CSM at a glance
Stage in our 50-year history
Partnership RINA and CSM
Widening specialist
competencies and presence in
international markets for
energy and oil & gas sectors
RINA acquires 50,5% of CSM
Piena scala - impianto pilota Business lines
Oil & Gas
Energy
Trasportation
Aerospace and Defence
Steel
Waste Valorization
CSM Approach for the Energy Industry
RESEARCH DEVELOPMENT INDUSTRIALAPPLICATION
1 2 3 4 5 6 7 8 9TRL
Idea Conceiving
Idea application
Idea Developing Prototype/ Demo Development
Demo & Performance
Development & Engineering
Mature Product & Processes
Applied R&D O2Gen,
AUSPLUS, MATTER, CRESTA, DELOC
Industrial Projects Ansaldo
Energia, GE, EMA, INAIL, Enel, Hitachi
Demo Projects
ENCIO, MACPLUS
Nano and micro-scale Testing
CSM uses Transmission Electron Microscopy (TEM) to characterize materials.Accelerating Voltage: 300 kVResolution 0.19 nm
Medium scale Testing
Testing and modelling
Full scale Testing – Pilot Plant
Combustion Station, CSM Dalmine
CSM in Europe
Start-up of ECCC Joint Industrial ProgrammeECCC
Energy&Trasport Business Area
CSM forEnergy & Trasport
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Content
CSM for Power Generation Industry
Markets and Main Customers
Recent Reference Projects
Technological Offer– Examples of CSM Services for Fossils
– Examples of CSM Services for Renewables
CSM Labs & Competences– Coatings & Surface Treatments
– High Performance Computing
– Lab and Full Scale Testing Facilities
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CSM for Power Generation
Steels for steam turbines and heat exchangers
Nickel superalloys for gas turbines
Materials for new manufacturing technologies (3D printing)
Powder metallurgy (ODS Alloys)
Refractories
Coatings
Material Design
Special components manufacturing (e.g. Turbine blades)
Melting & Remelting Technologies (es. VIM, VAR, PESR)
Gas atomization powderWelding (Arc, Laser, FSW Hybrid)
Additive Layer Manufacturing (ALM)
Components &
Technologies
Modelling for:
• Coatings degradation
• Hot corrosion
• Mechanical damage
• Creep-fatigue
High temperature testing
Failure Analysis
Inspection Systems
Life Cycle Assessment
Solid waste valorization
Water management
Emission reduction
Energy recovery
ENVIRONMENT &
SUSTAINABILITY
CSM Innovation Chain for the Power Generation Industry
For the Power Generation industry CSM provides support through the entire production line, from product development to design, production and performance assessment of materials and components for high temperature and corrosive environments
Energy & Transport Business Area
Technological OfferTechnological Offer
Near Net ShapeProducers
Alloy Design
Prototyiping by additive layer manufacturing
Definititon of manufacturing procedures
Environment Testing for materials qualification
Environment & Sustainability
Energy Companies
High Temperature material selection
Ceramic & coating innovative solutions
Structural Integrity Assessment
Modelling for life assessment (LCE)
Defence
Stealthness
Design & Testing of special components
Naval, Mechanical & Food Industries
Design & testing of special
components
Coating Solution for corrosive
Condition
Material Selection
Aerospace Companies
Advanced Materials Development & Characterization
Materials & Manufacturing
process for severe conditions
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• Qualification of materials/components for new process conditions• Improving manufacturing (casting, forging) and Joining techniques • Advanced materials and surface engineering solutions • Combustion/Gasification technologies• Advanced modelling and automation• Structural integrity (creep, fatigue, microstructural evolution
modeling)
….in all power generation sectors- Fossil Fuels (A-USC, Gas turbine, Oxyfuel, Co-combustion)
- Nuclear (Fusion, Gen IV)- Renewables (Wind, Biomass, Solar, Geothermal)
CSM typically offer its services to Materials/component manufacturers,Engineering Companies and End Users
CSM for Power Generation
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Main Customers in Power Generation
Ansaldo Energia DalmineEnel Acciai speciali TerniEnea Flame sprayEni ILTEMA SHAPINAIL SDFNuovo Pignone Kinetics TechnologiesTirreno Power Cogne Acciai SpecialiArchimede Solar Energy RTM Breda
