enabling flanders towards sustainable jef poortmans...•dc nanogrids allow efficient, affordable,...
TRANSCRIPT
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Enabling Flanders towards SustainableGeneration & Storage in an Urban Context
Jef Poortmans
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• Why this project:
• LCOE of PV has reached “grid parity”
• Further reduction of LCOE requires focus on kWh’s, not only on Wp
• Requires study/improvement of PV-modules & PV-system integration
• PV-system + storage system is the name of the game
• The rebirth of DC
What is it about?
SolSThore
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• Strong position in PV R&D • Global leader in PV-cell technology
• Presence in other parts of the PV value chain to be reinforced
• .. and is growing in battery research:• Material- and cell oriented R&D-activities in imec and
UHasselt
• Battery Management System R&D at VITO
• High potential in linking power device development-expertise to DC-application
SolSThore
Bringing the different expertise together ...
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• Objective 1: Investment in SoA lab-infrastructure for PV-module, storage and DC-systems research • TF-PV module process technology lab (EnergyVille 2)
• Si-PV module process technology lab (EnergyVille 2)
• Battery material & process technology lab (EnergyVille 2)
• DC-nanogrid (EnergyVille 1)
• Outdoor & indoor PV-system measurement setup (EnergyVille 1)
• BIPV set-up (EnergyVille 2)
• Commercial PV-roof setup (EnergyVille 1)
• Objective 2: Build up human expertise in the related fields
• Objective 3: Build up demonstrators for credibility
SolSThore
High-level Objectives
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• Activity 1: Innovative cell and module technology
• Activity 2: Towards safe and reliable highly performing local electrochemical storage based on Li-ion system
• Activity 3: Power electronics in a DC-nanogrid context
• Activity 4: Modelling and prediction of energy yield
• Activity 5: Demonstrators in BIPV and commercial roof
SolSThore
Project structure
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Activity 1Innovative cell and module technology
Eszter Voroshazi
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Technology seeds for world class innovation
Crystalline silicon PV module technology and characterisation
and their reliability testing &simulations
• Thin-film (perovskite) PV module technology
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10
LET’S WEAVE
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Bifacial cell and module tech’ for BIPV
• Woven cell interconnection technology for bifacial cells: from concept to 9-cell demonstration Optimised woven fabric combines encapsulation and
interconnection metallisation in one sheet
Optimised solder and lamination process
Proven <1% CtM current loss (while 1-3% with latest industrial technologies)
• Record performance busbarless and bifacial cells: 22.8% and 98% bifaciality Integration with SmartWire interconnection proven in
60-cell module
Optimised process to pass 200 thermal cycles < 5% loss
• Next: ICON project starting for industrial fabrication of the foils
For more: Poster in EV2 PV lab and live demo in EV2 entrance
glass
glass
woven fabric
cell
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3 generations of real-life BIPV demonstrators
2016: 9-cell (10 pcs)
modules with industry
baseline technology
2017: 9-cell modules (12 pcs)
with imec cells and SmartWire
interconnection
2018: 60-cell (5 pcs) and 9-cell (12 pcs)
BIPV modules benchmarking of latest
ribbon and industrial and imec multi-wire
interconnection technologies For more: Activity 5 presentation and demo sites
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• Potential induced degradation: in-depth insights on mechanism and its characterisation (up to 5000V)
• Thermo-mechanical stress modelling and measurement• multi-scale modelling of full-size
modules
• advanced adhesion and load measurement
Reliability testing and simulation expertise
Stress concentrations due
to the clamping method
PID
No PID
Increasing
voltage
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Back-end thin-film PV module technology
• Record performance large area modules with traditional patterning: 10% on 10cm2
• One step patterning of the thin-film layer to form the module interconnection
Laser process replaces mechanical scribe: 10 x faster, improved accuracy and reduced line width
• Next: Novel materials and upscaling to 900 cm2
literature benchmark
imec/Solliance results in orange
Insulator and
conductive ink
materials selected
For more: Poster in EV2 PV lab
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(BI)PV module prototyping and characterisation facilities
• cSi BIPV assembly line (1x1.6m2)• Automatic module assembly tool
• Laminator for glass/glass and curved modules
• TFPV assembly (30x30cm2)• Laser patterning
• Slot-die coating
• Vacuum evaporation/sputtering
• PV module performance and quality testing• Bifacial LED based solar simulator
• Spectral response and reflectivity
• Material characterisation tools
• Large area climate chambers
For more: Poster and visit in EV1 and EV2 labs
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In the last 3 years...we have made record modules, started two modules lines, moved
teams and labs...and it is just the start of a new innovation roadmap.
