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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - NOVUM (Pilot line based on novel manufacturing technologies for cellulose-based electrical insulation components)

Teaser

Summary

Electrical insulation components, which are used in oil-cooled power distribution transformers, represent a big market globally. Cellulose is a common raw material for these components due to its excellent properties for the end-use. However, when using cellulose sheets as the raw material, the manufacturing process is complex, consists of multiple stages, takes a long time, consumes a lot of energy, is labour-intensive and results in significant material waste. In addition, each transformer unit has usually a very specific and individual design and consequently, for each insulation component geometry an individual metal mould has to be fabricated in a time consuming process. Thus, there is a clear need to improve the manufacturing process of electrical insulation components using cellulose as the raw material, in terms of energy consumption, waste generation, duration and automation. In addition, it would be beneficial if the dependency of the process on moulds, especially metal moulds, could be reduced.
In the increasing global competition, there is a growing need to develop more efficient and agile manufacturing processes and thus to fortify the competitiveness of the European electrical insulation manufacturing industry. In addition, increasing sustainability demands require the industry to take a closer look on the raw material sourcing, including the circular economy considerations, energy and resource consumption which are linked to greenhouse gas (GHG) emissions, global warming and end-of-life of products with emphasis on recycling and re-use. With the development of the manufacturing concept for electrical insulation components, the NOVUM project targets at 40% reduced labour time, 20% increase in energy efficiency, 60 % decreased waste generation and 40% lower operating costs compared to the state-of-the art technology.
The main objectives of NOVUM are firstly to develop and demonstrate a compact and feasible pilot line concept based on novel processing technologies for rapid, design driven production of advanced cellulose-based electrical insulation components and secondly, to manufacture two different types of electrical insulation components meeting the technical product requirements in the new pilot line constructed in the project.

Work performed

WP1 started by sceering of potential raw materials for the selected technologies. Materials were obtained from the project partners and acquired from commercial sources. Material properties were collected and shared with the partners to be tested in WP2. A list of prohibited and restricted substances for insulation materials was collected. Further material development was performed for the cellulose fibers used in thermoforming and cellulose-based materials for 3D printing. The task on Circular Economy Considerations was initiated by collecting material data and calculating baseline for the current manufacturing process and currently used materials.
In WP2, the main emphasis was to investigate the limiting factors and possibilities for each manufacturing method to be studied in NOVUM - 3D printing, foam forming and thermoforming. 3D printing tests have been performed with various cellulose-based materials obtained from WP1. The most promising 3D printing technologies for NOVUM were identified. In foam forming, the main focus was in 2D structures and all work was carried out in lab phase and potential for energy saving was observed. Regarding thermoforming, the construction of the framework for the test-rig to be used in the project was completed.
In WP3, technical requirement specifications for the test components were defined. Testing stands and procedures as well as the required equipment for materials characterization were identified. Identification of crucial parameters for selected insulation components has been initiated. The oil compatibility test has been identified as the first priority test and has been initiated and performed for several materials.
The work of WP4 Pilot line: Assembly has not started yet and is scheduled to start at M22 with the pilot line design.
In WP5, a base technical specification for the current manufacturing process has been prepared and will be later compared to the novel, developed manufacturing concept. The specific LCA and LCC methodologies for the environmental feasibility study and economic validation of the insulation component production with the technologies tested within the project has been defined, as well as the scope of the study, functional unit and system boundaries and an inventory template for data collection has been prepared and collection started.
In WP6, an in-depth market intelligence and competitive analysis report on the potential of the three NOVUM process technologies in the Electrical insulation industry was prepared as D6.1. The project website was established at M4. The project communication and dissemination plan (D6.6) as well as a marketing report on the visual identity of the communication tools (D6.10) were prepared. The methodology to be used for the development of the NOVUM exploitation plan of the project results was put together in D6.4 Exploitation plan. Additionally, the exploitation and business model tasks initiated with the identification of the NOVUM exploitable results in M9.
In WP7, day to day management practices of the NOVUM project were performed, including overall management, administration, coordination and execution of the project, consortium and project meetings. Contingency plan including quality assurance and risk assessment (D7.2) was created and the the project risks are being followed in monthly meetings between the project manager and work package leaders. Projectâ€™s electronic working space has been set up and Data Management Plan (D7.1) created.

Final results

Testing and further development of cellulose-based materials for the various process technologies, especially 3D printing has progressed, and several of the materials have also passed the first test for the end-user requirements, i.e. oil compatibility test. This has potential in generating new markets for cellulose-based materials and widen their use beyond the NOVUM application. In parallel, technology development has proceeded and potential for significant reduction in energy consumption has been observed, for example in foam forming there is a potential of 40% saving in thermal drying. The SMART tools concept is already an advancement on state-of-the-art technology available in the thermoforming industry. The progress in implementing and heating the flexible mould onto the test-rig will serve in showcasing the advancement within this technology.
The main outcome of the project is expected to be an automated and flexible pilot line for the production of cellulose based electrical insulation for power transformers resulting in increased energy efficiency, reduced material waste, reduced labor time and reduced operating costs. In addition, the objective is to find new applications for the materials and technologies developed in the project, beyond the electrical insulation components. To achieve these goals, development of cellulose-based materials needs to progress so that we have enough suitable materials for each of the technologies in the focus of NOVUM in order to demonstrate their feasibility. Knowledge on Circular Economy (CE) consideration will play a central role in the selection.