carbon footprint offshore wind...
TRANSCRIPT
9-10-2014 1
Carbon Footprint Offshore Wind Foundations
Bauke Hoekstra Bonnema
Tata Steel Construction Centre NL
Together we make the difference
9-10-2014 2
Offshore wind market
Life Cycle Analysis
Tata Steel capabilities
Summary & Conclusions
1
2
3
4
5
Offshore wind foundations
2
Tata Steel Slide 3Tata Steel Offshore Presentation
Climate targets
EU 2050 Roadmap:
� 80% Greenhouse gas (GHG) reduction (ref 1990)
EU : 2014: EU Climate & Energy Package , 2030 targets:
� 40% reduction GHG
� 27% share renewable energy
� 40% increase energy efficiency in build environment
NL: SER akkoord
� Increase share renewable energy 4% -> 14% in 2020 (16% 2023)
� Offshore wind 3,450 MW (2020) -> 4450 MW in 2023.
� Present capacity approx 800 MW.
Source : cobouw 13 jan 2014 + feb 6
Tata Steel Slide 4Tata Steel Offshore Presentation
Offshore wind market
Total Wind Energy EU:
� 117 GW (on-shore + offshore) , growth 2013 : 28%
Offshore wind EU:
� 90% share world capacity offshore wind (China: 9%, Japan 1%)
� EU present installed capacity 1660 turbines @ 3-4MW = approx 6400 MW
Source : EWEA 2013
Tata Steel Slide 5Tata Steel Offshore Presentation
Offshore wind market
Offshore wind market growth :
� 2013: 1400 MW (growth)
� 2020: 40 GW (cumulative)
� 2030: 150 GW (cumulative)
Steel intensity :
� approx 1000 ton steel / 5MW
� 60% foundation
� 40% superstructure
Source : EWEA 2013
28% / year
Tata Steel Slide 6Tata Steel Offshore Presentation
Developments by country
Netherlands
� Present capacity NL: 730 MW
� Permits issued for 2,500 MW , 1500 MW to be issued
� Projects under development: Luchterduinen (43 turbines ,128MW ).
� North of the Netherlands ( total 600MW ) + test/demo site 300MW : Leeghwater
UK:
� 6000 MW operational /under construction
� Furthermore 8000 MW planned (a.o. Race Bank + Dungeon)
Denmark:
� Target 2020: 50 % electricity energy generating by wind .
� under development 2000 MW (Anholt, Kriegers Flak , Horns Rev III, etc)
Germany:
� 2000MW under construction / operational,
� 3500 MW for approval and financing.
Total steel opportuninty 3000+8000+1500+6000 / 5MW= 3,5 mio ton (excl. auxilary
equipment)
Source : EWEA 2013, various studies
Tata Steel Slide 7Tata Steel Offshore Presentation
Content Summary
Offshore wind market
Life Cycle Analysis
Tata Steel capabilities
Summary & Conclusions
1
2
3
4
5
Offshore wind foundations
7
Tata Steel Slide 8Tata Steel Offshore Presentation
Offshore Foundation types
Total: 74% (2012 :73%)
Total 5% (2012: 13%)
Total: 5% (2012:11%)
Total: 16% (2012: 3%)
Tata Steel Slide 9Tata Steel Offshore Presentation
Content Summary
Offshore wind market
Life Cycle Analysis
Tata Steel capabilities
Summary & Conclusions
1
2
3
4
5
Offshore wind foundations
9
Tata Steel Slide 10Tata Steel Offshore Presentation
� How do concrete designs (Gravity bases) compare with steel designs (monopiles/jackets)
� What is impact of installation
� What are impact options around recovery and end-of-life recycling?
10
“What is the carbon footprint associated with the
manufacture, installation, use and end-of-life of different
designs of off-shore wind turbine tower foundations?”
