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EPRI Proprietary Licensed Material Starsine Rotary UPS. The Starsine uses a large steel wheel that operates between 1980 and 1620 rpm and discharges via an induction generator using rotor power electronics to compensate for the speed change. They are targeting applications that provide continuous power for process industries. However, with some modifications to the power electronics and rotor current rating, the system may be suitable for higher powers for 1-2 seconds in a utility scale stabilizer application. The SatCon UPS product will operate in a fashion similar to other bridge-power devices, providing 12 seconds of ride-through power to cover short power quality events or momentary service interruptions, and relying on the diesel engine to cover longer interruptions. SatCon is unique among flywheel manufactures in their use of power electronic controls integrated into an induction generator, sometimes referred to as a doubly fed or double-output induction generator. This technology provides a soft interface between the variable speed flywheel or diesel generator and the fixed frequency of the load bus. Because of the interface SatCon expects to be able to parallel several flywheels without added paralleling switch gear and control. Urenco Power Technologies Urenco is a British company best known for uranium enrichment processes, for which they have developed and manufactured high-speed, composite gas centrifuges over the past thirty years. Urenco's flywheel technology is a direct spin-off from this experience and is being commercialised in a subsidiary called Urenco Power Technologies (UPT). Like the centrifuge the UPT flywheel uses a composite rotor and the same type bearing system that has allowed many of Urenco’s early centrifuges to run continuously for over twenty years. For the power quality market, UPT builds two models; one sized to provide 100kW and a more recent version capable of providing 250kW. Both systems provide full power for about 30 seconds. It should be noted that this high-speed flywheel provides as much power as many of the low-speed flywheel ride-through devices, for a longer period of time and in a much smaller flywheel package. On the other hand auxiliary electronics and cooling add to the package size and weight. UPT's flywheel is a DC output device and can be coupled with an inverter/rectifier if AC power is required. Beacon Power has plans to market a system incorporating a UPT 250kW flywheel together with an inverter/rectifier, under the Beacon label as the SmartPower BHP-250. The UPT flywheels are also being used in power management applications where the requirement is for repeated charge/discharge cycles. Examples include voltage support and energy saving in mass transit systems and power smoothing with wind turbines. Recent Developments in Flywheel Technology There are two major avenues of research in flywheel technology at present: improved passive magnetic bearings, and improved wheel materials. Research into these avenues is being conducted in various facilities, including universities, government laboratories, and Flywheels Page 20
EPRI Proprietary Licensed Material in industry. Table 3 lists important flywheel technology developers and the technology they are best known for developing. Table 3 Major Flywheel Research Groups Developer Boeing Phantom Works Lawrence Livermore National Laboratories Pennsylvania State University University of Texas Development Area High Temperature Superconducting Bearings Passive Magnetic Bearings Composite rotor materials Composite rotor materials Magnetic Bearings Research into new magnetic bearings is a significant part of flywheel research at present. New developments in active magnetic bearing technology have built hopes that similar advances in passive magnetic bearings may be possible. Passive bearings have the advantage of greater stability and reliability, and potentially lower parasitic loads than active bearings. Two groups are leading the field in research on bearings: Boeing Corporation, and Lawrence Livermore National Laboratories. Boeing is better known for its airplanes and defense contracts than its flywheel technology, but the Boeing Phantom Works, the R&D branch of the company, has a flywheel program geared in part towards electric utility applications. In 1998, the Department of Energy awarded Boeing a contract to develop flywheels with high-temperature superconductor (HTS) magnetic bearings. These bearings are made from superconducting materials that operate at somewhat higher temperatures than regular superconductors, although they still require cryogenic cooling with liquid nitrogen. The energy required to cool the materials is expected to be less than that required by conventional active magnetic bearings. Using this technology, Boeing has built 15kW, 2.5 kWh energy-storage flywheels for both aerospace and utility energy storage applications. The flywheels have graphite composite rotors spinning in a vacuum. With further development, the company hopes to achieve 10kWh flywheels, and eventually develop megawatt-hour systems for utility energy storage applications. It can be argued that modern flywheel technologies began at Lawrence Livermore National Laboratories (LLNL) in Livermore, CA, where Dr. Richard Post first proposed advanced flywheel systems for electric vehicles in the early 1970s. Later work at LLNL resulted in composite flywheels in place of the metal wheels predominant at that time. Much of LLNL’s technology – particularly its Halbach motor/generator technology – was licensed to Trinity Flywheel Power (now a part of AFS Trinity). LLNL’s present work in flywheel technology is concentrated on the development of passive permanent magnetic bearings. Permanent magnets, arranged asymmetrically in such a way as to minimize instability and losses, can form stable room-temperature Flywheels Page 21
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