Elcowire Rail Presentation

Page 1


BU RAIL IMAGE PRESENTATION 2024

Elcowire Rail

Elcowire

Elcowire Rail

AGENDA

Sustainability, Conductivity, Product Life, System Availability Certifications

Liljedahl Group

“Participatory ownership combined with financial strength to give us the freedom to act.”

• Creating stable conditions for long-term profitable growth at each holding

• Focused on development, driven by the joy of finding new ways to make our business better and better

• A family company that wants to deserve our reputation by behaving responsibly and working in harmony with the surrounding community

• Taking an active role as a long-term owner by providing expertise and opportunities for continuous development of each holding

Welcome to Elcowire

“Together for the sustainable design of our future.”

We are a dynamic international Group with strong attention to our customers’ demands. We work directly with you, providing excellent customer support, the highest quality products, reliability, a focus on detail and a close-knit technical partnership.

Core Values of Elcowire and how do these apply to our work in the rail sector?

Elcowire’s values address how we view enterprises, undertake business development and structure our relationship with customers, suppliers, employees and our surroundings.

RESPONSIBILITY:

We build on and nurture long-term relationships and we act responsibly towards customers, co-workers, partners, our shareholders and the society.

TRUST: We are committed and dedicated to fulfilling our promises. We act in a trustworthy and reliable manner.

RESPECT: We listen to and show consideration for one another. We recognize differences between each other.

PASSION: Our customers’ success is our passion.

It is our priority to meet the needs and challenges of our customers.

As Europe’s leading supplier of copper products and services for overhead contact lines, we are committed to sustainable copper sourcing for a modern and eco-friendly infrastructure. We are developing and offering advanced technologies in close cooperationwith our customers, always according to their needs. We strive to enable new possibilities with electric mobility, clean energy and transportation infrastructure.

From cathodes …

• High-quality, Grade A Cathodes

• Supplied only from the most trusted sources, with our copper coming from the eco-friendliest mines and smelters in the world

• Part of a responsible supply chain, with sustainable transportation throughout the product journey

• Certified low CO2 footprint and high recycled material content

• Re-melted at end of lifecycle, producing new cathodes to close the loop

Low

Carbon Copper

LCC

Electrification of Mining Processes

Reduction of CO2 emissions through electrification of transportation and other means!

Historic Underground Mining

Drawing Die

Drums filled with our Copper Products ready for shipment

Elcowire

Elcowire Rail

AGENDA

Sustainability, Conductivity, Product Life, System Availability Certifications

Railway Networks Around The World

Last 5 years supply history: 50 countries

New Projects: FemahrnBelt, Rail Baltica

Extended Use of Existing Networks: Night Train Network

Stranded Conductors and Contact Wires for all modes of transport around the World …

GERMANY | SWEDEN | SWITZERLAND | AUSTRIA | NORWAY

SPAIN | FRANCE | BULGARIA | ROMANIA | TURKEY

GREECE | GREAT BRITAIN | DENMARK | MALAYSIA

INDONESIA | BOLIVIA | USA | CHINA | AUSTRALIA …

Serving the overhead contact line market

Catenary Wire, Feeder Wire, Stitch Wire

Dropper Wire

Contact Wire

Jumper Wire

Earthing Wire

Serving the overhead contact line market –Standards Portfolio

Catenary Wire, Feeder Wire, Stitch Wire

Dropper Wire

Contact Wire

Jumper Wire

Earthing Wire

Selected sales references from our portfolio

World’s longest railway tunnel (double tube each 57km length), operated up to 250km/h. Supplies include Contact Wire CuAg 120mm² (170km), Catenary Wire BzII 70mm² (170km), Conductors (Cu 850km, Al 100km).

Supply of 500km of 150mm² CuMg contact wire, designed for 350km/h. First line in Europe with automatic tensioning devices up to 31,5kNmechanical force. Deliveries 2001 –2003.

Network of 2.060km with 900.000 travelers per day. Overhead contact line system operated at DC 1.500V.

Route length 25km replacing busiest bus line in Helsinki.

