3/4/2022 –

In January, WJI presented the 10 Stage 1 winners in the U.S. Department of Energy’s Conductivity-enhanced materials for Affordable, Breakthrough Leapfrog Electric applications (CABLE) conductor manufacturing initiative. Below, Francisco Flores, senior materials engineer, NanoAL, LLC, discusses the focus of his team’s winning entry. For more about the company, go to www.nanoalllc.com.

WJI: How did your team form?
Flores: NanoAL is a materials research and technology company that designs, develops, and commercializes high-performance aluminum alloys. The company was founded by two Northwestern University professors and a post-doc in 2013 after 17 years of research on advanced aluminum alloys.

WJI: What is your contest focus?
Flores: Our contest focus is designing and developing a new conductive aluminum alloy with specific strength equal to that of high-strength steel. This advanced aluminum alloy would potentially be a direct substitution for the typical high-strength steel used in applications carrying heavy loads. In the case of traditional steel-reinforced conductors for power transmission, this substitution would significantly boost the overall conductivity of the power lines.

WJI: How did the collaboration with the Prysmian Group help?
Flores: Through its subsidiary company, General Cable, Prysmian Group has been one of our long-term R&D partners. NanoAL and Prysmian Group have jointly developed multiple advanced aluminum alloys and conductors for overhead cable, automotive and industrial applications. The people we have worked with from Prysmian understand both the science and the applications, and have been a champion of research and innovation in the wire and cable industry. They have helped us define customer and application requirements for a new product, evaluate performances of lab-scale and prototype samples, and implement scale-up processes.

WJI: Where do you see your CNTs most benefiting wire and cable?
Flores: We see this technology playing an essential role in improving the efficiency of electrical energy transmission and distribution systems. Our ultra-high-strength, highly conductive aluminum alloy achieves a tensile strength of 500 MPa and electrical conductivity of approximately 48% of standard annealed copper. Its specific strength is higher than the traditional steel core, while its conductivity is nearly eight times greater than steel. The potential aluminum/steel substitution in a transmission cable’s core can significantly increase the conductor’s efficiency. As a result, it saves money and reduces carbon footprint by reducing energy loss from the power grids.

WJI: Can your process be commercialized on a large scale?
Flores: Our aluminum alloys and processes are highly scalable. However, since replacing steel with a high-strength aluminum alloy in a traditionally steel-enforced conductor is highly disruptive, we need to achieve several more product development and application milestones to achieve commercial success. This is why the CABLE competition is such a good opportunity for us to advance and mature this technology further toward commercialization.

Prysmian Group perspective
Aluminum is ideal for electricity transmission/distribution, but its inherent low emissivity retains heat, leading to energy losses and conductor sag. The U.S. has more than 450,000 miles of active overhead transmission lines, most over 50 years old. The Prysmian Group supports innovative materials to enhance transmission efficiency. NanoAL’s development through the CABLE prize has the potential to create a sustainable and high-performance solution for energy products. Dr. Sathish Ranganathan, North America R&D Director, Prysmian Group.

3/4/2022 –The Prysmian Group focus on speeding up innovation in the areas of ultra-rapid telecom networks and smarter, more sustainable power grids has been bolstered by financial support from the European Investment Bank (EIB), which has previously made available such funds.

A press release said that the EIB has finalized financing of €135 million intended to support the Group’s 2021-2024 R&D plans in Europe. That support is greatly appreciated as it will help the Prysmian Group’s R&D efforts. “Cable technology is a key enabler to face the challenges of digitalisation and energy transition,” said Srini Siripurapu, Chief R&D and Innovation
Officer Prysmian Group. The specific areas where the EIB support will make a difference include the following.

• Industrial research: research on innovative materials also involving the use of nanotechnologies, systems for the monitoring and management of land and submarine power grids and of low voltage power systems, new cables and materials for more sustainable solutions and hybrid energy and telecom cables.
• Innovation and experimentation: the use of alternative materials for cable design and product project optimisation, use of breakthrough technologies to execute cable jointing operations.
• New products development: submarine power transmission cable systems for installation at high depths; P-Laser Extra High Voltage land and submarine power transmission cable systems; dynamic cables for the offshore renewable energies sector; cable solutions for the e-mobility industry; high-performance optical fibres, cables for FTTH and FTTA applications, and connectivity; development of smart cable systems and sensing solutions for fault location, monitoring and management of power grids.
• Digital transformation and sustainability: development of machine learning and artificial intelligence solutions for enhanced quality in cable manufacturing process, and implementation of digital solutions for the management of operations from remote also through the use of IoT Industry 4.0 technologies and deployment of innovation data management software for a better on-going project portfolio management; development of data models for the continuous evaluation of sustainability impact of a Green IT Strategy and for the assessment of the sustainability of the product portfolio.

