enercon innovations for sustainable mining · 2015-03-12 · 20 years revolutions by enercon...
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© Copyright ENERCON GmbH. All rights reserved.Filename:
Bernard Moulins – Commercial Analyst
ENERCON Canada Inc.
ENERCON Innovations for Sustainable Mining
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OUTLINE
Company Overview
Technology
Market Overview
Remote Project Experience
Wind Power in Mining
Product Overview
2
Bear Mountain British Columbia
Copyright AltasGas
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COMPANY OVERVIEW
Gries Switzerland
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COMPANY OVERVIEW
Privately owned, multinational, vertically integrated manufacturing, state-of-the-art wind turbine manufacturer
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Aloys Wobben
CHRONOLOGY
1984Founded by Dr. Aloys Wobben
1993Launch of Direct-Drive technology with the E-40
2001Installation of first turbine in Canada in Lundbreck, Alberta
Direct-Drive Generator
Lundbreck Alberta
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Montreal, Quebec
CHRONOLOGY
2009Inauguration of Canadian
headquarters in Montreal, Quebec
2007Launch of E-126
E-126 Construction
2011Inauguration of Canadian manufacturing facilities in Matane, Quebec
WEC Tours Inc.
2012Inauguration of Canadian manufacturing
facilities in Beamsville, Ontario
Niagara Electric Inc.
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CHRONOLOGY
CANADA1 755 MW installed795 WECs650 employees
INTERNATIONAL37 181 MW installed
23 181 WECs16 000 employees
2015
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MARKET SHARE
2014 Installed Capacity
Canada3rd Position
Global3rd Position
Source: BTM Consult Source: CanWEA
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INNOVATION
E-Ship – Wind Powered Cargo Vessel
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INNOVATION
Advanced Logistics
Direct Drive Generator
Rotor Blade Design
Grid Integration
Storm Control
Cold Climate
Rotor Blade Heating
Cast Components
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INNOVATION
Grid Integration
Advanced Logistics
Direct Drive Generator
Rotor Blade Design
Rotor Blade Heating
Cast Components
Cold Climate
Storm Control
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INNOVATION
Reliable power generation at variable rpm
Low & stable operating temperatures
Fewer vibrations and less noise
Low cut-in speed (2.0-2.5 m/s)
Direct Drive Generator
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INNOVATION
Reliable technology
Fewer revolutions
20 years revolutions by ENERCON turbine = 3 months by geared turbine
Near 50% reduction in failures
Direct Drive Generator
Gearbox
Hydraulics
Main Shaft/Bearing
Mechanical Brake
Electrical System
Generator
Pitch Adjustment
Air Brake
Yaw System and Rotor
Sensors and Others
Not Applicable to ENERCON
Applicable to ENERCON
Basis for service-production synergy
*Hours of stoppage due to failures during the third quarter of 2008(Statistical basis: 4,737 WECs in Germany with 16,988 accumulated hours) [Source: Windstats Newsletter 2008. Vol. 21]
Stoppage Due to Failures (in hours)*
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INNOVATION
100% power output down to -30°C
25% power output at -40°C
Linear reduction with restart at -35°C
Cold Climate Package
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INNOVATION
Cold Climate Package
Cast Parts
Yaw and Pitch Systems
Bearings
Rotor Blades
Tower and Foundation
Unique alloy, notch tested
High viscosity gear oil
Low temperature capacity
Certified to -50°C
Site-specific structural calculations
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INNOVATION
Accurate ice detection system based on power curve operating maps
Energy self-sufficient hot air recirculation
Pre-emptive de-icing eliminating standstill energy losses
Case studies in Sweden, Czech Republic, and Canada reveal 83% icing loss recovery rate
Rotor Blade Heating System
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INNOVATION
Systems in Canada:
1 x E-53, 800kW (2011) 28 x E-82, 2.3MW (2011) 60 x E-70, 2.3MW (2012)
Rotor Blade Heating System
0
100000
200000
300000
400000
500000
600000
700000
OCT 09 NOV 09 DEC 09 JAN 10 FEB 10 MAR 10
En
erg
y Y
ield
[kW
h]
Yield per month between heated and unheated WEC E-82 2MW at a location in Czech Republic
Heated
Unheated
Reduction in standstill due to icing:
82%