Daily ridership increase from 40.000 to 91.000 by 2030 expected: >1,2km Dropper wire, >50km of Valthermo contact wire, >50km 70mm² Cu Catenary wire.

GOTTHARD BASE TUNNEL
MADRID-BARCELONA HIGH SPEED
SYDNEY & NEW SOUTH WALES
FINLAND RAIDE-JOKERI TRAM

3: 16 Bogies Horizontal Cross Section

ICE 3,BR 403+406 Power 8MW Train8 Wagons,201 mlength 16Bogies

ICE 3: DEUTSCHLANDS ERSTER ZUG FÜR TEMPO 300 (BAHN.DE)

Selected application references from our portfolio

HIGH SPEED >250KM/H

ROCB RIGID OVERHEAD CONDUCTOR BEAM

CATENARY + CONTACT WIRE

Ulm-Wendlingen (DE)

• Catenary BzII 120mm²

• Dropper BzII 10mm²

• Contact CuMg0.5 AC120mm²

Ceneri Base Tunnel (CH)

• Overhead Conductor Rail (Aluminium)

• Contact Valthermo AC107mm²

DVB Dresden (DE)

• Catenary 2 x 150mm²

• Dropper BzII 10mm²

• Contact Valthermo AC100mm²

Our support for all project phases: Delivery, Sustainability, Support and Expertise

Specification

Construction

Operation

Elcowire

Support

Contracting and Delivery of Goods

• Timely Delivery on-site including shipping notification (avis)

• Traceability of deliveries

• Delivery plan adjustment considering future hedging conditions

• Trusted and evaluated Freight Forwarders

• “Drum-Empty” web interface for drum recollection

• Storage of material upon request if necessary e. g. due to project delays

Sustainability Improvement

• Innovative Valthermo, Valcond, Valflex offering material properties beyond standard

• Low Carbon Copper (“LCC”) offering reduced CO2-Emissions in mining operations

• Certified CO2 footprint for all products manufactured by Elcowire

• Calculation of CO2 savings and energy savings based on application of above-mentioned innovative products

• Calculation of cost saving potential and LifeCycle-Cost comparing standard and innovative materials and processes

Support For Your Project

• Selection of suitable drum type and packaging

• Material selection and specification support considering design requirements (e. g. mechanical requirements, traffic density, ampacity, compatibility with components)

• Material Handling Training for Installation Teams

• Measurement Service “post installation” and “during operation” covering geometrical stability and wear

• Material investigation after adverse mechanical or electrical effects

We make it fit!

WE MAKE IT FIT!

Measurement and technical support

• Gauging of contact wire

• Measurement of remaining cross section

• Estimation of remaining life-time (contact wire)

• Creep measurement of contact and catenary wire

• Ampacity calculation reflecting customized environmental conditions

• Recommendations to select appropriate materials

Installation attendance for advice and measurement

• Specialist advice during installation regarding drawing forces, angles and radii, breaking forces, handling of material and drums

In-house training

• Product characteristics

• Product and material selection

• Production process of conductors

• Tests and test certificates content

• Installation and handling recommendations

• Pre-settings for installation of overhead contact lines

Elcowire

Elcowire Rail

AGENDA

Sustainability, Conductivity, Product Life, System Availability

The Paris Agreement

The Paris Agreement is a legally binding international treaty on climate change. It was adopted by 196 Parties at the UN Climate Change Conference (COP21) in Paris, France, on 12 December 2015. It entered into force on 4 November 2016.

Its overarching goal is to hold “the increase in the global average temperature to well below 2 °C above pre-industrial levels” and pursue efforts “to limit the temperature increase to 1.5 °C above pre-industrial levels.”

To limit global warming to 1.5 °C, greenhouse gas emissions must peak before 2025 at the latest and decline 43 % by 2030.

