ENERCON Innovations for Sustainable Mining
Total Page:16
File Type:pdf, Size:1020Kb
ENERCON Innovations for Sustainable Mining Bernard Moulins – Commercial Analyst ENERCON Canada Inc. Filename: © Copyright ENERCON GmbH. All rights reserved. OUTLINE Company Overview Technology Market Overview Remote Project Experience Wind Power in Mining Product Overview Copyright AltasGas Bear Mountain British Columbia Filename: © Copyright ENERCON GmbH. All rights reserved. 2 COMPANY OVERVIEW Gries Switzerland Filename: © Copyright ENERCON GmbH. All rights reserved. 3 COMPANY OVERVIEW Privately owned, multinational, vertically integrated manufacturing, state-of- the-art wind turbine manufacturer Filename: © Copyright ENERCON GmbH. All rights reserved. 4 CHRONOLOGY 1984 Founded by Dr. Aloys Wobben 1993 Launch of Direct-Drive technology with the E-40 Direct-Drive Generator 2001 Installation of first turbine in Canada in Lundbreck, Aloys Wobben Alberta Lundbreck Alberta Filename: © Copyright ENERCON GmbH. All rights reserved. 5 CHRONOLOGY 2007 Launch of E-126 Montreal, Quebec 2009 Inauguration of Canadian headquarters in Montreal, Quebec E-126 Construction 2011 Inauguration of Canadian 2012 manufacturing facilities in Matane, Inauguration of Canadian manufacturing Quebec facilities in Beamsville, Ontario WEC Tours Inc. Niagara Electric Inc. Filename: © Copyright ENERCON GmbH. All rights reserved. 6 CHRONOLOGY INTERNATIONAL 2015 CANADA 37 181 MW installed 1 755 MW installed 23 181 WECs 795 WECs 16 000 employees 650 employees Filename: © Copyright ENERCON GmbH. All rights reserved. 7 MARKET SHARE 2014 Installed Capacity Source: BTM Consult Source: CanWEA Global Canada 3rd Position 3rd Position Filename: © Copyright ENERCON GmbH. All rights reserved. 8 INNOVATION E-Ship – Wind Powered Cargo Vessel Filename: © Copyright ENERCON GmbH. All rights reserved. 9 INNOVATION Direct Drive Generator Cold Climate Rotor Blade Design Rotor Blade Heating Grid Integration Storm Control Cast Components Advanced Logistics Filename: © Copyright ENERCON GmbH. All rights reserved. 10 INNOVATION Direct Drive Generator Cold Climate Rotor Blade Design Rotor Blade Heating Grid Integration Storm Control Cast Components Advanced Logistics Filename: © Copyright ENERCON GmbH. All rights reserved. 11 INNOVATION Direct Drive Generator 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) Filename: © Copyright ENERCON GmbH. All rights reserved. 12 INNOVATION Direct Drive Generator Reliable technology Fewer revolutions 20 years revolutions by ENERCON turbine = 3 months by geared turbine Near 50% reduction in failures Stoppage Due to Failures (in hours)* Sensors and Others Yaw System and Rotor Air Brake Not Applicable to ENERCON Gearbox Pitch Adjustment Basis for service-production synergy Generator Applicable to ENERCON *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] Hydraulics Electrical System Main Shaft/Bearing Mechanical Brake Filename: © Copyright ENERCON GmbH. All rights reserved. 13 INNOVATION Cold Climate Package 100% power output down to -30°C 25% power output at -40°C Linear reduction with restart at -35°C Filename: © Copyright ENERCON GmbH. All rights reserved. 14 INNOVATION Cold Climate Package Cast Parts Unique alloy, notch tested Yaw and Pitch Systems High viscosity gear oil Bearings Low temperature capacity Rotor Blades Certified to -50°C Tower and Foundation Site-specific structural calculations Filename: © Copyright ENERCON GmbH. All rights reserved. 15 INNOVATION Rotor Blade Heating System 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 Filename: © Copyright ENERCON GmbH. All rights reserved. 16 INNOVATION Rotor Blade Heating System Yield per month between heated and unheated WEC E-82 2MW at a location in Czech Republic Systems in Canada: 700000 1 x E-53, 800kW (2011) Heated 600000 Unheated 28 x E-82, 2.3MW (2011) 500000 60 x E-70, 2.3MW (2012) 400000 300000 200000 Energy Yield [kWh] Yield Energy 100000 Reduction in standstill due to icing: 0 OCT 09 NOV 09 DEC 09 JAN 10 FEB 10 MAR 10 Czech Republic 82% Europe Sweden 93% Quebec 84% Canada Nova Scotia 80% Filename: © Copyright ENERCON GmbH. All rights reserved. 