SiemensSMSTHitachi Power EuropeVallourec & MannesmannSalzgitterVGB
E.ON EngineeringAlstom Power
TWIDoosan Babcock
GDF Suez energy International
Special Metals
YARA
DTU
Laborelec
BohelerSchaffler
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RecentReference Projects
INAIL(2012-2105)
“Grade 91 mechanical evolution Atlas”
“Material driven solutions for USC plants”Life prediction tools for materials and componentsAdvanced refractoriesMARBN steelsNew alloys for superheters
Encio(2013-2015)
“Material behavior of thick-walled components at 700°C”Qualification of new developed materialsExploration of manufactoring options
“life prediction of coatings in turbine components”Development of a diffusion-reaction model of chemical evolution of the coating to predict the grow of dense AL2O3 layer and the evolution in time of the profile of the phases in the alloy
Macplus(2011-2015)
Coating life prediction
18N°18
The content of this document is confidential and is reserved for the Customer only
Most Relevant EU and National funded R&D Projects:CRESTA (power generation - advanced 9-12Cr steels)AUSPLUS (power generation - advanced austenitic steels)DELOC (power generation - creep and fatigue crack growth)ENCIO (power generation – Ni-base alloys, thick-walled pipes)MACPLUS (power generation – adv. materials for A-USC)O2GEN (power generation – materials for Oxyfuels)SAFETOWER (wind farm off-shore – tower)STEELPV (solar energy - thin film solar cells)TUBOSOL (solar energy – exchange tubes)MATELIOS (renewables – national district)SARCO2 (CO2 transport – pipelines safety)MATTER (nuclear power – gen 4 materials)
Networking actionsECCC (European Collaborative Creep Committee) – CSM secretariatNational Working Group “Sustainable energy” – CSM president Intense participation in several EU initiatives (Industrial Platforms, EERA, PPP)
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Examples of CSM Services for Power Generation
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Materials for advanced power plants (USC and Oxyfuel in view of CCS) in collaboration with most important industrial players (EON, Enel, Hitachi Power, Alstom, RWE, Foster Wheeler, Air Liquide, Dong Energy , Ciuden ..).Component Life Assessment (proprietary models for Creep and creep crack grow)Main ongoing projects: Macplus, Encio, Ausplus, O2GEN…
Main CSM ongoing initiatives
Advances solution for gas and steam turbines protection in collaboration with Ansaldo and Alstom.
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Macplus -Advanced Refractory materials
The conditions occurring in oxy-combustion plants, coupled with the fuel flexibility, represent a critical factor for refractory materials,New low cost solutions are required.
CSM, is developing a functionally graded material consisting of a low cost refractory substrate coated with a protective layer having superior corrosion resistance that have be tested in industrial plants
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Protective coatings
MCrAlY for turbine blade protection, (M=Ni, Co + Iridium, Rhenium) deposition
with thermo spray technique o HVOF (High Velocity Oxy Fuel).
Aluminisation for heat exchanger tubes. Coatings on carbon steel tubes by HVOF technology. The produced coated tubes are used within the projects “Macplus” and
“O2Gen” for long term exposure tests in industrial plant.
N°22 CCS –WEC 18.10.2011
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Existing infrastructures for CO2 transportation are relatively short connections between plants and nearby storage sites or situated in remote areas.CO2 transport lines will probably cross populated areas.
CO2 transportation
N°23
Issues under study:
Effect of quality composition of CO2 mixture (impurities, H2O) due to the characteristics of the point of capture or the capture process adopted;
Supercritical transportation (to avoid two phase flow), P > 82 bar ;
CO2 behavior in case of pipeline failure:– ductile Fracture propagation (CO2 decompression behavior);– leak before break event
600 m
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Improvement of wind power plants mechanical properties (gearbox, tower)
Solution for high temperature corrosive environment Validation, failure analysis, reliability.