National Determined Contribution Plans

Contents aligned (July 2024) with: https://unfccc.int/process-and-meetings/the-paris-agreement https://www.climatewatchdata.org/

Achieve net zero GHG emissions early in first half century

Limit global warming to well below 2 °C preferably to 1.5 °C compared to pre-industrial level

United Nations Framework Convention on Climate Change / NDC Registry: https://unfccc.int/NDCREG

NDC:

The Elcowire Rail Way: Reducing Green House Gas Emissions

Mine, Smelter Producer

Mining, Crushing

Electrowinning or Electrolysis

LCC -Low Carbon Copper

• Primary LCC

• Secondary LCC (scrap)

Casting, Pressing, Drawing, Stranding

Contractor

Design, Installation, Testing, Setting into Operation

The Elcowire Rail Way

Valthermo Valcond Valflex Standard Products

Efficient Operations

Railway

Energize, Operate, Maintain

Efficient and Effective Installation Sustainable Public Transportation

Reduction

The Elcowire Rail Way to supply products made from LCC Cathodes

Supply of Cathodes

Elcowire Production Process Supply to Market

Standard Cathode < 3,2 LCC Cathode < 1,5

Wires/ Conform

Elcowire Self-Declarations acc. ISO 14021

Wires & Strands

Strands Trading Goods

Wires & Strands

Unitsof numbersshowninthispicture:

Example Trafikverket

(according specification dated 14.07.2023)

Other points to consider:

• Bonus: Trafikverket offers a financial bonus (increased price) if further reduction against the “Anforderungen” can be achieved (limited to -30%)

• EPD and verification thereof are requested (not “self declarations”)

Per capitagreenhousegas emissions, 2022 100 yearstimescale

Greenhouse gas emissions include carbon dioxide, methane and nitrous oxide from all sources, including land-use change.

They are measured in tonnesof carbon dioxideequivalents over a 100-year timescale.

Data source: Jones et al. (2024); Population based on various sources (2023).

OurWorldInData.org/co2-and-greenhouse-gasemissions | CC BY

Per country greenhouse gas emissions

Greenhouse gas emissions include carbon dioxide, methane and nitrous oxide from all sources, including land-use change.

They are measured in tonnesof carbon dioxideequivalents over a 100-year timescale.

Data source: Jones et al. (2024).

OurWorldInData.org/co2-and-greenhouse-gasemissions | CC BY

2018: Rail’s share in global CO2 emissions (8 bn tonnes) around 1% (80 Million tonnes).

Rail expected to stop fossil fuel consumption by 2050

Demanding Conductivity: Energy Flow in Public Transportation is on the rise …

Positive megatrend towards public transportation

Coupling of EMUs to larger units offering more transport capacity in peak hours

Dynamic Blocks (Digital Interlocking) more than 1 train per block

Operation Speed

Trend to higher operational speed of trains

Energy Recuperation causing internal energy flow in addition to feeding external energy

Tunnel Cross Sections

Small cross sections lead to increased air pressure especially in high-speed tunnels

Switch Heating Power supply in remote locations from OCL

Suggestions for Improvement

Sustainability Improvement

• Conductivity, Product Life-Time, System Availability

Contact Wires

• Consider replacement: Cu-ETP, CuAg -> Valthermo

• Consider replacement: CuSn0.2 -> Valcond

• to reduce wear, increase ampacity and lifetime

Catenary (Messenger) Wires

• Consider replacement: Cu-ETP -> Valthermo

• To increase ampacity and to reduce creep

Catenary (Messenger) Wires

• Consider replacement: Bz II (CuMg0,4) -> Valcond

• To increase conductivity from 62% to 76%

Dropper Wires

• Consider replacement: Cu-ETP, Bz II -> Valflex

• To increase product life and system availability

Low Carbon Copper

• Consider replacement: LCC-Cu-Cathodes

• To decrease Greenhouse-Gas-Emissions

LCC Copper

Innovative Materials in Sydney’s Public Transport

Annual savings of 10.000 AU$ per 10 route-km possible

Basic Assumptions

• 10 route-km (20 single-track-km)

• 16 hours per day operation

• Power Consumption 1.000 kW

• Voltage 1.500 VDC, Current 667 A

• Price of Energy: 0,25 AU$/kWh Effect

• Increase of Conductivity

• Reduction of Electric Loss

• Reduction of CO2eq. emissions per 10 route-km

-54.000 kWh per year

+ 10.000 AU$ per year

-XYZ emission of CO2eq.