Research question:
Tata Steel Slide 11Tata Steel Offshore Presentation 11
� LCA phases:
� Manufacture of foundation structure (excluding fabrication e.g. concrete pumping, welding and transport to site¹)
� Extraction/processing of ballast and scour protection materials
� Installation of foundation
� End of Life Recovery and benefits from recycling
¹ considered relative small impacts
LCA info
Re-use
Tata Steel Slide 12Tata Steel Offshore Presentation 12
EoL Scenarios:
� Steel Monopile which is recovered at end-of-life (EoL) for recycling
� Steel Jacket which is recovered at EoL for recycling
� Concrete Gravity Base which is either recovered for recycling or remains in place at EoL
LCA info
Tata Steel Slide 13Tata Steel Offshore Presentation
Analyses a.o. based on the Study by Danish Energy Agency for the Kriegers Flak
Windfarm.
13
1550
1750
2000
2250
3500
625
675
800
1075
1475
400
400
450
600
800
0 2000 4000
3.0 MW
3.6 MW
4.0 MW
8.0 MW
10.0 MW
tonnes of material
Steel jacket base
Steel monopile
base
Concrete gravity
base
Source Danish Energy Agency: study Kriegers Flak Windfarm
Average Water Depth ~23m
Materials
Tata Steel Slide 14Tata Steel Offshore Presentation
� Models built in GaBi6 LCA software
� Built using guidance from EN15804 & ISO14040/44
14
LCA Modelling
Tata Steel Slide 15Tata Steel Offshore Presentation
� Steel data (Global Average)
Obtained from The World Steel Association – 100% recycling rate
� Reinforced concrete data was modelled in GaBi and was compared with other data sources for consistency (BCSA, NL national database)
� CEMII RC50 concrete with 4.7% rebar (50% GGBS and 50% Portland Cement)
� Concrete modelled as a lower strength grade to account for carbon benefits of reduced Portland Cement content
� Rock/aggregate for scour protection – data from GaBi6 0.01tCO2e/t
15
Plate 0.90 tCO2e/t
Rebar 0.82 tCO2e/t
Not recycled at EOL 0.50 tCO2e/t
Recycled at EOL 0.22 tCO2e/t
Material data
Tata Steel Slide 16Tata Steel Offshore Presentation
� Use of rock and aggregates for ground preparation, ballasting of a concrete gravity base and scour protection
A Jacket has lowest CO2 footprint even when the gravity base is recovered for
recycling
16
170157
98 92
219203
11598
0
50
100
150
200
250
including ballast/scour protection excluding ballast/scour protection
tCO
2e
qu
iv.
/MW
Monopile - Recycled EOL
Jacket - Recycled EOL
Gravity Base - Not Recycled EOL
Gravity Base - Recycled EOL
+ 8 - 12%
Impact ballast/scour protection
Tata Steel Slide 17Tata Steel Offshore Presentation
� SMART Wind published information on the usage of vessels and fuel consumption for the installation
� Project One in the Hornsea Zone (water depth 25-40m)
17
¹ Emission factor for heavy fuel oil (direct and indirect) = 3.85tCO2e/t
Vessel Fuel consumption Time (days per installation) Total Fuel use (t per instal lation) Total Emission (tCO2 e)
ton/day Gravity Monopile Jacket Gravity Monopile Jacket Gravity Monopile Jacket
Tug 15 6 2 2 90 30 30 346 115 115
R ock dumping vessel 15 2 1 1 30 15 15 115 58 58
P ile installation vessel 15 1 0 0 15 0 0 58
D redging vessel 30 3 90 0 0 346 0 0
Grout support vessel 15 1 1 0 15 15 0 58 58
D iver support vessel 5 1,5 2 1 7,5 10 5 29 38 19
W ork boat 5 1 0 5 0 0 19 0
Safety boat 1,5 3 1 1 4,5 1,5 1,5 17 6 6
J ack -up installation vessel 30 2 2 2 60 60 60 231 231 231
Total 282 137 142 1084 525 544
Total per MW 93,6 MW W T)
3,85 CO2 e /ton 3,84 301 146 151
Impact Installation
The CO2e emissions associated with Heavy Fuel Oil usage were found to be considerable due to the size and number of vessels involved
¹
Tata Steel Slide 18Tata Steel Offshore Presentation
� Installation has a considerable impact on LCA values for all foundations
18
170
98
219
115
146
151
302
302
0
100
200
300
400
500
600
Monopile - Recycled
EOL
Jacket - Recycled EOL Gravity Base - Not
Recycled EOL
Gravity Base -
Recycled EOL
tCO
2e
qu
iv.
