Characteristics of Amorphous metal and

Energy Efficient Amorphous metal

Distribution Transformer

29 Mar 2019

Hitachi Metals, Ltd.Hitachi Metals, Ltd.Hitachi Metals, Ltd.Hitachi Metals, Ltd.Soft Magnetic Materials and Components Business UnitSoft Magnetic Materials and Components Business UnitSoft Magnetic Materials and Components Business UnitSoft Magnetic Materials and Components Business Unithttp://hitachihttp://hitachihttp://hitachihttp://hitachi----metals.co.jpmetals.co.jpmetals.co.jpmetals.co.jp

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1. Introduction of Amorphous metal, Core and Transformer

2. Energy Loss and Efficiency in Transformer

3. World Wide Situation of AMDT

4. Recycle of Amorphous Core

5. Conclusions

Outline

*AMDT*AMDT*AMDT*AMDT：（：（：（：（AMorphousAMorphousAMorphousAMorphous mmmmetal Distribution Transformeretal Distribution Transformeretal Distribution Transformeretal Distribution Transformer））））

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1. Introduction of Amorphous metal , Core and Transformer

History of Amorphous metal

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1960

1970

1980

1990

Discovery of amorphous metal (Au-Si alloy):Klement, Willens & Duwez., Nature 187, 869 (1960)

Discovery of the stable ferromagnetic Fe80P13C7 amorphous metal: Duwez & Lin., J. Appl. Phys. 38, 2267 (1965) (1967)

Developed amorphous metal, METGLAS® by Allied Signal (1973)Developed amorphous metal for distribution transformer

by Allied Signal (1976)1st amorphous distribution transformer (USA) (1982)

Mass production of amorphous metal (Metglas® 2605SA1) in Conway, SC, USA (1989)

2000

Started to produce amorphous pole transformer in Japan (1991)

Developed high permeability grade of amorphous metal (Metglas®2605HB1M) (2011)

Acquisition of amorphous metal business unit by Hitachi Metals from Honeywell (2003)

Scientific Research

Cooperate R&D

Mass-ProTechnologyDevelopment

Business Expansion

Commercia-lization

2010

Rapid quenching cast technology(Cooling rate：：：：106℃℃℃℃/s and over））））

Molten alloy is not crystallized to form solid alloy.

Metglas® 2605SA1 & 2605HB1MChemical composition: Fe, Si, BNominal thickness：：：： 25 µmStandard width：：：： 142 mm, 170 mm, 213 mm

Amorphous metal Casting Process

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Uses of Amorphous Metal Alloys

Wound Core

METGLAS®

Amorphous

Ribbon

METGLAS®

Amorphous

Ribbon

Wound Core

Distribution Transformer

Switched-mode Power Supply

Choke Coil

Current Sensor

Ribbon

Marker for Electronic Article Surveillance

Metal Joining

Brazing Foil

High Efficiency Inverter(Wind or Solar Generator)

Powerlite ® C-Core(Cut Core)

Automobile

Ni-based

Fe-based

Fe-based orCo-based

Ni-based or Co-based

Fe-based

Automobile

Ribbon

Copyright ©2013, Hitachi Metals, Ltd.

Transformer Segment is

Highest Volume

Fe-based Axial Gap Motor Stators

(Future)

Geographical Locations of our Business Unit

Geographical Locations of our Business Unit

Sales OfficesSales OfficesSales OfficesSales OfficesProduction (Components)Production (Components)Production (Components)Production (Components)Production (Material)Production (Material)Production (Material)Production (Material)

Conway, Conway, Conway, Conway, USAUSAUSAUSA

YasugiYasugiYasugiYasugi, Japan, Japan, Japan, Japan

Tottori, Tottori, Tottori, Tottori, JapanJapanJapanJapan

Pan Yu, Pan Yu, Pan Yu, Pan Yu, ChinaChinaChinaChina

Ayutthaya, Ayutthaya, Ayutthaya, Ayutthaya, ThailandThailandThailandThailand

GurgaonGurgaonGurgaonGurgaon, , , , IndiaIndiaIndiaIndia

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60,000Ton/Yr

40,000Ton/Yr

Features of Amorphous metal

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

-10 0 10 20 30 40 50 60 70 80

B (

T)

H (A/m)

HB1M

M90-23P5

Amorphous metal

Crystalline metal(CRGO)

