Seung Hyun Moon

SuNAM Co., Ltd.

11 Sep. 2018

Coated Conductors by RCE-DR:

Process details and scale-up issue

HTS 2G Wire : Brief History & Industrialization Issue.

SuNAM’s HTS 2G Wire(Coated Conductor).

SuNAM’s high field magnets by NI & MCI HTS 2G

Wire.

Summary.

Contents

Confidential 2

HTS 2G Wire : Brief History &

Industrialization Issue.

Confidential 3

Now 27 years, and what’s the differences?

Confidential 4

Can carry “extremely large current without loss”.

Can generated “extremely large magnetic field”.

High energy efficiency with compact volume & mass. Current carry

HTS 2G Wire

NMR

MRICrystal growth

Magnetic seperator

Motor

MagLev

FCLMotor & GeneratorTransformer

Cable

Fusion

Switcing

(resistive type)

Wind

Generator

Applications of Superconductivity

Confidential 5

1st Commercial Transmission class SFCL x2 by AMAT …

FCL Rating

System Voltage, Vs 115 kV

Maximum Load Current, IL 550 A

Prospective Fault Current, Ip 5 kA

Limited Fault Current, Ilim 2.5 kA

Current Reduction 50 %

Shunt Reactor Impedance 15 Ω

Voltage Drop Across FC 37.5 kV

BIL 550 kV

AC withstand Voltage 230 kV

RIV at 73 kV < 1200 μV

Ref. JOINT TNC CIGRE & IEEE PES SEMINAR ON Understanding Superconducting Fault Current Limiters : Design and Application at PEA BKK, Sep. 29, 2015

115 KV SFCL - 2 identical units

.

Albert Nelson, "Fault Current Limiters - Unlocking Capacity in Fault Constrained Electrical Networks", Webinar broadcast via on24.com, July 11, 2017

* 40 ~ 90 km of CC are needed for 1 unit.

World 1st fully commercialized HTS power cable installation

R&D in advance ▶ Pilot demonstration ▶ Commercialization

Project period: Sep., ~ 2019

System configuration: AC23kV 50MVA, 1km-cct + 7.5kW @69K Turbo Brayton Cooling system

Project cost: USD10M

Type test in progress

Installation SiteSystem configuration

Low voltage connection (154 kV 23

kV)

Removal of 2 transformer on each side

of power station

Type test in

(Director General

Dr. Y. J. Won)

• ~ 150 km of CC are needed for 1 km, 23 kV/50 MVA cable.

• ~ 600 km of CC are needed for 1 km, 154 kV/1 GVA cable.

Confidential 7

(Expected) Market Growth

By Prof. B. Holzapfel (KIT)@ EUCAS 2015 & 2017

Confidential 8

Copper Industry’s View on HTS Wire

How to achieve “100,000 km/yr with the competitive price within a short term?

Minwon Park, CCA 2016, 11~14 Sep., Aspen

9

Minwon Park, CCA 2016, 11~14 Sep., Aspen

Total cost comparison depending on the cable types (50MVA class, 5km)

CC power cable(tri-axial type)

??MUSD

HTS wire

Cooling system terminal and

connector

Cabling

73.6%

10.4%

16.0%

CC power cable(3 core type)

??MUSD

HTS wire

Cooling system terminal and

connector

Cabling

71.1%

11.8%

17.1%

Cu power cable

??MUSD

Reducing cost by 41%

6 times

Cost comparison between Cu and HTS power cable @ same power

Still3.5 times

Minwon Park, CCA 2016, 11~14 Sep., Aspen

10

Minwon Park, CCA 2016, 11~14 Sep., Aspen

Target cost

CC wire(200 A/wire; 4mm)

1/5 times

??$/m

?$/m

??$/m

?$/m

Crycooler(over 10kW @65K)

??$/kW

??$/kW

1/5 times

??$/kW

??$/kW

Key factor and target for CC power cable commercialization

To ensure competitive cost of the CC power cable comparing with conventional Cu power cable

Minwon Park, CCA 2016, 11~14 Sep., Aspen

11

Minwon Park, CCA 2016, 11~14 Sep., Aspen

CC power cable(tri-axial type)

??MUSD

HTS wire

Cooling system terminal and

connector

Cabling

52.7%

18.6%

28.7%

CC power cable(3 core type)

??MUSD

HTS wire

Cooling system terminal and

connector

Cabling

49.6%

20.6%

29.8%

Cu power cable

??MUSD

Reducing cost by 42%

2 times

Total cost comparison depending on power cable types based on the realizable targets

Key factor and target for HTS power cable commercialization

Confidential 12

Scale up Issues: IBAD & in-Situ High Rate E-Beam

Robert H. Hammond (Stanford Univ.)

New Ideas, Directions?

