Project with the Annual Output of 50,000km New Cable Carbon Fiber Composite Core Materials

Project with the Annual Output of 50,000km New Cable Carbon Fiber Composite Core Materials of Jilin City

 

1 Introduction to the Project

1.1 Project Background

1.1.1 Product Introduction

Carbon fiber, called the most vital new material in the 21^st century, is the high strengthen fiber material with the carbon content of more than 90%. The carbon fiber composite core lead is a new-structure energy saving capacity increment lead. Compared with the conventional lead, it has a series of advantages such as low weight, big strength, good heat endurance, small heat expansion coefficient, small high temperature arc verticality, high electric conductivity, low line loss, big carrying capacity, good corrosion resistance and uneasy covering with ice, etc. It comprehensively resolves all the technical bottlenecks existing in the overhead power transmission field and represents the technical development trend of the future overhead lead. It is helpful to build the safe, environmental-protection, high-efficiency and saving power transmission network. It can be widely applied in the capacity increment and reconstruction of the old lines and power station bus bars and construction of the new lines and it can also be applied for the lines in the special climatic and geographic occasions with the big span, big fall, heavy ice area and high pollution, etc. When it is applied in the new lines, it can improve the unit transmission capacity of the lines and assure the strong, long-run and economic grids. When it is applied in the grid power transmission line reconstruction and capacity increment projects, it can make use of some current facilities such as poles and towers, etc. to greatly improve the transmission capacity by times and save the channel resources, reduce the land occupation area and save investment, with short power-off time and low power-off loss of the lines. When it is applied in the big-span line, it can greatly reduce the height of the cross-span tower so as to effective decrease the material use of poles, towers and foundations and achieve the purpose of reducing the cost of the project. When it is applied in the lines in the heavy ice zone, it can improve the anti-icing capacity and the safety of the lines. On the whole, it is an “environmental-friendly lead for the power transmission lines”. Viewed from some aspects such as environmental protection, energy saving and discharge reduction and improvement of human ecological environment, it is of epoch-making realistic importance.

1.1.2 Market Prospects

(1) International market

The new carbon fiber composite material core lead is a new-concept lead for the power transmission lines. Its successful research is the revolution of the overhead power transmission lead. In the new carbon fiber composite material core leads, the carbon fiber core-aluminum stranded conductor of Japan and the carbon fiber and glass fiber mixed core-aluminum stranded conductor of the US are the typical ones.

Japan is the country that has developed a lot of special lead varieties of overhead lines. In 1990s, Japanese scholars studied the replacing of steel core by carbon fiber core and developed a new composite material lead, that is, ACFR. Compared with the conventional steel core lead, such a new lead has the same external diameter and strength and the original insulator and metal can still be used and the construction tool can also be used. It can replace the lead when the iron tower is kept invariable, which will greatly reduce the cost. It is a new epoch-making lead with the low weight, small line expansion coefficient and good arc characteristic. 

The US CTC（Composite Technology Corporation） is a company successfully developing ACFR. In 2003, CTC developed ACCC（Aluminum Con-ductor Composite Core）. Its core wire is the single core rod made of the mixed carbon fiber and glass fiber and on its external layer and adjacent layer is the aluminum wire and it is the trapezoid section. The conventional type test has been completed for such a lead, which was applied in the network of a 3KM line of Texas in August, 2004 and it was accepted and qualified in February, 2005. According to the report of CTC, the company sold the 3,500km-long ACCC product in 2005. The statistics in the middle of 2008 show that the demand for the product in the market is more than 6 billion USD every year. It is predicted that the demand of the new cable for the carbon fiber composite materials will have been 12,000 tons and 15,000 tons by 2014 and 2018, respectively.

(2) Domestic market 

Our country is a country lacking power. The power transmission lines have not been able to endure the demand for rapid expansion of the transmission capacity. Because the power cutoff failures caused by the overload frequently occur, the power transmission has become the “bottleneck” of the development of the power industry. According to the insufficiency of the transmission capacity of some power transmission lines in the grid and difficult technical transformation of some old lines, in order to effectively make use of the current power transmission lines in the grid, our country has started to taken into account the application of the new ACCC so as to improve the transmission capacity of the grid.