Improvement of solar receiver Components
Thin films solar cells
Efficient and low costs components for renewables plants
Gasification plant for biomass
conversion
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CSM activities Improving critical components performances: (receiving collector, piping, heat exchanger)Component/system design and modelling, molten salts
characterization
Aspects related to materialsHigh temperature, corrosive environments (diathermic oil, molten salts, steam )
Thermodinamic Solar Energy
TrendsImproving AffordabilityManufacturing cost reductionEfficiency increase (available areas)
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Example CSM Project: TURISOL Development and construction of a solar receiver for atmospheric air heating to be used for gas landfill reforming
Main Activities- Ray tracing modeling- Thermomechanical modeling- Engineering design - Component realisation
In collaboration with Tecnopolo Castel Romano and Shap R&D
Thermodinamic Solar Energy
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SteelPV – Direct Pv deposition on steel sheets 1/2
The objective of STEELPV is to promote the direct deposition (e.g by physical vapor deposition) of thin film solar cells (TFSC) , on steel substrates.Steels shows some desirable properties respect to glasses and plastics for PV application, such as:- Higher mechanical properties that will allow weight and thickness
reduction- Flexibility and lower risks of structural failure- Lightness
Partners: Centro Sviluppo Materiali, ITMA ,Schlenk Metallfolien GmbH, Abengoa Solar New Technologies, Bangor University, Un. Swansea.
The role of CSM will regard the realization of the interlayer (IL) and of the backside coating for steel integration in TFSC production.
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The IL require:• Electrical isolation of the steel
substrate• Barrier against diffusion of alloying
elements from the steel to the multilayer system
• Compensation of the thermal stresses due to mismatch between the thermal expansion coefficient of the steel substrate and the PV layers
The back side coating require:• Protection against corrosive media,
such as sea aerosol or water• Good adhesion on the steel
substrates• Inertness with the alloying elements
of the steel substrate
Example of PVD layer of chromium carried out on a metal substrate.
SteelPV – Direct Pv deposition on steel sheets 2/2
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CSM experience in gasification technologies for energy recovery and waste to energy Environmental platform, pilots plantsTechnologies for industrial wastes treatment, energy/material recovery, inertisationIndustrial process optimisation for micropollutant reduction (dioxine, PAH, PCB)
CombustionPlasm torch Gasification Pyrolysis
Biomass conversion/ Environmental protection
Asbestos Containing Wastes
Fly ash
30 N°30
Technological choice Prototyping
NG
Aria
NG
Aria
Design Experimental heats
Combustion/heating Systems
CSM experience in process optimization (energy efficiency, envronmental impact reduction)- Burner design- CFD modelling- Innovative process development
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Environment & Sustainability – Emission Reduction & Resource Valorization
Solid
Water G
as
Scale / sludge recovery in EAF
EAF slag inertisation
Water treatment (Boro)
NOx emission reduction
LF slag valorisation
EAF dioxin emission reduction
EAF Fume Energy Recovery
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Environment & Sustainability - Waste Valorization & Inertization
GASIFICATION OF OILY SLUDGES AND INERTIZATION OF THE ASHES PRODUCED BY THE PROCESS
(REFINERY ZERO WASTE PROJECT)
Pilot Plant Gasification Reactor (50 kg/h)
Pilot Plant Plasma Torch Reactor (0.3 MW)
Main results: Reduction up to 90% of sludge volume Inertization of treatment residues Self-sustaining advanced gasification process + export syngas
(patented) Process and plant set up at pilot scale Industrialization in progress (2 t/h, overall plant dimensions:
900 m2)
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CSM Labs & Competences
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CSM Labs & Competences
Coatings & Surface Treatments
Technical Competences and Equipments
Surface Treatments Cleaning, Degreasing Surface conversion Mechanical finishing
Metallic & Ceramic Coatings
Hot dip coatings (Zn, Al, alloys)
Electrolytic coatings Thermal spray coatings Vapour deposition coatings
(PVD)
Organic Coatings Painting Fusion and film laminating
coating
Polymeric Materials Adhesives and sealants Metal-plastic composites Rubber & plastics
Hot Dip Technology
Physical Vapour Deposition (PVD)
Thermal SprayThick (0.5mm min) inner metallic protection up to 6m
Polymeric materialsAdhesive bonding
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CSM Labs & Competences
Coatings & Surface Treatments
CSM experience
Develoment and optimisation of coating process : External coatings in PE and PP triple layers External coatings in epoxy powders (FBE) Internal coatings for pipe-line, flow-line and slurry
lines Fluidised bedcoating cycles for special
components
A
Topcoat
Primer
Coating selection Basic coating characterizations (microstructure,
thickness, hardness, …). Evaluation of the coating resistance to
deformations Evaluation of the coating resistance to
environments simulating actual applications by high temperature autoclave testing
Mechanical testingFlexural Test
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CSM Labs & Competences
High Performance Computing
CSM has great experience in complex simulation, routine development, deep knowledge of materials behavior and its modelisation into numerical code.
