Sustainable

economics

Anglo-saxon

Rhine-land

Mediterranean

Communist

Composites minimum energy, maximum performance

HHS Delft: Technologie, Innovatie en Samenleving, 26-11-14

Adriaan Beukers

co-creating Urban

Sustainable Mobility !

Aircraft Technology Cycles wood, linen & steel, 1880-1940 light alloys, ‘tubes’, 1930-2000 composites, ‘tubes’, 1998-2060

EC 2020, future requirements and societal demands, e.g. airplanes

EC 2020 AIRCRAFT, CARS, SHIPS, BUILDINGS?

Transport and velocity domains

Total (system + payload) weight, so reduce system weight!

Transport systems drag to overcome, per unit moving system weight

15kgf PREQ to move

100kg WTOTAL

urban

extreme efficiency

ratios

less system weight, more payload

Reduce (empty)

System Weight

Life-time energy savings per 100kg average values for energy

savings by

weight reduction

IFEU 2004, 1GJ is about 30lt kerosine

42,000lt

450,000lt

600,000lt

Life time ENERGY SAVINGS HIGH SPEED FERRIES

33% reduction by weight

-7% kerosine

1650GJ//35MJ/lt

47 ton/100kg.lifetime

E-GlassFRP, corrosion resistance, thermal & acoustic insolation

steel

aluminium

GFRP

+

addedo

values

system efficiency: Less urban transport mass, less energy (résumé)

payload versus

deadweight

Nowadays excessive weight is being fined (CO2), less sytem weight in exchange for more payload

engine efficiency programs,

10yrs: average saving from

0.7 to 0.5 lt/100kg.100km

liquid fuel history: ‘a one century history of slash and burn’

SABIC/GEP-DSM

BASF/DSM

Emirates

Delta Airlines

10-20 -->100 80$/barrel

Cheap Materials become Scarce eg cheap oil, easy exploitable wells, new economies, EC2020

From Liquid To Gaseous Energy Carriers 2013 Shale gas, deep well an-organic chemistry from global to local resources

equal to liquid fuel history: ‘a new century of slash and burn’

Shell 2013: US, China, Brazil,

‘very disappointing return

on investments’

CEO Peter Vosscher

transport and storage

Gaseous energy carriers

lightweight gascontainer, from liquid

to gaseous energy carriers

lpg, cng, H2, metaan

ref. S.Koussios and Lei ZU

Current H2 Storage Technologies and US DEPT of Energy (DOE) Targets

International Combustion

Engine Gasoline

D/d, no end caps and no geodetics, novel flexibel and impermeable liners

Energy carriers, energy transformers

Energy

Carrier

follows

Transformer

Transport system

Structure materials

Carrier follows transformer, it’s not a matter of scarcity

PERIOD ENERGY

CARRIER/TRANSFORMER TRANSPORT SYSTEM MATERIALS

up to 1830

direct: wood, wind, water,

animals, man

walking, horses, barges,

coaches

wood, linen,

copper, brass

and iron

1830-1900 Coal steam engines coaches, ships, trains wood, linen,

iron, steel

1900-1940 Coal electric dynamo trains, cars, buses wood, linen, plywood,

iron, steel

1903-2003 Oi l internal combustion

engines,

piston and

turbine engines

cars, buses, flying machines,

all aluminium aircraft with

pressurised fuselages

wood, plywood, linen,

iron, steel, aluminium,

polymers

1960-2025? Oi l high efficient by-pass

turbine engines supersonic aircraft (2001†)

classical subsonic aircraft iron, steel, aluminium,

polymers, titanium,

composites

1970-1990 Nuclear centralised electricity

distribution

high velocity trains, steel, aluminium,

composites

1990-2025? G a s clean and efficient

energy supply,

CH4 and H2

city transport steel, aluminium,

titanium, advanced

composites, advanced

alloys, ceramics

2025 – future? Hydrogen?

Nuclear?

Wind/Solar?

Oil

fuel cell?

gas?

bio-fuels?

direct electricity

direct elektrocutie

highest caloric value

per unit volume and

mass

sustainable transport:

smart cars, busses, new

train concepts,

high velocity trains

composite aircraft/BWB

new polymers, ceramics,

fibres, new reinforcing

materials and improved

metals.

