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  • Periodic Reporting for period 1 - EcoSwing (EcoSwing - Energy Cost Optimization using Superconducting Wind Generators - World’s First Demonstration of a 3.6 MW Low-Cost Lightweight DD Superconducting Generator on a Wind Turbine)

EcoSwing Report Summary

Project ID: 656024

Periodic Reporting for period 1 - EcoSwing (EcoSwing - Energy Cost Optimization using Superconducting Wind Generators - World’s First Demonstration of a 3.6 MW Low-Cost Lightweight DD Superconducting Generator on a Wind Turbine)

Reporting period: 2015-03-01 to 2016-02-29

Summary of the context and overall objectives of the project

The EU-funded EcoSwing project aims at demonstrating world's first superconducting low-cost and lightweight wind turbine drivetrain—demonstrated on a large-scale wind turbine.

During the 4 year project the EcoSwing ambitions are high, the consortium aims at nothing less than the following objectives:

• Design, develop and manufacture a full scale 3.6 MW direct-drive superconducting (HTS) wind generator including a dedicated power converter suitable for current mass mainstream markets.
• Install this superconducting drive train on an existing modern wind turbine in Denmark.
• Operate the superconducting drive train for at least one year, giving the community confidence in superconducting wind generators.
• Prove that the new HTS drive train is cost competitive to state-of-the-art direct-drive permanent magnet generators of world class suppliers.
• Prove that the new HTS drive train can be cost competitive to state-of-the-art geared drive trains in series production.
• Develop and manufacture a cost-efficient cryogenics package that can be maintained atop a wind turbine by regular service people.
• Develop and manufacture a low-cost and maintenance-friendly HTS coil package based on second generation (2G) wire. This will contribute to maturing and stabilizing the European Superconductor industry.
• Address unique aspects of HTS drive trains (for instance in terms of hazard analysis) and provide a way for type certification.
• Develop a risk technical & financial management strategy in order to pave the way for market entry of HTS drive trains.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

"The first one-year project period ended on February 29, 2016. We can report here on a very eventful and extremely successful period:

• Early-on in the project ENVISION spelled-out stringent integration requirements which guide the design decisions of all partners. For a 3.6 MW direct drive generator this has an outer diameter of only 4m--a very demanding requirement for a direct drive train, but driven by market pull
• ECO 5 replied with an outline design of the Generator to which JEUMONT contributed a high-performant, yet conservative, stator design. DELTA complemented a design of the power conversion equipment based on the latest innovations in IGBT technology.
• SHI Cryogenics conceived a design of the active cryocooling system. Two approaches for the critical rotary media coupling have been identified. They will be scrutinized on a dedicated test-rig in close cooperation with University of TWENTE and ENVISION.
• THEVA developed a superconductor performance in excess of the EcoSwing requirements. With design input by ECO 5, THEVA turned this wire successfully into robust superconductor coils. Prototype coils have already been qualified by TWENTE. HTS wire manufacturing has substantially stabilized as part of EcoSwing already.
• IWES is in the process of setting-up the testing infrastructure at its DyNaLab. This full ground-based test will occur after first rotary tests at JEUMONT, and before the installation on ENVISIONS wind turbine
• DNV GL provides continually oversight and guidance on new technology introduction and pre-certification issues. Ultimately, this could lead into a new drive train standard.

The consortium anticipates reporting "Design Complete" shortly, and will progress on its path towards installation of the EcoSwing generator on an existing modern 3.6 MW turbine in Thyborøn, Denmark. The consortium is progressing with vendor qualification. Certain long-lead items have already been procured. This includes for instance large steel parts, stator copper, steel laminations, IGBTs and capacitors.

The consortium is closely meshed and collaborating tightly. Substantial dissemination has taken place already."

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Accomplishments of this reporting phase significantly strengthen the European industrial technology base:

• Major impact was on quality and stability of European HTS wire manufacturing capability. We are on a very good path to reaching the projected lifts of TRL and MRL.
• Additionally, a conventional workshop for coil winding was successfully introduced into to handling superconducting wire – lifting TRL and MRL for coil manufacturing to the projected levels.
• The consortium has identified near-to-commercial solutions for the cryocooling technology such as cryocoolers and helium couplings. Experimental qualification will commence shortly.
• The stator concept is pushed significantly beyond conventional state of the art technology by means of a conservative and robust approach.

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