Air Force Research Laboratory Design of SMES Devices for Air and Space Applications 12 Oct 2011 Integrity Service Excellence Timothy J. Haugan, Ph.D. Research Physicist Propulsion Directorate Air Force Research Laboratory 19 October 2011 1
Authors, Acknowlegements D. Latypov, J. V. Holle, BerrieHill Research Corp. Acknowledgments: AFRL/RZP Power Division and Air Force Office of Scientific Research 2
Outline: Introduction Air and Space Applications - 0.2 MJ for INVENT energy management - 5-50 MJ for Directed Energy - 0.2 to 2 GJ for Electric Aircraft power SMES Design Criteria and Optimization - Weight - Volume - Energy and Power Densities (mass specific) - Machine and Lifecycle Cost - Efficiency (charge/discharge cycle) - Operability and Logistics 3
Ragone Chart E. Shaffer (Army RDECOM), Power and Energy Tutorial, DEPS Nov 2010 4
Ragone Chart E. Shaffer (Army RDECOM), Power and Energy Tutorial, DEPS Nov 2010 5
Ragone Chart ~ NbTi or BSCCO wire BNL YBCO wire SMES - 30 MJ SAFT Li Battery 30 MJ (Discharge) (Charge) Chevy Volt Li-Battery 38 MJ (Discharge) Fuel Cells (Charge) Base chart from ASC 10 6
Energy Storage Power Ratings lower? IEEE Power and Energy Magazine, pp. 32-41, jul/august 2009 7
0.2 MJ Systems: Integrated Vehicle and Energy Management (INVENT) 0.3 m 0.15 m 8
More Electric Aircraft http://www.ece.cmu.edu.pdf 9
Boeing 787 Electrical Systems http://www.ece.cmu.edu.pdf 10
INVENT Energy Management Electrical Accumulator Unit: stores and controls power coming back onto the bus off of the load Loads: electromechanical actuators (EMA), electrohydrostatic actuators (EHA), directed energy weapons (DEW), advanced radar J. Wells, et al, Electrical Accumulator Unit for the Energy Optimized Aircraft, SAE International Journal of Aerospace, v. 1(1): pp. 1071-1077, 2008 11
Peak Power (pu) Power Fluctuations on Modern Electric Aircraft (MEA) Power Draw Avg Load pu = power/avg power Representative Transient Power Profile Power back onto bus - Power: Pulsed transients of 150 kw can occur in about 10 ms - Regenerative Power: up to 150 kw waste heat - Duty Cycles: 25-100% - Switching frequencies: 0-20 khz J. Wells, et al, Electrical Accumulator Unit for the Energy Optimized Aircraft, SAE International Journal of Aerospace, v. 1(1): pp. 1071-1077, 2008 12
5-50 MJ Systems: Directed Energy 0.75 m 0.25 m 13
Hybrid Power for Laser Weapons DEPS 2010 Conference Proceedings, General Atomics Aeronautical Distribution A : Approved for public release; Distribution unlimited 14
58 MJ Electrical Energy DEPS 2010 Conference Proceedings, General Atomics Aeronautical Distribution A : Approved for public release; Distribution unlimited 15
500 kw Li Batteries for DE Power Energy: 58 useable, ~ 200 MJ actual (?) Discharge time: 30-60 sec Recharge Time: 10-15 min Weight: - Total ~ 500 kg Cost: ~ $0.5-1 M (?) DEPS 2010 Conference Proceedings, General Atomics Aeronautical Distribution A : Approved for public release; Distribution unlimited 16
37 MJ System* Li Batteries Chevy Volt Charge time: 6-6.5 hrs Weight: ~ 170 kg Cost: ~ $13K * Actual = 58 MJ, however useable = 38 MJ http://gm-volt.com/2010/07/19/chevrolet-volt-battery-warrantydetails-and-clarifications/ 17
Brookhaven National Lab SMES YBCO-wire ~ 30 MJ 0.75 m 0.25 m Charge/Discharge Time : 1 sec Mass: ~ 250-300 kg dominated by wire; wire mass could drop ~ 5-10 x with new wire architecture (?) Cost: YBCO ~ $2.1M (will reduce < $2M in future) 18
Energy Storage Comparison 30-60 MJ Class 38 MJ Li-Battery Chevy-Volt 58 MJ Li-Battery SAFT 30 MJ AFRL YBCO-wire SMES Energy 38 MJ* 58 MJ* 30 MJ Power 136 kw 500 kw > 30 MW Charge Time 6-6.5 hrs 10-15 min ~ 1 sec Discharge Time 280 sec** 30-60 sec ~ 1 sec Mass 170 kg ~ 500 kg*** ~ 320 kg # Cycles Lifetime ~ 3000-4000 ~ 30,000 > 200,000 (?) Efficiency ~ 96 % ~ 98 % Price (rough) $ 13K ~ $ 0.5-1 M ~ $ 1-2 M Issues Very long charge time Fire hazard Withstand g- forces and vibration (?) * For Li batteries, only useful capacity = ~ 60% of total capacity is shown; e.g. for Chevy Volt actual capacity = 58 MJ but only 30-90% of the cycle can be used ** Not sure if fire hazard for this discharge rate ** Includes fire suppressant system 19
