INTEGRATED GLASS SOLUTIONS TO REDUCE THE COST OF WIND ENERGY
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Transcript of INTEGRATED GLASS SOLUTIONS TO REDUCE THE COST OF WIND ENERGY
INTEGRATED GLASS SOLUTIONS TO REDUCE THE COST OF WIND ENERGY
Dr. Chris Skinner Director, Global Product Platforms
Composite Solutions Business
1
2
Introduction to Owens Corning
Owens Corning is a leading producer of fiberglass in the world and during its 80 year history has been responsible for all innovations in glass fiber
1935 1938 1952 1970s 1980 1987 1996 2007
Corning Glass + Owens Illinois work
on glass fiber
Owens Corning fiberglas launched Sales $2.5M 600
people
Owens Corning becomes listed on NYSE
Sales grow to $2Bn At then end of of the 1980’s Owens Corning has sales in excess of $3Bn and employed
18,000 people globally
Owens Corning fiberglas corporation changes its name to
Owens Corning
Owens Corning purchases the Saint Gobain glass fiber
business to create the worlds largest fiber
glass producer
Founded in 1938, an industry leader in glass fiber insulation, roofing, asphalt,
and glass fiber reinforcements with sales of $5.2 billion in 2013.
15,000 employees in 28 countries.
FORTUNE 500 company for 58 consecutive years.
Composite Solutions Business ($2.5Bn)
A global leader in fiberglass solutions composed of two major divisions
Known as a leading innovator in composites
2 major divisions, each the leader in its market
A Global leader in glass fiber for composites
with 37 plants in 15 countries
Inventor of all major glass types (E,ECR,S,R,H)
Reinforcements
Engineered Solutions
Composite Solutions Business
Investing in a global innovation network
Granville, U.S.
Chambery, France
Granville, U.S.
Chambery, France
Zele, Belgium
Apeldoorn, Holland
Shanghai, China*
Innovative Chemistry Customer Solutions Glass & Furnace Science
Leveraging our heritage of innovation
Granville, U.S.
Chambéry, France
Ibaraki, Japan
Apeldoorn, Holland
Engineered Solutions
Side-by-side development with customers for new solutions
Working side-by-side with customers to develop new solutions
Fundamental product and process innovation to develop advanced composites
Leveraging our expertise for future growth
Stiffness
Durability
(fatigue performance)
Blade Performance
Carbon > H > Adv > E
More Glass = higher modulus
Better starting point
Better laminate durability
More durable laminate
fiber Type
FVF (% fiber in laminate)
0o Deg Tensile Strength
0oDeg Tensile Modulus
90oDeg Tensile strength
How do composites create value in wind energy? ADDITIONAL STIFFNESS AND DURABILTY CREATES VALUE FOR BLADE PRODUCERS
High impact of sizing chemistry
Moderate impact of sizing chemistry
Moderate impact of sizing chemistry
Glass Chemistry
Glass Chemistry
Defined by Key features Mechanical Properties Correlated to Enabled by
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Market Trends: Wind Energy
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33.4
39.5
45.9
35.7
45 49 49.5
54.1 57
61 63
0
10
20
30
40
50
60
70
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
GW
GW
GW
Wind Energy is a major market for composites CONTINUED GROWTH IS PREDICTED
2011 2012 2013e 2014e 2015e 2016e 2017e 2018e 2019e 2020e
MAAKE FCST 39.5 45.9 35.7 45.0 49.0 49.5 54.1 57.0 61.0 63.0
Glass Demand total 284.000 309.000 295.000 365.000 350.000 353.000 380.000 400.000 420.000 440.000
Ratio (Tes / MW) 7,2 6,7 8,3 8,1 7,1 7,1 7,0 7,0 6,9 7,0
Source: MAAKE Consulting, 2013 and Owens Corning internal data
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Trend to longer blades made of glass HIGH PERFORMANCE COMPOSITES WILL PLAY KEY ROLE IN FUTURE
Source: MAAKE Consulting
5 2
30
70
62
28
4
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2011 2015e
<40m
40-49.9m
50-59.9m
60-69.9m
>70m
Market is quickly moving away from the older blades associated with 1.5Mw IEC 1 technology
There is an expectation that older 40-49m technology (1.5-2.0Mw) in China and India will transition to 50m technology
Evolution of the 2-3Mw turbines will drive growth of the 50-59m blades
As offshore technology develops (Europe) it will drive growth of 60-69.9m segment
>70m segment will be driven by majors such as Siemens, LM as turbines exceed 6Mw
Producers are finding that delivering the potential of carbon in blades is challenging and recent innovation in high modulus glass offering reduced tooling, less handling issues and significantly lower total material costs
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Owens Corning Innovations: T30
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What technology trends are being driven ADDITIONAL STIFFNESS AND DURABILTY CREATES VALUE FOR BLADE PRODUCERS
1: Source: EWEA and Roland Berger studies
Ultrablade ® registered trademark now
OWENS CORNING RESPONSE TO NEEDS
WINDSTRAND® PRODUCTS REDEFINING OUR PLATFORM TO MEET EMERGING INDUSTRY NEEDS
1994 to early 2000s
ON-SHORE Turbine sizes increase to utilize available wind at on-shore locations requiring cost effective material solutions to enable scaling of the industry across regions
LIMTED OFF-SHORE Offshore production started in early 2000s with small number of blades of around 50m+
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SE1500 Reliability
WINDSTRAND® PRODUCTS REDEFINING OUR PLATFORM TO MEET EMERGING INDUSTRY NEEDS
Present
ON-SHORE (LOW WIND) Expansion of the industry means turbines are now positioned in low wind areas requiring longer, lighter high performance blades to generate economic electricity
OFF-SHORE Drive to production of high performance blades, capable of operating in extreme environments (75m in glass and 80m in carbon) and driving turbines of up to 8Mw to reduce cost of energy.
