Optimal Power Conversion System Architectures for Utility-Scale Solar-Plus-Storage Farms

For utility-scale photovoltaic (PV) projects, solar-plus-storage (SPS) has become an increasingly favored configuration owing to significantly reduced PV and battery storage costs, improved energy dispatchability, and grid-support services with added storage. However, the state-of-the-art power conversion system (PCS) architectures based on central and string inverters feature a low-voltage direct-current (DC)/alternating-current (AC) distribution with underground cables inside solar farms, inducing significant copper losses and costs. Furthermore, these two approaches require additional converters to integrate the paired battery storage, resulting in extra investment and maintenance effort. These factors result in an increased Levelized Cost of Electricity (LCOE) of utility-scale SPS farms and thus dampen the continued proliferation of solar energy. The objective of this research is to propose three new medium-voltage AC (MVAC) PCS architectures to reduce the LCOE of utility-scale SPS farms and thus accelerate the deployment of dispatchable and low-cost solar energy. These three proposed approaches, namely tri-port medium-voltage string inverter (TMVSI), multi-port DC transformer (MDCT), and massively distributed micro-multiport converter (µMC), enable localized DC-coupled battery storage, an MVAC distribution network using standard and low-cost overhead lines, and distributed layout of power conditioning units across the plant with scalable SPS farm building block design. Throughout this dissertation, a 300 kVA/4 kVac TMVSI has been designed, built, and tested to validate its effectiveness and viability, with a focus on the medium-frequency transformer design and control optimization. In addition, enhanced energy dispatchability and grid-support services of a 20 MW/80 MWh TMVSI-based SPS farm have been demonstrated. Finally, a framework for system-level LCOE analysis has been established to validate the advantages of the proposed MVAC architectures in reducing system LCOE of utility-scale SPS farms over a wide range of inverter-loading-ratios.Ph.D

SCR-Based Wind Energy Conversion Circuitry and Controls for DC Distributed Wind Farms

The current state of art for electrical power generated by wind generators are in alternating current (AC). Wind farms distribute this power as 3-phase AC. There are inherent stability issues with AC power distribution. The grid power transfer capacity is limited by the distance and characteristic impedance of the lines. Furthermore, wind generators have to implement complicated, costly, and inefficient back-to-back converters to generate AC. AC distribution does not offer an easy integration of energy storage. To mitigate drawbacks with AC generation and distribution, direct current (DC) generation and high voltage direct current (HVDC) distribution for the wind farms is proposed. DC power distribution is inherently stable. The generators convert AC power to DC without the use of a back-to-back converter. DC grid offers an easy integration of energy storage. The proposed configuration for the generator is connected to a HVDC bus using a 12 pulse thyristor network, which can apply Maximum Power Point Tracking (MPPT). To properly control the system, several estimators are designed and applied. This includes a firing angle, generator output voltage, and DC current estimators to reduce noise effects. A DSP-based controller is designed and implemented to control the system and provide gate pulses. Performance of the proposed system under faults and drive train torque pulsation are analyzed as well. Additionally, converter paralleling when turbines operate at different electrical power levels are also studied. The proposed new Wind Energy Conversion System (WECS) is described in detail and verified using MATLAB®/ Simulink® simulation and experimental test setup. The proposed solution offers higher reliability, lower conversion power loss, and lower cost. The following is proposed as future work: 1) Study different control methods for controlling the SCR\u27s. 2) Investigate reducing torque pulsations of the PMSG and using the proposed power conversion method for DFIG turbines. 3) Explore options for communication/control between PMSG, circuit protection and grid-tied inverters. 4) Investigate the best possible configuration for DC storage/connection to the HVDC/MVDC bus. 5) Study the filtering needed to improve the DC bus voltage at the generator

High Power, Medium Frequency, and Medium Voltage Transformer Design and Implementation

