ieee presentationpower rectifiers
TRANSCRIPT
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AC to DC Power Conversion Now and in the Futu re
PCIC-2001-14
Tony Siebert Anders Troedson Stephan Ebner Member, IEEE Member, IEEE Member, IEEE
ABB Automation, Inc ABB Automation, Inc ABB Industrie AG
P.O. Box 372P.O. Box 372 CH- 5300 Turgi
Milwaukee, WI 53201 Milwaukee, WI 53201 Switzerland
USA USA
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Agenda
• Introduction
• System Design Factors
• Technology Assessment
–
• Technology Comparison
• Innovative Information Technology (IT) support• Conclusions
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Rectifier History
1913 Fist Mercury-Arc rectifier
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
1925 Mercury-Arc rectifier for grid control
1939 First 50 kV HVDC transmission
1950 Development of Contact Rectifier
1947 Invention of Transistor
1902 Invention of Semiconductor Diode (Crystal type)
Mercury Arc Rectifier Contact Rectifier
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Rectifier History
1958 First semicond. Diode rectifier
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
1960 First diode plant > 100 kA
1968 First thyristor rectifier 1970 First diode rectifier unit > 100 kA
Introduction of Thyristor Technology
Introduction of Diode Technology
Thyristor Rectifier Diode Rectifier
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Rectifier History
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
1990 First thyristor rectifier for DC-Arc Furnace
1985 First thyristor rectifier for Aluminium Smelter
Ongoing Development of Diode Rectifier Technology
Ongoing Development of Thyristor Rectifier Technology
3” Thyristor Rectifier 4” Thyristor Rectifier 2” Thyristor Rectifier
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Rectifier History
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
Mid-1990’s first Chopper rectifier in Eletrolysis
Introduction of GTO TechnologyIntroduction of IGBT Technology
Introduction of IGCT Technology
IGBT Chopper Module PowerPac3IGCT Chopper Module
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System design and decision factors
AC-Network Design Parameter Ä Voltage level / voltage variation
Ä Frequency / frequency variationÄ Available short circuit capability
Ä Allowed power factor
Ä Allowed harmonic distortion
DC-Process Design Parameter Ä Voltage / current operating range
Ä Voltage / current rippleÄ Voltage / current regulation accuracy
Ä Voltage / current regulation speed
Ä Overload capabilities
Further Decision FactorsÄ System reliability
Ä System efficiencyÄ Reparability and diagnostics
Ä Footprint and mechanical dimension
Ä Investment- / install- / life-cycle cost
Ä Production load schedule criteriaÄ Energy day-time tariffs criteria
Ä Plant start-up / lay-off criteria
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Process Ratings
Rectifier Application Current (Amps) Voltage (DC)
Chemical electrolysis 5,000 - 150,000 40 - 1,000 Volts
Aluminum potline 10,000 - 300,000 < 1,300 Volts
DC Arc Furnace 50,000 - 130,000 600 - 1,150 Volts
Graphitizing Furnaces 20,000 - 120,000 50 - 250 Volts
Zinc/Lead, etc electrolysis 5,000 - 100,000 100 - 1,000 Volts
Copper refining 10,000 - 50,000 40 - 350 Volts
Traction substations 1,000 - 5,000 500 - 1,500 VoltsLV AC Drive (DC bus) 0 - 10,000 250 - 1,000 Volts
MV Drive (DC bus) 0 - 5,000 3,400 - 6,000 Volts
Typical Rectifier Rating
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Technology Assessment
• Diode
• Thyristor
• Diode and DC/DC Converter
(Chopper)
• Active Rectifier
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Diode Rectifier Topology
Double wye connection with interphase transformer
LOAD
6 puls circuit
3 - phase bridge connection
LOAD
6 puls circuit
Di d S t R l ti P i i l
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Diode System Regulation Principle
Step of current setpoint
Step of OLTC
current without saturable reactor ramp control ( load impedance related )
current with saturable reactor ramp control
Range of saturable reactor control
T *) typ. 3 .. 5 s depending on OLTC drive
(saturable reactor control up to 5 ms depending on the load)
t [seconds]
Idc[kA]
T *)
Di d R tifi
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Diode Rectifiers
