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Ferroxcube in renewable energies

Ferroxcube in renewable energies. December 2010. Contents. Ferroxcube introduction Renewable energies market Energy distribution basics Magnetic cores in renewable energies: inverters Ferroxcube preferred cores for reactors Common mode choke Current sensors

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Ferroxcube in renewable energies

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  1. Ferroxcube in renewable energies December 2010

  2. Contents • Ferroxcube introduction • Renewable energies market • Energy distribution basics • Magnetic cores in renewable energies: inverters • Ferroxcube preferred cores for reactors • Common mode choke • Current sensors • Strengths of Ferroxcube products in renewable energies • Summary

  3. YAGEO: A Global Passive Component Leader • World’s leading provider of total passive component solutions with production, sales and logistic facilities in Asia, Europe and the Americas • One-stop-shop product offering inclusive of resistors, capacitors, and inductors/ferrites No. 1 in chip resistors No. 4 in ferrites No. 3 in MLCCs • Main brands: Yageo, Phycomp, Ferroxcube and Vitrohm • Yageo group: Teapo, Chilisin, Chipcera and Compostar • 2009 sales NT$19.1 billion (500MEur) • Common share listing on the TSE since October 1993GDR listing on the LUX since September 1994

  4. Ferroxcube, the founder of ferrites

  5. Renewable energies market Evolution and forecast of photovoltaic energy growing • Ferrite market size for this segment is 180M€. FERROXCUBE takes 15% of this • Europe (Germany, Italy, Spain) took so far leadership. It will be taken over by US in 2011 and onward Sales Growth Electronicsgrowthenginethatpullscomponentsindustryout of global economicdownturn Electronicsgrowthengine thatpulls componentsindustry out of global economicdownturn

  6. Energy distribution basics. Grid description Mid to big size power plants generate high voltage Voltage is raised to hundreds of kV at the transmission substation High voltage is transmitted over the grid to minimize transmission losses Power substations step down the HV to Mid Voltage a few tens of kV to enter the distribution grid Renewable energies (solar or wind) generate DC or AC at variable line freq. An inverter + transformer is used to stabilize the line freq and raise to MV Transformers step down the MV to low voltage (110 or 230 V, depending on the region) End customers are equipped with power meters and protection

  7. Inverters • Photovoltaic (PV) plants generate varying DC current at relatively low voltage • Wind power can be DC or AC at varying line freq (depending on the rotation speed) In both cases an inverter to transform source power into mains power is needed

  8. Inverters • Magnetic cores are involved in several parts of the inverter: boost transformer, inverter, EMI filter, etc • Ferroxcube supplies a wide variety of solutions for the different power conversion elements, and is continuously adapting to the market needs Flexible combination of shapes and materials, adaptation to the market and research in the latest technologies are FXC assets

  9. Inverters DC/DC boost: • Adapts the voltage supplied by the cell to the DC/AC working point • Provides galvanic isolation between the grid and the panels • It can be made out of laminated steel, ferrite or powder cores • E shapes in 3C90, 3C94, etc Reactor: • Smoothes the output of the DC/AC converter in order to obtain the grid power signal • Works with high currents, therefore high saturation flux density is needed • The energy storage capability relates the inductance and the current: • W=L· I2 = Bsat · Hsat · Effective volume

  10. Ferroxcube preferred cores for reactors Ferrites: large cross section with gap, preferably distributed along the magnetic path length so that Hsat is increased 3C92: The perfect combination of high saturation and low losses 3C95: Stability with temperature and the lowest power losses High saturation materials, with very high Bsat and Hsat 3P1: High saturation at the lowest cost in the market 3G1: Next generation of high saturation ferrites

  11. Ferroxcube preferred cores for reactors 3C92: The perfect combination of high saturation and low losses U cores E cores Assembled shapes Distributed gap 3C92 has the best performance in terms of saturation flux density

  12. Ferroxcube preferred cores for reactors 3C95: Stability with temperature and the lowest power losses U cores E cores Assembled shapes Distributed gap One of the most stable permeability with temperature Predictable behavior under different working conditions High Bsat

  13. Ferroxcube preferred cores for reactors 3C92 Vs3C95 materials Power losses with temperature measured at 25 kHz, 250mT Saturation flux density with temperature U cores E cores Assembled shapes Distributed gap 3C92 is optimal at higher temperatures in terms of saturation whereas 3C95 has the lowest power losses

  14. Ferroxcube preferred cores for reactors 3P1: High saturation at the lowest cost in the market • The new iron powder for low frequency reactors • Advantages of 3P1: • High Bsat • No thermal aging • Stable permeability with temperature • The lowest cost €/(T. kg)  less • material to withstand the same flux • density High saturation materials benchmark U cores E cores Assembled shapes Distributed gap

  15. Common mode chokes • The inverter requires protection against EMI noise coming from the lines connected to the generators. Common mode choke is used to prevent noise in the line • Complying with EMC regulations is a must • Optimal cores for this function are high permeability toroids which must filter harmonics within a range of frequencies The higher the permeability and the bigger the core, the lower the number of necessary turns, thus lower copper losses

  16. Preferred materials for common mode choke • Ferroxcube supplies large quantities of these cores to winding houses and inverter manufacturers 4A11 3E5, 3E6, 3E25 1-2 MHz 10-20 MHz New materials have been launched, improving features of existing ones: 3E10 and 3E12

  17. 3E10 and 3E12 materials Improvement in final product specifications 3E10: µ10000 3E12: µ12000 3E5, 3E6, 3E25 3E10, 3E12 4A11 1-2 MHz Frequency 10-20 MHz

  18. Impedance vs. frequency of different materials

  19. Current sensors • The power delivered from the panels depends very sharply on the environment: • Irradiation power • Temperature of the cells • Orientation of the panel • Linear current sensors are made out of a gapped magnetic core together with a Hall effect sensor placed in the gap • The hot wire passes through the core creating a magnetic field in the gap proportional to the current. The Hall sensor supplies a voltage proportional to this magnetic field

  20. Current sensors • The magnetic field is proportional to the gap length, thus its tolerance has to be tight • The core shape can be a toroid, but also square, or custom shape to ease the assembly • Material is high perm because of its linearity Preferred materials for current sensors 3E27, 3E5, 3E55, 3E10, 3E12, 3B7 FXC is supplying to several customers

  21. Strengths of Ferroxcube products in renewable energies Flexibility of shapes Variety of materials Core stacking to increase Ae Different gapped shapes U cores, E cores, assembled cores, customized shapes Low power losses at a wide range of temperature High Bsat materials Continuous research

  22. Summary

  23. Thank you

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