dr. michael baecker at basf science symposium 2015

chemistry meets energy

Dr. Michael BäckerDeutsche Nanoschicht GmbH

simply irresistible –energy efficiency with high-temperature-superconductors

Deutsche Nanoschicht GmbHHeisenbergstr. 1653359 Rheinbachwww.d-nano.com

Outline

- Deutsche Nanoschicht GmbH

- Breaking paradigms in electro technology

- Superconductors in electric grids

- High Temperature Superconductors (HTS)

- Process technology and challenges

- Performance and pilot line

- Summary

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Deutsche Nanoschicht GmbH

- Founded in November 2011 by Dr. Michael Bäcker

- In June 2013 BASF New Business GmbH aquired all shares of Deutsche Nanoschicht GmbH

- Deutsche Nanoschicht GmbH is part of IBU E-Power Management

- 58 employees , located in Rheinbach, Germany

- Expertise in High Temperature Superconducting (HTS) wires, chemical solutiondeposition, ceramic functional layers, ink-jet-printing, epitaxial growth

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Breaking paradigms in electro technology

- Energy efficiency – no electric losses- Grid protection – non-linear resistance T < Tc

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- Material efficiency – highest power density

5


- Energy efficiency – no electric losses

Source: Siemens

Verified loss reduction exceeding 50% for 4MVA HTS motor

6


- Underground cables – highest current carrying capacity at lowest footprint

Source: Nexans

Conventionalmedium voltage cable

High Temperature Superconductingmedium voltage cable

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- Fault current limiters – intrinsically safe grid protection

Source: Nexans

+ compact+ intrinsically safe+ strong limitation+ self recovering

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Superconductors in electric grids

- Energy distribution in dense urban areas – increasing demand & limited space

- High temperature Superconductors enable: Highest energy density at lowest footprint Lower ohmic losses in distribution grids Lower voltage level in distribution grids Redundant transformer substations

- E.g. International Finance Center 2, Hong Kong:

• Substation in 70th floor to be redundant- E.g. Distribution grid in Essen-City:

• Project AmpaCity9


- Energy distribution in dense urban areas – increasing demand & limited space

Source: Nexans, RWE 10


- Integration of renewables in existing grid architecture

Classical Substation

High voltageTransmission

Medium voltageDistribution

Low voltageDistribution

Existingarchitecture:

• Large power plants at highvoltage level

• Radial distribution

Source: Prof. Dr. ir. Dr. h. c. Rik W. De Doncker, E.On Energy Research Center, PGS Power Generation and Storage Systems 11







Integration ofrenewables:

• Large power generation athigh voltage level

• Actualarchitecturesuitable and to bestrengthened

… but









• Large power generation athigh voltage level

and

• Distributed power generationat every voltagelevel









• Distributed power generationat every voltagelevel

• Different prosumers must exchange energy via transmission grid




Source: Prof. Dr. ir. Dr. h. c. Rik W. De Doncker, E.On Energy Research Center, PGS Power Generation and Storage Systems

Intelligeht Substation





• Exchange between prosumers and higher utilization of distribution grid

• Superconductors enable • long length

AC or DC connection at medium voltage

• failsafe connection of distribution grids

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Source: Prof. Dr. ir. Dr. h. c. Rik W. De Doncker, E.On Energy Research Center, PGS Power Generation and Storage Systems

Intelligeht Substation





• Exchange between prosumers and higher utilization of distribution grid

• Superconductors enable • long length

AC or DC connection at medium voltage

• failsafe connection of distribution grids

High Temperature Superconductors in electricgrids enable the dream of electrical engineers:

„Copperplate Europe/Germany“

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- Demonstrators and prototypes worldwide

- More than 10 HTS cables• All voltage levels• Transmission and distribution level• 200m to 3km length

- More than 10 Fault current limiters• Medium and high voltage level• First commercial sales for medium voltage FCL

- Redundant and economic cooling systems• GM Coolers, Brayton turbines, Stirling machines

- More than 25 years of experience in test fields and grid installations

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High Temperature Superconductors

- Critical parametersIc [A]: critical current

Jc [A/mm²]: critical currentdensity HTS layer

Price [€/kAm]: pricing (opc)

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- Challenges in materials− Komplex ceramic oxides: YBa2Cu3Ox

− Komplex layered cristalline structure

− Strong anisotropic behaviour

Superconducting current:parallel CuO-planes >> perpendicular CuO-planes

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- Challenges in materials− Angular dependent inter-grain current

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- HTS wire architecture – orientated epitaxial crystal growth

Statistically orientated „crystals“ template

+

Highly orientated „crystalline“ layer

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- HTS wire architecture – thin flexible ceramic coatings

Superconductor layer

Buffer layer

Metal alloy substrate

Orientated epitaxial crystal growth

buffer

HTS

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- Challenges for development and production

• Best price performance ratio (€/kAm)

• Scalable large volume production• Reliable and in-time supply• Flexible but mechanically and

electrically stable

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Process Technology

- Chemical solution deposition

• Chemical solution deposition (CSD) for all layers is considered to be the"most promising and mostchallenging process„

• Unique and protected CSD-multi-layer technology

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Process Technology

- Chemical solution deposition

Advantages:• highest throughput (deposition rates)• lowest investment• lowest energy consumption• low raw material costs

⇒ favourable for energy applications

Continuous coating and annealing

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Process Technology


Superconductor layerYBa2Cu3Ox (YBCO)

Buffer layerLa2Zr2O7 (LZO), CeO2

Metal alloy substrateNiW-alloy

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Process Technology


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Process challenges

- Metallic substrates

Tilted grains in metallic substrate

Metallic substrate as delivered Metallic substrate after surface treatment 28

Process challenges

- Coating and drying

Drying andpyrolysis of YBCO layer: undesired pencil-maze structure

Coating and drying of buffer layers:undesired crack formation

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Process challenges

- Crystallization and epitaxial growth

Quench experiment: growth of LZO layer30

Process challenges


1x LZO 2x LZO CeO2

View along <100>

RHEED measurements of buffer multi-layer surface cristallinity 31

Process challenges


BaF2

BaF2

YBCO

YBCO

YBCOY2Cu2O5

Y2O3 CuOCuOCu2O

BaF2

Complex phase evolution: growth of YBCO layer32

Performance

- Development with industrial partners over nearly 10 years- Long lengths samples >20m

0

50

100

150

200

250

2008 2009 2010 2011 2012 2013 2014

Ic[A

/Acm

w]

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Performance

- Development with industrial partners over nearly 10 years- Short sample measurements of long length tapes

275 A/cmw @ 77K,sf600 A/cmw @ 30K,1T(@1000nm HTS layer) 34

Expanded pilot line

- EPL construction until mid 2015

- Planned capacity > 200km technical HTS wire

- Start sampling for customer projects end 2015

Lab processing Expanded Pilot Line

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Summary

- High temperature superconductors enableultra-compact systems with highest energydensity and lowest losses

- More than 50 demonstrators and prototypesworldwide realized

- Chemical solution deposition enableseconomic mass production of hightemperature superconducting tapes

- Deutsche Nanoschicht reached significantperformance increase over last years andwill start pilot production end 2015

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chemistry meets energy

Thanks for your attention

Deutsche Nanoschicht GmbHHeisenbergstr. 1653359 Rheinbachwww.d-nano.com

dr. michael baecker at basf science symposium 2015

Science

electric grids integration

electric lossessource

energy research center

highest energy density

pgs power generation

large power plants

safe grid protectionsource

ibu epower management