The new projects fulfill the goals set within Prysmian Group’s innovation roadmap and strategy, strongly oriented towards the support and promotion of digitalization and the energy transition.

Cable technology is a key enabler for electrical power transmission and distribution and for the development of telecommunications in Europe. Innovative solutions in these areas are a critical component to promote digitalization and the energy transition, thanks also to the expansion of 5G networks and the surge in renewable power installations, that could be interconnected via sustainable and innovative cable links.

The financing represents approximately 50% of the investments planned in Europe during the period concerned. Worldwide, Prysmian Group allocates approximately €100 million per year to R&D. This financing follows those already granted by the EIB to the Group in 2013 and in 2017, also in support of R&D in Europe, a sign of the trust that the company enjoys with the Bank.

“The agreement signed with Prysmian aims at developing technological innovations via cable based on sustainability criteria in order to reduce the consumption of raw materials, the generation of waste and CO2 emission,” said EIB Vice President Gelsomina Vigliotti. “Supporting the cabling sector helps to strengthen economic, social and territorial cohesion and to promote the energy and digital transition in Europe.”

3/4/2022 – Metals producer Ege Çelìk Endüstrisi Sanayi ve Ticaret A.Ş. has contracted with Primetals Technologies for upgrades to its wire rod mill in İzmir, Turkey.

A press release said that the addition of a new wire rod outlet will enable the company to expand its value-added product range for markets in Turkey and Europe, with greater capability for surface finish quality and dimensional tolerance in its wire rod products. Thermomechanical rolling will improve drawability while reducing overall heat treatment costs. Commissioning for the new wire rod outlet is expected in summer 2023.

The new mill will be capable of rolling rods with a diameter of 5.5 to 26 mm at speeds up to 134 tons per hour, or 120 tons per hour with thermomechanical rolling, using both 130 mm and 160 mm square billets. Ege Çelìk operations will produce low, medium and high carbon steels, along with cold heading quality, and welding wire grades for the automotive and other industries that are seeking higher-quality products.

The scope of supply for the contract includes upgrading an existing roughing/intermediate mill with new drives and automation, two roughing mill stands (1H +2V), and a new wire rod outlet with several Morgan products, including an individually driven eDrive 8-stand Vee No-Twist Mill, new inline cooling with an Enhanced Temperature Control System (ETCS), an on/offline reducing/sizing mill, intelligent pinch roll, high speed laying head, and 10½-zone Stelmor conveyor. Coil forming and handling will be accomplished through a vertical/horizontal conveyor system and compactor. A level 2 Process Expert automation package provides reliable material tracking functionality and leads to key performance indicator improvement.

Founded in 1986 with headquarters in Istanbul, Ege Çelìk began steel production in 2001. Ege Çelìk is the leading producer of quality steel wire rod in Turkey and supplies to local and worldwide steel customers.

3/4/2022 – Germany’s Schlatter Group announced that it has acquired a majority stake (51%) in Sokol Engineering Srl, a European manufacturer of wire processing equipment.

A press release said that Sokol Engineering, based in Tavagnacco (Udine), Italy, develops and builds a comprehensive range of wire production equipment. That includes cold rolling, wire drawing and stretching lines that generate net sales of €3 million a year.

With this deal, “Schlatter is strengthening its strategic position in wire production plants and taking a further step towards becoming a comprehensive solution provider in the wire industry.” Schlatter is known for its resistance welding technology and weaving machines for specialized purposes.