• Simplest Technology
• Longest use
• Used with On-Load-Tap-Changers
• Used with saturable core reactors
(amplistats, voltage controlled reactors)
2 4 - P u l s e D i o d e R e c t i f i e r
+ 7 . 5 °
- 7 . 5 °
L o a d
Th i t R tifi T l
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Thyristor Rectifier Topology
Double wye connection with interphase transformer
LOAD
6 puls circuit
3 - phase bridge connection
LOAD
6 puls circuit
Th i t S t R l ti P i i l
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Thyristor System Regulation Principle
Step of current setpoint
theor.current without phase angle ramp control () ( load impedance related )
current with phase angle ramp control in operation
Range of phase angle control
T *) typ. 100 ms .. 300 ms
possible up to 5 ms depending on the load
T *) t [milliseconds]
Idc[kA]
Steps only with OLTC
Th ristor Rectifiers
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Thyristor Rectifiers
• Simple Technology
• Widely Used
• Can be used with On-Load-Tap-
Changers• Relatively fast control of current
2 4 - P u l s e T h y r i s t o r R e c t i f i e r
+ 7 . 5 °
- 7 . 5 °
L o a d
Diode Rectifier + DC Chopper Topology
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Diode Rectifier + DC-Chopper Topology
3 - phase bridge connection
LOAD
6 puls circuit
DC Chopper Regulation Principle
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DC-Chopper Regulation Principle
Step of current setpoint
theor.current without PWM ramp control ( load impedance related )
current with PWM ramp control
Range of modulation control
T 1) typ. 100 ms .. 300 ms with electrolyis process load
possible up to 1 .. 5 ms depending on the load
t [milliseconds]
Idc[kA]
T 1)
Tmod 2) typ. 0.2 ms .. 1 ms
Tmod2)
Ton Toff
Diode Rectifier with Chopper Converter
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Diode Rectifier with Chopper Converter
• Newer Technology
• Relatively entering into Market
• Merging of older (diode) and new
technology• Fast control of current
+7.5°
-7.5°
Active Rectifier Topology (AC Chopper)
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Active Rectifier Topology (AC-Chopper)
3 - phase bridge connection
LOAD
6 puls circuit
Active Current Source Inverter
AC Chopper Regulation Principle
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AC-Chopper Regulation Principle
T 1) typ. 100 ms .. 300 ms with electrolyis process load
possible up to 1 .. 5 ms depending on the load
Step of current setpoint
theor.current without ramp control ( load impedance related )
current with ramp control
Range of modulation control
t [milliseconds]
Idc[kA]
T 1)
Tmod 2) typ. 0.2 ms .. 1 ms
Tmod2)
Ton Toff
Active Rectifier (AC-Chopper)
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Active Rectifier (AC-Chopper)
• Newest Application of Technology
• Limited Market entry
• Based upon proven technology• Fast control of current
Active Current Source Inverter
Load
Technology use by Process
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Technology use by Process
Application Diode Thyristor Chopper Active Rectifier Chemical Electrolysis Seldom Standard Seldom Future
Aluminum Potline Standard Seldom Not Acceptable Distant Future
DC Arc Furnace Not Acceptable Standard Seldom Future
Graphitizing Furnace Standard Seldom Future FutureZinc Electrolysis Standard Seldom Future Future
Copper Refining Seldom Standard Seldom Future
Traction Substation Standard Seldom Future Distant Future
LV AC Drive (DC Link) Standard Seldom Not Applicable SeldomMV Drive (DC Link) Standard Seldom Not Applicable Seldom
Technology Share
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Technology Share of Units > 10 kA
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
1 9 7 2
1 9 7 4
1 9 7 6
1 9 7 8
1 9 8 0
1 9 8 2
1 9 8 4
1 9 8 6
1 9 8 8
1 9 9 0
1 9 9 2
1 9 9 4
1 9 9 6
1 9 9 8
2 0 0 0
Chopper
Thyristor
Diode
Technology Share
Technology Comparison
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Technology Comparison
• Power Factor
• Efficiency
• Harmonic Distortion
• Reliability / Availability / Service Support
• Space Requirements• System Cost
The Process Load Characteristic
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The Process Load Characteristic
U d o
I d
Aluminium
Zinc
Chlorine
Copper
I Range
U Range
100 %
100 %
50 %