Valthermo, Valcond: innovative materials to reduce energy consumption and CO2 emissions

Elcowire Rail Product Portfolio

Choose the best material for your application!

Leading in Performance

Leading in Conductivity, Wear Resistance, Performance and Life-Time:

Valthermo

• Contact and Catenary Wires for maximum conductivity, wear resistance, thermal performance

Valcond

• Contact and Catenary Wires for required high tensile strength combined with high conductivity

Valthermo Contact Wire with multiple times the service life

Measurements in commercial operation

Neuss

-Field Test and surveillance ongoing since

-Distance Cologne-Neuss ca. 55 km

-Regional traffic, 6 trains phpd

-Contact wire wear measured

Average Wear of Valthermo against Cu-ETP reduced by 55%

Increase reliability and availability of railway transportation systems!

9’2012 Measurement 10’2016

Valthermo Contact Wire with multiple times the service life

Measurements in commercial operation

Neuss

-Field Test and surveillance ongoing since

-Distance Cologne-Neuss ca. 55 km

-Regional traffic, 6 trains phpd

-Contact wire wear measured

Average Wear of Valthermo against CuAg reduced by 32%

Increase reliability and availability of railway transportation systems!

Installation 9’2012

Measurement 10’2016

Valthermo Contact Wire to reduce Creep and increase Ampacity

Relative Creep contact/catenary wire (mm/m)

Relative Creep measured between Contact and Catenary Wire

Period: 3 months

Tensioning: 10 kN

(Amp) at max permissible temperature (°C)

Increase productivity of train operations by allowing higher traffic density!

Valthermo allows 100 °C as max permanent operating temperature

Catenary Wires for all speeds and applications made of standard and innovative alloys

• Ampacity acc. EN 50119

• Cross Section 120 mm² (19x2,8)

• 80 °C max (Cu-ETP)

• 100 °C max (Bz II, Valthermo)

• Wind speed 1 m/s

• Sun radiation 1000 W/m²

Valthermo and Valcond catenary wires to increase traffic density!

Improved Valflex Dropper Wires contribute significantly to overhead contact line system RAMS

• Dropper Wire DIN 43138 10 mm² 49x0,5

• BzII processed using sophisticated manufacturing processes

• Resulting in improved fatigue behaviour withsignificant higher number of load cycles

• Connection area fitting accessories to wire requires special attention

Increased Reliability, Availability, Maintainability and Safety to ensure seamless operation!

Dropper Wire principal arrangement
Valflex Load Cycles
BzII Valflex based on BzII

Re 250: Valthermo approved for high speed OCL Valcondrecommended as Catenary Wire

Valthermo Contact Wire approved for Re 250 of DB Recommendation: Valcond as Catenary Wire

Catenary Wire 70 mm²

BzII

Recommended: Valcond

Dropper Wire 10 mm² BzII

Recommended: Valflex

Contact Wire 120 mm² CuAg0,1

Approved: Valthermo

• Ampacity acc. EN 50119

• Cross Section 120 mm² (19x2,8)

• 80 °C max temperature (Cu-ETP)

• Ambient temperature 35 °C + 10,4 %

• 100 °C max temperature (Bz II, Valthermo)

• Wind speed 1 m/s

• Sun radiation 1000 W/m²

Valcond as catenary wire provides 10,4 % higher ampacity and 18 % less electrical losses!

Re 330: Valcond Catenary + Contact Wire providing significant higher Ampacity for OCL system of DB

Valcond for Re 330 of DB

Catenary Wire 120 mm² Bz II

Recommended: Valcond

Recommendation: Valcond as Catenary Wire

Dropper Wire 10 mm² BzII

Recommended: Valflex

Valcond as catenary + contact wire provides 11 % higher ampacity and 16 % less electrical losses!

