Académique Documents
Professionnel Documents
Culture Documents
LOGISTICS
Shipping of wind turbines:
With barges to the site
Page 7
INTERNATIONAL
First E-70 wind farm in
Greece: Renewable energy
supply for Arcadia
Page 10
TECHNOLOGY
100 % renewable energy
feasible: Hybrid power plant
geared to meet demand
Page 12
SUPPLIER
Siempelkamp GmbH:
Specialists for large cast
parts
Page 14
CLIMATE RESEARCH
Sergej Kirpotin: Permafrost
thaw aggravates climate
change
Page 16
ENERCON ADDRESSES
INTERNATIONAL SALES OFFICES Page 3 Editorial
ENERCON GmbH, International Dept.
Otto-Lilienthal-Str. 25 · 28199 Bremen · GERMANY
Phone +49 421 2441 520 · Fax +49 421 2441539
e-mail: sales.international@enercon.de
ENERCON News
AUSTRIA Page 4 Short news from the ENERCON World
ENERCON Austria Ges.mbH · Hauptstrasse 19
2120 Wolkersdorf · AUSTRIA · Phone +43 2245 82828
Fax +43 2245 82838 · e-mail: enercon@vienna.at
BENELUX
Title Story
ENERCON Benelux BV · Paxtonstraat 1 a
8013 RP Zwolle · THE NETHERLANDS
Page 7 Shipping of turbines: With barges to
Phone +31 38 4228 282 · Fax +31 38 4228 010
e-mail: sales.benelux@enercon.de the site
BRAZIL
Wobben Windpower Ltda.
Av. Fernando Stecca nº 100 · Distrito Industrial CEP
18087450 Sorocaba · São Paulo · BRAZIL
International
Phone +55 15 2101 1700 · Fax +55 15 2101 1701
e-mail: wwp@wobben.com.br
Page 9 France: ENERCON builds largest
CANADA French wind farm: Wind energy
Michael Weidemann · ENERCON GmbH
International Sales Department market in France booming
Oesterweg 9 · 59469 Ense · GERMANY
Phone +49 2938 9720 17 · Fax +49 2938 9720 49
e-mail: michael.weidemann@enercon.de
Page 10 First ENERCON E-70 wind farm
DENMARK
ENERCON Denmark in Greece: Renewable energy supply
Bredkær Parkvej 62 · 8250 Egaa · DENMARK
Phone +45 87 430 388 · Fax +45 87 430 344
e-mail: kristensen@enercon.de
for Arcadia
EGYPT
ENERCON Egypt
c/o Zaki International Trading · 23 Kasr El-Nil Street
Technology
Cairo 11111 · EGYPT
Phone +20 2 3923 670 · Fax +20 2 4170 023
Page 12 100 % renewable energy feasible:
e-mail: zit@starnet.com.eg
Hybrid power plant geared to meet
FRANCE
ENERCON GmbH bureau français
demand
1, rue des Longues Raies · ZAC des Longues Raies
F-60610 La Croix Saint Ouen · FRANCE
Phone +33 3 44 83 67 20 · Fax + 33 3 44 83 67 29
Supplier
GREECE
ENERCON Hellas S.A.
Page 14 Siempelkamp Foundry:
20, Pentelis Avenue · 15235 Vrilissia, Athens · GREECE
Phone +30 210 6838 490 · Fax +30 210 6838 489 Specialists for large cast parts
e-mail: enerconh@otenet.gr
INDIA
ENERCON India Ltd. Climate Research
Kolsite House, Plot No. 31 · Shah Industrial Estate
Veera Desai Road, Andheri (West) Page 16 Sergej Kirpotin: Permafrost thaw
Mumbai 400 053 · INDIA
Phone +91 22 569 248 48 · Fax +91 22 267 300 85
e-mail: info@enerconindia.net
aggravates climate change
ITALY
ENERCON Italia
Via Luciano Manara, 5
00044 Frascati (Roma) · ITALY
Phone + 39 06 94 01 69 1 · Fax + 39 06 94 01 69 299 Events and Addresses
e-mail: info@enerconitalia.it
PORTUGAL
Page 2 ENERCON Addresses
ENERCON Portugal
c/o Gellweiler S.A. · Rua Vitor Cordon, 37-4° Dt°
Page 6 Info-Service
1200-481 Lisboa · PORTUGAL
Phone +351 21 340 71 65 · Fax +351 21 340 71 69
e-mail: zgellweiler@gellweiler.pt
SPAIN
ENERCON Spain S.A.
