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