The  Scale-­‐Up  of  Wide  Bandgap  Power   Semiconductor  Technology  and  Power  Electronics Anant Agarwal and Marina Sofos Department of Energy April 16, 2014 High Megawatt (HMW) Variable Speed Drive (VSD) Technology Workshop, NIST, April 2016 1 Next Generation Power Electronics (WBG) Initiative Strategy Vision:      Capture  U.S.  opportunity  for  manufacturing  leadership  in:     –  Wide  Bandgap  Power  Devices  (SiC-­‐  and  GaN-­‐based)   –  Power  Electronic  Systems   Commercial   Foundry     Advanced     Modules   Power  Electronics         2 EERE  Relevant  ApplicaEons  for  WBG  Semiconductors   Device  RaEng   ApplicaEons   200  -­‐  600  V   Switch  Mode  Power  Supplies   Sensors  for  Drilling  Equipment   600  -­‐  2000  V   Solar,  Wind,  HVAC,  Light  Duty  Vehicles   DC  Quick  Charging,  UPS   2  -­‐  10  kV   Motor  Speed  Control  (up  to  10  MW),   Trains,  Heavy  Duty  Vehicles,  Mining   10  -­‐  15  kV     Motor  Speed  Control  (10-­‐50  MW),   Process  HeaVng,  DistribuVon  Grid  Tied   Renewables,  Grid  Storage  and  Server   Farms   3 ARPA F APEI PHEV S C-B E UNDED I ASED 4 C HARGER Toyota  Baseline   Prototype  #1   Volume 387.5 in3 52 in3 Weight 6.6 kg 1.165 kg Power 1 kW 6.3 kW Efficiency <90% 95.1% Present Toyota SiC Si PHEV Charger PHEV Charger (1 kW) (>6 kW) EV Fast Chargers- Essential for EV Adoption •  30-50 kW Charger •  Input Current: 79 A Max •  Weight: 1422 lb •  Total Capital + Operating Cost: $ 75 K 32 lb 50 Hz 23 lb 15 kVA 170 lb 5 Large  Power  Electric  Motors  (1-­‐50  MW)  in  COG  Industry   Approx.  14%  of  the  total  electricity  flows  through  Large  Motors     •  ApplicaVons  in  Chemical,  Oil  and  Gas  Industry  (COG)   –  Hydrogen  Gas  Compressors  (Hydro-­‐cracking  in  Oil  Refineries)   –  Booster  StaVons  in  NG  Pipelines,  High  density  polypropylene  extruders   –  Ethylene  Gas  Compressors,  Sea  water  injecVon  and  li^,  etc.   •  Steam,  Gas  Turbines  and  Diesel  Engines  for  off-­‐shore   applicaVons  are  being  replaced  by  large  electric  motors:   –  20-­‐25%  efficiency  of  off-­‐shore  installaVons  resulVng  in  huge  CO 2   emission  (230,000  tons  of  CO /year  in  a  typical  off-­‐shore  pre-­‐ 2 compression  project)   6 Poor  adopEon  of  HMW,  Medium  Voltage  Variable  Speed  Drives   Impact: 40% electricity can be saved per motor by using VSD 5% of the electricity can be saved Barriers: •  Initial Capital Cost of Variable Speed Drive 7 500  kW  Si-­‐IGBT  based  Variable  Speed  Drive  (VSD)   4 Interleaved Inverter each switching at 400 Hz, 96, 6.5 kV Si IGBTs Courtesy: Dr. Subhashish Bhattacharya, NCSTATE University 8 500  kW  SiC  Mosfet  based  drive  can  reduce  system  size   15 kV SiC MOSFET/Diode 9 1-50 MW class motors can be reduced in size by 5x using high voltage, high freq. SiC based Variable Speed Drive (VSD) – for COG DD high rpm applications Traditional VSD 4.16 kV 1-50 MW 1800 High RPM 3 phase, 50 Hz Si Based RPM Motor + Compressor From 50 HZ Big Footprint Gear Box Variable Speed TRANSFORMER Expensive 40% energy/motor system can be saved 10% adoption 5.88 kV V (1.96–5.88 kV) 50 Hz f = 20-50 Hz New Approach Delivered as one box 1-50 MW, High High freq. 13.8 kV RPM Motor High RPM Transformer + 3 phase 5x smaller, GEAR Compressor VSD, SiC Based 50 Hz BOX ELIMINATED Variable Speed 3x Smaller Low copper Cheaper f = 200 – 500 Hz usage 40% energy/motor system can be saved 10   Increased adoption