DOE Advanced Manufacturing Office - Wide Band-Gap Power Electronics Programs

Transcription

1 DOE Advanced Manufacturing Office - Wide Band-Gap Power Electronics Programs Allen Dr. Hefner Anant Agarwal (NIST) Acting Technology Senior Advisor, Manager, Wide Band WBG Gap Power Technology Electronics US Department of Energy Advance Manufacturing Office

2 AMO Vision and Mission AMO Vision and Mission Vision: U.S. global leadership in sustainable and efficient manufacturing for a growing and competitive economy. Mission: Catalyze research, development and adoption of energy-related advanced manufacturing technologies and practices to drive U.S. economic competitiveness and energy productivity. 2

3 AMO Activities Bridge the Technology Development Gap AMO pursues its goals through three subprogram approaches: Advanced Manufacturing R&D Projects Advanced Manufacturing R&D Consortia Industrial Technical Assistance 3

4 AMO: Three Subprogram Approaches Technical Assistance: Engagement with Industry Driving a corporate culture of continuous improvement and wide scale adoption of proven technologies to reduce energy use in the industrial sector R&D Consortia: Public-Private R&D Partnerships Shared R&D Consortia offer affordable access to physical and virtual tools, and expertise, to foster innovation and adoption of promising technologies R&D Projects: Bridging technology innovation gaps Research and Development Projects to support innovative manufacturing processes and next-generation materials and systems 4

5 AMO R&D Consortia PowerAmerica 5

6 The Institute Design Creating the space for Industry & Academia to collaborate White House Report NNMI Framework Design January

7 Interagency Advanced Manufacturing National Program Office AMNPO Executive Office of the President Advanced Manufacturing Partnership (AMP/PCAST) Advanced Manufacturing National Program Office (hosted by DOC - NIST) NSTC - Subcommittee on Advanced Manufacturing 7 Frank W. Gayle, Sc.D. Advanced Manufacturing National Program Office 7

8 Two upcoming DOE-led NNMI Institutes Network Status and 2016/17 Plans Since launching in 2012: $600M+ Fed matched by $1.3B+ non-fed 1,300+ companies, universities, and non-profits involved 30+ states Flexible Hybrid Electronics San Jose, CA Smart Manufacturing Los Angeles, CA Additive Mfg Youngstown, OH AIM Photonics Rochester, NY AFFOA - Fibers and Textiles, Cambridge MA Wide Bandgap Semiconductors Raleigh, NC Planned 2016/17 Open topic: 1 or 2 institutes Adv. Tissue Biofabrication Robots in Mfg. Environments Modular Chemical Process Intensification REMADE (Sustainable Mfg) Digital Mfg & Design Chicago, IL Lightweight Metals Detroit, MI Highlighted states have major participants in Manufacturing USA Institutes Advanced Fiber- Reinforced Polymer Composites Knoxville, TN 8

9 PowerAmerica Institute at NC State University Vision Energy savings through deployment of WBG Power Electronics & Development of a Manufacturing Base in the US through: Achieving low prices of WBG devices in 5 years Power Electronics Demonstrations Training Graduate students in the use of WBG Semiconductors PowerAmerica started operations on Feb. 01, 2015 with $140 M funding over 5 years 9

10 Current and Pending PowerAmerica Partners Institute Lead North Carolina State University Universities Arizona State University Auburn University Florida State University Kettering University The Ohio State University Rensselaer Polytechnic Institute University of California, SantaBarbara University of California, Davis University of Tenneesee, Knoxville Virginia Polytechnic Institute Laboratories National Renewable Energy Laboratory U.S. Naval Research Laboratory Argonne National Laboratory Industry Pending ABB General Motors Powertrain AgileSwitch Oak Ridge National Laboratory Atom Power CoolCad Electronics Delphi GeneSiC Infineon Technologies Americas Corp. InnoCit JENOPTIK Advanced Systems, LLC John Deere Electronic Solutions Lockheed Martin Monolith Semiconductor Navitas Power Electronics Industry Collaborative Qorvo Raytheon Toshiba Transphorm United Silicon Carbide, Inc Wolfspeed (formerly CREE + APEI) X-Fab 10

11 WBG Power Semiconductor Roadmap Reduce chip costs 50% every 2 years with improved performance Achieve WBG cost parity with Si in 5 years Reduce WBG cost below today s silicon price in 5-8 years Manufacturing 8-inch wafers in 5-8 years WBG devices replacing 600V-1700 V Si in mainstream applications within 5 years Development of kv devices enabling new applications in MV motor and Grid Power Control The market for WBG devices will double every 2 years from $100M to $3B in 10 years New Systems, enabled by WBG, will create $20B in new global markets 11

