© 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
#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