València Parc Tecnològic, Av. Juan de la Cierva, 27 IMPRINT
46980 Paterna (València) · SPAIN
Phone +34 961 366 461 · Fax +34 961 366 469
Publisher: ENERCON GmbH · Dreekamp 5 · 26605 Aurich · Germany
e-mail: enercon.spain@enercon.de Phone +49 4941 927-0 · Fax +49 4941 927-109 · www.enercon.de/en/_home.htm
SWEDEN Editorial office: Volker Uphoff, Ruth Brand
ENERCON Sweden
c/o Energy Converter AB Printed by: Steinbacher Druck GmbH, Osnabrück, Germany
Stenåldersgatan 19 Copyright: All photos, illustrations, texts, images, graphic representations, insofar as this is not expressly stated to the
21376 Malmö · SWEDEN
Phone +46 40 143 580 · Fax +46 40 222 420 contrary, are the property of ENERCON GmbH and may not be reproduced, changed, transmitted or used otherwise without
e-mail: scandinavia@enercon.de
the prior written consent of ENERCON GmbH.
TURKEY
ENERCON Servis Ltd. Sti.
Frequency: The WINDBLATT appears every three months and is regularly included in the
Bagdat Cad. No 187 A Blok daire 5 New Energy, magazine for renewable energies, of the Federal Association for Wind Energy, Germany.
Selamicesme Kadikoy
Istanbul · TURKEY Subscribe: Phone +49 4941 976-283 or www.enercon.de/en/_home.htm; stamp duty 2,- € per issue.
Phone +90 216 3854 715 · Fax +90 216 3606 492
e-mail: enercon@doruk.net.tr Cover photo: Barge loaded with WEC components running into a lock near Magdeburg.
EDITORIAL WINDBLATT 03 | 2007 3
Dear Readers,
We are extremely pleased to announce that this summer we moved our headquarters over to
the brand new administrative building at Dreekamp in Aurich. Spacious offices for more than
200 employees bring together our Sales, Project Management, Site Assessment, ENERCON
Invest, Tax, Accounting and R&D departments in one location and at the same time provide an
ideal setting to support even more efficient collaboration. By moving these departments into
the new building, space has now been freed up especially for our research and development
division. This expansion was essential, as our engineers now have more comfortable working
conditions to continue advancements in wind turbine technology.
This spring, Germany and the European Union have set highly welcomed but ambitious objec-
tives for renewable energy, so constant technological progress in our wind turbine technology
is a major contributing factor towards meeting these aims. Having committed to providing one
fifth of its energy supply from renewables by 2020, the European heads of state have also
agreed to reduce Europe-wide CO2 emission by 20 % within the same time period. This
means that major efforts still have to be made.
ENERCON has long taken on this challenge. The easiest way to reduce climate gases is the ex-
pansion of renewables, on-shore wind energy in particular. Thus, we do not only offer wind
turbines for choice wind sites, but also for sites with moderate wind conditions. Larger rotor
diameters and higher towers can achieve profitable energy production even in regions far from
the coast. This, however, requires political support! In Germany, we have some unfavourable
examples in this respect. As long as states such as Hesse, Bavaria and Baden Württemberg
continue to allocate too few or unsuitable areas for wind turbines, Southern Germany will not
develop into a favourable region for wind energy. Another factor of course is the widespread,
ecologically and economically absurd height restrictions: Restricting the total height to 100
meters reduces the yield of a wind turbine by up to 50 %.
Fortunately, German federal legislation has taken its first step to boost the regions’ acceptance
of wind energy: As of spring this year, night time hazard warning lights required on construc-
tions 100 metres high and above can now be adapted to local visibility conditions. Now, night
lighting can be reduced by 10 % of its previous light intensity on clear nights. This is just one
of the many possible steps towards dispelling still encountered rejection of wind energy and
present height limitations.
