Cost Projections For High Temperature Superconductors
Cost Projections For High Temperature Superconductors
Cost Projections For High Temperature Superconductors
I. INTRODUCTION
For over a decade, the emphasis of applied research on
high-temperature superconductivity (HTS) has been placed
on improving the properties of the materials, especially the
critical current JC. Until recently [1], little attention has been
given to considerations of manufacturing cost, because other
concerns and obstacles have always been of much more immediate concern. There seems to be a basic presumption that
if researchers can find a way to do something at all, then others will find a way to drive down manufacturing costs and
make a profit from it.
For power applications [2] of HTS, where many amperes
are to be transported over sometimes meters, sometimes
miles, there exists competition with traditional lowtemperature superconductors (LTS) such as NbTi and Nb3Sn,
because the latter can perform the exact same functions
whenever the temperature can be reduced into the liquid helium range (4 K). The very high cost of such refrigeration
has kept many superconducting power applications off the
market for years, despite their demonstrated technical feasibility [3]. The attitude of utilities and power equipment
manufacturers has been one of reluctance to accept superconducting technology because of the prohibitive costs (from
their point of view) in light of performance gained.
For electrical wire, the figure-of-merit for comparing costs
of different materials at a particular operating point has been
dollars per kiloamperemeter ($/kAm). This reflects the
Paper presented at the Applied Superconductivity Conference, Palm Desert,
CA, September, 1998.
$10 Bi-2223
1000
$1 /kAm
77K, 0T
Siemens
Target
$1,000
NbTi
4.2K, 2T
7.0
Nb3Sn
4.2K, 12-15 T
100
EURUS
100
Y-123 IBAD
Bi-2223
77K, 0T
NKT Target
Bi-2223
77K, 0T
IGC
10
1
1000
Bi-2212
4.2K, 0T
IGC
$/troy oz
$100
6.5
6.0
5.5
5.0
10
0.1
Cost ($/m)
Fig. 1. The "Sokolowski Plot" of a number of HTS and LTS wire embodiments. Data were obtained courtesy of the manufacturers as labelled in the
plot. When comparing performance, note the different operating points, i.e.,
temperature and field. The diagonal lines represent demarcation of various
constant C/P values in $/kAm.
As mentioned at the Applied Superconductivity Conference, ASC-96, two years ago [6], the cost of silver sheathing
for BSCCO carries a very severe price penalty. The calculation is straightforward, and might readily be left as an exercise for the reader; but nonetheless we will present our version now.
Assume a typical powder-in-tube configuration has a silver
tube 2 mm in diameter, with an inside diameter of 1.15 mm
filled with BSCCO. The ratio of cross-sectional areas is such
that silver is 2/3 and BSCCO 1/3; so the volume fraction of
superconductor is = 1/3. As the tube is stretched and
thinned, that ratio doesnt change. When a bundle of tubes is
combined to form a multifilament wire and crushed into a
tape, still the ratio doesnt change.
The silver tubes could perhaps have a thinner wall, but the
need for thermal protection [6] against burnout during
quench argues for having more than half the wire made of
non-superconducting material [7]. It would be dangerous to
run above = 0.5. In most previous applications, such as
NbTi for accelerator magnets, = 0.4 is common. For any
wire with adequate thermal protection, the silver cost component will certainly be nontrivial. Figure 2 gives an idea of the
variation in silver futures for the early part of 1998.
4.5
8/97
9/97
10/97
11/97
12/97
1/98
2/98
3/98
4/98
Month
Fig. 2. Variation in May 1998 silver futures since August 1997. The peak in
February displays the "Warren Buffet Effect" (the large volume silver purchases that month by Berkshire Hathaway) the and is suggestive of the volatility of silver prices against moves by large investment groups.
What are the future prospects for silver supply and prices
[10]? In 1997, total worldwide demand for silver was 27
million kilograms, outstripping supply by 6 million kg. Demand for silver has exceeded supply since 1990, not exactly a
good sign for a new technology that will make even greater
demand on reserves, in the ground, recycled and stored as
bullion. One of the largest consumers of silver is the photography industry (7.2 million kg/yr of which 1.4 million kg/yr
is recycled), and it is sometimes remarked that the replacement of silver halide-based photographic technology by digital methods will lower silver prices to the benefit of other
uses, e.g., power applications of superconductivity. Yet in
1997, photographic uses of silver increased 3%, a trend
which is expected by industry analysts to continue for some
time for amateur and some professional applications.
The annual production of NbTi by IGC is about 20,000
km/yr [11]. Annual installation of underground transmission
cable (three phase circuits) is around 360 km/yr in the US.
Assuming a form factor of 20 to acount for layering and
helicity, this would require 3,600 km/yr of HTS tape. Let's
say the total potential annual market for practical HTS tape is
twice this total number (i.e., complete takeover of all commercial applications of LTS and new HTS opportunities), or
nearly 50,000 km/yr in the US. For BSCCO/OPIT tape of
Derating Factor
TABLE I
VARIOUS C/P DERATING FACTORS
This Paper
ASC [13]
1.2
1.8
3.0
2.5
1.5
1.3
Cumulative Derating
31.6
1.15 (B ab plane)
1.05
7.1
Magneto-Optic Image
J C Paths @ 12 K
2
2
2
400000
350000
Jc (A/cm^2, 77 K, 0 T)
The truly startling consequence of Fig. 3 is that the overwhelming bulk of the filament (shown in blue) carries zero
critical current! Most of the critical current is preferentially
transported near the Ag/BSSCO interface, a result wellknown in the field [2, 15]. In this particular sample, the contiuous current path exceeded 160,000 A/cm2 (green and yellow), with a few small regions (red) reaching 360,000 A/cm2.
