Presentation - 3G-HTS

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July 2012
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•
Founded in 2011 to commercialize a new nanotechnology and superconductor
products resulting from a decade of self funded laboratory research by Dr.
Anatoly Rokhvarger. Unique , Patented, Cost-effective and Commercially Viable
Ceramic Processing to produce composite high temperature superconductor
(HTS) macro-ceramic leads and cost effective electric round wire round wire.
•
Goal: sublicense and/or manufacture the major electrical engineering material;
the next (Third) Generation High Temperature Superconductor electric wire
and related products (3G-HTS).
•
By replacing traditional electric copper wire with inexpensive 3G
superconducting multi-filament (round) wire, industries realize a 5 – 10x
decrease in cost, weight, size/diameter, and power heat losses of electrical
cables, motors, transformers and generator rotors saving up to 20% power
consumption, yet can transmit power at room temperature like copper.
•
Multi-billion dollar world market potential – Broad applications in power
transmission systems and cables, data centers, energy storage, Internet and
telecommunications networks, electrical equipment, super-computers, defense,
marine, aviation/transportation, MRI and other medical apps
July 2012
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3G HTS electric wire innovation consists of six interrelated patented inventions;
1) the initial material formulation consisting of YBCO ceramic powder, silver powder
dope and a silicone polymer multi-purpose additive;
2) a method of deep adhesion coating of continuous metal substrate round filament
with HTS ceramic powder suspension;
3) a method of uniform magnetic orientation of YBCO grains within green coating
layer;
4) a method for the chemical-ceramic engineering processing resulting in fullydense sintered HTS macro-ceramic leads;
5) a new product - HTS ceramic coated continuous round filaments that we named
3G HTS electric wire; and
6) the fully mechanized conveyor manufacturing method using inexpensive
equipment for “substrate-filament-reel” – to – “3G HTS-wire-reel” production.
July 2012
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Adhesion
coating layer
Metal core
substrate
filament
A photo picture of the flexible 3G HTS filament made at our laboratory
where a part of the ceramic coating layer was intentionally removed to
show the YBCO ceramic coating layer of 10 µm thickness on the metal
substrate
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As opposed to 2G HTS tape, 3G HTS filaments
are as reliable and workable as ordinary
copper wire filaments and they:
• high magnetic sustainability to be efficiently
used in coils of electric motors,
transformers and generator rotors ;
• can be woven into multi-filament electric
wire or cable of any diameter for any high
level current carrying capacity capacity;
•easy spliced with each other; do not need
silver sheath;
• 8-9 micron thickness of the HTS ceramic
coating layer makes 3G HTS filaments quench
effect resistant
• do not chemically degrade (are permanently
resistant) during storage and service in air
or liquid nitrogen environment.
July 2012
•3G HTS wire and cable at liquid
nitrogen temperature can transmit
electric current density 15-20kA/cm2,
which is the most beneficial range for
HTS cables and HTS wire applications;
• The Cost : Performance ratio (C/P,
$/kA – meter) of 3G HTS wire C/P=$79/kA-m while copper has a C/P= $2050/kA-m. C/P of 3G-HTS is at the
threshold of $10/kA-m being defined
by the US DOE as the ability of HTS
wire to compete with copper electric
wire;
• The technologically available minimum
diameter of the elementary 3G HTSYBCO filament is 60 microns or
0.06mm. This 3G HTS filament can
transmit electricity comparable to
copper wire with a diameter of 6
millimeters
but with 3-5 times
decreasing heat losses.
5
July 2012
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Our patents provide protection for lowest cost techniques & better HTS electric leads :
“Sintered Ceramic Composite Lead with Superconductive NanoArchitecture”, US Patent # 7,632,784,
“Superconductor Composite Material”, US Patent # 6,617,284,
”High Temperature Superconductor Composite Material”, US Patent
# 6,239,079,
“Method of Conveyor Production of High Temperature
Superconductor Wire, and Other Bulk-Shaped Products Using
Compositions of HTS Ceramics, Silver, and Silicone”, US Patent #
6,010,983
Intellectual Property
July 2012
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• Dr. Anatoly Rokhvarger – Senior Vice President & Chief Technology Officer
D.Sc. - in Ceramic Engineering and Materials Science, Tech. Un., Leningrad, f. USSR
Ph.D. - in Ceramic Engineering and Materials Science, Chem.-Tech. Univ., Moscow
MS - in Chemical and Ceramic Engineering, Chem.-Tech. Univ., Moscow,
MS - in Applied Statistics, Design of Experiment and System Analysis, Moscow State University.
