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COST-EFFECTIVE SUPERCONDUCTING CERAMIC ROUND WIRE

[Category : - CHEMISTRY- ELECTRICITY & LIGHTING- RENEWABLE ENERGY]
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COST-EFFECTIVE TERMO-CHEMICAL NANOTECHNOLOGY FOR CONTINUOUS PRODUCTION OF INEXPENSIVE, RELIABLE AND FLEXIBLE SUPERCONDUCTING CERAMIC MULTI-STRAND ELECTRIC WIRE AND OTHER LEADS.
We sell or license our US patent family and knowhow that teach cost-effective Chemical Ceramic nanotechnology to produce cost-effective Superconductive Ceramic Strands. These strands are usable, flexible and reliable as copper strands, but at liquid nitrogen (LN) temp-re transmit without heat losses 50x more electricity and have 7x less cost/performance ratio. Electrical Engineering applications of our multi-strand electric wire including electric cables, motors and transformers, would by 5 – 7x decrease their cost, weight, diameter (size), and heat losses.
32 years ago, two Nobel Prize winners discovered High Temperature Superconductor (HTS) ceramic crystals that at easily achievable cryogenic temp-re of cheap LN coolant transmit without heat losses enormous amount of electric current. Meanwhile, until now HTS macro-ceramic products and 1G and 2G HTS electric tapes are not yet on the open market due to high capital and production costs, tape form and usability, quality and reliability drawbacks.
In contrast with 1G and 2G HTS Mechanical Engineering technology, we invented Chemical Ceramic nanotechnology, which processes suspension in toluene of initial HTS ceramic nano- and micro-particles with liquid silicone and silver powder additives and consists of:
1) Thermo-chemical nanofabrication of full dense sintered 3G HTS composite macro-ceramic material with self-assembled honeycomb-like nano-architecture, where ceramic crystal grains surround (caged by) glass films and silver dots. These result in almost equal inter- and inner-grain uniform superconductivity;
2) Flexible 3G HTS ceramic wire strands, where metal substrate strands dip adhesion coated by said HTS ceramic suspension with further thermo-chemical nanofabrication and full dense sintering of 10 micron thin (and therefore, flexible) 3G HTS ceramic coating layer.
3) “[Metal substrate strand reel] – to – [HTS strand reel]” conveyor production line to continuously manufacture 3G HTS round strands that can be twisted into multi-strand electric wire or cable with required carrying capacity.
3G HTS strands at easily achievable LN temp-re can carry with insignificant heat losses electric current density J = 8 – 10kA/cm2 while copper wire at room temp-re is used with electric current carrying capability J = 0.2kA/cm2, which is 40 – 50 times less. Meanwhile, at room temp-re, 3G HTS strands transmit electricity as copper strands of equal diameters.
Thermo-chemical self-controlled process provides integral and continuously uniform 3G HTS ceramic coating layer of the strand to efficiency transmit electric current. Sintered 3G HTS ceramics are permanently reliable and durable in air or LN coolant ambience.
Our US Patent #7,632,784 and knowhow cover our previous US patents # 6,617,284, 6,239,079, 6,010,983 and approved: 1) by 3 groups of experts, 2) in 14 our peer reviewed journal publications, and 3) by 15 our presentations at the American Ceramic, Chemical Engineering, Mechanical Engineering, Materials Research, NSTI Nano-Tech and New Jersey Technical Council society meetings.


Financial information

At Polytechnic School of Engineering of New York University we produced and tested 3GHTS ceramic coated strands with dia. = 0.06mm have NiCr-metal strand substrate with dia. = 0.04mm. Production of 3G HTS strands with dia. = 0.06mm should cost $0.003/meter. These strands at LN temp-re carry electric current, as does it copper strands with dia. = 0.4mm at room temp-re. Electric copper strand with dia. = 0.4mm costs on the open market $0.023/meter. Therefore, a plant owner would assign for 3G HTS strands with dia. = 0.06mm the same price $0.023/meter and get profit $0.02/meter. The typical technological line would cost $2 mill and produce 100,000 km/year-strands. It brings plant owners $2 mill/year pre-tax profit at ROI = 100%. The plant with 20 typical production lines will bring $40 mill/year pre-tax profit. at ROI = 100%. The plant with 30 typical production lines will bring $60 mill/year pre-tax profit.
The US Department of Energy estimated the worldwide market for usable, reliable and durable HTS electric wire and its Electrical Engineering applications as $200bill/year.

Additional Technical Advantages of 3G HTS Wire include:
1). In contrast with a tape form wire, round form of 3G HTS strands and multi-strand wire are usable and efficient for cables as well as for coils of electric motors, transformers. 2). Open surface contacts of round 3G HTS strands allow compensation of the breaches of superconductivity in neighbor strands, which assure reliability of the multi-strand wire or cable. 3.) Surface contacts allow splitting connection/joining of pieces of multi-strand wires or cables. 4.) Round form of 3G HTS wires and cables makes easier design of their cooling systems. 5). The use of 3G HTS cables with their cooling jackets 5x decreases width of high power cable underground tranches within towns or cities.
6. Permanent reliability of 3G HTS multi-strand wire and its Electrical Engineering applications. 7.) Nonflammable LN coolant substitutes flammable oil in electric motors and transformers.

Invented 3G HTS multi-strand electric wire can be used for::
1) Electric motors, transformers and generator rotors with 5x reduced costs, weights and sizes, 2) Electric cables of any carrying capacity with 5x reduced costs, weights and diameters; 3) Cost-effective electric grids; 4) Electromagnetic propulsion jet engines for aircrafts and high-speed ships; 5) Supercomputers and a supercollider; 6) Current limiters on the electric systems and grids; 7) Superconducting magnetic energy storage (SMES) systems for: a) an assurance of the electric grids and b) fast recharging of electric cars to support or substitute large batteries;

Invented nanotechnology and HTS composite material can be used for::
1) 3G HTS ceramic coating metal surfaces of any configuration for antennas 2) Pellets and other bulk leads for rails of magnetic levitation (MagLev) high-speed trains; 3) Gyroscopes and other devices employing unique levitation effect; 4) The spectrum of electronic precise systems and devices using signals filtration or definition

Broad use of 3G HTS wire and invented HTS material will result in saving 10% power, which now just heat Environment. For the US it is equal to power capacity of 50 working atomic (nuclear) power stations and their reactors.















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