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© ABB Group September 30, 2014 | Slide 1 High power electronics innovation Peter K. Steimer, Corporate Research Fellow, Power Electronics, ABB Switzerland Ltd, 15.09.2014

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© ABB Group September 30, 2014 | Slide 1

High power electronics innovation

Peter K. Steimer, Corporate Research Fellow, Power Electronics, ABB Switzerland Ltd, 15.09.2014

© ABB Group September 30, 2014 | Slide 2

Introduction World’s Consumable Resources

0

16

32

48

64

80

…of sunlig

ht

hitting the e

art

h

Hours…

“Conventional” “Future”

Bre

eder

Reacto

rs

References: [1] Electricity in 2030: PV’s Role, Brent P. Nelson, IEEE Energy 2030, Atlanta 2008

© ABB Group September 30, 2014 | Slide 3

Solar Hydro Wind

Biomass

Introduction The most important Renewables – driven by the Sun

References: [2] Earth’s Annual Global Mean Energy Budget, JT Kiehl and KE Trenberth, Bulletin

of the American Meteorological Society, Vol 78, No. 2, February 1997

© ABB Group September 30, 2014 | Slide 4

High power electronics innovation

Energy Efficiency and New Renewables

Power Semiconductor Trends

Power Electronics Applications

Conclusions

Electrical Energy Systems Energy efficiency and 20% new Renewables

CO2 emissions [3]: - 2/3 of the electrical power based on fossil fuels

- transportation is second largest contributor

#0: Transition to gas: 2 to 3 times lower emmissions than coal

#1: Energy efficiency from primary energy to end user

1. High effciency combined cycle plants (up to 60% efficient)

2. Use of waste heat in bulk power generation (up to 85% efficient)

3. Variable speed drives for pump, fan and compressor applications

4. More electric transportation for scooters, cars, buses, trains, ships

#2: New Renewables (Wind, Solar) will contribute 20% in 2030

1. up to 12% contribution of Wind (2013: 2.5%, CAGR = 10%) [4]

2. up to 7% contribution of Solar (2013: 0.4%, CAGR =15%) [5]

References: [3] World Energy Outlook 2012 (International Energy Agency)

[4] Global Wind Energy Forecast 2012-2025 (IHS Emerging energy reserach)

[5] Projections on solar power, 2013 (IHS Emerging energy reserach)

© ABB Group September 30, 2014 | Slide 6

# 1: Energy Efficency Pump and fan applications

60 - 65% of industrial electrical

energy is consumed by motors

Substantial energy saving by

variable speed drives in pump and

fan applications [5]

30 to 40% energy saving, when

running below nominal flow

Applies to 30% of all industrial

pump and fan applications

Globally appr. 1900 TWh of annual

energy saving potential

Saved power (VSD)

Losses

Useful work

Flow (%)

Power (%)

0

20

40

60

80

100

120

140

160

0 10 20 30 40 50 60 70 80 90 100

References: [6] Impact of Motor Drives on Energy Efficiency, P. Barbosa, P. Wikstroem,

M. Kauhanen, PCIM 07

© ABB Group September 30, 2014 | Slide 7

# 1: Energy Efficency Energy saving priorities

#1: ENERGY EFFICIENCY Potential / year

Power generation (installed base)

Use of waste heat 3000 TWh

Transportation (installed base)

Hybrid, 30% savings (equivalent to) 3000 TWh

Industry (installed base)

VSD for pump and fans 1900 TWh

#2: NEW RENEWABLES Potential / year

New Windpower installations

New installations in 2009 – 2020 2000 TWh

References: [7] Enabled by High Power Electronics - Energy efficiency, Renewables and Smart

Grids, P. K. Steimer, ECCE Asia (IPEC) 2010

#2 New Renewables 90% Renewables in Switzerland in 2050

Electrical energy systems with 90% renewable power generation

References: [8] SCS Energiemodell für die Schweiz, 2013 (Supercomputing Systems)