Join us!
Thank you for the incredible effort of the team!
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Activity 2Battery Technology
An HardyJeroen Büscher
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Electrochemical energy storage
• Framework of decentralised energy generation & electric mobility
• Energy storage is crucial
• Enabling high penetration of renewable energy
Why?
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EnergyVille electrochemical energy storage roadmap
Solid-state Li-ionSolid-state Na
Solid-state LiS
Pouch cellsElectrode coatings - A4 sheets - mesh current collectors
1-phase grid inv.3-phase grid inv.
DC nanogrid inv.Modular DC nanogrid inverter
Voltage balancing SoC balancing Battery reconfiguration
Model-based SoCModel based SoH
Insulation mon.Connectivity check
Li-air
Battery
Modules
Systems
Materials &Cell
technology
UpscalingAssembly (Cutting/stacking and Lamination)
mAh Ah
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• Design battery labs
• Installation of pouch cell manufacturing line
• Platform process for solid state batteries• materials development: solid composite electrolytes over 1 mS/cm
• cell development: functional solid state batteries demonstrated
Results during EFRO 936 – SolSThore activities
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Battery lab designFrom the drawing table to reality today
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Installation of pouch cell manufacturing lineFrom tough selections into fully installed dry room today
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Installation of pouch cell manufacturing lineFrom tough selections into fully installed dry room today
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OxidesSulphidesPolymer PEO
Expensive large scale
production
Medium conductivity
Low stability to oxidation,
moisture, cathode materials
Very high conductivity
Low oxidation voltage
Limited thermal stability
Taken from Manthiram et al. doi:10.1038/natrevmats.2016.103
Solid composite electrolytes
Inexpensive
Compatible with current LIB
production methods
High conductivity
High oxidation voltage
Versatility
Platform process for solid state batteriesMaterials development: solid & composite electrolytes
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SCE or ETG precursor
CC
Coating (AM/C/Binder)
Electrolyte+membrane
Compatibility to current
manufacturing lines
Platform process for solid state batteriesCell development: solid state batteries
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EnergyVille electrochemical energy storage roadmap
Solid-state Li-ionSolid-state Na
Solid-state LiS
Pouch cellsElectrode coatings - A4 sheets - mesh current collectors
1-phase grid inv.3-phase grid inv.
DC nanogrid inv.Modular DC nanogrid inverter
Voltage balancing SoC balancing Battery reconfiguration
Model-based SoCModel based SoH
Insulation mon.Connectivity check
Li-air
Battery
Modules
Systems
Materials &Cell
technology
UpscalingAssembly (Cutting/stacking and Lamination)
mAh Ah
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Results during EFRO 936 – SolSThore activities
• Extension battery Testing Lab
• Development of Battery Management System
• Tool to asses total cost of ownership
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Battery Testing Lab
• Cell, module and system testers up to 1000VDC , 30kW
• Climate chambers for testing [-20⁰C, +55⁰C]
• Standardised and application specific tests with a focus on performance and ageing
• Testing of commercial and prototype batteries
• Risk analysis and system design review
State-of-the-art testing infrastructure at your service
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• Ensured safe battery operation
• Optimised performance and lifetime
• Maximised usable battery capacity
• Improved lifetime prediction
• Benchmarking SoC estimation for Li-ion
• Better than competition• Especially in case of “solar cycles” and
when using old cells
Battery Management SystemsAdvanced technology in a modular concept
Time
Time
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Total Cost of Ownership (TCO) tool
• Application specific guide for
• Storage technology choice and dimensioning
• Decision support
• CBA* of service delivery
*CBA = cost benefit analysis; **DPP = discounted payback period
Energy price
(€/kWh)
DPP**
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Activity 3Development of power electronics
Johan Driesen
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LVDC for smart citiesTowards more energy efficiency, distributed generation and internet-of-things
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LVDC for smart citiesTowards more energy efficiency, distributed generation and internet-of-things
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LVDC for smart citiesTowards more energy efficiency, distributed generation and internet-of-things
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LVDC for smart citiesTowards more energy efficiency, distributed generation and internet-of-things
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LVDC for smart cities
Three arguments: compatibility, power transfer capability and controllability
• Motivation for LVDC distribution systems• Compatibility with DC devices• Increased power transfer capability• Increased controllability
• Motivation for bipolar LVDC [1-4]• Increased power transfer capability• Two voltage levels available• Conduction losses are reduced• Potentially more reliable• But: voltage balancing converters required
[1] G. Van den Broeck, S. De Breucker, J. Beerten, M. Dalla Vecchia, and J. Driesen, “Analysis of Three-Level Converters with Voltage Balancing Capability in Bipolar DC Distribution Networks,” in International Conference on DC Microgrids, 2017, 8 pages.[2] H. Kakigano, Y. Miura, and T. Ise, “Low-voltage bipolar-type DC microgrid for super high quality distribution,” IEEE Trans. Power Electron., vol. 25, no. 12, pp. 3066–3075, Dec. 2010.[3] J. Lago, J. Moia, and M. Heldwein, “Evaluation of power converters to implement bipolar DC active distribution networks—DC-DC converters,” in Energy Conversion Congress and Exposition (ECCE), 2011, pp. 985–990.[4] T. Dragicevic, X. Lu, J. Vasquez, and J. Guerrero, “DC Microgrids–Part II: A Review of Power Architectures, Applications and Standardization Issues,” IEEE Trans. Power Electron., vol. 8993, no. 99, pp. 1–1, 2015.
