Трансформатор с керамической изоляцией

Breakthrough Power Transformerwith ceramic insulation of winding

«If we did all the things we are capable of, we would literally astound ourselves»

Thomas A.Edison

Vladimir Stepanchuk

2. MarketTransformer applications

Power transformers Instrument transformers

Electric devices And other(incl. welding transformers)

The world market by Grandview Research:

Power transformers:2013: 11,375 units, total $18,55B2020: 16,994 units, total $28,22B

The largest submarket: Asia (42%)

The largest suppliers: ABB Ltd., Alstom SA, Siemens Energy, Toshiba Corp., GE Co., Crompton Greaves Ltd. etc.

Russia market

More then 10-12 bln. RUB*

The largest segment: transformers with power up to 100 kV*AThe largest suppliers of transformers with power up to 100 kV*A:• «METZ V.I. Kozlova», Belarus, Minsk• OJSC «ETK BirZST», Birobidzhan• CJSC «Group Elektroshchit-TM Samara», Samara

2. Market

*Source: http://www.rus-trans.com/?ukey=auxpage_sovremennie-transformatory

2. Market (transformer types)

Dry Oil

Insulation type Epoxy compounds, air and others.

Oil

Market share in Russia up to 10% up to 90%

Cost high low

Reliability high low

3. Problems of power transformer

Transformer with oil insulation:

The frequent occurrence of oil (the need for periodic monitoring)Explosive

The need for protective structures, should not be placed near the human flows

The need for frequent inspection (at least 1 time per quarter)

High operating costs for the Power Grid Company

Dry power Transformers:

Over time, the insulation material microcracks appear. They lead to microbreakdown that entails eventually charring insulationand short-circuiting the transformer (its failure)

Works range (-25C + 40C)

Afraid of dust

The need for frequent inspection (at least 1 time per quarter)

Expensive repair

High operating costs for the Power Grid Company

3. Problems of power transformer

4. Solution – Ceramic Insulation

We invented low-cost, having no analogues in the world technology of application of ceramic insulation thickness of 300 microns on a winding of the transformer by micro-arc oxidation.

microarc oxidation (MAO), is an electrochemical surface treatment process for generating oxide coatings on metals

Oxidation occurs simultaneously with the process of winding

𝑨𝒍𝟐𝑶𝟑𝑨𝒍

Aluminium - metal Corrundum - ceramic

wire effective insulator

The advantages of ceramic insulation:

1. High, more than 0.9 winding factor (the ratio of total conductor cross section (usually copper cross section) to the area of the core window)

2. High temperature resistance;

3. High mechanical strength;

4. Radiation resistance;

5. Fire safety.

Aluminum wires in conjunction with ceramic insulation superior copper and aluminium wires with dry or oil type of insulation on the mechanical and temperature resistance.

4. Solution – Ceramic Insulation

Transformer 10kV/400V with power of 100 kV*A is one of the most common transformer on the market. Comparison of new and existing types of transformers:

Features Dry«ТСЛ-100/10»

Oil«ТМГ11-100/10»

Ceramic Insulation

Short-circuit loss, watt

1570 1970 not higher 750

No-load loss, watt 465 290 not higher 250Efficiency at nominal power, %

98 97,7 99

Efficiency under load of 200% of nominal

- - 95

Temperature class F С (до 4500С)

Operating temperature, 0С

От -45 до +40 От -60 до +40 От -70 до +150

Mass, kg 670 490 not higher 350 кгPrice (2015), th. RUB 253 120 до 300

5. Features of the New Transformer

Due to high insulating properties of ceramics it is possible to use very thin layer of ceramic that provides a high (more than 0.9) winding factor;

Small volume transformer requires less material (steel) for body

Winding density provides high efficiency (low losses of electricity power) even with aluminum wire, comparable to dry and oil transformers with copper windings

Reduce costs (aluminum is three times cheaper than copper)

Low Cost Factors

5. Features of the New Transformer

6. ApplicationsTransformer with ceramic insulation is beneficial in all areas of traditional (oil and dry) transformer.

However, we want to highlight in particular:

The Far North and the zone of the tropics / subtropics

The possibility of the transformer to work atwide temperature range (from -70C to + 70C) and any humidity eliminating the need for design and construction, installation of protective covers, booths, structures, which gives substantial reduce in CAPEX

Transformers on drilling rigs

In conditions of relatively frequent changes of location of the transformer, there is no need to have housing for stabilize the temperature. So this reduces CAPEX

Nuclear Power Plants

Transformer with ceramic insulation is absolutely radiation-resistant

in the United States at NPP there are widely used of radiation-resistant «Nomex» insulation (provided by DuPont)

Nomex - an expensive synthetic aromatic polyamide, i.e. plastic. Ceramic insulation has surely better performance

6. Applications

7. Existing transformer prototype

9. Next Steps

• Make transformer 10kV/400V with power of 100 kV*A

• Test it in cooperation with the Electric Grid Company

• Patent protection

• Demonstrate device to large transformer manufactures (Siemens, ABB Ltd., etc.)

• Need Investment: 500 000 USD for 14 monthes

• Need partner: Electric Grid Company or Transformer manufacturer

8. Team8 personы

Key persons:CTO (author)A.NikiforovInstitute of Inorganic Chemistry of RAS (Novosibirsk)17 years of tech-managerial experience in commercial structures. Under his leadership, small companies made about ten scientific developments: • technology for super-pure scandium and cesium, • technology for production of absolute pure ethanol, • power supplies for micro-arc oxidation,• analyzer dispersion of solid particles in a liquid, and others.CEOVladimir Stepanchuk awarded honorary radio operator of the Russian Federation 5 years experience: director of venture fund15 years of tech-backed companies management

Project managerRyabykh Viktor7 years experience: project manager of innovation venture projects