Ragone Chart ~ NbTi or BSCCO wire BNL YBCO wire SMES - 30 MJ SAFT Li Battery 30 MJ (Discharge) (Charge) Chevy Volt Li-Battery 38 MJ (Discharge) Fuel Cells (Charge) Base chart from ASC 10 20
0.2-2 GJ Systems: Aircraft Power 1.2 m 0.4 m 21
Electric-Aircraft: YUNTEC Int. e430 4 Passenger Aircraft @ 100 kw 2 passenger aircraft http://yuneeccouk.site.securepod.com/aircraft. html Impacts: - Flight Efficiency: 25% or more - Fuel Cost : 10x - Maintenance: only a few parts - Ownership Cost : extremely low - Noise: ultra-quiet - CO 2 emission: potentially zero - Other: vertical lift, distributed, etc.. Specifications Fuel Cost @ 100 kw Motor Efficiency ~ 10-15 % Fuel @ 100 kw Combustion All-Electric Engine (glider-style) (typical) ~ $50/hr ~ $3/hr (?) 95 % 9 gal/hr 90 MJ/hr Fuel Weight 70 lbs 150-300 lbs (Li-Polymer) 22
Electric Aircraft: Pipestrel G4 Taurus NASA $1.35M Winner Green Flight Challenge Largest prize in aviation history http://www.wired.com/autopia/2011/08/pipistrel-taurus-g4-electric/ http://www.ens-newswire.com/ens/oct2011/2011-10-04-01.html, other Capacity: 4 passenger Battery Size: 270 MJ / 2 hr Battery Weight: ~ 450 lbs per 270 MJ (one source 1100 lbs) Battery Type: Li-polymer; non-insurable fire hazard Fuel Efficiency: ~100 miles/gallon (!) Fuel Cost: $3/hr (!) Other Specifications Motor: 150 kw Motor Efficiency: 95% (includes controller) Drivetrain+Propeller Efficiency: ~ 60-70%? (gearbox needed) Total Empty Weight = 1250 lbs (without battery) Max. Possible Weight: 3300 lbs 23
Electric-Aircraft: EADS VoltAir EADS VoltAir all-electric aircraft concept unveiled in Paris European Aeronautic Defense and Space Company N.V. (EADS) parent company of Airbus Battery Size: 20-100 GJ VoltAir's two next-generation lithium-air batteries would power two highly efficient superconducting electric motors as batteries approach and exceed energy densities of 1000 Wh/kg within the next two decades. http: http://www.earthtechling.com/2011/06/eads-voltair-concept-the-ev-of-the-skies/ http://www.gizmag.com/eads-voltair-electric-airliner/18988 24
Hybrid-Electric Aircraft: NASA Subsonic Airliner (~2030) 30 MW Superconductor Power Transmission Superconductor Applications Needed Generators Motors Power Transmission Cables Power Inverters Class 30-40 MW 4-6 MW 5-70 MW, DC 270V 1-30 MW H. D. KIM 30 MW Superconductor Electrical Generator ~ 6 MW Superconductor Electrical Motor TurboFans Power Electronics 30-40 MW - Fuel Efficiency: +70% - Potential World-Market Pull: $400B/yr savings Recent NASA contract awards of $12.6M @ http://www.aeronautics.nasa.gov/nra_awardees_10_06_08.htm C.A. Luongo, et al, IEEE Trans. Appl. Supercond. 19(3), 1005 (2009) 25
Design Criteria Summary 0.2 MJ INVENT 5-50 MJ Directed Energy 0.2-2 GJ Electric Drive Aircraft High Duty Cycle 10 4 1 AC Loss 10 8 1 High Efficiency 7 8 10 Low Weight/Volume 5 8 10 Operability/Logistics 9 7 6 Cost 7 9 10 Rating Scale: 10 is highest and 1 is low for importance (approximate) 26
J E (A/mm²) 10000 J E vs Applied Field km-length Wires @ 4-5K YBCO B Tape Plane YBCO B Tape Plane 1000 Nb-Ti RRP Nb 3 Sn Complied from ASC'02 and ICMC'03 papers (J. Parrell OI-ST) 2212 427 filament strand with Ag alloy outer sheath tested at NHMFL SuperPower tape used in record breaking NHMFL insert coil 2007 100 10 MgB 2 18+1 MgB 2 /Nb/Cu/Monel Courtesy M. Tomsic, 2007 Maximal J E for entire LHC Nb Ti strand production ( ) CERN- T. Boutboul '07, and (- -) <5 T data from Boutboul et al. MT-19, IEEE- TASC 06) Bronze Nb 3 Sn 4543 filament High Sn Bronze-16wt.%Sn- 0.3wt%Ti (Miyazaki- MT18-IEEE 04) 0 5 10 15 20 25 30 35 40 45 Applied Field (T) YBCO Insert Tape (B Tape Plane) YBCO Insert Tape (B Tape Plane) MgB 2 19Fil 24% Fill (HyperTech) 2212 OI-ST 28% Ceramic Filaments NbTi LHC Production 38%SC (4.2 K) Nb 3 Sn RRP Internal Sn (OI-ST) Nb 3 Sn High Sn Bronze Cu:Non-Cu 0.3 http://magnet.fsu.edu/~lee/plot/plot.htm 27
SMES Power Density Power Density B 2 /(2*μ o ), so YBCO wire can achieve much higher power densities by making small magnet coils = 25-30T (?) YBCO wire is 5-7x stronger than BSCCO or LTS, which is needed for high-field magnets. 28