Sokol Engineering will continue and expand its existing activities under the name Schlatter Italia Srl. Company founder Sokol Haxhiaj, who has many years of experience, will continue to support the Schlatter Group as managing director and a shareholder. Schlatter’s customers will benefit from the takeover with expanded system expertise and a comprehensive partner across the entire value chain

3/4/2022 – JDR Cable has been awarded a government grant for £1,606,711 for Accelerated development of Higher-voltage Export & Array cables for Dynamic applications (AHEAD).

A press release said that the Department for Business, Energy & Industrial Strategy issued a total of £31,600,000 in 11 grants related to innovative floating offshore windfarm technologies. The application from JDR Cable was related to array cable. Its entry noted that no dynamic cable rated above 66 kV has ever been deployed in an offshore wind environment, and that due to increased turbine sizes, distances from shore, and water depths, the industry would benefit from having significantly higher voltage dynamic cables.

The grant was issued to help JDR Cable achieve these goals: demonstration of innovative polymer insulation systems to be capable of operation above 66 kV and to 132 kV, potentially as a wet-design; extension of dynamic array cable construction to larger and heavily dynamic export cables at 132 kV; advanced dynamic cable modelling to engineer cable configurations with higher loadings or stiffer cabling; and integration of next generation optical fibre strain sensing technology into dynamic high-voltage export and array cables to improve offshore cable monitoring and maintenance.

The new cables will be developed at JDR’s Hartlepool facility and tested at ORE Catapult at Blyth. The project is also well aligned to the government-supported new JDR HV Cable Facility in Cambois, Northumberland, where project construction is planned for this summer.

3/4/2022 – The Prysmian Group has signed a new framework agreement with Réseau de Transport d’Electricité (RTE), France’s Transmission System Operator, confirming its role as major partner of the French TSO in its plan of upgrading and developing national power girds.

A press release said that the Prysmian Group, which has been awarded with the largest share of the agreement, will be responsible for supplying, jointing and testing some High Voltage Alternating Current (HVAC) cable systems for underground grid connections from 90 kV up to 400 kV. The framework agreement will cover the period 2021-2023, with two potential optional additional years. To support the upgrade of France’s power grids, Prysmian Group will leverage its French centers of manufacturing excellence, located in Gron and Montereau.

These plants employ more than 1,400 people and are renowned for the production of high-voltage cables and P-Laser technology.
This framework agreement confirms Prysmian Group’s primary role in supplying RTE with HV cable systems, consolidates their long-term and successful relationship, and highlights once again RTE’s trust in Prysmian.

“We are proud to have the opportunity to play a key role in the upgrade of such a strategic infrastructure for our country, by making available our Made-in-France cable technology,” said Laurent Tardif, CEO of Prysmian Group South Europe Region. “Based on our long-term partnership, over the last years Prysmian has already provided RTE with innovative, efficient and sustainable power transmission cable solutions, both submarine and terrestrial,” concluded Tardif.

Prysmian Group’s projects include: Fécamp, Courseulles-sur-Mer, St. Nazaire and Noirmoutier offshore wind farms; the IFA2 submarine interconnection linking the UK and France; the Piedmont-Savoy HVDC underground interconnection between Italy and France; and the INELFE underground interconnection (Baixas – Santa Looggia), the first extruded 320 kV DC XLPE underground interconnection linking Spain and France.

3/4/2022 – Greece’s Hellenic Cables recently reported two contracts, both related to Dogger Bank (A, B and C), the world’s largest offshore wind project, which is located in the North Sea, between 125 and 290 km off the east coast of Yorkshire.

Per Wikipedia, since 2017, Dogger Bank Wind Farm Ltd. has developed what is known as Dogger Bank A, B and C, while a fourth wind farm has been developed by Sofia Offshore Wind Farm Ltd. as Sofia Offshore Wind Farm.

A press release said that Hellenic Cables has been awarded the Dogger Bank C array cable contract by DEME Offshore, the renewables business unit of DEME Group. Already the designated supplier for Dogger Bank A and B, with this contract Hellenic Cables becomes the sole inter array cables’ supplier for the massive project.

Under the new contract, Hellenic Cables will supply some 240 km of 66 kV XLPE-insulated inter-array cables and associated accessories. This is in addition to 650 km of array cables already awarded for phases A & B. The cables will be produced at the company’s plant in Corinth, Greece. Production of the cables for Dogger Bank C is set to begin in 2023 and delivery will be a phased roll out in line with the project execution program.

