Hochdynamische Schwungmassenspeicher für Industrie- und ...€¦ · Flywheel Storage Systems and Applications Advantages of HTS ... April 2014, duration 3 years collaboration with:

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

Page 2Babcock Noell GmbH

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

Babcock Noell GmbH Page 4

• 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


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


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


Source Enercon GmbH

Source Calnetix

Source Powerthru

high storage

density (kW/kg)

long lifetime

(>20 years)

large number of

cycles

Flywheel the „Power Storage“


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


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


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


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


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


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


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)


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



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


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


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:


ENERSPHERE – Material Tests


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


Determination of outgassing rates

of fiber composite materials:

ENERSPHERE – Further Test Setups


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


Summary


▪ 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

[email protected]

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

Page 26Babcock Noell GmbH

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Hochdynamische Schwungmassenspeicher für Industrie- und ...€¦ · Flywheel Storage Systems and Applications Advantages of HTS ... April 2014, duration 3 years collaboration with: