superpower’s path to leadership in clean, green and smart ...adv...superpower’s path to...

superior performance. powerful technology.

SuperPower Inc. is a subsidiary of Furukawa Electric Co. Ltd.

superior performance. powerful technology.

SuperPower’s path to leadership in clean, green and smart energy technologyTraute F. LehnerSr. Director, Marketing & Gov’t Affairs

Advanced Energy Conference May 1, 2013 New York, NY

Advanced Energy Conference New York, NY May 1, 2013All Rights Reserved. Copyright SuperPower® Inc. 2013

Topics

• Role of superconductivity in clean energy• Three stage evolution of SuperPower as a clean-energy company• Technology scale-up• Device demonstrations• Learning from the marketplace• Current status and a look ahead

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SuperPower’s evolution as a clean energy company

• 2000-2006: The Intermagnetics Years– 2G HTS technology development– Pilot production scale-up – Demonstration projects – energy focus

• 2006-2012: The Philips Years– Transition to commercialization– Exploration of other commercial markets– Buildup of broad customer base

• From 2012 onward: The Furukawa Years– Mass production focus– Drive to long-term sustainability in a slowly evolving market

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What is a superconductor?

• A material that, when cooled to a critical temperature, loses all resistance to the flow of electrons (no losses!!)– Initial (LTS) discovery 1911– New (HTS) materials discovered in

1986

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Magnet levitating over a superconductor –Meissner Effect

Liquid Nitrogen

Liquid Helium

HTS LTS


The power of energy density

• More power in less space– Smaller, lighter – compact and efficient devices

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Current carrying capability of copper ~ 100 A/cm2

Current carrying capability of superconductor film ~ 5,000,000 A/cm2

Current carrying capability of 2G wire ~ 25,000 A/cm2

Superconductor (black dot)area = 0.01 mm2

Total wire area = 1.019 mm2#6 bare copper: area = 13.27 mm2

=


Clean, green and smart energy solutions

• Devices fabricated with HTS– Greater efficiency– Environmentally friendly– Safer – Smaller footprint– Lighter– Aesthetics (NIMBY concerns)

• Security benefits• Improved quality and reliability• Form fit replacement for copper!

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SuperPower formed in 2000 to develop 2G HTS for energy tech applications

• Superconductivity group spins off from GE in 1971 – forms Intermagnetics General Corporation

– Successful business built around supplying superconducting (LTS) magnets for highly successful MRI business (Philips and others)

• Early focus on HTS begins at IGC in 1987, with discovery of HTS– Development of wire with 1G HTS materials (BSCCO)– Early device demonstrations (transformer, fault current controller) with 1G– Realization of superiority of 2G HTS materials – first to transition

• Multiple factors predict enormous market potential for 2G-based utility devices

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2G HTS1G HTS


A power grid in need of improvement

• 2-3% annual increase in demand for reliable, high quality power• Aging utility infrastructure in need of upgrade and replacement

– power outages, brownouts, power sags regularly highlight limitations of the nation’s energy delivery system

• 2 billion people worldwide without electricity - long term sustained growth• More efficient, reliable, clean and cost-effective devices are needed• $400M in VC funding provided to innovative energy tech solution providers in

2000 vs. $10M in 1995

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2003


Initial focus - 2G HTS technology development and wire production scale-up

• 2G HTS expected to provide benefits for power applications– higher current densities– higher operating temperatures– ultimately lower cost

• New manufacturing techniques akin to semiconductor industry– automated, reel-to-reel– fast, high throughput– modular and scaleable– expected to be economical in long

lengths.• Technology licensed from Lucent, LANL• Aggressive IP portfolio program

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And teaming with industry to demonstrate the technology • Leverage capabilities with industry + technology partners to reduce risk• Government support to leverage industry investment• Demonstration programs to generate visibility and confidence

– Albany HTS Cable - Sumitomo, BOC (now Linde), National Grid (DOE, NYSERDA)– HTS Transformer: Waukesha Electric (now SPX Transformer Solutions), RG&E (DOE)– Superconducting Fault Current Limiter: Nexans, AEP (DOE, EPRI, NYSERDA)

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1 MVA HTS Transformer with Waukesha Electric

Fault Current Controller with General Atomics

Albany HTS Cable with National Grid

Matrix FCL with Nexans


2006-2012 The Philips years

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• 2006: Intermagnetics is acquired by Philips for MRI magnet business– SuperPower is part of package – is there a fit?– Six years to build value, find the right home

• Build-up of strong technical and business team• Transition from pilot production scale-up to pilot-scale manufacturing

– Separation of R&D from manufacturing to focus on process standardization– Strategic Research Agreement with Univ. of Houston - TcSUH

• Strong market focus– Exploration of wide range of commercial markets – beyond energy-only

focus– Buildup of broad global customer base


HTS addresses a broad application range

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• Large market potential lies outside the capability of LTS wire• A wide range of applications with broad operating conditions & unique

requirements – needs a highly sophisticated & engineered wire.