Many industrial applications that require high-power and high-voltage DC-DC conversion are emerging. Space-borne and off-shore wind farms, fleet fast electric vehicle charging stations, large data centers, and smart distribution systems are among the applications. Solid State Transformer (SST) is a promising concept for addressing these emerging applications. It replaces the traditional Low Frequency Transformer (LFT) while offering many advanced features such as VAR compensation, voltage regulation, fault isolation, and DC connectivity. Many technical challenges related to high voltage stress, efficiency, reliability, protection, and insulation must be addressed before the technology is ready for commercial deployment. Among the major challenges in the construction of SSTs are the strategies for connecting to Medium Voltage (MV) level. This issue has primarily been addressed by synthesizing multicellular SST concepts based on modules rated for a fraction of the total MV side voltage and connecting these modules in series at the input side. Silicon Carbide (SiC) semiconductor development enables the fabrication of power semiconductor devices with high blocking voltage capabilities while achieving superior switching and conduction performances. When compared to modular lower voltage converters, these higher voltage semiconductors enable the construction of single-cell SSTs by avoiding the series connection of several modules, resulting in simple, reliable, lighter mass, more power dense, higher efficiency, and cost effective converter structures. This dissertation proposes a solution to this major issue. The proposed work focuses on the development of a dual active bridge with high power, medium voltage, and medium frequency control. This architecture addresses the shortcomings of existing modular systems by providing a more power dense, cost-effective, and efficient solution. For the first time, this topology is investigated on a 700kW system connected to a 13kVdc input to generate 7.2kVdc at the output. The use of 10kV SiC modules and gate drivers in an active neutral point clamped to two level dual active bridge converter is investigated. A special emphasis will be placed on a comprehensive transformer design that employs a multi-physics approach that addresses all magnetic, electrical, insulation, and thermal aspects. The transformer is designed and tested to ensure the system’s viability

Comparative Analysis of Multilevel Converters for Medium-Voltage Applications

The electric energy demand has been steadily growing during the last century, and all forecasts indicate that it will keep growing in the following years. Within this frame, and due to all the problems that this demand increase generate in the environment, it is necessary improving the current techniques of electric energy conversion and transmission in order to increase the whole system efficiency. On the other hand, it is also necessary increasing the renewable energy resources exploitation through more efficient generation systems. According to these lines, the power electronics systems that have been installed in the last decades allowed to obtain better efficiency from the renewable natural resources like the wind or the solar power. These systems have also notably improved the quality of the power supplied, reducing the losses through what are known as power quality applications. Power converters are currently essential in any power electronics system. Within them, the multilevel converters specially suppose a breakthrough compared with the classical two level converters, as they allow obtaining voltage and current signals with lower harmonic content, what means fewer losses in high power medium voltage applications. In this Thesis a comparative study of some multilevel converter topologies normally used in high power medium voltage applications is done. The objective is analyzing in detail each topology and comparing it with the rest following different criteria, with the aim to know the advantages and drawbacks of each one and to realize which one is more suitable for each application

Multilevel Converters: An Enabling Technology for High-Power Applications

| Multilevel converters are considered today as the state-of-the-art power-conversion systems for high-power and power-quality demanding applications. This paper presents a tutorial on this technology, covering the operating principle and the different power circuit topologies, modulation methods, technical issues and industry applications. Special attention is given to established technology already found in industry with more in-depth and self-contained information, while recent advances and state-of-the-art contributions are addressed with useful references. This paper serves as an introduction to the subject for the not-familiarized reader, as well as an update or reference for academics and practicing engineers working in the field of industrial and power electronics.Ministerio de Ciencia y Tecnología DPI2001-3089Ministerio de Eduación y Ciencia d TEC2006-0386

Power Semiconductors for An Energy-Wise Society

This IEC White Paper establishes the critical role that power semiconductors play in transitioning to an energy wise society. It takes an in-depth look at expected trends and opportunities, as well as the challenges surrounding the power semiconductors industry. Among the significant challenges mentioned is the need for change in industry practices when transitioning from linear to circular economies and the shortage of skilled personnel required for power semiconductor development. The white paper also stresses the need for strategic actions at the policy-making level to address these concerns and calls for stronger government commitment, policies and funding to advance power semiconductor technologies and integration. It further highlights the pivotal role of standards in removing technical risks, increasing product quality and enabling faster market acceptance. Besides noting benefits of existing standards in accelerating market growth, the paper also identifies the current standardization gaps. The white paper emphasizes the importance of ensuring a robust supply chain for power semiconductors to prevent supply-chain disruptions like those seen during the COVID-19 pandemic, which can have widespread economic impacts.The white paper highlights the importance of inspiring young professionals to take an interest in power semiconductors and power electronics, highlighting the potential to make a positive impact on the world through these technologies.The white paper concludes with recommendations for policymakers, regulators, industry and other IEC stakeholders for collaborative structures and accelerating the development and adoption of standards

Induction heating converter's design, control and modeling applied to continuous wire heating