25 %
75 %
Power Factor Comparison
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Power Factor Comparison
Power Factor vs Transformer Impedance
0.8800
0.8900
0.9000
0.91000.9200
0.9300
0.9400
0.9500
0.9600
6 7 8 9 10 11 12
Transformer Impedance
P o w e r
F a c t o r
Diode / DB
Thyristor / DB
Note: Low Transformer Impedance = High Voltage
Harmonics
Power Factor Comparison
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Power Factor Comparison
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
250.00 300.00 350.00 400.00 450.00Ud [V]
P F
[ - ]
Diode OLTC Thyristor OLTC Thyristor Uncompensated Thyristor Compensated
Diode vs Thyristor with Electrolysis Process Load
Ud
Id
Power Factor Comparison
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Power Factor Comparison
• Diode Good
• Thyristor Low
• Diode and Chopper Good
• Active Rectifier Best
Efficiency vs. Voltage
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y g
0.9
0.91
0.92
0.93
0.94
0.95
0.96
0.97
0.980.99
1
0 200 400 600 800 1000 1200 1400 1600Voltage
E
f f i c i e n c y
Typ Dio/Thy Bridge Typ Dio/Thy Single Way
Typ Chopper Dio/Thy Projects
Comparison at Nominal load Operation
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p p
Nominal Load Operation DC-Voltage: 500 V
DC-Current: 70 kA
DC-Power: 35 MW
Diode
System
Thyristor
System
Chopper
System
AC-Power (12p-Transformer) 39 MVA 41 MVA 38 MVA
Power Factor without correction 0.91 0.86 0.93
Compensation up to PF=0.93 3 MVAR 8 MVAR -Compensation up to PF=0.98 10 MVAR 15 MVAR 7 MVAR
Losses
Transformer (including harmonics) 430 kW 450 kW 400 kW
Rectifier 183 kW 192 kW 170 kW
Chopper 250 kWLine Filter (for PF=0.93) 56 kW 84 kW
Total 669 kW 726 kW 820 kW
Relative Difference -151 kW -94 kW 0 kW
Efficiency (for Components considered) 0.981 0.980 0.977
Comparison at Reduced load Operation
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p p
Reduced Load Operation DC-Voltage: 440 V
DC-Current: 50 kA
DC-Power: 22 MW
Diode
System
Thyristor
System
Chopper
System
AC-Power (12p-Transformer) 25 MVA 34 MVA 24 MVA
Power Factor without correction 0.90 0.65 0.93
Compensation up to PF=0.93 3 MVAR 8 MVAR -Compensation up to PF=0.98 10 MVAR 15 MVAR 7 MVAR
Losses
Transformer (including harmonics) 240 kW 260 kW 170 kW
Rectifier 105 kW 120 kW 100 kW
Chopper 250 kWLine Filter (for PF=0.93) 56 kW 84 kW
Total 401 kW 464 kW 520 kW
Relative Difference -119 kW -56 kW
Efficiency (for Components considered) 0.982 0.979 0.977
Efficiency Comparison
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y p
• Diode High
• Thyristor Medium - High
• Diode and Chopper Low
• Active Rectifier Medium - Low
Harmonic Comparison
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p
15
711
1317
1923 25
2931
3537
4143
47
0o
20o
40o
6 0 o
0
2
4
6
8
10
12
14
16
AC Current in [kA]
Harmonic Number
2 0 k A , 20 0 V DC , 6 P u l s e R e c t i f i e r
D i o d e a n d C h o p p e r ( 0 d e g r e e s ) a n d T h y r i s t o r d e p e n d i n g o n o u t p u t D C v o l t a g e )
0o
10o
20o
30o
40o
50o
60o
Harmonic Comparison
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• Diode Good
• Thyristor Lower
• Diode and Chopper Good
• Active Rectifier Best
Reliability Comparison
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Based Upon Component Count ofRectifier Devices
• Diode High
• Thyristor High
• Diode and Chopper Low• Active Rectifier Medium
Service Skill Comparison
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• Diode Low
• Thyristor Medium
• Diode and Chopper High
• Active Rectifier High
System Cost Comparison
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Diode Rectifier 105%
Thyristor Rectifier 100%
Diode & Chopper 124%
Active Rectifier 115%
Based upon past projects, component count and further
developments.
Space Comparison
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• Diode Average
• Thyristor Larger
– (with power factor included)• Diode and Chopper Larger
• Active Rectifier Average
Conclusions
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Considerations
• Total System Requirements• Future Provision of System
Requirements
• Customer’s Experience / Background
• Technology comparison for exact
project
– All Technologies Will continue for near
future
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- Thank You -