� Random Atomic structure

•Lack of crystalline anisotropy⇒⇒⇒⇒ Lower hysteresis loss

•Higher resistivity⇒⇒⇒⇒Lower eddy current loss

� Small thickness (0.025 mm)⇒⇒⇒⇒Lower eddy current loss

1/3 of core loss compared to CRGO

****CRGO: CRGO: CRGO: CRGO: CCCCold old old old RRRRolled olled olled olled GGGGrain rain rain rain OOOOriented Electrical Steelriented Electrical Steelriented Electrical Steelriented Electrical Steel

Less heat from core

Infrared Photographs of (a) Metglas® Amorphous Infrared Photographs of (a) Metglas® Amorphous Infrared Photographs of (a) Metglas® Amorphous Infrared Photographs of (a) Metglas® Amorphous metal& (b) Grain Oriented Steel Distribution metal& (b) Grain Oriented Steel Distribution metal& (b) Grain Oriented Steel Distribution metal& (b) Grain Oriented Steel Distribution Transformer CoreTransformer CoreTransformer CoreTransformer Core

(a) (b)

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Amorphous metal Transformer Core Manufacturing

CUTTINGCUTTINGCUTTINGCUTTING STACKINGSTACKINGSTACKINGSTACKING

PRESPOOLINGPRESPOOLINGPRESPOOLINGPRESPOOLING

EDGE FINISHINGEDGE FINISHINGEDGE FINISHINGEDGE FINISHINGANNEALINGANNEALINGANNEALINGANNEALING

V

CORE FORMINGCORE FORMINGCORE FORMINGCORE FORMING

CORE LACINGCORE LACINGCORE LACINGCORE LACING

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2. Energy Loss and Efficiency in Transformer

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Amorphous metal Distribution Transformer(AMDT)

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Core

WindingWindingWindingWinding

BushingBushingBushingBushing

Oil TankOil TankOil TankOil Tank

Example: OilExample: OilExample: OilExample: Oil----Immersed Immersed Immersed Immersed Single Phase Single Phase Single Phase Single Phase DTDTDTDT

◎◎◎◎ Difference of parts Difference of parts Difference of parts Difference of parts in DTin DTin DTin DT

between AMDT and between AMDT and between AMDT and between AMDT and

CRGOCRGOCRGOCRGO----DT is DT is DT is DT is just a corejust a corejust a corejust a core....

◎◎◎◎ You can produce AMDT You can produce AMDT You can produce AMDT You can produce AMDT

using traditional using traditional using traditional using traditional techniquetechniquetechniquetechnique....

◎◎◎◎ Many people are worriedMany people are worriedMany people are worriedMany people are worried

that AMthat AMthat AMthat AM----core is very difficultcore is very difficultcore is very difficultcore is very difficult

to handle. But to handle. But to handle. But to handle. But handling of handling of handling of handling of

AMC becomes easy AMC becomes easy AMC becomes easy AMC becomes easy after after after after

they have some experience.they have some experience.they have some experience.they have some experience.

◎◎◎◎ Hundreds Hundreds Hundreds Hundreds of AMDT makers of AMDT makers of AMDT makers of AMDT makers

have mastered its have mastered its have mastered its have mastered its

production.production.production.production.

Energy Loss in Transformer

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Loss Site Major reason Feature

No load loss Core Hysteresis loss & Eddy current loss Constant at all times

Load loss Coil Electric resistance Increase as square of load factor

96.0%

96.5%

97.0%

97.5%

98.0%

98.5%

99.0%

99.5%

0

500

1000

1500

2000

2500

3000

3500

0% 20% 40% 60% 80% 100% 120%

Eff

cie

ncy

Loss

(W

)

Load factor

No load loss

Load lossTotal loss

Efficiency

Example of loss and efficiency vs. load factor**Load factor*Load factor*Load factor*Load factor＝＝＝＝(Output)/(Rated capacity)(Output)/(Rated capacity)(Output)/(Rated capacity)(Output)/(Rated capacity)

When LF is high :

Load Loss (LL) is

dominant in total loss

When LF is low :

No Load Loss (NLL) is dominant in total loss

Test siteRated

capacity(kVA)

Number of households

RMS load factor (%)

Max. load factor (%)

Min. load factor (%)