12 AMO Workforce Development WBG Power Electronics Traineeships 12

13 Wide Bandgap Traineeship--$ 5M for 5 Yrs Purpose Provide hands-on training of students in WBG power electronic devices and their application. Benefits Ensure a pipeline of well-trained professionals entering industry and academia Enable a chain reaction of higher education in WBG technology for decades University of Tennessee Virginia Polytechnic Institute Program Impact: > 45 U.S. citizen M.S. and Ph.D. graduates in power engineering over 5 years 7 new graduate courses developed focusing on WBG Converters, electrical systems packaging, WBG characterization and applications Students involved with National Laboratory and Industrial Internships Goal: Train at least 100 Graduate students in 5 years 13

14 AMO R&D Projects Next Generation of Electric Machines 14

15 Opportunities for WBG: Electric Motors (1-50 MW) Approx. 14% of total electricity in COG flows through Large Motors Hydrogen Gas Compressors (Hydro-cracking in Oil Refineries) Booster Stations in NG Pipelines, High density polypropylene extruders Ethylene Gas Compressors, Sea water injection and lift, etc. Opportunity for significant Energy Savings: 2-4% of Electricity through WBG Variable Speed Drive 15

16 500 kw, 3000 lb Motor Drive More Expensive than the motor 16

17 500 kw SiC MOSFET Based Drive Size and weight reduction, increased efficiency, lower cost 15 kv SiC MOSFET/Diode Much Cheaper than Si Solution Courtesy of Subhashish Bhattacharya (North Carolina State University) 17

18 US Manufacturing Advantage by combining Several Key Technologies in an Integrated Approach Traditional 20-40% energy is wasted with throttles and other mechanical devices 13.8 kv 3 phase 60 Hz Big 60 Hz Transformer 4.16 kv 3 phase 60 Hz 1-50 MW 60 Hz Motor 1800 RPM Gear Box 1:G(5-10) Compressor Fixed Speed 9 K-18 K RPM NGEM: 1 Integrated System ($22M) 13.8 kv 3 phase 60 Hz Variable 18 Smaller Foot-print (up to 5x) Speed Drive SiC Based New Approach 1-50 MW Gx60 Hz Motor G x smaller Volume Big 60 Hz Transformer replaced by small high frequency Transformer Motor size reduced by 5x cheaper, less magnets Delivered as one box Compressor Variable Speed 9 K-18 K RPM 20-40% energy per motor system is saved due to Variable Speed Drive pay-back < 3 years Gear Box eliminated NGEM 2: Enabling Technologies ($25M)

19 NGEM I Megawatt Class Machines Objective: Establish US manufacturing advantage by combining Wide Band Gap technology in a drive integrated, gear free, high speed motor approach. Impact: 90% deployment of MV VSDs to motors used in >500 HP applications throughout the industrial sector would present an energy savings opportunity of up to 1.2% to 3.2% of total U.S. electricity consumption, assuming 30% to 80% energy savings by using MV VSDs. FOA Targets: Metrics Si-based VSD integrated motor system WBG-based VSD integrated motor system NGEM 1 improvement targets Efficiency 90% 93% 30% loss reduction Inverse volumetric power density m 3 /MW 6.31 m 3 /MW 217% increase in power density Foot print 7.44 m 2 /MW m 2 /MW 243% decrease in foot print. 19

20 NGEM II Key Enabling Technologies Objective: Leverage advancements in key technologies enabling more efficient use of electricity, as well as reduce system size and weight in a cost effective way, while addressing the limitations of traditional conductive metals and electrical steels. Impact and FOA Targets: Topic Areas Technical Target Performance Metrics High performance conductors >33% reduction in stator I 2 R losses Electrical conductivity at 150 C > MS/m Low loss electrical steels >37.5% reduction in core losses Electrical resistivity > 80 μω-cm in > 0.5mm thick lams Amorphous materials >50% reduction in core losses Efficiency 96% in 5kW RE free industrial motors Superconducting electric machines >3x improvement in J e at 77 K, 1.5T J e > 1440A/cm-width at 77 K, 1.5T Other Enabling Technologies Key to NGEM I and Technical Targets Insulation materials High temperature (>300 C) insulation materials for WBG MV (>4.16kV). high frequency (>500Hz,) megawatt class motors Bearings Lead and Bismuth free journal bearings and bushings for WBG MV (>4.16kV), high frequency (>500Hz), megawatt class motors 20