Road Truck Overhead Contact Line

60913 under development

Current System Configuration Recommended System Configuration

Catenary

2 X 120mm² BzII 19 x 2,8 (62 % IACS)

Dropper

2 X 10mm² BzII 49 x 0,5

Contact

2 X CuMg0,5 AC-150 (62 % IACS)

Current System Configuration (system test phase)

• Voltage 600 V DC

• Standard: IEC (1.200 V)

Catenary

Valcond 72 % IACS

Dropper Valflex

Contact

Valcond 72% IACS

System Configuration

• Voltage 1.500 V

• +750 V DC / -750 V DC

• System Standard EN50119/IEC 60913 underdevelopment

Reduction of Electric Loss Against “Current System Configuration” 16%

Transportation Systems benefitting from innovative materials and processes around Valthermo, Valcond, Valflex

Elcowire Contribution

Wear Resistance

Thermal Resistance

Fatigue Resistance

Material

Characteristics

Installation Characteristics

Other Contribution

Valthermo and Valcond Customers around the world

Canberra LRT

Elcowire

Elcowire Rail

AGENDA

Sustainability, Conductivity, Product Life, System Availability Certifications

Certified according to ISO 9001, 14001, 45001 and 50001

Certification passed for

• ISO 9001:2015 Quality Management Systems

• ISO 14001:2015 Environmental Management System

• ISO 45001:2018 Occupational Health and Safety Management System

• ISO 50001:2018 Energy Management Systems

Certifying Body

• TÜV Rheinland

Relevant Dates

• Surveillance Audit passed 17 July 2024

• Certificates valid from 25 July 2022

• Certificates valid until 24 July 2025

Certified as Q1 Supplier to Deutsche Bahn

Certifying Body

-Deutsche Bahn

Relevant Dates

-Certification issued 28 November 2023

-Validation of Certificate extended until 26 November 2024

New Certificate

-Will be issued by Deutsche Bahn

SPC Certificates ProRail, The Netherlands

Elcowire Rail GmbH has again passed the Surveillance Audit according to

• SPC00069, 00070 and 00071

• Contact Wire for Overhead Catenary Systems in accordance with SPC00069 version 003 dated 1-6-2004

• • Low-Alloy Copper Cables for Overhead Catenary Systems in accordance with SPC00070 version 003 dated 1-6-2004 and

• Non-Alloy Copper Cables for Overhead Catenary Systems in accordance with SPC00071 version 003 dated 1-6-2004

Date passed: 5 September 2023

Surveillance Audit: 22 August 2024

Certified according to Criteria for Securing Load (cable drums on trucks)

Certificate for Securing Load

• Safe transportation of cable drums on trucks

• Drums are being fixed on specific racks

• Friction coefficient between racks and truck increased

• Connection through lashing straps, edge protectors and positive locking

Validity

• 24 August 2024

Elcowire

Elcowire Rail

AGENDA

Sustainability, Conductivity, Product Life, System Availability Certifications

Useful information & links

Websites Elcowire

HOME -ELCOWIRE

RAIL -ELCOWIRE

Elcowire Rail Product Catalogue

ENG-PRODUCT CATALOGUE BY ELCOWIRE –ISSUU

Interview: Core Values of ourCompany

Interview with Jan Siebert, MD and Head of Business Unit Rail, Elcowire Rail (globalrailwayreview.com)

Questions & Answers: Why are Overhead Contact Line Systems necessary?

ELCOWIRE RAIL: LET US MAKE YOU READY FOR YOUR PROJECT WITH THE MOST SUSTAINABLE SOLUTION! (GLOBALRAILWAYREVIEW.COM)

Publications (pdf format)

Technical and scientificarticlesmaybeprovidedupon request

Jan Siebert

Dr.-Ing.

Managing Director Head of Business Unit Rail

Phone +49 (0)3476 8714 10 Mobile +49 (0)152 5873 4951 jan.siebert@elcowire.com

Elcowire Rail GmbH Lichtlöcherberg 40 D-06333 Hettstedt, Germany elcowire.com

Elcowire | LinkedIn

Elcowire Rail GmbH Registered office: Hettstedt Company Registration No.: HRB26635| Registration Court: Amtsgericht Stendal | VAT Reg. No:DE 322762 645| Board of Management: Dr. Jan Siebert, Paul Gustavsson

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