplicationsUPS (Uninterruptible Power Supply)

Source: Bilfinger HSG

Parameters

• Performance: 250 kW per unit

• Capacity: < 5 kWh

• Maintain mains voltage for more than 20 sec. (until diesel generator starts)

• Improvement of power quality

• Low cycle application

Benefits

• No air conditioning and safety infrastructure

• Long life-time

• Low maintenance and operating costs

• Modularity and compactness

Benefits of High-Temperature Superconductors

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Source: TU Braunschweig, Prof. Canders

Simplest example for demonstration of magnetic levitation state

Levitation of a permanent magnet (PM) over a high temperature

superconductor (HTSC)

Characteristics of HTS:

▪ Reaction to changing external field by shielding current

▪ Feature of keeping an existing field constant frozen field

→Stable levitation!

HTS - Bearings Active Magnetic Bearings

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Safety advantages of SC-bearings compared to active magnetic

bearings:

• A stable equilibrium without active feedback control

• Active bearings may crash due to sensor or controller failure

thus safety bearings indispensable

▪ SC-bearings have a high heat capacity

even in case of cooling failure enough time to shut down

▪ Overcritical operating range due to soft bearing characteristics

Superconducting is BetterAdvantages for Flyhweels

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Advantages of superconducting bearings in a flywheel:

• Frictionless bearing

• Self centering

• Passive control (compared to electromagnetic solutions)

• Vacuum compatible

Solution requires:

• Cooling at LN2 temperature sufficient

• HTS material

• High system integration

~= Bidirectional

inverter

Cryocooler

Vacuum pumpBearing unit

Motor-generator

Composite rotor

(‚Flywheel‘)

Vacuum vesselRotor hub

HTS bearing stator

(High Temperature Superconductor)Bearing excitation system

(Permanent magnets)

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ENERSPHERE

Energiespeicher hoher Energiedichte

für regenerative Energieerzeuger

(energy storage with high energy density

for renewable energy generation)

public funding project (BMWi) for Power Quality flywheels

project start: April 2014, duration 3 years

collaboration with:

Deutsches Zentrum für Luft- und Raumfahrt, DLR,

(German Aerospace Center)

Technical University Braunschweig,

Institute for Electrical Machines, Traction and Drives (IMAB)

ENERSPHERE – Motivation

Change to renewable energy on energy market

Quick-reacting short-term storage systems required:

▪ For deviation from forecast

▪ For buffering of short-term variations in renewable energy feed-in

(e.g. solar plant + clouds passing)

▪ System services – grid stabilization

Demands on storage system:

▪ High cycle efficiency (<90%)

▪ Low stand-by losses

▪ Competitive price

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Flywheel Development at Babcock Noell

2011 2013 201420122010

Bearing prototype

HTS material tests

Technology demonstrator

ENERSPHERE

2015 2016 2017

Sketch of the ENERSPHERE system

Project structure

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rotating mass

bearing rotor

vacuum vessel

motor rotor

bearing stator

motor stator

stator shaft

motor-generator

fiber composite rotor

HTS bearing + project leader

IMAB

DLR

BNG

ENERSPHERE – Project Structure

ENERSPHERE – Design Parameters

500 kW per unit

Usable capacity 5 kWh

Highly-cyclic system (~ 200 cycles a day)

Rotating mass ~300 kg

Maximal rotation frequency 15,000 rpm

▪ Two radial HTS- bearings (external rotor)

▪ One permanently excited synchronous machine

▪ Complex highly-integrated fiber composite rotor

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rotating mass

bearing rotor

vacuum vessel

motor rotor

motor stator

stator shaft

bearing stator

ENERSPHERE – Material Tests

Qualification of HTS material from different suppliers

Setup:

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ENERSPHERE – Material Tests

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Stiffness measured in planar setup is converted to a cylindrical bearingThree material probes (material 1a unmachined, 1b shaped)

Radial Stiffness Axial Stiffness

ENERSPHERE – Bearing Test Setup

Complex test setup

Full size full speed bearing test of ENERSPHERE

Full electrical operation

Three linear motors, one rotation motor

and one lifting motor

Serves as

▪ Cold test of bearing

▪ Independent translation in three directions

and force measurements Bearing stiffness

▪ Rotation up to maximal rotational frequency

Losses, temperature rise

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Determination of outgassing rates

of fiber composite materials:

ENERSPHERE – Further Test Setups

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Outgassing rate per probe surface after one hour:

GFK: 2.2 E-10 mbar*l/(s*cm²)

CFK: 1.9 E-10 mbar*l/(s*cm²)

Surface GFK probe ~100 cm²

Surface CFK probe ~50 cm²

Pressure increase measurement in closed vacuum chamber

Outgassing rate:

ENERSPHERE – Status

▪ All technologies validated separately

▪ Additional tests of full bearing in preparation

▪ All geometries, materials are defined and qualified

▪ Final design review Q2/2016

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Summary

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▪ Technology demonstrator realized and tested

▪ All relevant technologies qualified individually:

▪ Qualification of YBCO materials

▪ Measurements of bearing characteristics

▪ Measurements of outgassing rates

▪ Cryogenic measurements

▪ …

▪ Flywheel systems designed

▪ Commissioning of flywheel systems for UPS and Power Quality in 2016

Contact

Babcock Noell GmbH

Alfred-Nobel-Str. 20

97080 Würzburg

Germany

Phone +49 931 903-0

Fax +49 931 903-6000

info.bng@bilfinger.com

www.bng.bilfinger.com

Registered at Local Court Würzburg, HRB 7156

VAT-Id. No.: DE211420259

Executive Management:

Helmut Welp, Chairman

Dr. Ronald Hepper

Roland Pechtl

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