ACCC is the ideal new product replacing the traditional steel core aluminum twisted lead, aluminum covered steel lead, aluminum alloy lead and imported invar lead in the power transmission and transformation system in the whole world at present. China is the second country developing and applying such a technology following the commercial application of the US in 2004. With the application of ACCC, the energy conservation, environmental protection and safety of power transmission have been realized.

During the 12^th Five-Year Plan, the State Grid, Southern Grid and West Inner Mongolia Grid have the annual demand for about 1 million km overhead lead. The planned lines mainly include the new high-voltage grid, new ultra-high-voltage grid, new special-high-voltage grid, reconstruction of the current grid of old cities, capacity expansion of the current grids, reconstruction of grids in the rural area and reconstruction of the coal grid, etc. It is predicted that the demand for the carbon fiber composite core lead for meeting the current grids will reach 0.4-0.5 million km every year. If the annual use will reach 0.2 million km at the end of the 12^th Five-Year Plan, 0.4-0.5 million tons of aluminum can be conserved every year, tens of thousands of land can be conserved, the power transmission loss will be reduced, thousands of millions of power will be conserved and the development of the domestic carbon fiber industry can be effectively promoted.   

1.1.3 Technical Analysis

(1) Technical source:

The project mainly takes the US technology to produce ACCCC and the technologies of ShandongUniversity and North China Electric Power Research Institute can also be taken, and Sinosteel Jilin Carbon Fiber Co., Ltd. has signed the technical cooperative agreement with ShandongUniversity.

(2) Technical and process analysis

The manufacturing technology of carbon fiber composite core aluminum twisted cable is mainly the continuous pultrude method. The core technology is the manufacturing of core rod and the key material is the high-temperature flexible epoxy resin. The tensile strength of the carbon fiber used is high and the breaking elongation is big and T700S is taken as core rod to provide flexibility and impact resistance performance; the glass fiber is the alkali-resistant E type (E-GF), E-GF is an insulator, providing insulation for the core rod. The epoxy resin used is the high-temperature flexible resin, its curing temperature reaches 260℃（500℉）, with the special heat resistance structure, and at the same time, flexibility should be strengthened and it should be modified to make the core rod made flexible.

Key technology of the pultrude process: The preparation process of carbon fiber composite cable core is the pultrude process. The composite material pultrude products have many advantages such as good mechanical property, corrosion resistance, stable dimensions, low thermal conductivity, good insulation performance and aging resistance, etc. It is the continuous pultrude process with the high automation in the current production of composite materials. The important process parameters of pultrude include the temperature, pressure, pultrude speed, traction force and resin curing reaction, etc. The working flow of pultrude is that the continuous carbon fiber is soaked in the resin matrix and pre-shaped under the pulling force of the traction machine, the heat is transmitted to the liquid resin/carbon fiber composite system via the heated die, the cross linking reaction is started and the resin is cured from the periphery of the composite material to the center. After the resin is cured, the volume shrinks, making the composite material separate from the die and it is finally rolled by the wire-rewinding machine via the flow of demolding, post-curing and cooling, etc.

The process flow is shown in the figure below.

Yarn		Dehumidification		Yarn setting		Soaking of glue		Pre-shaping
Rolling		Traction		Cooling		Post-cure		Heating and shaping

Description of the process flow: Put the carbon fiber cylinder on the processing bracket, clustered in the single way (0₀), covered with the glass fiber, soaked in the epoxy resin liquid cement, passes the steel die orifice so as to control the diameter and then cured and shaped via the curing furnace.  