The huge investment cost demands ultimate reliability of operation to ensure cost effective operation
ON-SHORE (HIGH WIND) Continued pressure to reduce capital/operating cost of turbines to make electricity more competitive requiring optimization to enable reduction in material consumption, manufacturing and operating costs
WINDSTRAND®
2000 Design
Optimization
WINDSTRAND®
3000 High
Performance
WINDSTRAND®
4000 Ultimate
Reliability 14
OWENS CORNING RESPONSE TO NEEDS
WINDSTRAND® ROVINGS PROVIDING SOLUTIONS FOR HIGHER PERFORMANCE LAMINATES
WINDSTRAND®
2000 ROVING Design
optimization 1100 - 1200
1000 - 1100
850 - 900
35
45
55
60
40
45
52
Tensile Modulus at 0o (GPa)
Tensile Strength at 0o (MPa)
Tensile Strength at 90o (MPa)
WINDSTRAND®
4000 ROVING
Ultimate reliability
WINDSTRAND®
3000 ROVING
High performance
ADVANTEX®
SE1500 ROVING
Cost effective
15 * Owens Corning internal tests, laminate properties, 2014.
WINDSTRAND® PRODUCT POSTIONING REDEFINING OUR PLATFORM TO MEET EMERGING INDUSTRY NEEDS
FVF Owens Corning internal tests - fiber fraction on 2 plies laminates, Amarillo, Jan. 2014. 90° Owens Corning internal tests - Transversal Tensile Test ISO 527-5, Fabrics LTX1190 <X1200 (136 tex in weft), Amarillo, Jan. 2014.
* Owens Corning internal tests - ** External test by designer, depending on the application, 2013.
WINDSTRAND®
2000 ROVING Design
optimization
Production in 5 locations
Enhanced 90o properties
Operation at increased FVF (fiber
Volume Fraction) levels
1-2% blade weight reduction*
0o glass modulus greater than 88 GPa
Enhanced 90o properties
Operation at increased
FVF levels
3-6% blade weight reduction**
Maximum 90o deg properties
Operation at increased FVF
Optimal use of resin performance
2-3% blade weight reduction*
WINDSTRAND®
3000 ROVING
High performance
WINDSTRAND®
4000 ROVING
Ultimate reliability
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Owens Corning Innovations: Fabrics
2012 2014 2013
High modulus fabrics Operation at 55% FVF
High modulus fabrics Operation at +57% FVF Excellent 90oC performance 5% blade mass reduction2 20% longer blades
High modulus fabrics 17% load reduction
High modulus fabrics 3% blade mass reduction1 Operation at 57% FVF
1) Spar cap weight reduction 2) Spar cap weight reduction and use in skin laminate
ULTRABLADE® Fabrics REDEFINING OUR FABRICS PLATFORM TO MEET EMERGING INDUSTRY NEEDS
LONGER BLADES ON-SHORE AND OFF-SHORE AND IN LOW WIND AREAS INDUSTRY TRENDS LONGER BLADES ON-SHORE
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TRIA
X
G2
G3
G1
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ULTRABLADE® UD Fabrics FABRIC SOLUTIONS FOR HIGHER PERFORMANCE UD LAMINATES
Source: Owens Corning internal data Ultrablade ® registered trademark now
Ultrablade®
+20% compression strength compared to traditional reinforcements
Ultrablade®
+15% stiffness compared to existing reinforcement fiber
Ultrablade®
Better fatigue performance by +20% strength retention
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ULTRABLADE® TRIAX Fabrics PROVIDING SOLUTIONS FOR INCREASED COMPRESSION STIFFNESS
Source: Owens Corning internal data Ultrablade ® registered trademark now
17% Reduction on
the transferred loading to bolt
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Summary: WINDSTRAND® & ULTRABLADE® reinforcements
ADVANTEX® fiber
Product produced in 5 plants across the world
Significantly improved mechanicals with significantly increased transversal strength delivering superior reliability for the industry
Patented R-Glass Technology
Next generation of the high modulus materials
Significantly improved mechanicals with increased transversal strength delivering high reliability at high fiber concentrations
ADVANTEX® fiber
New sizing and production process delivering significantly increased tensile and transversal strength
High reliability at high fiber concentrations
Summary WINDSTRAND® PRODUCTS: A PLATFORM TO MEET THE NEEDS OF THE INDUSTRY
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Triax Fabric Technology
New fabric design offering increased compression stiffness
Enables improvement in root joint designs to reduce fatigue loads of T-Bolt flanging solutions
Summary ULTRABLADE® FABRICS: A PLATFORM TO MEET THE NEEDS OF THE INDUSTRY
UD Fabric Technology
New fabric design parameters offering better strength & fatigue
Enables higher fiber concentrations versus ULTRABLADE® G2
TRIA
X
G3
If you have questions or inquiries, please contact: wind [email protected]
or
Copyright © 2014 Owens Corning. All Rights Reserved.