Yours sincerely
Aloys Wobben
Managing Director ENERCON GmbH
4 WINDBLATT 03 | 2007 NEWS
ENERCON to supply turbines for zes and deployment sites. Currently, the wind turbines near the border of the northern
hydropower plant on the river Weser Weserkraftwerk Bremen GmbH is carrying out Czech Republic are currently in the preparati-
the planning and design work. At the end of on stage.
the year, the project will move to a call for ten-
der for the construction of the 10 megawatt Industry association’s working group
power plant. Once the contract has been “Europe” off to Brussels
awarded, construction should start in the This spring, EU leaders agreed to a legally bin-
spring of 2008. This would allow for the com- ding objective of meeting 20 % of Europe’s
Montage: Weserkraftwerk GmbH
missioning of the power plant to take place at energy consumption with renewables by
the end of 2009. 2020. Now, the renewables industry and its
associations are eagerly waiting for this target
Weserkraftwerk Bremen GmbH manages the to be substantiated after the summer break.
power plant project and its realisation. It is a
View of the hydropower plant near Bremen
joint venture of Bremen-based TANDEM GmbH Fierce debates about how to implement this
and Hamburg-based Planet energy GmbH, target in member states supported by an EU
ENERCON will supply turbines for the hydro- subsidiary of GREENPEACE energy eG, a pro- guideline are already going on in Brussels.
power plant that is currently being planned at vider of green energy. One option being discussed is equal distribu-
the weir on the river Weser near Bremen. Ger- tion of expansion commitments to all member
many’s leading manufacturer of wind turbines states – meaning that each country would ha-
and Weserkraftwerk Bremen GmbH, manager Construction work underway at ve to build up their share of renewable energy
of the hydropower project, have signed the Czech Republic’s largest wind farm by the same percentage. Some EU states
relevant contracts in June. though are hoping to be able to buy themsel-
ves out of part of their obligation by purcha-
ENERCON will deliver two Kaplan turbines sing negotiable certificates.
with 5 megawatts maximum power each.
They allow for an average annual yield of The main goal of Germany’s renewables indu-
42 million kilowatt-hours, about 10 percent stry is to maintain fair power purchase prices
more than previous turbine concepts had en- for electricity from renewable sources – simi-
visaged. “Beside the very good power yield, lar to those found in the German EEG (Rene-
ENERCON’s concept has convinced us by fur- wable Energies Act). Brussels is currently
ther improving fish life protection”, says contemplating introducing a quota model,
Hucky Heck, Managing Director of Weserkraft- which however has already proven to be an
werk Bremen GmbH, about the new contract. Earth works at Kryštofovy Hamry. inefficient means of promoting renewable
The turbines will run at a much lower speed energy in several European countries. A fur-
than foreseen in previous designs. In spring, construction work for the Czech ther discussion topic is the question of Europe-
Republic’s largest wind farm to date began wide harmonisation of funding instruments.
The gearless design of ENERCON’s wind ener- near Kryštofovy Hamry along the German- Here, however, it is doubtful whether standar-
gy converters has also been applied to the Czech border in the Ore Mountains (Erzgebir- disation would lead to any type of power
water turbines. The speed variability increases ge). Once completed, this windy site at over purchase price or funding instrument.
yield compared to a turbine with rigid coup- 600 metres altitude will contain a total of
ling, as tidal differences in the fall of water at twenty-one E-82/2 MW turbines. “We have fi- In September, representatives of the German
the weir can be exploited more efficiently. nished foundations and are now starting in- associations along with interested parties
“This project marks the beginning: ENERCON stallation work”, reports project manager from member firms will be meeting with ex-
is becoming serious about hydropower”, an- Jens-Uwe Stähr from ENERCON GmbH in perts from Brussels for a one-day workshop to
nounces company founder Aloys Wobben. Magdeburg. All turbines of the farm are instal- map out an effective strategy of maintaining
“We’ve spent a lot of time and effort finding led with 78 metres steel towers, five of them support of renewables also in the European
ways to transfer our experience with wind have already been erected. EAB Projekt- arena. The working group “Europe” of the BEE
energy to hydropower. The Weser hydropower entwicklungs GmbH in Freiberg are in charge (German Renewable Energy Federation) will
plant will be our proof of concept.” of this development. A 50 MW transmission be correlating the particular concerns of the
substation will be transforming the electricity renewable energies industry and taking them
The principle of hydropower turbines with va- produced so that is can be fed in at the 110 kV to the European level. The group actively
riable speed can be applied to all machine si- level. Several other projects with ENERCON works with representatives from trade asso-
NEWS WINDBLATT 03 | 2007 5
ciations but also coordinates individual pro- however, the overall German market is under- strong domestic market it is unlikely that a
jects with the companies involved. ENERCON, going a slump. One fourth less wind power high global market share be sustained. In or-
amongst others, is consulted on issues con- was installed in first term 2007 than in the sa- der to maintain its technological edge and
cerning wind energy. me period of the previous year: 347 turbines hold a strong position on the international sta-
with a total capacity of 665 MW. ge, Germany must ensure that its onshore
market remains viable.