Running river Hydro

Reservoir Hydro PV Solar

Wind

Pumped Hydro

Biomass

Gas

Geothermal

PV: 11 GW

Wind: 2.85 GW

PHP: 5 GW

200 GWh

Thermal

week of the year

#2 New Renewables Future high penetration of renewables

Combine best of old and new electrical energy systems :

1. Fossil fuel Power plants

Combined cycle and gas power plants with more power ramping

2. Extension of grid infrastructure

Transmit greater power over greater distances (DC, UHV)

Voltage stability in distribution grids (V-control, battery storage, DC )

3. Hydro power plants

Pumped hydro as low cost storage option (4 to 8 hours typical)

4. New renewables

Wind prefered due to highest energy return on invested energy

PV Solar prefered due to simple application incl. storage option

CSP attractive due to molten salt thermal storage option

© ABB Group September 30, 2014 | Slide 10

High power electronics innovation

Energy Efficiency and New Renewables

Power Semiconductor Trends

Power Electronics Applications

Conclusions

- 6 inch IGCT

- IGBT / BIGT

Power Semiconductors Medium Voltage Converters

0 1 MVA 10 MVA 100 MVA

33 kV

11kV

2.3 kV

IGCT / IGBT

Presspack

No Plasma in

Failure mode

(SCFM)

High Voltage

IGBT Module

Low Voltage

IGBT Module

Cost

Higher

Efficiency

SCFM: Short-circuit failure mode

© ABB Group

September 30, 2014 | Slide 11

BIGT Wafer

Backside

Power Semiconductors Bi-mode IGBT technology (BIGT)

Integrates an IGBT & diode in one structure

=> Reverse Conducting (RC) IGBT

Lower Losses due to larger Area for IGBT and diode

both use whole silicon area

References: [9] M. Rahimo, et al., “The Bi-mode Insulated Gate Transistor (BiGT) - A Potential

Technology for Higher Power Applications”, ISPSD 2009

High Safe Operating Area (SOA) due to corrugated base junction profile

Combined with RC technology

Power Semiconductors High performance IGCT technology (HPT)

6 inch HPT RC-IGCT

9.5 kA @ 2.8 kVdc

References: [10] The 150 mm RC-IGCT: a Device for the Highest Power Requirements, T. Wikström

M. Arnold, T. Stiasny, C. Waltisberg, H. Ravener, M. Rahimo, IEEE ISPSD 2014

© ABB Group September 30, 2014 | Slide 13

© ABB Group

September 30, 2014 | Slide 14

Power Semiconductors Bi-mode IGCT technology (BGCT)

Integrates IGBT & diode in one structure

=> Reverse Conducting (RC) IGCT

Lower losses

Low leakage currents

References: [11] The Concept of Bi-mode Gate Commutated Thyristor, U. Vemulapati, M Bellini,

M. Arnold, M. Rahimo and T. Stiasny, IEEE ISPSD 2012

© ABB Group September 30, 2014 | Slide 15

Mature Si

technology

1

Power Semiconductors Future trends for high power semiconductors

Silicon devices up to 10 kV

1. BIGT and BGCT as new

high power device options

Wide band gap material devices

2. Unipolar 1.2 kV / 1.7 kV devices

3. Extension to 10 kV unipolar SIC

devices, up to 20 kHz

4. Later bipolar SiC

Packaging

1. Higher temperature and

2. Higher voltage packaging

[kV]

20

10

5

Si SiC

10 kV

0.3 kHz

1 5 20 [kHz]

4

2 1.2 – 3.3 kV

unipolar SIC

3

10 kV

20 kHz

© ABB Group September 30, 2014 | Slide 16

High power electronics innovation

Energy Efficiency and New Renewables

Power Semiconductor Trends

Power Electronics Applications

Conclusions

- 6 inch GCT

- IGBT / BIGT

© ABB Group September 30, 2014 | Slide 17 3BHT490557R0001 Rev. A

High power electronics applications Topologies

0 1MVA 10 MVA 100 MVA

33 kV

6.6 kV

3.3 kV

1 kV

Cell-based Multi-level

Module Presspack

(A)NPC(ML)