93%
84%
80%
Czech Republic
Sweden
Quebec
Nova Scotia
Europe
Canada
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INNOVATION
Storm Control
Linear reduction of rated speed
Resumes energy production instantaneously
Avoids hysteresis losses
= 34 m/s (10 min)
Without Storm Control With Storm Control
= 25 m/s (3 min) 30 m/s (15s)
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INNOVATION
Storm Control
Operational at 36 m/s
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INNOVATION
Storm Control
Operational at 36 m/s
Increase in Power Output
High Operational Capacity
No Cut-In / Cut-Out Standstill
Reduced Energy Losses
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INNOVATION
Grid Integration
High tolerance to grid electrical disturbances
Wide voltage and frequency operating range with continuous operation through frequency deviations of ± 7Hz
Under and overvoltage in events up to 5 seconds
Grid stability enhancement options including inertial frequency support
Wide reactive power range and availability in absence of wind
Replaces external capacitor banks or other sources of VAR
Advanced wind farm controller available for fast voltage and power control
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INNOVATION
Grid Integration
High tolerance to grid electrical disturbances
Wide voltage and frequency operating range with continuous operation through frequency deviations of ± 7Hz
Under and overvoltage in events up to 5 seconds
Grid stability enhancement options including inertial frequency support
Wide reactive power range and availability in absence of wind
Replaces external capacitor banks or other sources of VAR
Advanced wind farm controller available for fast voltage and power control
Components protected from faults in power system
Support for power system stability during disturbances
Control of small scale distribution to large scale wind power plants
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REMOTE PROJECT EXPERIENCE
Ross Island - Antarctica
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REMOTE PROJECT EXPERIENCE
Bonaire, Caribbean1 x E-33, 330 kW
Mawson Station, Antarctica2 x E-33, 330 kW 70 % diesel displacement
2003
Utsira, Norway1 x E-33, 330 kW 1st full-scale stand-alone wind-hydrogen
project in the world Autonomous wind-hydrogen system with
flywheel and battery storage
2004
Falkland Islands6 x E-33, 330 kW 40 % diesel displacement
2007
Ross Island, Antarctica3 x E-33, 330 kW Annual savings of 463k litres diesel Annual reduction of 1.2k tons CO2
Ascension Island5 x E-33, 330 kW Annual savings of $700k Annual reduction of 4.5k tons CO2
2009
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Bonaire, Caribbean12 x E-44, 900 kW 40 % island’s energy supply generated by
wind
2010Griess, Switzerland1 x E-53, 800 kW Highest turbine in the world at 2465 m above
sea level Custom designed millipede transporter used
on steep ascents
2011
Northwest Territories, Canada4 x E-70, 2 300 kW Installed at Diavik Diamond Mine Annual savings of 4.3M litres diesel
Faroe Islands5 x E-44, 900 kW
2012
Quebec, Canada1 x E-82 E4, 3 000 kW Installed at Raglan Mine Hybrid wind-diesel system with hydrogen,
battery, flywheel storage
Faroe Islands18x E-44, 900 kW 60% renewable penetration using pumped-
storage hydroelectricity
2014
REMOTE PROJECT EXPERIENCE
Canary Islands3 x E-44, 900 kW2 x E-48, 800 kW1 x E-70, 2 300 kW Repowering of existing wind farms Created grid stability for pre-existing turbines
2013
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REMOTE PROJECT EXPERIENCE
Hybrid Systems
Diesel
Solar Photovoltaic
Flywheel
Battery
Hydrogen
Pumped-Storage Hydroelectricity
Including in-house R&D experience
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WIND POWER IN MINING
Diavik Mine – Northwest Territories
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WIND POWER IN MINING
Reliable technology, proven in extreme climates
Low OPEX with no fuel cost
Low cost of energy, levelized for 25-30 years
Reduction in greenhouse gas emission
Opportunities
Fossil fuel precedence well-suited to micro-grid stability
High CAPEX, Return on investment > 4 years
Wind resource variability
Inertia
Challenges
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Tipping the Balance Historical trend in fossil fuel prices Increasing energy costs
Third party owner (IPP) Avoids high CAPEX and ROI period (PPA)
Storage technology Energy integration capacity