ENERCON consolidates German This dramatic decline is ascribed to increa-
market leadership singly confining framework conditions for
German wind turbine Energy Summit emphasises national
Fuhrländer Gamesa operators. The trend of climate protection goals
Nordex 2,1% others
2,6% restrictive planning and Speaking to participants at the most recent
4,8% 0,4%
Siemens Wind Power generalised height limi- national energy summit, German Chancellor
5,9%
tations is gradually Angela Merkel emphasised that Germany will
REpower Systems narrowing down the hold on to its climate protection goals. She al-
9,0%
feasibility of many pro- so announced a new climate protection con-
jects – one of the rea- cept and rejected demands for abandoning
ENERCON
sons why the installed the nuclear power phase-out in Germany.
Vestas 56,5 % capacity has decreased
18,7% and repowering so far Aloys Wobben, Managing Director of
only represents 10 % of ENERCON GmbH, is pleased with the result of
the domestic market. the summit: “Climate protection goals do not
On top of this, turbine impede economic growth; rather, they provide
manufacturers have al- an important impetus to the continued deve-
so been obliged to raise lopment of climate-friendly technologies.”
German wind energy market, first half year 2007
their prices to compen- Germany only stands to benefit from fulfilling
sate for major increa- its international obligations – increasing ener-
In the first six months of 2007, ENERCON fur- ses in the price of raw materials. In view of gy efficiency and more energy from renewable
ther consolidated its lead in the German wind upcoming amendments to the Renewable En- resources. At the same time, Wobben empha-
energy market. The rise to 56.5 % of the mar- ergies Act (EEG), the industry is hoping that sises that Germany does not need to prolong
ket share represents a substantial growth power purchase prices will be adjusted to the life of its nuclear power plants – regenera-
compared to 31.1 % in the same period last meet current market conditions so that the tive energies can make up for the shutdowns
year. In the first term alone, 36 % more changeover to a more sustainable energy sup- and render the creation of new large-scale po-
ENERCON wind turbines were erected in Ger- ply in Germany will continue to be promoted. wer plants unnecessary.
many than in 2006. Meanwhile, the capacity
of ENERCON’s worldwide installations has On a more positive note, wind energy is soa- “The proposed law for accelerating climate
reached 12,333 MW. On the downside, ring on the global scene: Germany’s EVA (eco- protection must create a reliable framework.
nomic value added) of all We expect to see a continuation of the
wind turbines and compo- successful Renewable Energy Act. In addition,
REpower Gamesa
Fuhrländer nents produced worldwide we need a law for regenerative heating, and
Systems 3,5% 2,3%
Siemens Wind 2,2%
Power 5,0%
others shot up to 5.6 bn euros in innovative traffic ideas such as electric ve-
0,2%
Nordex 2006 compared to 4.0 bn hicles”, says Wobben. Appropriate laws are
5,7% euros in 2005 – a 40 % gro- needed to ensure that such innovative ideas
GE Energy wth. Exports rose from 71 % can prevail over the established mobility con-
8,9%
Vestas in 2005 to 74 % in 2006. cepts that are harmful to climate.
41,1% Taking installation, operati-
ons and service into ac- At the summit, ENERCON presented an elec-
count, the wind sector even tric drive Audi A4 with a lithium-ion battery.
attained 7.2 bn euros. Thus, Whereas a diesel-powered Audi consumes
ENERCON Germany’s wind industry approximately 8 litres of fuel on 100 km, the
31,1%
continues to remain the un- equivalent of 80 kWh, the electric version on-
disputed market leader. De- ly uses a quarter of the energy: 22 kWh are
German wind energy market, first half year 2006 spite this though, without a needed to travel 100 km.