(3) Material analysis

Main production materials of the carbon fiber composite core material lead: Because the carbon fiber composite material cable core requires the higher mechanical property, only the carbon fiber at the level of T700 and above can meet the requirement. The carbon fiber at the level of T700 needed by the project will be purchased to meet the supply. Some 12K carbon fiber such as TC12K36 series of Formosa Plastic Corporation, UT500 series of TOHO, HT series of TRH50 and TR50S of Mitsubishi and T700 series of Toray, etc. can meet the operating requirements. After the 1,500 tons carbon fiber production line of Sinosteel Jiangcheng Carbon Fiber Co., Ltd. is built, the carbon fiber produced will reach the level of T700, which can provide the local matching materials for the project. 50,000km carbon fiber composite core materials need 2,600 tons of carbon fiber and 1,200 tons of resin.

1.1.4 Advantageous Conditions of Project Construction

(1) Policy conditions

Jilin Carbon Fiber New and High-tech Industrial Base where the project is located is the only national carbon fiber new and high-tech industrial base determined by the Ministry of Science and Technology in January, 2010. Jilin Economic Development Zone is the core district of the carbon fiber industrial base. It exercises the current policy of the national economic and technological development zone and enjoys the special preferential policy of reviving the old industrial base of Northeast China, the foregoing and pilot policy of Changchun-Jilin-Tumen Opening and Development Guiding District and the preferential policy of accelerating the carbon fiber industry promotion measures of Jilin Municipal Government.

Tax policy: The local retained parts of the value added tax and enterprise income tax paid by the new project within 3 years should be subsidized to the enterprise as the support funds by the financial department of the city and the zone, respectively as of the day it is put into production.

Land policy: The land price is 150 yuan/m²; if the project is put into production in time, the retained parts of its land transfer fees by the city and the zone should be rewarded to the enterprise for the project construction in the total amount.

(2) Basic industrial conditions

The Carbon Fiber Industrial Park of the Economic Development Zone where the project is located has met the infrastructural conditions of “7 connections and 1 leveling” (that is, power supply, water supply, water drainage, heat supply, telecommunication, road, leveling of plant area), and the good external matching facilities has laid a solid foundation for the project construction.

By now, the park has introduced a number of carbon fiber development and production enterprises such as Jilin Carbon Valley Carbon Fiber Co., Ltd., Sinosteel Jiangcheng Carbon Fiber Co., Ltd., Jilin Jiyan High-tech Fiber Co., Ltd., Jilin Tenghua New Materials Co., Ltd. and Jilin Herun Chemical Co., Ltd., etc., with the current capacity of 5000 tons of precursor carbon fiber, 660 tons of polyacrylonitrile carbon fiber, 15 tons of viscose carbon fiber, 20000 carbon fiber bicycles, 50000m² carbon fiber electric heating film and 3200 tons of carbon fiber solvent and established complete carbon fiber industry chain with the matching upper-stream and lower-stream products. It is predicted that it will have established the capacity of 26000 tons of precursor carbon fiber, more than 5000 tons of carbon fiber, 3000 tons of carbon fiber composite materials and products, output value of more than 10 billion yuan and “Carbon Valley of China”, the largest carbon fiber and products production base of China by 2015.

(3) Material resource advantages

The chemical industry of JilinCity, with a long history, has established the complete production system including petrochemical engineering, synthetic materials, chemical fertilizer, refined chemical engineering and biochemical engineering, etc. with the development for decades of years and become one of the pillar industries of JilinCity. The city has gradually established some leading enterprises such as PetroChina Jilin Chemical Co., Ltd. (hereinafter referred to as Jilin Chemical Co., Ltd.), PetroChina Jilin Fuel Alcohol Co., Ltd. and Jilin Chemical Fiber Group, etc. With the industrial promotion of the leading enterprises, some major industrial chains of utilization of oil refined ethylene, lower-stream ethylene products, lower-stream propylene products, lower-stream arene products and ethylene by-products, chemical fertilizer, refined chemical engineering and biochemical engineering, etc. JilinCity is the national largest propylene production base at present, with the commodity quantity of 0.43 million tons/year, which can provide the sufficient materials for the carbon fiber production. In addition, depending on the rich experience and powerful strength of production of the multiple basic chemical materials of JilinCity, it can provide the sufficient basic chemical materials (such as organic accessories and dimethyl sulphoxide, etc.) for production of carbon fiber to assist in the development of the carbon fiber industry. It can be seen that it has the indispensable resources advantages to carry out the production and development of carbon fiber in Jilin Economic Development Zone.

