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Composites Future: ‘minimum mass, minimum energy, maximum performance’
EFRO, Uitgeest, 14-12 -2016,
‘Valorisatie Hightech Sector Composieten Noord-Holland’,
Adriaan Beukers
Composites Future: ‘minimum mass, minimum energy, maximum performance’
SUSTAINABLE
Circular
ECONOMICS
Anglo-saxon
Rhine-land
share vs
stakeholders value
LIFE TIME
TRAVEL HISTORY:
(spec. drag, time,
speed, capacity)
for moving
or being moved
objects
SUSTAINABLE
POLITICS:
Paris Climate
treaty
Shell & Exxon
CEO’s plead
for CO2 tax
PROACTIVE vs REACTIVE
GB’s decline in
manufacturing jobs
(>96: >750.000 fte)
in change for
services & trading,
a rise in rest of EU
Transport and velocity domains
Total (system + payload) weight, so reduce system weight!
15kgf PREQto move
100kg WTOTAL
Transport Systems (price of speed, G. Gabrielli – Th. von Kármán, 1950)
force to overcome drag, per unit moving system weight
liquid fuel history: ‘a one century history of slash and burn’
SABIC/GEP-DSM
BASF/DSM
Emirates
Delta Airlines
10-20 -->100 30$/barrel
Cheap Materials become Scarce, even dumpedeg cheap oil, easy exploitable wells, new circular economies, EC2020
Exploration
(<5$/barrel
is based on
shared profit1/31/7
classical markets
aerospace & wind
energy show
highest global
growth now,
be in front
of the big
volume
composite
markets!
ref. Lucintel
CAGR: compound anual growth rate
size of bubbles: indicating for market size
Global Composites Market Opportunity 2012-2017
NL
Specialties:
Marine
Aerospace
Pipe & Tank
Construction
Composieten Nederland 2020
GrootComposiet1 2009-2014, EFRO
2 2016-2020, PNH
CompoWorld1 2011-2015, ZZL, PF&NF
2 2016-2018
BioComposieten 2014-2018, EDR
World Class Composite Solution, Het Noorden > 2015
Maritiem - Luchtvaart 2014-2018, Rijn Delta, Drechtsteden
& een aantal Field Labs
‘the knowledge chain’
kennis
ontwikkeling
kennis
verspreiding
kennis
valorisatie
TU’s
HBO’sMBO’s
Composieten NHInternationale ontwikkelingen en trends
Begroot Gerealiseerd Restbudget % besteed
5.264.825€ 2.279.184€ 2.985.641€
ATO 1.049.000€ 661.574€ 387.426€ 63%
Syntens 849.600€ 529.887€ 319.713€ 62%
WMC 297.025€ -€ 297.025€ 0%
TUD 240.000€ 88.224€ 151.776€ 37%
Inholland 400.000€ 125.249€ 274.751€ 31%
TNO 370.000€ 96.491€ 273.509€ 26%
NHN 63.750€ 32.172€ 31.578€ 50%
Solico 107.000€ 14.990€ 92.010€ 14%
Polux 152.000€ 161.035€ -9.035€ 106%
2MV 135.200€ 31.170€ 104.030€ 23%
Schaap Composites 127.000€ 21.861€ 105.139€ 17%
NPSP 127.000€ 127.000€ -€ 100%
Smit/Utec 127.000€ 105.038€ 21.962€ 83%
Manshanden 149.500€ 32.654€ 116.846€ 22%
Rhebergen 107.000€ -€ 107.000€ 0%
Everstrip 127.000€ 73.982€ 53.018€ 58%
CPT 517.000€ 124.507€ 392.493€ 24%
Duneworks 107.000€ 53.351€ 53.649€ 50%
GBT 212.750€ -€ 212.750€ 0%
Innovatiebudget
GrootComposiet1 2009-2013, EFRO
valorisatie 2 2016-2019, EFRO
HTSM