Induction heating is a heating method for electrically conductive materials that takes advantage of the heat generated by the Eddy currents originated by means of a varying magnetic field. Since Michael Faraday discovered electromagnetic induction in 1831, this phenomena has been widely studied in many applications like transformers, motors or generators' design. At the turn of the 20th century, induction started to be studied as a heating method, leading to the construction of the first industrial induction melting equipment by the Electric Furnace Company in 1927. At first, the varying magnetic fields were obtained with spark-gap generators, vacuum-tube generators and low frequency motor-generator sets. With the emergence of reliable semiconductors in the late 1960's, motor-generators were replaced by solid-state converters for low frequency applications. With regard to the characterization of the inductor-workpiece system, the first models used to understand the load's behavior were based on analytical methods. These methods were useful to analyze the overall behavior of the load, but they were not accurate enough for a precise analysis and were limited to simple geometries. With the emergence of computers, numerical methods experienced a tremendous growth in the 1990's and started to be applied in the induction heating field. Nowadays, the development of commercial softwares that allow this type of analysis have started to make the use of numerical methods popular among research centers and enterprises. This type of softwares allow a great variety of complex analysis with high precision, consequently diminishing the trial and error process. The research realized in last decades, the increase in the utilization of numerical modeling and the appearance and improvement of semiconductor devices, with their corresponding cost reduction, have caused the spread of induction heating in many fields. Induction heating equipments can be found in many applications, since domestic cookers to high-power aluminum melting furnaces or automotive sealing equipments, and are becoming more and more popular thanks to their easy control, quick heating and the energy savings obtained. The present thesis focuses on the application of induction heating to wire heating. The wire heating is a continuous heating method in which the wire is continuously feeding the heating inductor. This heating method allows high production rates with reduced space requirements and is usually found in medium to high power industrial processes working 24 hours per day. The first chapters of this study introduce the induction heating phenomena, its modeling and the converters and tanks used. Afterwards, a multichannel converter for high-power and high-frequency applications is designed and implemented with the aim of providing modularity to the converter and reduce the designing time, the production cost and its maintenance. Moreover, this type of structure provides reliability to the system and enables low repairing times, which is an extremely interesting feature for 24 hours processes. Additionally, a software phase-locked loop for induction heating applications is designed and implemented to prove its flexibility and reliability. This type of control allows the use of the same hardware for different applications, which is attractive for the case of industrial applications. This phase-locked loop is afterwards used to design and implement a load-adaptative control that varies the references to have soft-switching according to load's variation, improving converter's performance. Finally, the modeling of a continuous induction wire hardening system is realized, solving the difficulty of considering the mutual influence between the thermal, electromagnetic and electric parameters. In this thesis, a continuous process is modeled and tested using numerical methods and considering converter's operation and influence in the process.Postprint (published version

Modular Battery Systems for Electric Vehicles based on Multilevel Inverter Topologies - Opportunities and Challenges

Modular battery systems based on multilevel inverter (MLI) topologies can possibly overcome some shortcomings of two-level inverters when used for vehicle propulsion. The results presented in this thesis aim to point out the advantages and disadvantages, as well as the technical challenges, of modular vehicle battery systems based on MLIs in comparison to a conventional, two-level IGBT inverter drivetrain. The considered key aspects for this comparative investigation are the drive cycle efficiency, the inverter cost, the fault tolerance capability of the drivetrain and the conducted electromagnetic emissions. Extensive experiments have been performed to support the results and conclusions.In this work, it is shown that the simulated drive cycle efficiency of different low-voltage-MOSFET-based, cascaded seven-level inverter types is improved in comparison to a similarly rated, two-level IGBT inverter drivetrain. For example, the simulated WLTP drive cycle efficiency of a cascaded double-H-bridge (CDHB) inverter drivetrain in comparison to a two-level IGBT inverter, when used in a small passenger car, is increased from 94.24% to 95.04%, considering the inverter and the ohmic battery losses. In contrast, the obtained efficiency of a similar rated seven-level cascaded H-bridge (CHB) drivetrain is almost equal to that of the two-level inverter drivetrain, but with the help of a hybrid modulation technique, utilizing fundamental selective harmonic elimination at lower speeds, it could be improved to 94.85%. In addition, the CDHB and CHB inverters’ cost, in comparison to the two-level inverter, is reduced from 342€ to 202€ and 121€, respectively. Furthermore, based on a simple three-level inverter with a dual battery pack, it is shown that MLIs inherently allow for a fault tolerant operation. It is explained how the drivetrain of a neutral point clamped (NPC) inverter can be operated under a fault condition, so that the vehicle can drive with a limited maximum power to the next service station, referred to as limp home mode. Especially, the detection and localization of open circuit faults has been investigated and verified through simulations and experiments.Moreover, it is explained how to measure the conducted emissions of an NPC inverter with a dual battery pack according to the governing standard, CISPR 25, because the additional neutral point connection forms a peculiar three-wire DC source. To separate the measured noise spectra into CM, line-DM and phase-DMquantities, two hardware separators based on HF transformers are developed and utilized. It is shown that the CM noise is dominant. Furthermore, the CM noise is reduced by 3dB to 6dB when operating the inverter with three-level instead of two-level modulation