The Mohammed bin Rashid Al Maktoum Solar Park in Dubai (UAE) is the world's largest single-site renewable-energy project. The latest section of the Park to come onstream uses structural steels protected with Magnelis®, ArcelorMittal’s innovative breakthrough in corrosion protection. Thanks to its unique composition, Magnelis® will provide the solar structure with an unprecedented level of surface and cut-edge protection, even in this hostile desert environment.

The structural elements of the Solar Park are being supplied by PV Hardware (PVH), a leading provider of innovative solar solutions for the utility-scale solar market. The company initially began supplying Phase 2 of the Solar Park with batch galvanised steel, but quickly switched to Magnelis® when they became aware of the product: “We were impressed by ArcelorMittal’s guarantees on corrosion and abrasion – two issues that are critical for this project,” notes Emilio José García, Director of PVH. “We have noted a remarkable difference in the performance of Magnelis® compared to batch galvanised steel and have increased our production capacity considerably as a result.

Process step eliminated

Magnelis® also simplifies processing says Emilio José García: “It is easier than post-galvanised hot rolled coil because we eliminate the post-galvanisation step of the production processes. Magnelis® enables us to offer a higher quality product and improve our final guarantee.”

Due to the harsh effects of sand and the desert climate, PVH specified steel with a Magnelis® coating weight of 310 grams per square metre. This was almost half the coating weight of the batch galvanised material for a better level of protection.

Self-healing effect, a key advantage

A key advantage of Magnelis^® is its ability to self-heal. When exposed to the environment, Magnelis^® forms a very dense zinc-based protective film. This unique dense film also forms on edges, welds, perforations, and scratches. Even deformed zones will be protected. It is almost impossible for the environment to penetrate the film.

The Magnelis® coated coils were produced at ArcelorMittal Bremen (Germany) and on the new production line at ArcelorMittal Avilés (Spain). They were then shipped to Forfle, a Spanish company which specialises in the transformation of flat steel products. “The coils, typically in widths of 1,200 mm and thicknesses ranging from 1.5 to 5.0 mm, were slit by Forfle before being sent to PVH,” explains Mario Gallardo, Quality Manager at Forfle. At PVH, the slit Magnelis® coils were profiled to create the different parts of the solar support structure.

When all phases are complete in 2030, the Mohammed bin Rashid Al Maktoum Solar Park will supply up to 5,000 megawatts (MW) of energy and contribute significantly to Dubai’s goal of generating a quarter of its energy needs from renewable sources by that time. The Park is being built in a number of phases. Phase 2 began producing energy in April 2017, with the first part of phase 3 due to come onstream by April 2018. Together, phase 2 and the first part of phase 3 will add a total of 400 MW to the Park’s capacity, with another 600 MW scheduled to come onstream by 2020.

About PVH

PV Hardware (PVH) provides innovative solar tracking solutions for solar installations around the world. PVH product lines are designed and engineered by leading industry professionals to deliver the lowest total cost of installation. The company provides unparalleled customer service and support during all phases of the project including assembly. Based in Valencia (Spain), PVH has offices and projects across the globe.

More info: http://pvhardware.com/

About Forfle

Based in Sagunto, Spain, Forfle undertakes a range of operations on flat steel products such as slitting and cutting to length. Forfle also advise their customers on the characteristics of different steels and coatings, and the benefits they offer.

More info: http://www.forflesa.com/

Text: ArcelorMittal Europe - Flat Products
Photos: zhangyang13576997233, Kandinskiy Dmitriy / Shutterstock.com, PVH

Innovative system reduces carbon footprint, installation time, and costs

A new steel mounting system developed by Hanwha Q CELLS has won a 2017 Intersolar innovation award. The revolutionary design replaces traditional aluminium frames which support the photovoltaic (PV) modules on a solar mounting rack. By utilising ArcelorMittal Europe – Flat Products’ breakthrough Magnelis® coating, Hanwha Q CELLS have significantly reduced the carbon footprint and cost of PV installations.

Known as the Q.PEAK RSF L-G4 (the RSF stands for Reinforced Steel Framing), the new framing solution was recognised by the Intersolar judging panel for its: “…combination of innovative design with a strong focus on product sustainability.” Hanwha Q CELLS estimate that the RSF frame will reduce the module’s carbon footprint by around 15 percent compared to the traditional aluminium frames in use today.

By utilising Magnelis® coated steel, Hanwha Q CELLS have ensured the long-term performance of the frame. As well as offering corrosion resistance on the surface, Magnelis® protects deformed zones, edges, and perforations thanks to its self-healing effect. It is also highly resistant to abrasion – a key factor in the sandy desert environments where solar energy is plentiful.

The development of the RSF frame took almost a year of research and prototyping. During this phase, ArcelorMittal R&D provided Hanwha Q CELLS with technical advice and support regarding the long-term performance of Magnelis®.

One of the key advantages of the new Hanwha Q CELLS frame is its ease of installation. Hanwha Q CELLS has demonstrated that labour and material costs can be reduced significantly thanks to the innovative design and use of Magnelis®. As the Intersolar jury noted, “With these innovations, the cost of installation, and of the entire system, is minimised.”

Text: ArcelorMittal Europe - Flat Products
Pictures: courtesy Hanwha Q CELLS