• Lyubov Chigirinskaya – Vice President - Research
Ph.D. in Chemistry Institute of Physical Chemistry of the USSR Academy of Science, Moscow
M.S. in Chemical Resistance of Materials – Metals, alloys, Polymer, The Inst. of Physical
Chemistry, Moscow,
B.S. in Metallurgy -Institute of steel and alloys, Department of Physical Chemistry, Moscow
• Norman Kaish, CEO
An innovative corporate startup developer and technology entrepreneur with over 30 years
experience specializing in the launch and development of industrial and technology based
companies. Mr. Kaish holds a BS in Business from Pace University and US and International
patents in electronic, electro-mechanical and electro-chemical technologies . He also has
extensive experience in patent and trademark filings and prosecution.
• Arthur Goldberg – Chief Financial Officer
Mr. Goldberg earned his B.B.A. from the City College of New York, his M.B.A. from the
University of Chicago and his J.D. and LL.M. from the New York University School of Law. Mr.
Goldberg is also a Certified Public Accountant
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July 2012
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Dr. Anatolii Polyanskii , Director of Magneto-Optical laboratory, Applied Superconductivity
Center (ASC), The National High Magnetic Field Laboratory Applied Superconductivity Center.
Dr. Miriam Rafailovich, Chief Scientist Advanced Energy Research & Technology Center
(AERTC) Professor of Materials Science & Engineering Program in Chemical Engineering at
the State University of New York at Stony Brook
Dr. Inna Talmy, Distinguished Ceramic Scientist Naval Surface Warfare Center (NSWC), 27
year career in superconductor and ceramic weapons applications
Mr. Michael Parizh, Electromagnetic Platform Leader, General Electric - Global Research.
Formally Senior Manager at Philips Healthcare for almost 20 years.
Mr. Mark Senti, President, Advanced Magnet Lab , Contracts with NASA and DOE in
designing, optimizing, manufacturing and testing electromagnetic systems
Dr. Eugene Medvedovski, Ph.D. in Ceramic Engineering Scientific and Project Engineering
Institute of Cable Industry, Moscow, Russia. 25+ experience in development and production of
ceramic materials and products for power transmission and other advanced applications
Dr. Sergey Drabkin, President Consela Engineering, Professional Engineer licensed in New
York, New Jersey Connecticut and Pennsylvania
July 2012
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Estimation of the wholesale market price of 3G HTS electric wire of one meter in length,
diameter 0.06mm, and conservative cost $0.30, which can transmit electricity as copper wire
with diameter 6mm and cost of one meter $10.00 - $20.00
COPPER
2G HTS
3G HTS
Current Carrying Capacity JE , kA/cm2
0.2 - 0.4
8 - 12
15-20
Cost : Performance Ratio, C/P, $/kA-m
15 - 50*
75 - 90
7-9
10-20*
450 – 600
110
4.8 – 24**
Unavailable
50
0.05 – 0.24*
Unavailable
0.5
(0.27)***
Cost of Wire 1 m x d= 1cm, $
Cost of Wire 1m x d= 0.6cm **, $
Cost of one Elementary Filament (strand), - 1
meter x d = 0.006cm, $
Estimated selling price of 1 meter of 3G HTS
electric round wire, d = 0.06mm, $
10.00 -20.00
* = wholesale market price; ** = wholesale price of #2 AWG stranded (1/4 inch) wire;
*** = initial YBCO and silver powder additive cost
July 2012
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Major Engineering Advantages
Multi-filament 3G HTS wire is
flexible, reliable, and workable as
ordinary copper wire but at liquid
nitrogen temperature transmits with
insignificant heat losses 50 – 100
times more power than ordinary
copper wire does at room temperature.
The 3G HTS-YBCO filaments can be
woven into multi-filament electric wire
or a cable of any diameter and
capacity carrying electric current as
10 – 20kA/cm2, which is the most
beneficial range for HTS cables.