6 WINDBLATT 03 | 2007 NEWS
1
1
1
4.0
4.0
4.0
4.0
4.0
4.1
6.0
5.0
5.0
5.0
5.0
5.0
5.1
6.0
6.0
6.0
6.0
6.1
7.0
alone, resulted in
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
pig iron, crude and rolled steel as well as iron alloy an increase of
RENEXPO 2007 hot wide strip for direct use, made of unalloyed steel
heavy plate made of unalloyed steel close to 36 % for
(Augsburg/Germany)
raw materials in
Trade fair and conference for Steel prices 2004 to 2007, 100 % = January 2004
renewable energies and energy generator and
efficient building and renovation choke production.
Wind turbine prices increase due to
27.09. – 30.09.2007 higher costs for raw materials
www.renexpo.de Compared to the raw materials market,
At the beginning of this year, ENERCON had to ENERCON has managed to keep the increase
take the price of its wind turbines up by four in the price of their wind turbines rather mo-
CanWEA 2007 to five percent compared to the previous year. derate. This is only possible because through
(Québec/Canada) This measure was taken in order to keep up wise purchasing strategies (e.g. for copper)
International conference and with current developments in prices for es- the company has been able to evade at least
exhibition of the Canadian Wind sential raw materials and increased expenses a portion of this cost inflation. Büker points out
Energy Association (CanWEA) for components from suppliers. Major cost dri- that no suppliers have been able to pass on
30.09. – 03.10.2007 vers in the wind energy sector are raw mate- the full amount of the rise in their costs for
ENERCON at stand 129/228 rials such as copper, steel, nickel and thus al- raw materials to ENERCON.
(Québec Convention Centre) so components such
135 %
www.canwea.ca as electroplates,
transformers and 125 %
005
006
005
06
006
004
05
006
004
I.20
I.20
I.20
II.2
IV.2
III.2
III.2
II.2
IV.2
IV.2
III.2
100 % security
2004.01 2004.07 2005.01 2005.07 2006.01 2006.07 2007.01 through long-
term con-
Copper prices 2004 to 2007, 100 % = January 2004 tracts.
TITLE STORY WINDBLATT 03 | 2007 7
Photos (4): Loading and transporting rotor blades ex Hanseatic harbour in Magdeburg.
to Portugal where they are expected at the the detour we can’t make the trip to Emden
Alto Minho site. in one night”, says Wilhelm.
Arcadia is situated at the heart of the Pelo- and approximately 20 kilometres away from “Tripolis is the first project we’ve realised
ponnese: a mountainous part of the penin- the region’s capital Tripolis is spread out for Arkadika Meltemia. And we’re now plan-
sula which in many myths dating back to over three mountain tops: “Agriokerassia” ning several other similar-sized projects to-
antiquity has been celebrated as paradise with 5 WECs, “Asprovouni” with 6 WECs and gether with the customer”, reports
on earth. This is a rocky region with barren “Ano Splitharia” with 9 WECs. This was a Stefanos Garyfalakis, Managing director of
mountains towering up to more than 1000 first for ENERCON Hellas: connecting ENERCON Hellas in Athens.
metres above sea level sometimes covered E-70/2 MW turbines to form a wind farm.
with a deep mantle of snow in winter. Con- The first excavations were started in spring
stant winds blow, speeds ranging between Two project companies belonging to the sa- 2006 and the final turbines were installed in
6.5 and 7 m/s. The Tripolis wind farm situa- me group – a Finland fund named PEMF – spring this year. Both projects were con-
ted at around 1000 metres above sea level collaborated in this project. The first, “Aeo- tracted with ENERCON as turn-key inclu-
INTERNATIONAL WINDBLATT 03 | 2007 11
ding foundations, crane, platforms, high The power purchase price on the mainland technicians, originally from Tripolis, are also
voltage/mid voltage substantions, overhead (including the Peloponnese peninsula) is scheduled to take over maintenance and
lines etc. The farms have been hooked up to 75.82 euros per MWh, on the islands it is service of other upcoming farms in the Pe-
the grid since May. Last winter’s favourable 87.42 euros. Every year, the government loponnese. Besides, ENERCON Hellas in
weather conditions (warm and no snow) fa- can adjust the purchase price relatively to planning other projects for the same custo-
cilitated the last installation phase. the electricity tariffs, or – at least – by 80 % mer in other regions. And in the year 2008,
of the Consumer Price Index. The power two dozens of E-70 turbines are planned to
Involvement of local firms purchase price is paid for ten plus ten years be installed for another customer.