(4) Technical personnel advantages

JilinProvince has the developed scientific research and education undertaking. In JilinProvince and the province, there are a number of opened labs reaching the international level and the first-rate domestic test and testing equipment. Some carbon fiber, chemical and textile research and design institutions such as PetroChina Jilin Petrochemical Institute, Changchun Institute of Applied Chemistry, Changchun University of Technology, Northeast China Branch of PetroChina Group Engineering Design Co., Ltd., Jilin Provincial Textile Industry Design Institute and Jilin Chemical Institute, etc. have established the complete and matching scientific research, production, test and teaching system, which can provide the strong personnel and technical support for the carbon fiber industry.

1.2 Content and Scale of Project Construction

1.2.1 Product Scheme and Scale

Annual output of 50,000km new cable carbon fiber composite core materials

1.2.2 Construction Content

Purchase the land of 30000m², build the production building and auxiliary building of 12000m² and purchase 60 sets of advanced continuous pultrude equipment.

1.3 Total investment and fund raising of the project

1.3.1 Total investment of the project (see Table 1 for details)

The total investment of the project is 400 million yuan RMB, including the construction investment of 280 million yuan and no interest in the construction period is taken into account.

Table 1: Summary Table of the Total Investment of the Project Unit: 10 thousand yuan

Note: “10 thousand yuan” in the table refers to RMB.

1.3.2 Fund raising

It is planned to raise the funds of 400 million yuan RMB. The equity financing is mainly taken into account and it is input in the mode of project capital.

1.4 Forecast of Economic and Social Benefits

1.4.1 Major Indexes for Forecast of Economic Benefits（See Table 2 for details）

Table 2:      List of the Major Indexes for Forecast of Economic Benefits

Note: “10 thousand yuan” in the table refers to RMB.

1.4.2 Analysis of Social Benefits

The structural design presented in the project has the good environmental protection effects. The technique will not only bring about the remarkable economic benefits for the customers but also bring about the good social benefits in some aspects such as energy saving and environmental protection, etc. In the meantime, the project can resolve the problem of employment of some common people around it, with the obvious social benefits.

After the project is completed, it will bring about the remarkable economic benefits for the local economic development, and at the same time, it will resolve the problem of employment of some laborers and play the important role of promoting the local social stability and economic development.

1.5 Ways of Cooperation

Some ways such as sole investment, joint venture and cooperation, etc. can be taken.

1.6 What to be Invested by Foreign Party

Funds, other modes interviewed.

1.7 Construction Site of the Project

CarbonFiberIndustrial Park of Jilin Economic and Technology Development Zone

1.8 The On-going Condition of Project

Some previous work such as plan and land, etc. and the matching construction of some infrastructure such as “9 throughs and 1 leveling”, etc. has been completed.

2 Introduction to Project Undertaker

2.1 Basic Conditions

Name: CarbonFiberIndustrial Park of Jilin Economic and Technology Development Zone

Address: 516-1 Jiuzhan Street, Jilin City, Jilin Province

Legal representative：Zheng Guoxue (Director of the Management Committee)

2.2 Overview：

Jilin Economic and Technological Development Zone, completed at the end of 1998 and approved as the national-level economic and technological development zone by the State Council of the People’s Republic of China in April, 2010, exercises the current policy of the national-level economic and technological development zone. Jilin Economic and Technological Development Zone is the only national-level patent industrialization pilot base in the north of the Yellow River. It has passed the certification of the ISO14001 environmental management system and ISO9001quality management system. The administrative districts under it are 103 km², with the planned area of 44 km², permanent population of 68,000 and 1,605 enterprises at present, including 86 enterprises above the scale. According to the general plan and development strategy of Jilin Economic and Technological Development Zone, Jilin Economic and Technological Development Zone, depending on the current resources and industrial advantages, puts emphasis to development some dominant industries such as chemical industry and new materials, carbon fiber, automobile parts, textile industry and brand food, etc. In the national strategy of economic development, the role of the key node of the economic and development zone as the Changchun-Jilin-Tumen leading development and opening zone, the radiating and leading roles of the leading zone of Changchun and Jilin integration and the roles of the important autonomous innovation demonstration zone of Northeast China will be given full play. In the future 5 years, depending on the policy advantages, system advantages and environmental advantages of the national-level economic and technological development zone, Jilin Economic and Technological Development Zone will be developed into the development zone with 100 billion yuan and become the core zone of the new industrial district in the north of JilinCity.