By means of the Finite Element design tools the time to market is shortened. Prototypes are obtained with fast on-shop works
The main fields of application are: Forming simulation:
- Sheet and tube metal forming- Hydroforming- Springback evaluation and tool reshape compensation- Tool design
In service performances of components working also in severe thermo mechanical conditions- Fatigue, thermal and stress analysis- Fluid Dynamics (chemical reactions, gas burners,...)
Casting and hot forming processes High performance calculation hardware and software, including
almost all the main relevant FE codes.
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CSM Labs & Competences
High Performance Computing
Main fields of application are: Rolling Forging Hot forming processes Continuous casting process In service performances of components working
in severe thermo mechanical conditions Fluid Dynamics Casting
In almost all these fields microstructure solid phases evolution is taken into account by means of in house developed softwares.
Deep knowledge of related industrial processes
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CSM Labs & Competences
High Performance Computing
Framework Field Software
Process design
Hot/Cold Forming
ABAQUS
LS-DYNA
MSC-MARC
Welding SYSWELD
Casting PROCAST
Fluid Dynamic analysis FLUENT
Product design
Stress/Fatigue/Thermal/Shock analysis
MSC-MARC
MSC-NASTRAN
ABAQUS
OPTISTRUCT
BallisticLS-DYNA
ABAQUS
Crash analysisABAQUS
LS-DYNA
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CSM Labs & Competences
Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory
Evaluation of the mechanical behaviour of metallic materials and components on both small and large scale by means of conventional and innovative testing dedicated laboratories. Tests can be carried out simulating service life environment (air, saline fogs, sea water, cathodic protection) in a temperature range from -196°C up to +1100°C).
Testing typologies: Facilities:
20 Servo hydraulic testing machines from 100 up to 2500 kN
53 Testing machines mono e multispecimens (325 specimens in parallel can be tested) for creep tests (temperature max 1300°C)
1 Servo mechanical testing machine for creep fatigue
1 Servo mechanical testing machine for creep ceramic
Multipurpose platform for testing on component
Special testing carried out by sized frames
Mechanical testing at low and high temperature (tension, compression, bending). Hardness survey.
Fracture mechanics (CharpyV, KIC, CTOD, J-int. measured by SENB and SENT specimen, Segment test).
Creep and creep-fatigue on metallic and ceramic materials.
Fatigue (constant and variable amplitude, HLC, LCF and TMF).
Multi Plastic Straining Cycling (reproducing plastic strain history of interest).
Multiaxial fatigue testing on large scale components (pipes, plates, rails, welded joints)
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CSM Labs & Competences
Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory
Welded plate, fatigue, max
frequency 2 Hz, max load 1000 kN Pipe Circumferentially Tensile Test from 2” to 48” OD
Creep Testing LabMechanical Testing Lab
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CSM Labs & Competences
Lab & Full Scale Testing Facilities – Residual Stress Laboratory
The Laboratory is located in Roma, within the Central Full Scale Testing Laboratory.
Methods that are available for residual stress measurement are: Strain gauge methods (Hole drilling, Sachs, sectioning, etc.); X-Ray Diffraction System (XRD).
Stress X-3000
Hole drilling
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CSM Labs & Competences
Lab & Full Scale Testing Facilities – Stress Corrosion Testing Laboratory
Evaluation of the material corrosion behaviour by accelerated test campaigns in simulating operating conditions using dedicated laboratories :
Corrosion and electrochemical laboratory Stress corrosion laboratory. High Temperature High Pressure (300bar, 300°C) testing in autoclaves.
Uniform Corrosion and Stress Corrosion Resistance of stainless steels in industrial environments: inorganic acids, chlorides, heavy brines, sulphides, caustics.
CSM’s attendance of Corrosion Standardisation Committee: NACE, EFC, ISO, API
CSM is qualified ACHILLES as a supplier for the Oil Industry of the North Sea
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CSM Labs & Competences
Lab & Full Scale Testing Facilities – Full Scale Testing Laboratory
Drop Weight Tear Test (DWTT) Device
Equipment main features: Max fall height : 4m. Max Impact energy available : 29,000 Joule. Test at low temperature cooling down the sample at
the required temperature