Most inexpensive and Efficient HTS
ceramic forming and sintering methods
July 2012
3G HTS round filaments working at liquid
nitrogen t-re:
• have high magnetic sustainability to be
used in coils of electric motors,
transformers, generator rotors, and jet
propulsion engines;
• can transmit electricity with 3 - 5 times
less heat losses than copper wire
3G HTS wire at room temperature can
transmit power as ordinary copper wire and
multiple magnitudes more power at 77k.
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Industrial cost forecast
An industrial plant will be composed by
typical conveyor lines for “substrate
filament reel” – to – “3G HTS filament
reel” production;
- Each line should cost about $800,000
and annually produce 500km 3G HTS
wire;
- 3G HTS electric wire (filament) has
diameter 0.06 millimeter and transmits
electricity as copper wire with diameter 6
millimeter;
The production cost of one
meter of 3G HTS wire
(filament) of 0.06
millimeter diameter is
estimated as $0.30;
- The wholesale price of
one meter 3G HTS wire
(filament) of diameter 0.06
millimeter is estimated as
$10-$20 in full production.
- 3G HTS wires (filaments) can be twisted
(woven) into multi-filament electric cable.
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YBCO ceramic particles, Silver nano-powder, Silicone polymer,
Toluene solvent, and Continuous NiCr filament substrate
↓
1. Materials preparation consisting of mechanical mixing and ultrasonic homogenization of YBCO and
silver-dope powders suspension in silicone-toluene solution
↓
2. Forming HTS filaments using adhesive dip coating the core filament substrate by solid particle
suspension
↓
3. Uniform magnetic orientation of YBCO grains within green coating layer
↓
4. Polymerization in tunnel oven of silicone resin with embedded YBCO grains
↓
5. Ceramic firing consisting of multiple steps including; organic burnt out, heating, liquid-phase sintering,
cooling, oxygenation, and final cooling; all in a tube/tunnel electrical furnace with programmable
multi-step controller and oxygen flow in opposite direction of continuous movement of 3G HTS
filaments
↓
6. Finishing - twisting HTS-YBCO filaments into multi-filament electric wire w/ further coating 3G HTS
wire by silicone polymer resin and thermal polymerization of insulation sheath
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A cost-effective thermo-chemical (Ceramic Engineering) method for nanofabrication of the formed and sintered
(backed) macro-size ceramic leads from initial high temperature superconducting (HTS) ceramic particles making equal
inter-grain superconductivity of 3G HTS ceramic macro-leads to inner-grain nano-scale superconductivity of the initial
HTS ceramic particles and their crystal grains.



Thermo-chemical method of multi-step
firing of YBCO coated filament in vertical
tube furnace, which results in unique
superconductive nano-architecture of full
dense sintered YBCO macro-ceramics
coating NiCr substrate filament;
Dip adhesion coating of 3G HTS filament
by silicone insulator;
“Substrate filament reel” – to – “3G HTS
filament reel” conveyor processing using
original filament handling conveyor
system;

Scrap free thermo-chemically
self-controlled manufacturing process;

The application of inexpensive and
market available equipment components.
July 2012





Raw Material Composition comprising any
superconducting ceramic (YBCO) powder),
silver
powder
dope,
and
unique
organic/inorganic
silicone
polymer
additive;
Ultrasonic
particle
dispersing
and
homogenization of the raw materials
suspension;
Chemically self-controlled dip adhesion
coating of the metal substrate by
ceramic-silver powder suspension;
Uniform orientation of ceramic grains
within coating layer of the filament
moving between magnet poles;
Polymerization hardening of the ceramicpolymer composite in vertical tube oven;
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Major Engineering Advantages
3GHTS wire is well competitive with traditional copper wire
•
3G HTS wire at LN t-re can transmit with insignificant heat losses electric
current density, JE = 12– 15kA/cm2 while electric copper wire can transmit JE =
0.2 – 0.4kA/cm2. This makes 3G HTS wire very efficient for HTS cables and
other electric engineering applications;
•
The Cost : Performance ratio (C/P, $/kA – meter) of 3G HTS wire is C/P=$7 –
$9/kA-m, while copper wire has C/P=$20 – $50/kA-m. C/P ratio of 3G HTS
wire is at the threshold of $10/kA-m being defined by the US DOE for the
ability for HTS wire to compete with traditional copper electric wire;
•
The technologically available minimum diameter of the elementary 3G HTSYBCO filament is 60 microns or 0.06mm. This 3G HTS wire can transmit
electricity as copper wire with diameter 6 millimeters but 3 – 5x decreasing
heat losses.