High rate, large area, high IC and low cost of

materials processes will eventually be required –

not immediately but in 10 years.

High rate may require growth in liquid flux.

Cost Example

External Use

EB Web Coating provides:

– Highest Rate Evaporation Process

– High Flexibility for many different Coating Materials

– High Coating Thickness Uniformity

Electron Beam Web Coating – Why?

13

External Use

EB Web Coating - Processes

Evaporation of Metals

►Al, Cr, Cu, Ni, Ag, Ti,...

Evaporation of Oxides

►SiO, SiO2, Al2O3, MgO, ....

Multi Layers

( with reversible winding system )

14

Coating Thickness Speed [m/min]

Rate [nm

m/min]

Al OD 4 300 > 20,000

Cr OD 1 270

Ti OD 1 60 1,500

Cu 70 nm 100 7,000

MgO 50 nm 100 5,000

SiOx 25 nm 700 17,000

SiO2 350 nm 36 12,600

Confidential 15

Merits of RCE(Reactive Co-Evaporation)

Throughput : Important for availability & cost!!

RCE-DR : ~ 100 nm/sec or faster (SuNAM)

RCE-DR : easy to scale-uo to wide strip.

3 Companies(SuNAM, Theva, STI) use RCE process !!

Wide web

process ! Depend on Process(liquid flux)

Confidential 16

SuNAM’s RCE-DR process

Confidential 17

SuNAMDR path

(single time)

Conventional CDR path

(repeat morethan >>1,000 times)

MOCVD

PLD

Sputtering

MOD

(BaF2 is very

Important for

High Jc)MBE

Comparison of various deposition methods

500 nm

Gd

Ba

Cu

O

Cu

Cu

Cu

CuGd

Ba

Cu

O

O

CuCu

Gd

BaO

O

L

Gd2O3

GdBCO

Gd2O3

Cu-O

• Very low PO2 zone (~ 10-5 Torr): Amorphous Film

• Lower PO2 zone (~30 mTorr): Gd2O3 + Liquid (< 5 sec)

• Higher PO2 zone (~100 mTorr): GdBCO Film (< 20 sec)

GdBCO growth mechanism: a seeded melt-textured growth!!!

Growth mechanism of the GdBCO film by RCE-DR

18Seoul National UniversityDepartment of Material Science & Engineering

By Prof. SangIm Yoo (SNU)

Confidential 19

Confidential 20* We-SuNAM-are ready for RCE co-work!!

Confidential 21

SuNAM’s

HTS 2G Wire

Electro polishing IBAD (Buffer layers) RCE-DR (Superconducting layer) Ag coating CCs

Protecting layer (~1 um)

Superconducting layer(1.4 um~)

Buffer layer (~40 nm)

Homo epi-MgO layer(~20 nm)

IBAD-MgO layer (~10 nm)

Seed layer (~7 nm)

Diffusion barrier (~40 nm)

Substrate (~100 um)Hastelloy orStainless steel

Al2O3

Y2O3

IBAD-MgO

Epi-MgO

La(Sr)MnO3

RE1Ba2Cu3O7-d

Ag

DC magnetron

HTS 2G Wire Process of SuNAM

Confidential 23

HTS 2G Wire Production Example

Min Ic (A/cm-width) x L (m) > 0.6 Million A-m

Production speed of 120 m/hr (12 mm width)

( 1 km for ~ 8 hrs)

0 20 40 60 80 1000

200

400

600

800

1000

1200

I C (

A )

Position(m)

Thicker GdBCO layer

1.3 mm,

600 ~ 800 A/12 mm

1.6 mm,

700A/12 mm ~ 900 A/12 mm2.2 mm,

900 A/12 mm ~ 1200 A/12 mm2.7 mm, 600 A/12 mm

Increasing superconducting layer thickness with deposition

layers, deposition rate, and moving speed.

Optimized thickness of now RCE-DR system 2 ~ 2.3 mm

423 A/4 mm → 1,058 A/cm-w

0 100 200 300 400 500

0

5

10

15

20

25

30 Center : 428 A / 4 mm

Left : 407 A / 4 mm

Right : 435 A / 4 mm

Volta

ge (mV

)

Current (A)

428 A

Various roll to roll quality control system : Buffer layers

67 68 69 70 71 72 73 74 75 76 77

2.8

3.0

3.2

3.4

3.6

3.8

4.0

o

f M

gO

(00

2)

(deg

ree)

RHEED Spot Angle (degree)

5.8

6.0

6.2

6.4

6.6

6.8

7.0

o

f Mg

O(2

20

) (deg

ree)

Real time RHEED spot inspection program

RHEED spot vision inspection

Angle dependence of and

0 100 200 300 400 500 600 700 800 900 100030

40

50

60

70

80

Deposition rate

fluctuation

An

gle

(d

eg

ree)

Position (m)