Can we use the example of Fig. 3 to estimate an "as good
as it gets" outcome for BSCCO/OPIT wire? The data were
taken at 12 K, but a reasonable way to extrapolate to 77 K
might be as follows: 1) the relative JC at all temperatures and
fields is distributed more or less as shown in Fig. 3, i.e., with
the maximum at the Ag/HTS interface; 2) the maximum
JC(77 K, 0 T) for epitaxial BSCCO films is roughly one million A/cm2; 3) one might assume it is possible to achieve
perhaps 1/3 this magnitude near the Ag surface in BSCCO
tape; and 4) let's just assume that would be 360,000 A/cm2,
the same value seen in Fig. 3 for 12 K (after all, the data of
Fig. 3 is now three years old, and recently JC values near this
figure have been observed by at least one institution [16]).
The "as good as it gets" scenario for BSCCO/OPIT would
then be played out if this 3.6 105 A/cm2 could be realized
throughout the entire cross-section of the filament.
How long might it take before such could be accomplished? To date, JC in meter-scale lengths has increased
linearly in time since the birth of BSCCO wire technology
around 1991a kind of linear "Moore's Law" which in fact
has been christened "Malozemoff's Law" after the ASC scientist who first observed this trend. The slope of JC vs. t is
about 9200 A/cm2/yr, and this allows, under an assumption
Malozemoff's Law will continue to hold, an estimation of
when "as good as it gets" for BSCCO is realized. This speculative scenario is exhibited in Fig. 4.
300000
250000
200000
150000
100000
50000
0
1990
1995
2000
2005
2010
2015
2020
2025
2030
2035
Year
We see that BSCCO/OPIT wire, subject to our assumptions and the continuance of Malozemoff's Law, will top out
around the year 2030quite a long time to wait. We suspect
JC vs t will deviate from linearity long before then. Which
way, of course, will prove crucial to its future application.
Some estimation of expected trends for the "real" C/P can
be made by combining our derating exercise above with the
extrapolation of Malozemoff's Law just discussed and displayed in Fig. 4. Figure 5 shows the result.
Derated C/P for BSCCO/OPIT
120.00
100.00
80.00
60.00
40.00
1998 ASC JC
$10.30/kAm
20.00
$10/kAm
0.00
1990
1995
2000
2005
2010
2015
2020
2025
2030
2035
Year
Fig. 5. Prediction of the decrease in BSCCO C/P per year employing the data
of Fig. 4 since about mid-1995, the geometrical, Ag-filling, materials, and
L&O numbers of our earlier example, all derated by a factor of 7.1. The
"call-out" displays the "unburdened" C/P associated with the record value of
JC = 70,500 A/cm2 announced by ASC in 1998 [17].
ful, could dramatically lower production costs and quite possibly approach this number. As always, time will tell.
IV. SUMMARY
We believe we have made a strong case in our paper for
thoughtful reconsideration of $10/kAm as a target marketentry cost/performance criterion for high temperature superconductivity wires and tapes. Indeed, if the only result is for
us to have provoked controversy and discussion of this vital
issue in HTS power applications, then our purpose has been
served. It just doesn't look possible to achieve this number
as a practical C/P result for a very long time to come, if
everpractical meaning manufacture and sale at a profit for
a wide variety of power uses. We suspect, in fact we are
convinced, there is no single C/P market-entry value whose
realization would constitute a declaration of victory. Competition with LTS wires and devices will remain for a substantial period, especially, in our view, in very large applications
such as high energy physics, and large generators and motors
where helium cryogenics is both mature and improving.
Nevertheless, certain applications definitely benefit from a
higher temperature refrigeration system, cables being the
most dramatic example. The authors are aware of several
instances where installation of low voltage, equivalent power
distribution cables could enable a given utility to release urban real estate occupied by intermediate voltage step-down
substations. The enormous savings and cash return therefrom
could justify a C/P of perhaps as high as $1000/kAm (although this would surely be a niche business!).
We urge our colleagues in manufacturing companies to
seriously consider issuing wire "specification sheets" so those
of us in the end-user community can begin to intelligently
engineer and financially plan our respective potential applications. This is most difficult if all we are given are artificial
targets which have meaning only under laboratory conditions. Let's get going. There's a lot of work and, as always
the case with applied superconductivity, a long road ahead of
us.
ACKNOWLEDGEMENT
The authors have drawn on a large reserve of colleagues
and network associations for the material used in this paper,
and it would be impossible to cite them all. It would be also
inappropriate to expose them to perceived support of our
conclusions. Nonetheless, we are grateful to all, especially
those willing to let us have a "peek under the covers" at otherwise proprietary issues.
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