17 INNOVATION Storm Control Linear reduction of rated speed Resumes energy production instantaneously Avoids hysteresis losses Without Storm Control With Storm Control = 25 m/s (3 min) 30 m/s (15s) = 34 m/s (10 min) Filename: © Copyright ENERCON GmbH. All rights reserved. 18 INNOVATION Storm Control Operational at 36 m/s Filename: © Copyright ENERCON GmbH. All rights reserved. 19 INNOVATION Storm Control Operational at 36 m/s High Operational Capacity No Cut-In / Cut-Out Standstill Reduced Energy Losses Increase in Power Output Filename: © Copyright ENERCON GmbH. All rights reserved. 20 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 Filename: © Copyright ENERCON GmbH. All rights reserved. 21 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 Components protected from faults in power system 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 Support for power system stability during disturbances Advanced wind farm controller available for fast voltage and power control Control of small scale distribution to large scale wind power plants Filename: © Copyright ENERCON GmbH. All rights reserved. 22 REMOTE PROJECT EXPERIENCE Ross Island - Antarctica Filename: © Copyright ENERCON GmbH. All rights reserved. 23 REMOTE PROJECT EXPERIENCE 2003 Bonaire, Caribbean Utsira, Norway 1 x E-33, 330 kW 1 x E-33, 330 kW 2004 st 1 full-scale stand-alone wind-hydrogen Mawson Station, Antarctica project in the world Autonomous wind-hydrogen system with 2 x E-33, 330 kW flywheel and battery storage 70 % diesel displacement 2007 Falkland Islands 6 x E-33, 330 kW 40 % diesel displacement Ross Island, Antarctica 3 x E-33, 330 kW 2009 Annual savings of 463k litres diesel Annual reduction of 1.2k tons CO2 Ascension Island 5 x E-33, 330 kW Annual savings of $700k Annual reduction of 4.5k tons CO2 Filename: © Copyright ENERCON GmbH. All rights reserved. 24 REMOTE PROJECT EXPERIENCE 2010 Griess, Switzerland Bonaire, Caribbean 1 x E-53, 800 kW 2011 12 x E-44, 900 kW Highest turbine in the world at 2465 m above 40 % island’s energy supply generated by sea level wind Custom designed millipede transporter used on steep ascents 2012 Northwest Territories, Canada Canary Islands 2013 4 x E-70, 2 300 kW 3 x E-44, 900 kW Installed at Diavik Diamond Mine 2 x E-48, 800 kW Annual savings of 4.3M litres diesel 1 x E-70, 2 300 kW Repowering of existing wind farms Faroe Islands Created grid stability for pre-existing turbines 5 x E-44, 900 kW Quebec, Canada 1 x E-82 E4, 3 000 kW 2014 Installed at Raglan Mine Hybrid wind-diesel system with hydrogen, battery, flywheel storage Faroe Islands 18x E-44, 900 kW 60% renewable penetration using pumped- storage hydroelectricity Filename: © Copyright ENERCON GmbH. All rights reserved. 25 REMOTE PROJECT EXPERIENCE Hybrid Systems Diesel Solar Photovoltaic Flywheel Including in-house R&D experience Battery Hydrogen Pumped-Storage Hydroelectricity Filename: © Copyright ENERCON GmbH. All rights reserved. 26 WIND POWER IN MINING Diavik Mine – Northwest Territories Filename: © Copyright ENERCON GmbH. All rights reserved. 27 WIND POWER IN MINING Opportunities 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 Challenges Fossil fuel precedence well-suited to micro-grid stability High CAPEX, Return on investment > 4 years Wind resource variability Inertia Filename: © Copyright ENERCON GmbH. All rights reserved. 28 WIND POWER IN MINING Opportunities 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 Tipping the Balance Challenges Historical trend in fossil fuel prices Increasing energy costs Fossil fuel precedence well-suited to micro-grid stability Third party owner (IPP) Avoids high CAPEX and ROI period (PPA) High CAPEX, Return on investment > 4 years Storage technology Energy integration capacity Wind resource variability Project Champion + corporate and operator buy-in Conquer learning curve & build confidence Inertia Incentives Grants, R&D funding, tax incentives Integration complexity Reduced with penetration below 15-20% Filename: © Copyright ENERCON GmbH. All rights reserved. 29 WIND POWER IN MINING Challenges