E-beam off

Various roll to roll quality control system : Superconducting layer

CC color0 m 900 m

0 200 400 600 800-400

-300

-200

-100

0

600 A

Magnetic F

ield

(G

auss)

Position (m)

700 A

From RGB colors, can expect superconducting properties

0 200 400 600 800

RG

B v

alu

e

Position (m)

Expected values

Measured values

RGB color system is the most powerful quality control program in RCE-DR system

Various roll to roll quality control system : defect detection by X-ray

Continuous void measurement system :

measurement speed : ~ 9 m / min, resolution : ~ 50 mm

0 50 100 150 200 250 300

0

200

400

600

800

1000

Position ( m )

Void

siz

e (

mm

)

Void-free splice joint

~ 200 um size void

Various roll to roll quality control system : dimension & Ic

Continuous dimension measurement system :

measurement speed ~ 10 m / min

Transport Ic measurement system with Bending-double

bending rollers :Measurement speed ~ 500 m / hr

0 100 200 300 4000.0

0.1

0.2

0.3

0.4

0.5

Thic

kness (

mm

)

Position (m)

Thickness of laminated CC

Concept of

thickness

measurement

0 100 200 300 4000

50

100

150

200

250

300

350

I C (

A / 4

mm

)Position (m)

Confidential 29

SuNAM’s high field magnets by NI

& MCI HTS 2G Wire

Confidential 30

< Linear synchronous motor >

(small coil)

Smooth but powerful movement

No voltage fluctuation or field decay

Ma

gn

etic

Fie

ld [T

]

Field profile at AC copper coil on track

17 cm

133 cm

78 cm

Ref.) C.-B Park et al, “Development of a Small-Scale Superconducting LSM…,” IEEE Trans. Energy Conversion

2 Poles and 3 double pancake coils per pole

Peak field on the rail : > 1 Tesla (65 mm apart from magnet

bottom)

Racetrack Coil for Motor Application

Confidential 31

Multi-width Double Pancake Coils

Stacked Double

Pancake Coils Fully assembled

No-insulation, multi-width, and compact !

4.1mmW 5.1mmW 6.1mmW 7.1mmW 8.1mmW

327 m

m

O.D. 172mm

I.D. 35mmImmersed in liquid Helium

(Designed by S. Hahn (MIT NHMFL/FSU)

26.4 T all HTS 2G one-body(non-nested) Magnet(World highest magnetic field (all HTS))

Confidential 32

World 1st All HTS Commercial Magnet for Axion Detection

: Delivered to

Confidential

Confidential 33

We fabricated the large-sized two HTS magnets for induction furnace in the world.

The HTS magnet size: length 1.25m X height 0.62 m

(12 mm SuNAM wires, SS tape cowinding)

Commercial proto-type DC Induction Heater (All HTS Coil)

Confidential

1,500 A Charging Charcteristics

400 mH HTS DC Reactor : Applying 1500 A & Cryogen Free

Assemble Process of conduction cooled 30 toroidal coils for 400 mH reactor

400 MHz conduction cooled NMR : Magnet Design

< Field profile of NMR magnet design >

No-Insulation with Metal cladding HTS tape

enclosed as STS with 1 mm thick

Multi-width winding for high Iop

Inside notch design for homogenous field

400 MHz conduction cooled NMR : Magnet Assemble

400 MHz NMR Magnet Assemble

Ferro-Shimming TechniqueBefore shim

With O

With O+M

With O+M+I

HTS M

agnet

Curr

ent

Leads

Metal current lead HTS current lead Conductio

n C

oolin

g

DPC Winding Magnet Stacking < Final Assemble >

400 MHz conduction cooled NMR : 1H NMR Signal

Future works

Faster charging rate

Investigation of field profile

Shimming

Confidential 38

Summary

Price Reduction in RCE DR process

100

2510

(Unit: USD / kAm)

12 mm 120 mm 360 mmWidth :

Capacity : 1,000 km/y 15,000 km/y 75,000 km/y

Achievable with Existing Line of

SuNAM

“Increasing Demand for HTS

2G wire has surpassed the

supply”

“For market entrance $ 50 /

kAm is the threshold ”

“Price Reduction will ignite

an exponential growth of

demand for HTS 2G wire”

“High throughput, low

material cost, High yield is 3

Critical Success Factor”

Direction of Technology Development in the Future

- HTS 2G wire

CAPEX : ~10 M$ ?? M$ ?? M$

Direction of Technology Development in the Future

- HTS Magnet For NMR magnet, near term(2018), 400 MHz cryogen free system with shimming.

will go to > 1.2 GHz proto-type.

For R&D magnet, next goal is 35 T, 35 mm user magnet (2019 KBSI-MagLab-SuNAM).

Acknowledgement

Thanks for Attention !Danke für die Aufmerksamkeit !