Project Champion + corporate and operator buy-in Conquer learning curve & build confidence
Incentives Grants, R&D funding, tax incentives
Integration complexity Reduced with penetration below 15-20%
29
WIND POWER IN MINING
Reliable technology, proven in extreme climates
Low OPEX with no fuel cost
Low cost of energy, levelized for 25-30 years
Reduction in greenhouse gas emission
Opportunities
Fossil fuel precedence well-suited to micro-grid stability
High CAPEX, Return on investment > 4 years
Wind resource variability
Inertia
Challenges
© Copyright ENERCON GmbH. All rights reserved.Filename: 30
WIND POWER IN MINING
Fossil fuel precedence well-suited to micro-grid stability
High CAPEX, Return on investment > 4 years
Wind resource variability
Inertia
Challenges
Tipping the Balance Historical trend in fossil fuel prices Increasing energy costs
Third party owner (IPP) Avoids high CAPEX and ROI period (PPA)
Storage technology Energy integration capacity
Project Champion + corporate and operator buy-in Conquer learning curve & build confidence
Incentives Grants, R&D funding, tax incentives
Integration complexity Reduced with penetration below 15-20%
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WIND POWER IN MINING - DIAVIK
Rio Tinto Diamond Mine – Northwest Territories, Canada
1 500 kg/yr production capacity, 1 165 workforce
Operational since 2003, 16-22 year lifespan
100% diesel energy production approx. 70 million liters diesel
Energy costs > 25% OPEX
Average wind speed: 6.3 m/s
Context
Copyright Rio Tinto Copyright Rio Tinto
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WIND POWER IN MINING - DIAVIK
4 x E-70 2.3MW installed in 2012
Transportation: via ice roads (6 week access period)
Installation: team effort between ENERCON and Rio Tinto
O&M: Mine workforce training + Alberta service team deployment
Project
Copyright Rio Tinto Copyright Rio Tinto
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WIND POWER IN MINING - DIAVIK
CAPEX: $33M
Return on investment < 8 yrs
Average availability: 95% in 2013-2014
Penetration : average 9%, max 52%
Offset 2.3M liters/yr diesel Reduced risk exposure
Strong cold climate performance
1.3MW output at -36°C
Result
Copyright Rio Tinto Copyright Rio Tinto Copyright Rio Tinto
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WIND POWER IN MINING - RAGLAN
Glencore Raglan Nickle Mine – Nunavik, Northern Quebec
1.1 Mt ore/yr production capacity, 950 workforce
Operational since 1997, 30-40 year lifespan
100% diesel energy production approx. 60 million liters diesel
Average wind speed: 8.8 m/s
Context
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WIND POWER IN MINING - RAGLAN
1 x E-82 E4 / 3.0MW installed in 2014 using innovative foundation design
Hybrid System (COD 2015):
Li-ion batteries 200 kw Hydrogen Storage 200 kw Flywheel 250kw
Transportation: shipping (no roads to site)
Installation: team effort between ENERCON and Tugliq
O&M: Tugliq workforce training + Quebec service team deployment
Project
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WIND POWER IN MINING - RAGLAN
IPP: Tugliq Energy Co.
NRCan & MNR incentives : $13M
Average availability: 96% since installation
Penetration : forecast 35-55%
Offset 2.4M liters/yr diesel 5% diesel consumption
Phase II : 9-12 MW turbine power (COD 2016-2017)
Result
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PRODUCT OVERVIEW
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PRODUCT OVERVIEW
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CLOSING
Robust Technologies
Extensive Experience
Sustainable Solutions
Long Term Reliability
39
Seigneurie de Beaupré Québec
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COPYRIGHT:
© ENERCON GMBH. ANY REPRODUCTION, DISTRIBUTION AND UTILISATION OF THIS DOCUMENT AS WELL AS THE COMMUNICATION OF ITS CONTENTS TO THIRD PARTIES WITHOUT EXPRESS AUTHORISATION IS PROHIBITED. VIOLATORS WILL BE HELD LIABLE FOR MONETARY DAMAGES. ALL RIGHTS RESERVED IN
THE EVENT OF THE GRANT OF A PATENT, UTILITY MODEL OR DESIGN.
CONTENT SUBJECT TO CHANGE:
ENERCON CANADA INC. RESERVES THE RIGHT TO CHANGE, IMPROVE AND EXPAND THIS DOCUMENT AND THE SUBJECT MATTER DESCRIBED HEREIN AT ANY TIME WITHOUT PRIOR NOTICE.
ENERCON CANADA INC.
700 De La Gauchetière Street West, Suite 1200 ▪ Montreal ▪ QC ▪ H3B 5M2 ▪ Canada
Phone: (514) 363-7266 ▪ bernard.moulins@enercon.de
www.enercon.de
THANK YOU FOR YOUR ATTENTION
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