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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●●●● 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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