5+ years


Broad market application opportunities identified

Energy Defense Transportation Industrial Medical Science/ Research

• FCL• Cable• Generators• Transformers,

incl. FCL• Storage

–SMES–Flywheels

• Motors• Cables• Directed

energy weapons

• Maglev• EV Motors• Rail engines• Rail transformers

• Induction heaters

• Motors• Generators• Magnetic

separation• Bearings

• Current leads

• NMR• MRI

• HF magnets• Space

exploration• SQUIDS• High energy

physics• Electronics• Cell tower

base station filters

Key:• Near-Term addressable: 1-5 years• Mid-Term: 3-7 years• Longer term: 5-10 years

Courtesy of Oswald

Courtesy of Waukesha

Courtesy of SuperPower and Furukawa

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The Voice of the Customer provides our roadmap

Application-specific requirements:

• Performance: critical current, in-field performance, engineering current density, low ac losses, piece length

• Mechanical properties: wire strength, joint options• Finishing options: insulation, stabilization, multiple geometries• Quality: uniformity, delivery time, price optimization, reliability

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A new strategic owner steps up

• Furukawa Electric acquires SuperPower in February 2012– Adding the world leader in 2G HTS to Furukawa’s long history in

LTS – Focus on long-term sustainability in a slowly evolving market

• Concentration on continuous manufacturing improvements over established baseline capabilities … to address market needs

• Steady expansion of production capacity to meet market requirements

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Market expectation: at 20-30% of device cost, significant growth is expected for HTS wire market by 2017

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Global Market for S/C Materials ($M)2012 2017 CAGR

LTS Materials $353.70 $441.80 4.50%HTS* Materials $12.30 $370.00 97.50%Total $366.00 $811.80 17.30%

$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

$300.00

$350.00

$400.00

$450.00

S/C Device Market in 2017 ($M)

HTS Wire Market ($M)

Superconducting Device Market ($M)HTS Wire

Source: Superconductors: Technologies and Global Markets, BCC Research, Oct. 2012

* HTS = MgB2, BSCCO and YBCO

The global market for Superconductivity applications is expected to grow to about $3.3B by 2017; for electrical equipment, this will amount to about $920M!

The global market for Superconductivity applications is expected to grow to about $3.3B by 2017; for electrical equipment, this will amount to about $920M!


We are meeting the requirements for today’s HTS-based devices• High performance: 100A standard; 110-150+ A premium (4 mm width)• Uniform Ic over long lengths, across wire width• High engineering current density: more energy in less space• Chemistry: two formulations suited to unique operating conditions• Flexible architecture: variety of widths and thicknesses• Superior mechanical properties: handles operating forces• High quality: thoroughly tested and qualified• Long piece lengths: routine 100-300 m lengths• Increasing capacity to meet market demand

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And making further progress with Continuous Improvement Programs …• Performance – higher critical current• Piece lengths – longer single lengths

without joints• Uniformity – tighter bandwidth, along

the length and across the width• Mechanical properties – stronger in tension, compression, and other

stresses• Capacity/Delivery time – larger quantities, faster delivery• Price – lower price per meter, improved price/performance ratio• Options – additional options including new types of insulation,

additional geometries• Major focus on product quality and performance

certification in operating conditions – Six Sigma, Lean manufacturing …

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Government funding changes – new sources enable further device demonstrations that align with key goals

• ARPA-E SMES (Oct 2010 – Sept 2013 )– $2.3M project / 80% funded by ARPA-E (ABB, BNL, UH)– In-field performance and price improvement

• DOE Smart Grid Demonstration Program - 2G HTS FCL Transformer (Dec 2010 – Sept 2015)

– $11.0M project / 50% funded by DoE (SPX, UH, SoCalEd)– Bonded wire architecture; FCL functionality, ac loss and wire

performance improvement• ARPA-E REACT program – Phase 1 (Jan 2012 – June 2013)

– $1.9M project / 50% funded by ARPA-E (UH, TECO-W, Tai-Yang, NREL)

– Improvement in process equipment, wire performance, price• DOD Army Research Lab: SMES for Micro-grid (2013-2015)

– $4.2M project; 100% funded by DOD ARL (expand on SMES work in ARPA-E) (BNL, MTECH, UH)

– AC loss reduction through superconductor tape design; adaptation of coil from utility MV interface to LV military performance requirement

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Summary

• Funding for SuperPower provided by corporate parents: Intermagnetics, Philips, Furukawa

• Partnerships and government programs critical to technology development and demonstration

• SuperPower’s wire production scaled up - stable and sufficient to meet today’s market requirements– Market requirements become more demanding– Manufacturing initiatives directed toward improvements to meet

application requirements and to speed adoption rate

• For more information: [email protected]

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