Pietro Gimondo, ESTEP Energy Working Group Chairman

STEEL TECHNOLOGY PLATFORM
"Materials for Energy: recent achievements
and next steps of the European steel
Technology platform ESTEP"
Dr. P. Gimondo
EWEC Wind Conference
Marseille – 17 March 2009
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ESTEP’s main characteristics
• Among the first ETPs (first contacts in 2002)
created in Europe
• Financially supported by the EU steel industry
(no support from the EU Commission)
• Focused on topics of general interest for
Europe (CO2, energy, sustainable use of
resources)
• Living SRA
• On its way to its first general approach
(ULCOS project)
2
The SRA of ESTEP answers these
challenges
Reducing CO2 emissions directly in
steelmaking and indirectly by
offering light steel solutions
Development of safe, clean,
energy-efficient and cost-effective
technologies
Contributing to the development
of energy sources for the future
Promoting conservation of
resources, recovery of wastes and
societal value of materials
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Organisation
Mirror Group
Member States
Decision-making level of
the Stakeholders
Steering Committee
M. Wurth (Arcelor Mittal)
P. Erkkillä (Outokumpu)
E. Gibellieri (EMF/CCMI)
J.C Charbonnier
Secretary General
Support Group
P.Schwab (VoestAlpine)
K. P Imlau (TKS)
Management-level
working body
Working Groups
Expert-level
working groups
Organisational
&
Management
Support
Implementation group/Communication
J.C Charbonnier/W. Moonen(Corus)
Profit
Innovation
Partners
Automotive
Partners
Construction
Partners
Energy
Ch.Marique
(CRM)
C.Wuppermann
(Stahl Zentrum)
T. Hurd
(Corus)
P. Gimondo
(CSM)
Planet
People
J.P Birat
R.C Meiler
(ArcelorMittal)
(TKS)
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ESTEP vs WIND Platform
• Mr. Charbonnier (ESTEP Secretary
General) is invited at level of Steering
Committee of the Wind Platform
• Mr Dias Lopes is member also of the Wind
platform - Working Group 2: Wind Power
Systems
5
Wind Energy
Basics providing better access to
wind energy resources
6
Impact on kWh cost (%)
datio
n
cable
s
Parameter
tower
by 0,
25 %
-8.00%
ARMINES, “Bilan et prospective de la filière éolienne française”, study co-funded by ADEME, 2006. Online.
Mast
1% l
ess in
terest
rate
Gear
box
Blade
s
10 m
highe
r
sts re
duced
Assem
bling
Hydr
aulic
s
Nace
lle ho
u s in g
10 km
less c
onne
ction
100 h
cable
more
l oad
capac
Gene
ity
rator
Conn
ectin
g to t
he Gr
id
0,1 m
ore m
ean w
in sp
O&M
eed
co
Foun
on &
ransf
orme
r
n
r con
verte
r&t
Isolat
i
Po w e
h ub
Syste
m
Rotor
Yaw
F i n an
cial c
osts
Terra
in
cy
const
ructi
o
Cons
ultan
Road
Cost impact of R&D developments
0.00%
-1.00%
-2.00%
-3.00%
-4.00%
-5.00%
-6.00%
Cost reduction > 2 %
-7.00%
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To tackle two main aspects
1 – gear box life and maintenance
2 – wind farm height
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Gears: integrated approach
MATERIAL – PROCESS – COMPONENT
(metallurgy + heat treatments + testing + component design)
Material/Product
Testing
Conditions
DEEP NITRIDING
(NITREG®)
vs.
CASEHARDENING
Process/Tecnology
Heat treatment
susceptibility to surface
damage
- Steel
- Component Design
- IN-SERVICE
Conditions
Component/System
Testing for gears
ROLLING CONTACT FATIGUE (RCF) TESTS: SURFACE ANALYSES
On- / offshore wind energy
Reduction of the energy production costs of wind farms by
technological improvements trough reliable global concepts at
higher efficiency
Onshore
Increase of the hub heights of the towers to 120 - 160m
Develop efficient low cost structures (braced structures, sandwich shells)
Offshore
new foundation techniques
multifunctional coatings (corrosion protection, monitoring, self repairing, ..)
swimming offshore platforms (experience from the oil & gas field)
combination of hydropower and wind energy
11
Offshore Structures
Welding of thick plates
Economical construction by steels with yield strength up
to 500 MPa and higher strength
Onesided welding
Fatigue tests on one sided welds regarding the loads
(tension, compression, bending)
and weld preparation
Partial welding
Fatigue of the notch of the
intersection
12
Ideas for projects (FP7, RFCS)
•
Composite- or sandwich-solutions for monopiles
• New joining methods for segments of monopiles
• steel braced girder towers
• materials and welding for offshore-structures
• corrosion protection for offshore-WEP (splash-zone)
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ESTEP - WG6 Energy
• Next meeting is scheduled for the 26 of
May in Brussels in the EUROFER offices
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Thank you for your attention
• Steel Technology Platform (ESTEP)
WG6 – Energy
Dr. Pietro Gimondo
p.gimondo@c-s-m.it
http://cordis.europa.eu/estep/home_en.html
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