Periodic Reporting for period 2 - Super-HEART (Super-HEART: a fault-tolerant and highly efficient energy hub with embedded short-term energy storage for high availability electric power delivery)
Période du rapport: 2023-04-01 au 2025-03-31
Electrification of society is reaching mission-critical applications. However, power electronics devices remain prone to failure, and high availability is typically achieved through redundancy—an approach that is both costly and bulky. Meanwhile, power electronics enables hybrid (AC & DC) electric distribution, which is key to large-scale solar power integration and using hydrogen as an energy carrier. Multi-source integration, including renewable generators and energy storage, is also required to ensure operational continuity, compensate for the limited dynamics of power sources like fuel cells, and filter out grid disturbances.
Super-HEART focused on developing a multiport power converter, an isolated converter capable of interfacing multiple sources and loads in an integrated manner. This converter constitutes a versatile power electronics building block. The project also advanced the development of high-density, long-lifetime MXene-based supercapacitor electrodes and devices, using novel 3D networked porous structures and solvothermally treated MXene to achieve superior performance. Their co-integration with power electronics converters was a key research focus. Finally, the project analysed use cases and potential applications, paving the way for commercialisation.
The project builds on the results of the HEART and U-HEART European excellence grants (led by Prof. Liserre at the Chair of Power Electronics at Kiel University), with support from Fraunhofer ISIT, as well as developments in high-power, high-energy-density supercapacitors from the Chair for Functional Nanomaterials (Prof. Adelung) at Kiel University and Trinity College Dublin (Prof. Nicolosi).
Key Features of the Power Converter
• High efficiency
• High power density
• Modular & scalable at high power
• High availability through fault tolerance
Target Applications:
• Uninterruptible power supplies (UPS), e.g. for datacentres
• Charging stations (MW) and infrastructure (LV and MVDC)
• DC industrial applications
• MVDC grids, including on-board systems (ships, etc.)
Super-HEART focused on developing a multiport power converter, an isolated converter capable of interfacing multiple sources and loads in an integrated manner. This converter constitutes a versatile power electronics building block. The project also advanced the development of high-density, long-lifetime MXene-based supercapacitor electrodes and devices, using novel 3D networked porous structures and solvothermally treated MXene to achieve superior performance. Their co-integration with power electronics converters was a key research focus. Finally, the project analysed use cases and potential applications, paving the way for commercialisation.
The project builds on the results of the HEART and U-HEART European excellence grants (led by Prof. Liserre at the Chair of Power Electronics at Kiel University), with support from Fraunhofer ISIT, as well as developments in high-power, high-energy-density supercapacitors from the Chair for Functional Nanomaterials (Prof. Adelung) at Kiel University and Trinity College Dublin (Prof. Nicolosi).
Key Features of the Power Converter
• High efficiency
• High power density
• Modular & scalable at high power
• High availability through fault tolerance
Target Applications:
• Uninterruptible power supplies (UPS), e.g. for datacentres
• Charging stations (MW) and infrastructure (LV and MVDC)
• DC industrial applications
• MVDC grids, including on-board systems (ships, etc.)
The project delivered advancements in supercapacitor electrodes and devices, as well as in power converters.
In the field of supercapacitors, the synthesis of Ti₃C2Tx MXene was refined to achieve greater yields as well as higher-quality MXene flakes for use in electrochemical energy storage. Furthermore, a novel ambient drying approach was used to create larger MXene aerostructures, thereby avoiding the need for costly equipment. In addition, solvothermally treated MXene flakes were successfully employed in blade-cast lithium-ion capacitor devices, which exhibited high capacity values.
Different electrode materials were investigated as counter electrodes to fabricate high-capacitance devices based on MXene electrodes. Conductive polymers such as PANI and PEDOT:PSS, as well as activated carbon, were investigated. Both aqueous and non-aqueous electrolyte systems were tested. Ultimately, a large number of pouch cell devices demonstrating superior performance had been created, showcasing the potential to scale up the technology.
Finally, an innovative impedance spectroscopy measurement tool capable of measuring the capacitance, leakage current, internal resistance, and heat evolution of a supercapacitor or stack thereof was developed.
As for the power converter, two demonstrators were developed and tested. One is a 4-port converter, with each port rated for 400 Vdc and a nominal power of 20 kW. It uses SiC transistors and a low-profile planar transformer, achieving 98.0% efficiency. It was tested in a Power Hardware-in-the-Loop (PHiL) environment, where it was subjected to realistic mission profiles, allowing for the testing and validation of its operation under representative dynamic loads. The demonstrator is intended for micro-grid applications, where it can operate as a solid-state transformer (SST) or a "smart energy router". The second demonstrator, a 400V:48V 20 kW converter, targets data-centre applications. Its embedded fault tolerance is critical to meeting stringent availability requirements.
Finally, system-level integration of supercapacitors and power converters was undertaken. This included multiobjective optimal sizing, interface converter development, and the creation of robust balancing and monitoring circuits.
The project also explored and evaluated potential application fields for the developed technologies and devices, assessing both their unique technical advantages and market compatibility.
In the field of supercapacitors, the synthesis of Ti₃C2Tx MXene was refined to achieve greater yields as well as higher-quality MXene flakes for use in electrochemical energy storage. Furthermore, a novel ambient drying approach was used to create larger MXene aerostructures, thereby avoiding the need for costly equipment. In addition, solvothermally treated MXene flakes were successfully employed in blade-cast lithium-ion capacitor devices, which exhibited high capacity values.