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Towards LVDC in commercial buildings
Bottom-up evolution of LVDC power systems• Fixed, high-power loads first
• PV installations, including BIPV installations
• Electric vehicle charging stations• HVAC systems (already inverter-driven)• Elevator drives (already inverter-driven)• Simplify the power conversion steps
(read: cost reduction)
• From a DC back-bone• Power LED lighting• Power office spaces
• Interconnect multiple LVDC commercial buildings
Source: AEG PS
Source: SMA AG
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LVDC test facility
A ±500V bipolar DC test grid developed in the SolSThore project
Lab infrastructure100 kW ±500V DC test grid
Unipolar and bipolar configurationTN-S grounding or IT groundingReconfigurable
Power flow monitoringVoltage measurementsPower electronic converter testingCommunication interfacesConnected to other labs
Rooftop PV test siteBattery laboratoryEV Parking
TestsVoltage stability - power sharingProtection systemsEquipment interoperabilityEfficiency assessment
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LVDC test facility: example set-up
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Power electronic building blocks
• Smart AC/DC grid coupling
• Unbalance compensation on AC side
• Bipolar supply on DC side
• Solar converter
• DC/DC converter architecture• Non-isolated / isolated
• Design for reliability
• GaN-based circuits
• DC grid management
• Balancing/protection
• Conversion to LV busses (e.g. 48 V, USB-C)
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Place of the DC-DC converter in the BIPV concept
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Design specifications - Electrical
• Input voltage: 10 – 50 V
• Input current: max 10 A
• Output power: max 300 W
• Output voltage: 380 V (DC)
• DC bus gets stabilised by central inverter
• Unipolar
• MPPT
• Modularity
• Communication with central inverter
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• General design
• Low component count
• Simple and robust
• Limit temperature rise
• Redundancy
• Use components that are rated up to 125°C
• For cooling
• Only passive is a viable option
• Temperature sensors?
• For switches
• Limit internal temperature (die)
• Soft switching?
