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Meeting the expectation of a 30+ PV project
operation lifetime, from the ground up
4th February 2021
© P
VH
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Experienced in high quality production
of continuous galvanised steelsDeep knowledge of galvanised steels
durability mechanisms & performances
ArcelorMittal: strong & long lasting experience
in galvanised coated steels
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Galvanised coil production
Durability is key at each step of the lifecycle of solar PV
plants
Coil slitting Profiling / tubing
Operating Transporting, storing
and assembling
Engineering
MaintainingRetro-fittingRecycling
What matters = durability
What matters = range of grades & coating thickness / good processability
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Lifetime expectation for solar utility-scale plants is
continuously increasing
Source: Lawrence Berkeley National Laboratory – Survey June 2020
https://emp.lbl.gov/publications/benchmarking-utility-scale-pv
Project Life Expectations for Utility-Scale PV, over time
Average today is 32.4 yearsRange between
25 to 35 years
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Why longer durability expectations for mounting structures?
Why improved protection of steel?
Build in more
demanding locations
→ Islands, coastal deserts,
industrial roofs…
→ Poles in aggressive or
polluted soils
→ Floating solar
→ Agrivoltaic with fertilisers
Increase VALUE:
- Longer period for
pay back & amortisation
- Longer Private
Purchase Agreements
- End of life higher value
- Retrofitting potential with
newest PV panels on
initial mounting structure
Reduce O&M COSTS:
- Postpone time to 1st
maintenance
- Reduced repairs leading to
increased operation &
maintenance costs
- Risk avoidance of
mechanical failure in case
of heavy loads
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How to evaluate corrosivity? The theory
ISO 9223: corrosivity of atmospheres
• Experimental method: direct measure
corrosion rate / weight loss of specimen after
1 year of field exposure
• Calculation based environmental measured
data: temperature, relative humidity, and
measured Cl- & SO2 deposits
→ Local measurements needed for both
methods
ISO 9224: guiding values
• Mathematical extrapolation of 1st year measurement
• Applicable only to pure Zinc: Zn alloys not included
• Many restrictions:
→ “Performances for Zn might not be accurately
predicted”… even with B1 & B2 coefficients
→ Specific phenomena not considered (abrasion...)
→ Lifetime values only informative NOT contractual
ISO 14713 – table 2 : lifetime calculation (years)
=
Nominal coating thickness (µm)
/
Corrosion Rate (µm/y)
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In real life, durability is influenced by many other parameters
which require additional protection
Product variations - ISO1461 and EN10346Climatic variations
• Abrasion (sands)• Pollution (industrial…)• Vegetation (grass, leaves, moss….)• Animals (excrements, …)• Site maintenance (lawn mower, herbicide…)• Impacts (maintenance tools…)• Cleaning (tools & cleaning agents….)
Additional aggressions (mechanical & chemical)
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1. The basis = use coated steel with LOWER
corrosion rates than regular galvanised steels
→ Magnelis®
2. FIELD EVALUATION of the corrosivity of the site:
- field knowledge of product behavior
- field knowledge of weather data +
deposited Cl and SO2
3- Coating weight / thickness adjusted
- to the expected lifetime
- considering safety margin to protect against
additional aggressive parameters
How to increase durability ?
Corrosion
category (ISO 9223)Unit
Zinc
corrosion rate
C2 µm/year 0.1 < rcorr ≤ 0.7
C3 µm/year 0.7 < rcorr ≤ 2.1
C4 µm/year 2.1 < rcorr ≤ 4.2
C5 µm/year 4.2 < rcorr ≤ 8.4
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Magnelis® is the answer to longer lifetimes and
more demanding environments & applications
Continuous process
Automated
On-line control
A unique composition
A full range of grades
And thicknesses
Compact and stable structure
Porousstructure
Compact and stable structure
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Specific corrosion products
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RailsPurlins, rails, brackets (U, C, Ω, Σ...)
Torque tubesHF Induction or laser welded tubes
Poles, columnsRammed in soil, embedded in concrete
Electrical componentsCable trays, cabinets, …
Wind deflection (roof top)
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Magnelis® is already widely used for many
components of mounting structures
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El Romero, Chile, 255 MW (PV)
ACCIONA STI Norland (Spain )
Magnelis® for upper structures
NOOR III, Morocco, 100 MW
(CSP)
ACWA POWER, SENER
Magnelis® used for hollow
sections & stamped parts
Europe, main market for
Magnelis® (PV):
Spain, Germany, Poland, France,
Benelux, UK, Greece,
(Fix, trackers, roof top, floating California, USA, 250 MW (PV)
Magnelis® used for girder parts Delingha Supcon, China, 50 MW
(CSP)
SOLAR RESERVE
Magnelis® used for stamped parts
Saran, Kazakhstan 100 MW (PV)
GOLDBECK Solar / CWF
Magnelis® for rails
PV & CSP, racking & foundations, fix & trackers systems, ground mounted, rooftop & floating
Australia, 110 MW (PV)
Magnelis® used for
girder parts
UAE, 300MW
(PV)
DEWA III
PVH
Magnelis® for
upper structures
(trackers)
Abu Dhabi, 1177
MW (PV)
SWEIHAN -
FORMING
Magnelis® for
upper structures
(Fix)
~20 GW around the world installed on Magnelis®
Jordan, 10 MW (PV)
PHILADELPHIA SOLAR
Magnelis® used for
upper structures
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Field sites where Magnelis® is tested
Extensive product behaviour knowledge
has been collected for Magnelis® coating
• We have tested Magnelis® in various types of
environments covering the range of corrosion
categories– Rural
– Urban
– Industrial
– Marine
– Tropical
– Deserts (coastal, continental…)
– Floating (fresh / brackish / sea)
• Similar approach for corrosion in soils (geological,
physical, chemical & electrical parameters)
• Comparatively with pre- & batch- galvanised
steels
What we measure on atmospheric field tests:
Corrosion rates (weight losses)
Visual aspect of surface and along edges
Cut edges behaviour (image analysis)
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Magnelis® exhibits lower
corrosion rates.
