Microgrids for industrial

Smart microgrids with on-site renewables (DER) are essential for resilient, low-carbon industrial electrification. Key elements include SSTs, MVDC/DC buses, smart switchgear, and advanced controllers to integrate renewables and storage with real-time resilience. While benefits include emissions reduction, operational efficiency, and autonomy, scaling depends on domestic supply chain development, standards, and specialized workforce training.

Features & Components

Onsite Renewables & Storage

• Typically includes solar PV, hydrogen, wind, or CHP.
• Battery Energy Storage Systems (BESS) balance supply-demand fluctuations.

Smart Microgrid Controls & Switchgear

• Real-time microgrid management systems enable automatic islanding, synchronizing, and load prioritization.
• Smart switchgear and circuit breakers ensure rapid fault isolation and secure power flow.

Transformer Technology

• Traditional MVAC/LVAC transformers are key but bulky and limited in flexibility.
• Solid-State Transformers (SSTs): leverage wide-bandgap semiconductors (SiC/GaN) and medium-frequency conversion for compact, efficient, and intelligent distribution.

DC and MVDC Buses

• DC-native microgrids connect solar arrays, batteries, electrolyzers, and EV chargers directly via DC, reducing conversion losses and enhancing efficiency.
• MVDC systems (e.g., 6 kV DC) become feasible with SSTs, enabling streamlined distribution in industrial campuses.

Industrial Impact

• Energy resilience: Decouples critical industrial processes (e.g., battery plants, fabs, steel mills) from grid outages.
• Renewable integration: Enables onsite solar, wind, and waste heat recovery to power high-energy processes.
• Peak load & demand management: Smooths electricity demand and lowers grid impact during heavy draw.
• Grid services: Through smart switchgear and automated controls, supports voltage regulation, frequency response, and islanding.

Emissions & Efficiency Impact

• Reduced CO2 emissions: Onsite renewables and battery storage reduce dependency on grid-generated or emergency diesel; fossil fuel use drops significantly.
• Efficiency gains: DC-forward distribution reduces AC/DC losses. SST-integrated MVDC microgrids cut line and conversion losses by up to ~5–10%.
• Resilience: Critical industries avoid costly downtime due to outages—benefiting both emissions and operational continuity.

Supply Chain & Bottlenecks

Transformer & SST Manufacturing

• Grain-oriented electrical steel (GOES) is the critical material for transformer cores. U.S. production is concentrated at a single facility, with long lead times and dependency on Japanese and European imports. The surge in electrification demand—from EV chargers to factory microgrids—has created a transformer backlog that is now a primary constraint on industrial decarbonization timelines. Used in distribution transformers, power transformers, and solid-state transformer cores for industrial and grid applications.
• Every microgrid system requires at least one step-down or isolation transformer using grain-oriented electrical steel (GOES).
• Grid interconnection: Limited GOES availability slows deployment of medium-voltage and distribution transformers, delaying EV charger rollouts and factory connections.
• SST components (SiC/GaN converters, medium-frequency transformers) are emerging globally; few domestic producers remain.
• Dependence on imported power electronics raises vulnerability in U.S. reshoring efforts.

Smart Switchgear & Controls

• Requires certified digital controls, secure communications, power-quality protection—sourced from specialized OEMs.
• Cybersecurity constraints and regulatory compliance slow deployment.

MVDC and DC Bus Adoption

• Standards for MVDC are nascent; integration guidelines are maturing alongside SST rollouts.
• Industrial expertise in DC microgrid design remains limited.

Skilled Workforce

• Commissioning smart microgrids demands combined skills in power electronics, cyber-physical systems, and control engineering.