• Use GaN
• For capacitors
• No electrolytic capacitors
• Limit current ripple
• Limit max voltage
Consequences of the required lifetime
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455/06/2018
Comparison of Si vs. GaN in circuits:boost converter• Two PCB prototypes have been developed
• (a) employs Si MOSFETs
• (b) employs GaN HEMTs and is three times more compact
115x250x30
mm³
(b)
(a)
55x175x30 mm³
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465/06/2018
Comparison of Si vs. GaN in circuits:isolated flyback converter
Si Mosfets, bulky transformer with undesired resonances GaN HEMTs: improved density
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• Energy transition at building level: need to rethink the whole internal electricity system
• DC nanogrids allow efficient, affordable, safe integration of BIPV, storage, smart loads
• Living lab meeting safety standards constructed at EnergyVille
• Power converter development using GaN technology
• In EnergyVille, Imec + KU Leuven = full chain research in power electronics : components – circuits – systems - applications
Conclusions
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Activity 4Modelling and Forecasting PV Energy Yield
Hans Goverde(Georgi Yordanov)
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SolSThore – Activity 4
Trias Politica
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515/06/2018
SolsThore – Activity 4Trias Policita PV Energy Yieldica
Indoor
Characterisation Characterisation
Outdoor
Modelling
Physical-
E-yield estimation
Measurement design
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• Development of dedicated characterisation
tools and measurements
SolSThore – Activity 4Indoor characterisation
290
300
310
320
330
340
350
360
0 1000 2000 3000
Cel
l tem
per
atu
re [
K]
Time under 1000 W/m2 irradiance [s]
Thin white
Thick white backsheet
Thick white
(2x 2mm glass)
(4mm glass)
(2x 3.2mm glass)
Reduced time constant thin vs. thick
290
300
310
320
330
340
350
360
0 1000 2000 3000
Cel
l tem
per
atu
re [
K]
Time under 1000 W/m2 irradiance [s]
Thin white
Thin black
Thick white
Thick black
Reduced time constant thin vs. thick
independent on white/black
Reduced temperature white vs. black
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SolSThore – Activity 4Outdoor measurement
0
0,2
0,4
0,6
0,8
1
1,2
thin white thick white thin black thick black
No
rmal
ized
En
ergy
p
rod
uct
ion
Energy production – Measured [kWh]
+2.3%+5.3% +1.1%
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SolSThore – Activity 4Energy yield Simulations
0
0,5
1
1,5
Thin White ThickWhite
Thin Black Thick BlackNo
rmal
ised
ener
gy
pro
du
ctio
n
Energy Production - prediction [kWh]
+1.3%+2.6%+5.1%
0
0,2
0,4
0,6
0,8
1
1,2
thin white thick white thin black thick black
No
rmal
ised
Ener
gy
pro
du
ctio
n
Energy production – Measured [kWh]+2.3%+5.3% +1.1%
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SolSThore – Activity 4Summary
E-yield estimation
Measurement design
Custom-made
measurement
equipment and
methods
Beyond state-of-
the-art outdoor
PV module
characterisation
setup
Validated
physics-based
energy yield
prediction
framework
Indoor
Characterisation
Modelling
Physical-
Characterisation
Outdoor
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Activity 5PV System Demonstrators
Kris Baert
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SolSthore Activity 5 : PV system integration
• PV integration in facades
• Commercial roof PV connected to a bipolar DC grid -> see
• poster : Low Voltage DC grid (EV-1, 2F, Home Lab)
• demo : rooftop PV installation (EV-1)
• Grid compliance testing by Real-Time Grid Emulator-> see
• Poster : Grid Compliance Testing of DC/AC PV Inverter (EV-1, Matrix Lab, 0F)
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The case for integration of PV in facades of high-rise buildings
2020 NZEB directives => enhanced use of PV on buildings
• rooftop area for PV often scarce
• aesthetics suited for office-buildings
• high facade engineering capacity
• benign to the local grid (congestion !)• generation close to consumption
• in sync with airco load
• East – South – West facades => flatter day profile
• seasonal profile
• façade cost Euro/m2 marginally increased and compensated by enhanced “greening”
Heron Tower London
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595/06/2018
The case for PV in ‘’curtain walls”
North Galaxy, Brussels
• Industrially pre-fabricated
• Semi-standardized dimensions
• Millions of m2 / year of facades installed
• multi-GW /yr. production opportunities for PV for facade-integration
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605/06/2018
=> See Demo “Curtain wall BIPV” in Matrix Lab (0F)
Prototype: PV in curtain wall
PV module
Glass
Ventilation
holes
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Thermal and electrical performance
Impact of black vs. white
backsheet in PV module:
- on operating temperature
- on energy yield
Impact of ventilation :
- on operating temperature
- on energy yield
Curtain wall BIPV element
feeding into DC Nanogrid
• Temperature distibution
• Energy yield
• DC/DC converter effic
=> See Poster “BIPV set-ups” in Matrix Lab (EV-1, 0F)
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Modelling of BIPV solutions: Modellica IDEAS
Key features
• Object-oriented modelling
tool
• Open source library of
building components
• Clear and organized
documentation
Simulation examples
• BIPV configurations
• shading effects @cell level
=> See poster ‘’ Incorporation
of Façade-Integrated PV
models (Hygrothermal,
Electrical) in IDEAS ” in
Matrix lab (EV-1, 0F)
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Simulations and measurements of BIPV curtain wall
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What’s next ?
• Frame integration of EnergyVille’s DC/DC converter
• Develop, test and model otherfacade-BIPV building solutions
• for non-office buildings
• for integration in solar shades
• …
See demo : Facade-BIPV panels on East –South- West of EnergyVille-2 (2F)