INTEGRATED GLASS SOLUTIONS TO REDUCE THE COST OF WIND ENERGY

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Information about INTEGRATED GLASS SOLUTIONS TO REDUCE THE COST OF WIND ENERGY
Technology

Published on March 11, 2014

Author: OwensCorningComposites

Source: slideshare.net

Description

Presentation by Dr. Chris Skinner @JEC Europe 2014 on market trends for wind energy and Owens Corning integrated glass solutions to reduce the cost of wind energy for blade producers.

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 SolutionsGlass & 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

8 Market Trends: Wind Energy

9 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

10 Trend to longer blades made of glass HIGH PERFORMANCE COMPOSITES WILL PLAY KEY ROLE IN FUTURE Source: MAAKE Consulting 52 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

11 Owens Corning Innovations: T30

12 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+ 13 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® 2000Design Optimization WINDSTRAND® 3000High Performance WINDSTRAND® 4000Ultimate Reliability 14 OWENS CORNING RESPONSE TO NEEDS

WINDSTRAND® ROVINGS PROVIDING SOLUTIONS FOR HIGHER PERFORMANCE LAMINATES WINDSTRAND® 2000ROVING 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® 4000ROVING Ultimate reliability WINDSTRAND® 3000ROVING High performance ADVANTEX® SE1500ROVING 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 &LTX1200 (136 tex in weft), Amarillo, Jan. 2014. * Owens Corning internal tests - ** External test by designer, depending on the application, 2013. WINDSTRAND® 2000ROVING 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® 3000ROVING High performance WINDSTRAND® 4000ROVING Ultimate reliability

17 Owens Corning Innovations: Fabrics

2012 20142013  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 AREASINDUSTRY TRENDS LONGER BLADES ON-SHORE 18 TRIAX G2 G3 G1

19 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

20 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

21 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 22

23 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 TRIAX G3

If you have questions or inquiries, please contact: wind energy@owenscorning.com or technicalfabrics@owenscorning.com Copyright © 2014 Owens Corning. All Rights Reserved.

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