“The road to the site in the mountains was under a power purchase agreement, signed
sometimes quite a challenge for our tractor- between investors and HTSO. 200 MW of new wind energy
trailers”, says Kostas Makris, project mana- capacity needed every year
ger at ENERCON in Greece. “We laid out an Upcoming farms in Greece More parks are expected to follow. The
intricate network of access roads to make Part of the Tripolis wind farm contract inclu- Greek government’s goal is to meet 20 per-
transport safer and more convenient. The ded a small 50 MVA transmission substati- cent of the electricity demand with renewa-
components were shipped to the harbour in on which transforms the current from all ble energy by the year 2010. Hydropower,
Lavrio where they were loaded onto trucks however, is expected
and then transported by night to the con- to take the lion’s sha-
struction site.” Local firms were also invol- re, though for wind
ved in shipping the parts which was very energy the sector
helpful and everything went smoothly right target is around 8 %.
from the beginning. “So far wind energy
is short of target”, re-
The execution of the works had a positive ports Garyfalakis. “If
influence on the acceptance of the wind we want to reach our
farm by people in the surrounding towns goal, we need to add
and villages. Makris: “Residents in Agrioke- at least 200 MW of
rassia think the wind farm will be extreme- wind energy per year.
ly beneficial for the region.” Amongst other I hope ENERCON will
benefits, a small share of the gross income get roughly one third
(3 %) from the sale of electricity will flow in- of the market share.”
to the community coffers. Another positive
aspect for the locals is the construction of The expansion of re-
access roads to mountainous regions which newable energies
before were inaccessible because there would be commen-
were no roads. dable for the Pelo-
ponnese as Mega-
Feed-in tariffs guaranteed for lopolis, a 800 MW
ten plus ten years lignite power plant, is
In Greece, wind farm construction is spon- situated only about
sored by European and local funds, under 40 km from Tripolis.
two main programs. Subsidy is 30 to 50 % Despite flue gas de-
of the investment costs for renewable ener- sulphurisation it is
gy projects. The amount of the subsidy de- still intensely pollu-
pends amongst other things on the job si- ting the environment.
tuation in the individual prefecture, where Access roads to the mountains were specially constructed for the project.
the project is located. Hellenic Transmission With the new wind
System Operator (HTSO) has to pay owners three wind farms to the high voltage level farm, the Arcadians can directly compare
of renewable energy power plants a fixed before it is fed into the grid. Turbine mainte- systems: Forecasts expect the power pro-
power purchase price. Guaranteed access nance and service will be carried out by a duction of the Tripolis turbines to be around
to the grid and priority on dispatch for rene- four-man ENERCON Service team stationed 100 GWh per year – which can supply
wable energies are other main provisions of in the farm. Meanwhile, this is the com- roughly 25,000 households with environ-
the legal framework. pany’s eighth service station in Greece. The ment-friendly electricity.
12 WINDBLATT 03 | 2007 TECHNOLOGY
Siempelkamp Foundry
Photo: Siempelkamp
for the E-126.
Construction workers are currently prepa-
ring the area for the foundation of a new Engineer pouring molten iron into a mould.
steel structure production hall on the Siem-
pelkamp Gießerei premises in Krefeld. Part strength, cast iron with spheroidal graphite The foundry has more than 450 permanent
of this area is being dug out by hand and the (also called spheroidal graphite cast iron) is employees as well as 50 to 60 temporary
remaining part of the foundation of the old especially suited for castings such as axel workers who are constantly in action. Most
brick building where they used to make the pins, blade adapters, stator stars, rotor hubs of these people are in production. Engineers
moulds is being torn out by heavy machi- and main carriers used in wind turbines. in the patternmaking division create a pat-
nery. “The new construction is for the moul- tern for the finished component out of wood
ding shop. Here we’ll be able to prepare a lot High-strength properties are achieved and plastic. One pattern can be used for up
more castings simultaneously than we could through the spheroidal structure which de- to 200 castings. The patterns are moulded
before”, says Stefan Mettler, Managing Di- velops the amount of carbon in the iron ca- in pits or big steel formwork. Resin bonded
rector at the Siempelkamp Foundry. sting. Cast iron has a higher percentage of sand is filled into the cavities and compac-
carbon (>2.06 %) than steel. In addition to ted. Once it has hardened, the casting en-
This increased capacity is Siempelkamp’s various alloying elements, the casters also gineers remove the pattern from the form
response to rising worldwide demand for add magnesium which has a spheroidising and place recess-forming elements where-
ductile iron (spheroidal graphite). “In 2006, effect. “High-strength material such as duc- ver recesses are required.