Technologie programma >2011, NL
Construction
Pipe & tank
Marine
NH composites
on the move
Composites penetrating tradional material sectors
Begroot Gerealiseerd Restbudget % besteed
5.264.825€ 2.279.184€ 2.985.641€
ATO 1.049.000€ 661.574€ 387.426€ 63%
Syntens 849.600€ 529.887€ 319.713€ 62%
WMC 297.025€ -€ 297.025€ 0%
TUD 240.000€ 88.224€ 151.776€ 37%
Inholland 400.000€ 125.249€ 274.751€ 31%
TNO 370.000€ 96.491€ 273.509€ 26%
NHN 63.750€ 32.172€ 31.578€ 50%
Solico 107.000€ 14.990€ 92.010€ 14%
Polux 152.000€ 161.035€ -9.035€ 106%
2MV 135.200€ 31.170€ 104.030€ 23%
Schaap Composites 127.000€ 21.861€ 105.139€ 17%
NPSP 127.000€ 127.000€ -€ 100%
Smit/Utec 127.000€ 105.038€ 21.962€ 83%
Manshanden 149.500€ 32.654€ 116.846€ 22%
Rhebergen 107.000€ -€ 107.000€ 0%
Everstrip 127.000€ 73.982€ 53.018€ 58%
CPT 517.000€ 124.507€ 392.493€ 24%
Duneworks 107.000€ 53.351€ 53.649€ 50%
GBT 212.750€ -€ 212.750€ 0%
Innovatiebudget
Begroot Gerealiseerd Restbudget % besteed
5.264.825€ 2.279.184€ 2.985.641€
ATO 1.049.000€ 661.574€ 387.426€ 63%
Syntens 849.600€ 529.887€ 319.713€ 62%
WMC 297.025€ -€ 297.025€ 0%
TUD 240.000€ 88.224€ 151.776€ 37%
Inholland 400.000€ 125.249€ 274.751€ 31%
TNO 370.000€ 96.491€ 273.509€ 26%
NHN 63.750€ 32.172€ 31.578€ 50%
Solico 107.000€ 14.990€ 92.010€ 14%
Polux 152.000€ 161.035€ -9.035€ 106%
2MV 135.200€ 31.170€ 104.030€ 23%
Schaap Composites 127.000€ 21.861€ 105.139€ 17%
NPSP 127.000€ 127.000€ -€ 100%
Smit/Utec 127.000€ 105.038€ 21.962€ 83%
Manshanden 149.500€ 32.654€ 116.846€ 22%
Rhebergen 107.000€ -€ 107.000€ 0%
Everstrip 127.000€ 73.982€ 53.018€ 58%
CPT 517.000€ 124.507€ 392.493€ 24%
Duneworks 107.000€ 53.351€ 53.649€ 50%
GBT 212.750€ -€ 212.750€ 0%
Innovatiebudget
Kennis is zilver,
bedrijvigheid is goud
≈ 20 years Crossover Luchtvaart-Maritiem, 2014
Infra StructuresFibreCore, LSPolyproducts
Pressure vesselshoses, et ceteraALE, Taniq, CPT
Lighter transport countspackaging on the move 2010
domestic gasses and fluids
lightness, dematerialization
Dutch Recent Infra Composites
Architecture & Civil engineering meets Aerospace
ruled by:
New regulations (health & safety)
Maintenance cost reduction
Lightness and architectural freedom
(refurbishing old structures, without weight penalty)
supported by
LCA premium
Composites on the Move1: ‘minimum mass, minimum energy, maximum performance’
LIFE TIME
TRAVEL HISTORY:
(time, speed,
capacity)
VABO,Volvo, CompoW, NLR
CTC, Luinstra, CompoW, UT
Tankwell, CPT, GrootComp, TUD
TenCate, DTC, K&vE, Airborne, TUD
EML, Jan Veenendaal, TUD
Low8, Koppert, TUD
Composites on the Move2: ‘minimum mass, minimum energy, maximum performance’
LIFE TIME
TRAVEL HISTORY:
(time, speed,
capacity)
Taniq, Zumro,
Futura, Airborne
K&vE/Fokker,TUD
Boeing, TenCate, DTC, K&vE, TUD
Walter Extra
400&500, TUD
Euro Enaer,
K3C, TUD
CATO, Sumitomo,
Bond Laminates,
TUD
DTC/Dornier, TUD