Minimize Airmiles (point to point)

Amsterdam - Dubai - Bejing: KLM direct flight: -30% airmiles, 2 x ticket price

Emirates policy: ‘sell A380-seats instead of oil’

Aircraft profit breakeven at ≈85%,

KLM profit ≈5$/passenger÷0.05$/kg, Easy Jet profit

1.2$/passenger

EFFICIENCY improvements since the 50’s, aerodynamics: L/D ≈ 15% propulsion: SFC ≈ 40 % structure : 0.50 > OEW/MTOW > 0.60

Major R&D Challenges:

Structures, Materials &

Manufacturing Techniques

A320/B737 - alikes structure efficiency used for aircraft

OEW / MTOW = 42 ton / 74 ton = 0.56

Johnston distribution OEW: 50%: 21ton for systems, crew and power-plant(s) 50%: 21ton for structure in total

• 10.5ton for wing , undercarriage (6% ) and movables (6%), (12%=5 ton) • 10.5ton for fuselage and empennage (13%) • 16.0ton for wing, fuselage and empennage shell structures (38%)

Cooled trailer 1995, 3 ton weight reduction per trailer!!!!

max weight saving by changing alu shell structures into composites is about 25%, equal to 4ton (≈ 10% OEW), for A320/B737 alikes!

Energy saving: 667 GJ/year.100kg

Specific energy content: 35 MJ/litre

So fuel saving per year per 100kg: 19000 litre

Sell tickets priced per kilogram not per seat

A320/B737 AIRCRAFT e.g. mass reduction pays

Material & Structure Efficiency elastic properties of natural and synthetic fibres compared to steel wires

Cytec

Zoltec

Toray

Toho

SGL

Hexcel

Mitsubishi

Nippon Graphite

Dupont

Teijin

PPG

Owens Corning

St Gobain

proof of

the

structure

is

in the

testing

material specific efficiencies determine:

Structure efficiency

slender beams and plates

dominated by bending

or compression buckling

Composites

HHS Delft: Technologie, Innovatie en Samenleving, 26-11-14

Allmost The end

co-creating Urban Sustainable Mobility !

classical markets

aerospace & wind

energy show

highest global

growth now,

be in front

of the big

volume

emerging

composite

markets!

CAGR: compound anual growth rate

size of bubbles: indicating for market size ref. Lucintel

Global Composites Market Opportunity 2012-2017

Cross-over Composieten open innovatie

‘the knowledge chain’

GrootComposiet1 2009-2013, EFRO

2 2014-2018, PNH

CompoWorld 2011-2015, ZZL, PF&NF

BioComposieten 2014-2018, EDR,

Maritiem- Luchtvaart 2014-2018?,

Rijn Delta

Urban Holland;

één science-technologie park, meer uitdagingen en minder funding

Onderwijs

0nderzoek

Bedrijvig

heid

lmbo

hbo

3TU

GrootComposiet

06112013, Almaar

Composiet in Opmars 1

civil constructions 2013

GrootComposiet

06112013, Almaar

Composiet in Opmars 2 America’s Cup 2013

GrootComposiet,

06112013, Almaar

Composiet in Opmars 3

2013 BMWi3

Composites

HHS Delft: Technologie, Innovatie en Samenleving, 26-11-14

The end

co-creating Urban Sustainable Mobility !

LOW PRESSURE, LOW COST void free infusion free of autoclaves micro bubles carry entrapped voids

5.1 Classical laminated skins,

stringers and frames

accomplished redesign

A300 A330 tail section,

1 to 1 metal to composite replacement

> 455kg saving

Source: Airbus

Table 5.1.1:

preliminary estimated

savings per structural

group, CFRP vs. AL

notes:

1 max. allowable values: stiffness, instability and fatigue

2 maximum strain: stiffness, instability

3 saving potential: higher in stability critical areas

4 weight estimation: 435kg CATIA

5 optimistic value: simple beam bending

6 saving potential: experience stabilizer fitting

aluminium: 100 MPa 1400 strain

cfrp gfrp alu

Structure Design Efficiency (factored for environment)

global material efficiency, load intensity

structures free of discontinuities

final structure efficiency, integrity and durability depend

on ‘smart’ design of joints, cut outs and load trajectories

flat plate testing instead of barrel testing,

curvature parameter (Lekkerkerker, 1964)

CURVED CUT OUTS stress concentrations around holes in cylindrical sandwich shells

fig. 6.2:

Excluding rockets, where system mass is mainly

propellant, all other transport have the potential for a

reduction of system mass 20-30% when composite materials

are fully exploited

fig. 6.1:

System drag of less than 0.05 or 5% per 100kg mass

could be the standard for all travelling velocity/range

domains

6. MOVING VEHICLE EFFICIENCY

1932-2003

• resistance to overcome per unit (total) mass

• system mass required for carrying pay load

Sources: Toorenbeek, Beukers

Average Prices ($/Barrel): Crude Oil (Spot) and Jet Fuel (Paid)

$10

$20

$30

$40

$50

$60

$70

$80

$90

$100

$110

jan-8

6

jan-8

7

jan-8

8

jan-8

9

jan-9

0

jan-9

1

jan-9

2

jan-9

3

jan-9

4

jan-9

5

jan-9

6

jan-9

7

jan-9

8

jan-9

9

jan-0

0

jan-0

1

jan-0

2

jan-0

3

jan-0

4

jan-0

5

jan-0

6

jan-0

7

Crude Oil Jet Fuel

1. CHEAP OIL AND NEW ECONOMIES

1998-2008

one decade of rising consciousness that

burning precious oil is a cheap activity

fig. 1.1:

A centennial of oil well discoveries

versus a yearly growing customer demand

fig. 1.2:

One decade of a steep

price rise of

both crude oil and jet fuel

Source:

Air Transport

Association of America

5 april 2010

November 2014

3.2.

WEIGHT REDUCTION COUNTS

A320 short and long range

Source: Helms

tab. 9.1:

Snowball effect of operational empty

weight reduction 2.5t , via fuel

reduction to a total take of reduction

of 3.0t on average, the relative

energy savings are calculated by

“mission performance calculations”,

Lufthansa AG.

tab. 9.2: resulting A320 life-time savings

weight

reduction

less

lift

reduced

propulsion

less

drag

fuel

reduction

optimal non-geodetic path is equal to 0 of cylindrical vessels

Seamless ‘Toroids’ filament-wound pressure vessels (the flatter the better) family of rims, frames, et cetera

∆W for R/r = 4

fig. 6.2:

Excluding rockets, where system mass is mainly

propellant, all other transport have the potential for a

reduction of system mass 20-30% when composite materials

are fully exploited

fig. 6.1:

System drag of less than 0.05 or 5% per 100kg mass

could be the standard for all travelling velocity/range

domains

6. MOVING VEHICLE EFFICIENCY

1932-2003

• resistance to overcome per unit (total) mass

• system mass required for carrying pay load

Sources: Toorenbeek, Beukers

“For a B747-400, 1% mass reduction is equivalent to 0.344 million

litres of kerosene per year and the cost saving, at the price level of

100 $/158 litres, is at least 218000 $ per year with a CO2 emission

reduction of about 160 tons, tax free, per year”.

B747 average:

OEW = 181 ton

1% 1810 kg, 4% structure

savings

1.9 million miles/year

19 litre/mile = 5 gallon/mile

11 litre/km or 3/100 l/pass.km

1% OEW = 4% structure ≈ 0.96 % fuel

system efficiency: Less system mass, less energy

state of the art

metal transport

vehicles

Wempty/Wpayload

indicative

busses

cars

2.5

3 (12)

8 (27)

Mercedes Benz S-class, 1st edition, value dominated by propulsion

and system weight

subsonic aircraft 4 balanced division of weight fractions

intercity trains 10 value dominated by structural weight

supersonic aircraft 12 value dominated by propulsion, systems and fuel weight

global orbit 66 value dominated by fual weight, ..... miniaturization, micro..nano

lunar orbit 500 value dominated by fual weight

payload versus

deadweight

Nowadays excessive weight is being fined (CO2), less sytem weight in exchange for more payload

engine efficiency programs,

10yrs: average saving from

0.7 to 0.5 lt/100kg.100km

Design and Development Strategy

Design and Production of Composite Structures cooled trailer system weight reduced from ca. 9300 to 6500 kgf ‘integration’

1995, Focwa/Cintec 30% weight reduction challenge, > A320 & B737

2. AIRCRAFT TECHNOLOGY

CYCLES

the rise and fall of

wood, linen & steel, 1880-1940

light alloys, ‘tubes’, 1930-2000

composites, ‘tubes’, 1998-2060

fig. 2.1:

2020 Societal and Economical

demands (EEC & NL authorities)

Sources: A. Beukers, et all