“We’re proud to be the exclusive array cables supplier for the world’s largest offshore wind farm, which provides the U.K.’s largest single source of renewable energy,” said Alexis Alexiou, CEO of Cenergy Holdings and Hellenic Cables.

The second project, for the Sofia Offshore Wind Farm, is for RWE, a German energy firm that contracted Van Oord Offshore Wind UK to provide the engineering. The project calls for Hellenic Cables to supply some 360 km of 66 kV inter-array cables and accessories to the Sofia offshore wind farm. The company will also make the cables at its Corinth plant. Cable production is set to begin in 2022 and be completed in 2023. The cables will be installed by Van Oord’s cable-laying vessel, Nexus.

The 1.4 GW Sofia offshore wind farm is located 195 km from the nearest point on the U.K.’s North East coast on a site of 593 sq km. “Building on the expertise and know-how demonstrated in previous projects, such as the Hollandse Kust (South) project, our goal is to successfully implement this project as well. Together with our investment in the next-generation custom-built green cable-laying vessel Calypso, this highlights Van Oord’s drive to continuously reinforce its market position,” said Arnoud Kuis, managing director at Van Oord offshore wind.

The Dogger Bank is an attractive location for offshore wind farms because it is far away from shore, avoiding complaints about the sight of wind turbines, yet at a water depth shallow enough for traditional fixed foundation wind turbine designs to be deployed. Fixed-foundation wind turbines are economically limited to maximum water depths of 40 to 50 meters, whereas greater water depths require new floating wind turbine designs that cost significantly more to build. All four farms have a delivery date between 2023 and 2025.

3/4/2022 – NKT has entered into an agreement to acquire U.K.-based Ventcroft Ltd. to bolster its position in the European power cable market by adding the company’s fire-resistant cable technology to the portfolio.

A press release said that the acquisition was an important step in the NKT strategy to grow the business with a strong product portfolio including fire-resistant power cables, telecom power cables and building wires. It noted that there is a growing focus on such products in the construction industry. “We are pleased to welcome Ventcroft to NKT and add their leading technology to our portfolio and expect them to benefit from our broad reach across the European market as part of our growth journey,” said NKT Executive Vice President and Head of Applications Will Hendrikx.

“We are looking forward to starting a new chapter with NKT and the acquisition brings some interesting possibilities to create future growth for Ventcroft,” said Ventcroft owner and Chairman Frank Rotheram. At the website of the family owned business, located south of Liverpool, Ventcroft notes that it is the U.K.’s largest independent manufacturer of fire and security products. The company, founded in 1989 and based in Runcorn, Cheshire, supplies cable and electronic products to a global client base in more than 50 countries.

3/4/2022 – Alcatel Submarine Networks (ASN), part of Nokia, has signed a contract to be the supplier for a Mediterranean project that will require 8,700 km of submarine cables.

A press release said that the order is from AFR-IX telecom, a Spanish infrastructure and telecom operator. Dubbed the Medusa, the cable will connect the two shores of the Mediterranean. It will interconnect nine countries of the Mediterranean Sea through landing points in Portugal, Morocco, Spain, Algeria, France, Tunisia, Italy, Greece and Egypt.
The submarine cable is expected to be operational between late 2024 for its West part and the beginning of 2025 for its East part, with segments accommodating up to 24 fiber pairs with a capacity of 20 Tbit/s per fiber pair.

Per multiple media reports, citing a statement from AFE-IC CEO Albi Norman, “There is a combination of factors that lead us to invest in this cable: in addition to the fact that there are some submarine cables in the Mediterranean that are reaching the end of their life cycle (and that need alternatives), it is known that the telecommunications traffic generated in Africa has grown at an average of 55% per year.”

Per submarinenetworks.com, the AFR-IX telecom is part of a public-private consortium that also includes the University of Alcalá, the Institute of Marine Sciences (ICM-CSIC) and Aragón Photonics. The Medusa cable, which follows the open cable standard, is estimated to cost €326 million.

Greenblatt said he wants to aggressively grow the Madsen workforce— now about three dozen employees—by about 20%, to keep up with new business. “We’re planning to get Madsen to 45 or so in the next couple of weeks. We just want smart people who want to be part of a growing company.”