Life-time energy savings per 100kgaverage values for energy
savings by
weight reduction
IFEU 2004, 1GJ is about 30lt kerosine
42,000lt
450,000lt
600,000lt
EFFICIENCY improvements
since the 50’s,
aerodynamics: L/D ≈ 15%
propulsion: SFC ≈ 40 % (Genx/CSMleap)
structure : 0.50 > OEW/MTOW > 0.60
Major R&D Challenges:
Structures, Materials &
Manufacturing Techniques
Boeing 787: composites content Wf > 50%, Vf > 70%, 1/R ≈ 2
KLM rounding Spijkerboor
A320/B737 - alikes
structure efficiency
used for aircraft
OEW / MTOW =
42 ton / 74 ton = 0.56
Johnston distribution OEW:
50%: 21ton for systems, crew and power-plant(s)
50%: 21ton for structure in total
• 10.5ton for wing , undercarriage (6% ) and movables (6%), (12%=5 ton)
• 10.5ton for fuselage and empennage (13%)
candidate aluminium structure for change into CFRP
• 16.0ton for wing, fuselage and empennage shell structures (38%)
ColdFeather ’95 & Tankwell ’15: 3&4ton weight reduction per unit!
max weight saving by change
is about 25%, equal to 4ton (≈ 10% OEW), for A320/B737 alikes! (0.51)
B787.8
OEW/MTOW
≈117t/228t≈
0.51
Energy saving: 667 GJ/year.100kg Specific energy content: 35 MJ/litre
So fuel saving per year per 100kg: 19000 litre
Sell tickets priced per kilogram not per seat!
A320/B737 AIRCRAFT, -100kgmass reduction pays for itself
‘TankWell’ Composite Containers
Inter-modal transport containers:
road transport limits capacity, grossweight <44, <40 & <32ton
STAINLESS STEEL
replaced
by E-GLASS FRP:
-40% empty weight
reduced
per road transport
+3000kg more payload
7-9% cost reduction
• Vessel capacity (31000lt)
• tare weight/pay load
up to 36ton
• Temperature controlled
• max pressure 4 bar
Design and Development StrategyDesign and Production of Composite Structurescooled trailer system weight
reduced from ca. 9300
to 6500 kgf
‘integration’
1995, Focwa/Cintec 30% weight reduction challenge, > A320 & B737
Cheap Buoyancysupply inter and intra modality transport chains
(road, rail and water)
human supply chain or the transport of
food, water, minerals, energy & building materials
River and sea
harbours
permanent
dwellings
3%
transport cost
expenditure rule
Bouyancy is more efficient than Wheels and Aerodynamic lift
higher aquisition cost, less maintenance cost, more added value
WATER CARRIESbarges for European
canal transport
Kempenaar & Spits
(cooled food) barges
new materials & processes
Wempty / Wpayload =
800 / 2300 ≈ 1/3,
potential glass FRP
from 800 to 550 ton,
+ 250 ton > - 10 trailers
Life time ENERGY SAVINGS HIGH SPEED FERRIES
33% reduction by weight
-7% kerosine,1650GJ//35MJ/lt
47 ton/100kg.lifetime
E-GlassFRP, corrosion resistance, thermal & acoustic insolation
steel
aluminium
GlassFRP
+
addedo
values(integration)
Lightweight composite Structures
Aerospace meets Maritime,from technology push to market pull
Royal Huisman, Damen, v.Lent, De Vries, VABO, Holland Jachtbouw?