The Carbon Fiber Industrial Park of Jilin Economic and Technological Development Zone, reviewed by the Ministry of Science and Technology in 1992, was officially determined as the national-level new and high-tech industrialization base. It is located in the northwest of JilinCity, with the planned area of 3 km². The base owns 6 backbone enterprises and 11 projects under construction. The planned total investment is more than 4 billion yuan and the investment of 1.3 billion yuan has been completed. In the zone, a lot of carbon fiber development and production enterprises such as Jilin Carbon Valley Carbon Fiber Co., Ltd., Sinosteel Jiangcheng Carbon Fiber Co., Ltd., Jilin Jiyan High-tech Carbon Fiber Co., Ltd. and Jilin Herun Co., Ltd., etc. have been built and the matching upper-stream and lower-stream carbon fiber industrial chain has been established. A series of carbon fiber products developed by the companies in the zone have the structures and performances reach the level of the T300 carbon fiber product of Toray. It is predicted that the park will have become the largest domestic, leading, safe and environmental-protection carbon fiber production and application base in the world, with the annual output value of 5 billion yuan realized by 2013. The preferential policy of “discussion on a specific event” will be exercised in some aspects such as land and tax revenue, etc. for the enterprises settled in the park.

The leading industry of the park is the production of precursor carbon fiber and carbon fiber products, the performances of the products are in the leading status in the whole country and the products have been widely applied in some fields such as military industry, energy, traffic and sports and leisure articles, etc. By the end of 2010, the total accumulative industrial output value of 0.3 billion yuan had been realized, with the sales income of 0.28 billion yuan, profit of 0.1 billion yuan and tax of 18 million yuan. In January-July, 2011, the accumulative sales income of 0.52 billion yuan was realized, with the profit of 0.16 billion yuan. By August, 2011, there have been 4 carbon fiber enterprises in the park, all of which are the enterprises above the scale, including 3 backbone leading enterprises.

The total investment of the carbon fiber project of the planned park of Jilin Economic and Technological Development Zone has been more than 10 billion yuan by now. After the output is reached, the annual output value of 50 billion yuan and the tax of 10 billion yuan will be realized. The carbon fiber industry will become the key support for Jilin Economic and Technological Development Zone to realize the industrial output value of 100 billion yuan during the “12^th Five-Year Plan”.

Zheng Guoxue, director of the management committee, male, born in October, 1961, in the Han nationality, member of the Communist Party of China, with the bachelor’s degree, who worked as member of the Standing Committee of Shulan Municipal Committee of the Party, Director of the Department of Publicity and Deputy Mayor of Shulan, member of the Standing Committee of Chuanying District, Jilin City of the Party and Deputy Director of the District, Deputy Director of the Management Committee of Jilin Economic and Technological Development Zone, Deputy Director of the Bureau of Personnel of Jilin City, Director of the Management Committee and Secretary of the Party Working Committee of Jilin Beidahu Sports Tourism Economical Development Zone, now works as Director of the Management Committee of Jilin Economic and Technological Development Zone.

2.3 Contact Method

Postal Code : 132101

Contact Person: Zhao Xia

Tel: 0432-63451928

Fax: 0432-63451984

E-mail: jlzhaoxia@126.com

 

Contact Method of the City (Prefecture) of the Project:

Contact Persons: Wei Xiaoli, Liu Aiguo

Tel: 0432-62026489

E-mail: proinvest@126.com

Website: www.jlszsw.gov.cn