Low parts count

Better than 2L

Voltage scalability

Low harmonics

#1 Efficiency: MV Drives Cell-based Multi Level Converter

MV drive: 5-level converter based on supplied NPC RCIGCT cells

© ABB Group September 30, 2014 | Slide 18 3BHT490557R0001 Rev. A

36-pulse diode

rectifier

Control unit

Auxiliary power for

control hardware

DC-link capacitors

Inverter unit

Transformer cable

connection

section for top

and bottom entry

Motor cable connection

section for top

and bottom entry

Water cooling unit

with stainless

steel piping

Vollbrücke mit zwei

RCIGCT NPC Phasen-

bausteine

#1 Efficiency: Transportation Power Electronics Transformer

Power Electronics Transformer: 8+1 MMC cells for 15 kV, LLC

resonant DC/DC, MF Xfrms at 1.8 kHz

© ABB Group September 30, 2014 | Slide 19

Reference: [12] D. Dujic, Power Electronics Transformer for on-board applications – an overview,

Industrial session on HV and high power, APEC 2013

15kV, 17 Hz

1.5 kV

DC machine

PE transformer

10’000 km of

operation

© ABB Group September 30, 2014 | Slide 20

DolWin 1 (MMC transmission system

based on Presspack IGBT technology)

Commissioning year: 2013

Power rating: 800 MW

No. of poles: 2

DC voltage: ±320 kV

Length of DC lines: sea 75 km

land 90 km

Reference: [13] B. Jacobson, P. Karlsson, G. Asplund, L. Harnefors, T. Jonsson: VSC-HVDC

Transmission with Cascaded Two-Level Converters,Cigré session 2010, paper B4-110

#2 New Renewables HVDC connection for Offshore Windpower

Grimsel Lake Grimsel 2 PSP

Oberaar Lake

Variable speed Pumped Hydro

#2 New Renewables Variable speed Pumped Hydro

The converter-fed synchronous machine (CFSM) is the future variable

speed solution (replacing complex DFIM)

First retrofit reference rated at 100 MVA in commerical operation

(since April 13)

Converter grid

side transformer

3-level

Grid side

inverters

3-level

Machine side

inverters

Voltage

limiting units

Converter machine

side transformers

DC-link

filter

Bypass

disconnector

Synchronous

Motor / Generator

220 kV / 50 Hz

Grid side

disconnector

Machine side

disconnector

13.5 kV / 50 Hz

DC-link

circuit

S = 100 MVA

U = 13.5 kV

Generator

nN = 750 rpm

Pump

n = 450…765 rpm

Large Drive PCS 8000 3.3kV

Medium Voltage Static Frequency Converters

S = 2x 50 MVA

F1 = 50 Hz

F2 = 0...51Hz

ABB

ABBABB

Converter Block

HP Filter

+

-

0

ABB

Converter Block

HP Filter

+

-

0

ABB

ABB

Transformers

Frequency

converter

Cooling

Unit References: [14] 100 MW Full-Size Converter in the Grimsel 2 Pumped

Storage Plant, Hans Schlunegger, Andreas Thöni,

Hydro 2013 conference, Innsbruck

© ABB Group September 30, 2014 | Slide 23

High power electronics innovation

Energy Efficiency and New Renewables

Power Semiconductor Trends

Power Electronics Applications

Conclusions

High Power Electronics Innovation Conclusions

Electrical power system

1. Optimum co-existance of the old AND new electrical energy system

needed to mitigate the very costly CO2 impact

Power Semiconductors

1. Silicon based IGBT, IGCT, BIGT and BGCT are todays choices

2. SiC based devices to grow with selected volume applications

Applications

1. Energy effciency is #1 to minimize our CO2 footprint (short-term)

Strong driver for drives applications and electrical transportation

2. New Renewables are #2 to miminize our CO2 footprint (long-term)

Strong driver for multiple power electronics applications © ABB Group September 30, 2014 | Slide 24

© ABB Group September 30, 2014 | Slide 25