Composites Future: TTintoB‘minimum mass, minimum energy, maximum performance’
Almost THE END
‘the knowledge chain’
Knowledge
dissemination
Knowledge
development
Knowledge
valorisation
EFRO ‘Valorisatie Hightech Sector Composieten Noord-Holland’
Uitgeest, 14-12 -2016
Concept, materials and manufacturing techniques selection
Fast structures, maximum performance driven
Composiet in Opmars 1America’s Cup 2013
Concept, materials and manufacturing technique selection
Life cycle cost driven
Composiet in Opmars 2civil constructions 2013
Concept, materials and manufacturing techniques
Performance/price driven
Composiet in Opmars 3
2013 BMWi3
CompositesGlobal Automotive Materials Market (2011-2017) in $B
2013 BMW i3
Concept, materials
and manufacturing technique selection
Price/performance driven
Airbus 350, 2013
Taniq
Actiflow
Infinious
ALE
Airborne
K&vE
WMC/CompEx
Bond Laminates
Conform/Hylid
DTC / Mupio
Feltrin Composites
CLC / LS
Euro Enaer (‡)
Senz/Protension
MOCS/CTC
a challenge
for entrepreneurs
Composiet in Opmars 4
glass, aramide and carbon fiber
reinforced thermoplastics:
PA, PES, PEI and PPS
Sumitomo, Fonteijne
TenCateAC, Bond laminates
DTC, K&vE, Airborn,ALE, Fokker
Thermoplastic
Composites
low pressure
short cycle time
proces development
material development
Design and Production of Composite Structuresit takes 20 years for take off
Since 1995 > 25 innovations, spin off’s & techno starters
?
?
NWO!?
IP or Exclusive Know How (EKH) is essential for technostart up’s
Sharing Knowledge and Opportunities is seed for growth
Pro-active attitude of key players is a prerequisite
‘Design and Production of Composite Structures’ 2012
Knowledge
dissemination
Knowledge
development
Knowledge
utilization
an example
fundamentalresearch
appliedresearch
utilization
GTI ’S
TNO (SBIR))NLR (CompoWorld)et cetera
GB’S &MULTINATIONALS(20%)
‘off shoring’
innovations by ‘in shoring’ academic techno starters
TU’s
Uni’s NEW SME’S
‘YesDelft’GrootComposiet
et cetera
STW
demonstrator
valorisatie
grants
TTI’s HBO’s
Ir. Lianne Waghto
The endFuture exhaust system paradigm: ‘from assembly to integral system’Manage heat, pressure, sound & CO2 + Nox emmision in a 3D shell structure
Design and Production of Composite Structures ‘COMPOSITES’
DISSEMINATION
UTILIZATION
DEVELOPMENT
KNOWLEDGE
• Ferrari Maranello
Structures
Processes
Materialscomposites
Actual position:
DSM
‘flying doctors’
Lightweightinsulating
hot gas exhaustsystems
PyrogelSuperwool
Carbon/Peti330phenylethynyl-terminated imide oligomer
(LaRC PETI-5)
Patent Pending
Temperature decline:
from 700o to 100oC
Transmission loss:
ca 50 dB, ΔW≈60%
Protension:
blue helmets,
radomes, wheels
FOCWA:
cooled trailers
Bosal/Agusta:
exhaust systems
Turn Implicit Knowledge into Explicit IP TTintoB
Zumro Resque Bags
Taniq Turbo hoses
ALE pressure vessels
Turn Implicit Knowledge into Explicit IP TTintoB
KeyKeg packaging
Airborne
oil & gas tubing
CPT containers
Kennis is zilver,
bedrijvigheid is goud
Crossover Luchtvaart-Maritiem
Gemeente Papendrecht, 10 maart 2014, Apollo Hotel
AXBow, Lex Keuning TUD & Marin
K&vE: inductie lassen
Downhole tubes , AirborneFlexible hoses, Taniq
Composites Future: TTintoB‘minimum mass, minimum energy, maximum performance’
THE END
‘the knowledge chain’
Knowledge
dissemination
Knowledge
development
Knowledge
valorisation
EFRO ‘Valorisatie Hightech Sector Composieten Noord-Holland’
Uitgeest, 14-12 -2016