orders saw a 35 % increase compared to tile cast iron is used in constructions which
the previous year”, reports Michael Szuka- have to withstand extreme forces”, explains Then, the formwork is closed and the over
la, Managing Director at the firm’s holding Mettler who is a casting engineer. In the 1300° C molten iron is poured into it. After
company Siempelkamp GmhH & Co. KG. past, steel components were used for this the metal has cooled off they carefully take
Demand from the wind power industry as purpose. However, ductile iron offers a sig- the casting out and remove the sand with
well as the mills and machine tool manu- nificantly higher amount of security under sandblasters. The castings are disconnec-
facturing sectors is booming. Due to its high constantly high loads. ted from the feeders and gating system in
SUPPLIER WINDBLATT 03 | 2007 15
the “cleaning shop” and finally treated with and expanding the facili-
an anti-corrosive coating. ties.” Over the past five
years a total of 40 million
“This technique allows us to produce huge euros has been invested in
continuous seamless components”, reports updating casting technolo-
Mettler. “Our record was two arbours for a gy. New melting furnaces
14 metre long press cross beam which had were purchased and the
an unfinished casting weight of 260 tons.” cleaning shop enlarged.
Cast components of these dimensions are
especially in demand in the energy conver- The favourable develop-
sion, shipbuilding, mills and machine tool ment in the wind energy
manufacturing industries. This is how Siem- sector was a significant
pelkamp casts huge press components, factor in the decision to ex-
compressor casings for turbines, crank ca- pand. Casting technologies
sings for diesel ship engines and castor accounted for roughly five
containers as well as rotor hubs for wind percent of the company’s
turbines. 412 million euro turnover.
And again, one fifth of that
This long-established Krefeld enterprise will amount can be attributed
be celebrating its 125th anniversary next to wind energy. Compared
year. Siempelkamp started out with the ma- to the previous year, orders
Photo: Siempelkamp
nufacture of presses for processing silk from the wind industry
with pressure and heat. The foundry has went up 80 % in 2006 – a
been part of the firm since 1923. Initially stronger growth than in
Stefan Mettler, Managing Director of the foundry (left), and Michael
established to guarantee sufficient high other sectors. Judging by Szukala, Managing Director of Siempelkamp’s holding company.
quality cast parts for their own machines these figures the upward
and facilities, it later had more and more trend is expected to continue in 2007. its comprehensive and reliable quality ins-
business from customers outside the group. pection. The quality assurance division em-
After the Second World War, Siempelkamp ENERCON has been doing business with the ploys 30 people. A sample of the material is
realised that ductile graphite iron was a Siempelkamp foundry for seven years now. taken before each casting, its chemical pro-
good market niche. After the first order made in 2000, series perties are checked and its microstructure
production began the following year. “To- examined under a microscope as well as
“Today, the foundry is one of our main day, we provide castings for four to five with ultrasound. Its strength is tested with
growth divisions”, explains Managing Direc- E-70/E-82 turbines per week”, reports Szu- pounding devices: They test whether the
tor, Szukala. “This year alone, the foundry is kala. Currently Siempelkamp and ENERCON ductile iron withstands loads at extreme
investing 20 million euros in modernising are designing the main carrier, blade adap- subzero temperatures of -20 to -40° C.
ters and axel pin
for the E-126/ “Siempelkamp is a major supplier for our
6 MW. The first main series product the E-70/E-82 and of
patterns have al- course for our multi-megawatt turbines”,
ready been cast. says Oliver Smidt, purchaser for amongst
other things cast components at ENERCON’s
“In a business Aurich site. “The company has outstanding
partnership, it’s expertise when it comes to large dimen-
important that we sions and excellent experience in series
are always able to production.” Greatly appreciated is feed-
maintain constant back they give on the technical feasibility of
high-quality stan- ENERCON component designs. There are al-
dards”, says Mett- so similarities in company philosophy. Oliver
ler. One decisive Smidt: “Siempelkamp is not interested in
factor in Siempel- making a quick profit, but rather sees itself
Rotor hubs and main carriers ready for transport to finishing. kamp’s success is as a long-term reliable partner.”
WINDBLATT