July 2012
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Pictures of 3G HTS
lead prototypes
a
b
c
a, Four 3G HTS-YBCO filaments;
b, Slip cast formed and sintered HTS-YBCO plate, 20 x 20 mm;
c, The rare-earth magnet (0.225g, 5mm in diameter) levitating in air, 7mm above a dry-pressed and sintered HTSYBCO tablet of 30mm in diameter immersed in liquid nitrogen coolant.
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Resistivity, Ohm∙cm and heat power dissipation, Watt/cm for
a) 3G HTS ceramic coated silver substrate strand (green) and b)
silver strand (red), both at 77K and c) silver strand at 300K
(blue) VS. current density (logarithmic scales)
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Volt - Ampere characteristics of metal and HTS strands;
each metal strand and HTS strand silver substrate diameter ~ 0.127mm
0.05
0.045
0.04
Voltage, V/cm
0.035
0.03
0.025
HTS-15-2001, LN
0.02
HTS-15-2004, LN
0.015
HTS-S 2004, LN
Copper, Room T
0.01
Silver, Room T
0.005
0
0.0E+00
July 2012
3.0E+03
6.0E+03
9.0E+03
1.2E+04
Current density, A/cm2
1.5E+04
1.8E+04
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Engineering characteristics of 1G or OPIT (oxide ceramic powder loaded in silver tube), 2G or
TFD (ceramic film deposition on multi-metal template tape), and 3G ceramic coated / sintered
filaments (metal substrate filaments coated with sintered ceramics) HTS wires.
1
Substrate and/or cover material
silver
multi-layer metals
NiCr alloy
2
Geometrical form of wire element
tube
tape
filament
3
Wire forming method
rolling/drawing
template deposition
adhesion coating
4
Thickness of the workable HTS ceramic layer, µm
5 – 20
0.2 – 0.3
6–8
5
Magnetic susceptibility
low
low
high
6
Cross-section ratio for ‘substrate & cover’ : ‘HTS ceramics’
(2 – 3) : 1
(500 – 1000) : 1
1:1
7
Ratio of production costs to raw material costs
(2 – 3) : 1
(5 – 8) : 1
1.1 : 1
8
Capital costs of manufacturing in comparison with each other
5–7
7 – 12
1
9
Eng. electric current density of the HTS wire, kA/cm2
1–2
8 – 12
10
Cost/performance ratio of wire (C/P) $/kA-m
200 - 300
75 - 90
7–9
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Insulation of HTS wire
silver tube
silver cover tape
silicone resin
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Comparison of AC current losses of electric wires
1 (round)
5 (tape)
1 (round)
13
Scrap during prototype wire production
significant
significant
insignificant
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Estimation of flexibility as max. wire bent, grads
30 - 50
40 - 60
140 - 150
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Achievable Cost/Performance ratio of wire (C/P), $/kA-m
200 – 300
75 – 100
4–6
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Quench effects
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Superconductivity degradation after 3-5 year long service
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Complicity of ceramic grain alignment and orientation
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Possibility to splice two wire pieces
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End-use applications in electric motors and transformers
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Electro-magnetic shielding of HTS wire
significant
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Conductivity of HTS wire at room temperature, as
Long length variability of wire thickness/diameter and
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superconductivity
April 2012
July 2012
remarkable
significant
25 – 30
self-compensated
remarkable
no degradation
incomplete
complete
complete
difficult
difficult
easy to do
ineffective
difficult
effective
self-shielded
difficult
self-shielded
as silver metal
as copper metal
as silver metal
significant
significant
no variations
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3GHTS.COM
Third Generation High Temperature Superconductor
Contact: Norm Kaish [email protected] 516-993-9727
July 2012
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