/MW
Installation
Material impacts
Material + Installation impacts
Jacket has a 27% advantage over a Monopile foundation and 110% advantage
over Gravity Base.
Tata Steel Slide 19Tata Steel Offshore Presentation
� Decommissioning /Dis-assembly: assumed to be similar to installation impacts as a worst case scenario.
19
17098
219
115
146
151
302
302
146
151
302
0
100
200
300
400
500
600
700
800
Monopile - Recycled
EOL
Jacket - Recycled EOL Gravity Base - Not
Recycled EOL
Gravity Base -
Recycled EOL
tCO
2e
qu
iv.
/MW
Recovery
Installation
Material impacts
Material + Installation + End of Life impacts
Even if the Gravity Base is not recovered a recovered Jacket still has a 30%
advantage.
The carbon footprint of a recovered Gravity Base is higher than a Gravity Base that
is not recovered.
Tata Steel Slide
� A concept developed by ARUP/ Gravitas was also included in the analysis:
� ARUP/Gravitas concept Brochure
� 4584t Concrete vs. 2250t Concrete for Kriegers Flak gravity base (8MW)
� Significant quantities of Rebar required –380kg/m3
� water depth – 35m
20
Materials Gravitas structure
Tata Steel Slide
� No data available on installation but assumed to be the same as a conventional gravity base in this study.
� Significant increase in materials 35m vs. 23m
21
Gravitas Concept Comparison
17098
375
189
146
151
302
302146
151
302
0
100
200
300
400
500
600
700
800
900
Monopile - Recycled
EOL
Jacket - Recycled EOL GRAVITAS - Not
Recycled EOL
GRAVITAS - Recycled
EOL
tCO
2e
qu
iv.
/MW
Recovery
Installation
Material impacts
Tata Steel Slide 22Tata Steel Offshore Presentation
� Variation between studies arises for a number of reasons and makes direct comparisons difficult
� Use of different data sets for steel manufacture (EAF vs. BF/BOF)
� Water depth and turbine size (MW)
� Installation was found to be significant in those studies where it was included but there was variation in the estimates.
22
Gravity base – not recycled
Monopile
Jacket
UK Concrete centre studies
TSE study
Tata Steel Slide 23Tata Steel Offshore Presentation
Content Summary
Offshore Wind market
Life Cycle Analysis
Tata Steel capabilities
Summary & Conclusions
1
2
3
4
5
Offshore wind foundations
23
Tata Steel Slide 25Tata Steel Offshore Presentation
We have a dedicated team serving all aspects of the Energy & Power sector
25
Tata Steel Slide 26Tata Steel Offshore Presentation
Ex-stock service to our customers enables flexible supply
Stock locations in Rotterdam, Singapore, Dubai and Houston
26
Tata Steel Slide 28Tata Steel Offshore Presentation
Offshore structures
28
Semi-processing of components so you can increase
productivity in your own businesses and shorten
leadtimes for your customers
Product kits of parts so you do not have to use valuable
fabrication areas for stock holding
Single sourcing contracts by working with approved
sub-suppliers to deliver the widest size and product
ranges
Dedicated contract managers to ensure that projects
are delivered in accordance with your project
requirements
Complete traceability of all materials to ensure
compliance with your customers’ quality
specifications
Tata Steel Slide 29Tata Steel Offshore Presentation
Content Summary
Offshore Wind market
Life Cycle Analysis
Tata Steel capabilities
Summary & Conclusions
1
2
3
4
5
Offshore wind foundations
29
Tata Steel Slide 30Tata Steel Offshore Presentation
Summary
� Growth renewable energy at the heart of EU policies
� Offshore wind rapid growth market, with goodopportinities for steel
� Life Cycle Analysis offshore wind foundation: production, installation, recycling/end of life/disassembly and recycling phases to consider
� Ballast/Scour protection increase footprint byapprox 8-12%
� Installation /decommissioning has considerable impact (factor 1,5 - 5 x materialimpact) on CO2 footprint
� Jacket foundation results lowest CO2 footprint
� Tata Steel provides wide productrange / services for Offshore (Wind) and Energy market