Different electrode materials were investigated as counter electrodes to fabricate high-capacitance devices based on MXene electrodes. Conductive polymers such as PANI and PEDOT:PSS, as well as activated carbon, were investigated. Both aqueous and non-aqueous electrolyte systems were tested. Ultimately, a large number of pouch cell devices demonstrating superior performance had been created, showcasing the potential to scale up the technology.
Finally, an innovative impedance spectroscopy measurement tool capable of measuring the capacitance, leakage current, internal resistance, and heat evolution of a supercapacitor or stack thereof was developed.
As for the power converter, two demonstrators were developed and tested. One is a 4-port converter, with each port rated for 400 Vdc and a nominal power of 20 kW. It uses SiC transistors and a low-profile planar transformer, achieving 98.0% efficiency. It was tested in a Power Hardware-in-the-Loop (PHiL) environment, where it was subjected to realistic mission profiles, allowing for the testing and validation of its operation under representative dynamic loads. The demonstrator is intended for micro-grid applications, where it can operate as a solid-state transformer (SST) or a "smart energy router". The second demonstrator, a 400V:48V 20 kW converter, targets data-centre applications. Its embedded fault tolerance is critical to meeting stringent availability requirements.
Finally, system-level integration of supercapacitors and power converters was undertaken. This included multiobjective optimal sizing, interface converter development, and the creation of robust balancing and monitoring circuits.
The project also explored and evaluated potential application fields for the developed technologies and devices, assessing both their unique technical advantages and market compatibility.
The project demonstrated the validity of the multiport power converter concept with embedded fault tolerance at high power levels. It also advanced the approaches for optimal supercapacitor stack sizing and the design of their interface converters. Finally, innovative methods were developed for the optimal multi-objective sizing and control (power and energy management) of multi-energy systems (e.g. using batteries, fuel cells, photovoltaics, etc.).
Beyond these scientific and technical advancements, the project investigated multiple applications in which the developed multiport power converter concept could be beneficial. It quantitatively assessed the benefits in terms of efficiency, volume, and cost compared to the state of the art. Clear benefits were demonstrated for data centre server supply, grid integration of batteries and charging stations, and vertical farms and greenhouses, among others. In these use cases, loss and volume reduction of 15% to 70% were identified.
Future work will focus on further developing the technology and conducting field testing in collaboration with industry partners, aiming to demonstrate its performance in real-world environments and validate its value proposition.
In the field of supercapacitors, the project has output 3 main materials science developments beyond the state of the art.
First, the templating method allowed the creation of tuneable, highly porous electrodes, minimising diffusion-related performance loss in high areal loading electrodes. This allowed the creation of electrodes with a combination of areal, volumetric, and gravimetric performance which surpasses the state of the art.
Second, techniques which are not reliant on critical point to dry highly porous structures, but instead operate in ambient conditions, and without specialised equipment, were developed. The project demonstrated structures with similar quality and performance without the need for expensive equipment or large amounts of energy, and where there would be no barrier to recycling the solvent used for drying at industrial scales. These techniques have implications for a range of porous structures and aerogels, opening the door to lower-cost and faster production. This innovation is the subject of an invention declaration in TCD.
Last, the project demonstrated a rapid, low-cost solvothermal treatment process for MXene which achieved a >60% capacity improvement in industry standard lithium electrolyte. This material was used to create proof-of-concept pouch cell lithium-ion supercapacitors, using a standard blade casting method to prepare electrodes. This material is being further developed, and follow-on funding is being sought to continue optimisation, and upscaling of the material synthesis. This would pave the way to lithium-ion capacitors which can approach batteries in terms of energy density, while exceeding them in cycle life and power density.
Beyond these scientific and technical advancements, the project investigated multiple applications in which the developed multiport power converter concept could be beneficial. It quantitatively assessed the benefits in terms of efficiency, volume, and cost compared to the state of the art. Clear benefits were demonstrated for data centre server supply, grid integration of batteries and charging stations, and vertical farms and greenhouses, among others. In these use cases, loss and volume reduction of 15% to 70% were identified.
Future work will focus on further developing the technology and conducting field testing in collaboration with industry partners, aiming to demonstrate its performance in real-world environments and validate its value proposition.
In the field of supercapacitors, the project has output 3 main materials science developments beyond the state of the art.
First, the templating method allowed the creation of tuneable, highly porous electrodes, minimising diffusion-related performance loss in high areal loading electrodes. This allowed the creation of electrodes with a combination of areal, volumetric, and gravimetric performance which surpasses the state of the art.
Second, techniques which are not reliant on critical point to dry highly porous structures, but instead operate in ambient conditions, and without specialised equipment, were developed. The project demonstrated structures with similar quality and performance without the need for expensive equipment or large amounts of energy, and where there would be no barrier to recycling the solvent used for drying at industrial scales. These techniques have implications for a range of porous structures and aerogels, opening the door to lower-cost and faster production. This innovation is the subject of an invention declaration in TCD.
Last, the project demonstrated a rapid, low-cost solvothermal treatment process for MXene which achieved a >60% capacity improvement in industry standard lithium electrolyte. This material was used to create proof-of-concept pouch cell lithium-ion supercapacitors, using a standard blade casting method to prepare electrodes. This material is being further developed, and follow-on funding is being sought to continue optimisation, and upscaling of the material synthesis. This would pave the way to lithium-ion capacitors which can approach batteries in terms of energy density, while exceeding them in cycle life and power density.