Average improvement:
~ 3 compared to regular
galvanised steel
Large scale atmospheric testing around the world
demonstrates the lower corrosion rate of Magnelis®
Average improvement ratio of Magnelis® corrosion rate
vs regular galvanised after 6 years
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Al55Zn45
Magnelis®
6 months 1 year 2 years 4 years 5 years 7 years 10 years
Magnelis® protection
overperforms
Al55Zn45 and regular
galvanised steel
Galva
Improved protection of perforated steels
(surface & cut edges) with Magnelis®
Dense perforation rate on 2 mm steel coated with 20 microns
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Soils
Others testing fields
for specific harsh environments
Brest
Dunkerque
Dubai
Offshore
Magnelis® Batch galva
Significant reduction of corrosion rates vs batch galvanisation
and more stable behaviour
Magnelis® Batch galva
Magnelis® Batch galva
Average coating consumption (µm)
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Durability performance is linked to the coating composition
Magnelis® results can not be extrapolated to others ZnAlMg alloyed coatings
Dunkerque
Lower corrosion rate with Magnelis® in comparison to
other less alloyed Zn-Al-Mg coatings
Performance improvement
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Corrosion
category
ISO 9223
Magnelis®
ZM310
Magnelis®
ZM430
C2 > 50 y > 50 y
C3 30 y to > 50 y 40 y to > 50 y
C4 15 y to 30 y 20 y to 40 y
C5 15 y 10 y to 20 y
Magnelis® ZM310 offers a minimum 30 years of expected
design coating life in C3 environment
C3 category, the most
frequent case =
temperate / urban...
DESIGN COATING LIFE = average duration until 100% of the undamaged coating, exposed to outdoor
conditions only, will be consumed on the surface. At this point in time, the structural integrity of the part is
no longer ensured and a major repair is necessary. → Structural criteria
C4 category =
tropical /
industrial / coastal...
These durations are indicative and non binding.
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Thickness range → up to 6,0 mm
Coating range → up to ZM430
Surface:
Edges:
• Edges can remain unprotected
with ZM310 or ZM430 up to 6.0
mm thickness
• No aesthetical requirement &
corrosion allowance
Magnelis® ZM310
possible use in C5
corrosion category
with 15 years of
expected lifetime
Expected lifetimes with Magnelis® in atmospheric
conditions have been certified by third parties
http://publiccert.extweb.sp.se/ https://www.dibt.de/de/
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From lifetime to guarantees: Magnelis® can be guaranteed
by contract on a project basis
▪ Based on project locationafter location analysis by ArcelorMittal
▪ A contract per project
▪ For Magnelis® profiles(after bending & perforation)
▪ For Magnelis® tubes(after preliminary audit by ArcelorMittal)
Extension to soils or concrete foundations:
▪ On project basis
▪ Based on soil physical, chemical and electrical analysis
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How do we support the increase of lifetime?
Enlarged range of high
strength steels protected
with Magnelis®
Enlarged range of coating
weights
ZM200ZM250
ZM310
ZM430ZM620 S550GD HyPer®
S700GD HyPer®
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Site analysis: climate + corrosion tools
Thanks to Magnelis® range & performance knowledge
it is possible to increase durability beyond 30 years
Transportation / storageguidelines
Magnelis® coating weight recommendation
Design guidelines with respect to resistance to corrosion
ZM200
ZM250ZM310
ZM430ZM620
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Maintenance / inspectionguidelines
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Material Environmental Product Declaration (EPD) available
online to perform Life Cycle Analysis:
• Manufacturing: less resources (Zn) used in comparison
to continuous & batch galvanised steels
• Use phase: less zinc run-off in soils & waters
• End of life: steel is entirely and infinitely recyclable
NEW : Magnelis® can also be purchased with Green Steel
certificates in the frame of the existing and future
investments of ArcelorMittal in Green Steel production
processes
https://ibu-epd.com/en/published-epds/
Magnelis® contributes to reducing the environmental impact
of mounting systems
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[email protected] [email protected]
More info industry.arcelormittal.com/magnelis
Watch the video www.youtube.com/watch?v=ER0R8K3nLXY
Thank you !
Your questions?
© Zimmermann