1 400 300 16.6 35.9 5.92 400 320 35.2 107.7 4.53 1500 Hotel 28.4 57.2 5.34 560 factory 29.8 130.2 1.15 25 50 22.3 80.3 1.56 50 45 44.9 129.8 16.77 25 20 33.2 86.8 9.68 50 63 31.9 72 12.3

Load factor in Distribution Transformers (DTs)

RMS load factor: 20~40％％％％ should be considered to choose an adequate transformer

Measured load factors of DTs in VietnamMeasured load factors of DTs in VietnamMeasured load factors of DTs in VietnamMeasured load factors of DTs in Vietnam

1.Residential area in suburbs of Hanoi, 2. Residential area near industrial park in 1.Residential area in suburbs of Hanoi, 2. Residential area near industrial park in 1.Residential area in suburbs of Hanoi, 2. Residential area near industrial park in 1.Residential area in suburbs of Hanoi, 2. Residential area near industrial park in suburbs of Hanoi, 3 Hotel in Ho Chi Minh City, 4. Factory in Dong Nai, 5suburbs of Hanoi, 3 Hotel in Ho Chi Minh City, 4. Factory in Dong Nai, 5suburbs of Hanoi, 3 Hotel in Ho Chi Minh City, 4. Factory in Dong Nai, 5suburbs of Hanoi, 3 Hotel in Ho Chi Minh City, 4. Factory in Dong Nai, 5----6,Residential area in6,Residential area in6,Residential area in6,Residential area inBinhBinhBinhBinh Duong The data measured from Oct to December 2011 as a part of project supported by NEDO.Duong The data measured from Oct to December 2011 as a part of project supported by NEDO.Duong The data measured from Oct to December 2011 as a part of project supported by NEDO.Duong The data measured from Oct to December 2011 as a part of project supported by NEDO.

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Transformer Loss Comparison

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CRGO-DT AMDT

2nd Top Runner DT in Japan 1000kVA 50 Hz

95.50%

96.00%

96.50%

97.00%

97.50%

98.00%

98.50%

99.00%

99.50%

100.00%

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

0% 20% 40% 60% 80% 100%

Effi

cien

cy

Loss

in tr

ansf

orm

er

(W)

Load factor

No load loss

Load loss

Total loss

Efficiency

95.50%

96.00%

96.50%

97.00%

97.50%

98.00%

98.50%

99.00%

99.50%

100.00%

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

0% 20% 40% 60% 80% 100%

Effi

cien

cy

Loss

in tr

ansf

orm

er (W

)

Load factor

No load loss

Load loss

Total loss

Efficiency

3. World Wide Situation of AMDT

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AMDT in operation

AMDT under development

Unit: MVA

*Estimated by Hitachi Metals in Mar. 2016

China 230,000USA 61,500India 57,000Japan 24,000Mexico 17,000South Korea 13,500Taiwan 7,000Canada 6,000Philippines 4,000EU 4,000Brazil 1,800Vietnam 1,800Thailand 16

4. Recycle of Amorphous Core

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Recycle processRecycle processRecycle processRecycle process

Retrieve AM core from AMDT

Recycle Flow of AMT (2013Recycle Flow of AMT (2013Recycle Flow of AMT (2013Recycle Flow of AMT (2013～～～～))))

AM ribbon Crushed AM core

Energy saving and Resource circulation

Wash and Dry

Crush and Screen

Discard AMDT

（産機）に掲載（産機）に掲載（産機）に掲載（産機）に掲載

写真依頼中写真依頼中写真依頼中写真依頼中

AMDT core

AMDT

Capacity：：：：50 MT/mo（（（（April, 2013～）～）～）～）

5. Conclusions

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1. Amorphous alloy has been used in transformer more than 25 years

2. Manufacturing process of amorphous core and transformer are well-established under proven technologies.

3. Amorphous transformer is suitable for low RMS load factor areabecause of its low no load loss.

4. Amorphous transformers are installed in many countries.

5. Amorphous core recycling process has been established.

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●●●● Do not duplicate in part or in its entirety this brochure without written permission from Hitachi Metals, Ltd.

●●●● This brochure and its contents are subject to change without notice; specific technical characteristics are subject to consultation andagreement

●●●● Please inquire about our handling manual for specific applications of Metglas® products, these manuals detail the exact guaranteed characteristics of Metglas® products for a specific application.

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