Reduction of overall the Carbon Footprint of the leading global Wind Turbine Manufacturer, Arhus, Denmark, 2012
Challenge
Life Cycle Assessments are conducted to identify the environmental footprint of products or services throughout their lifetime: From the extraction of raw materials and their processing via pre-products to the manufacture of the product or service, its life time usage up to dismantling and disposal, including all transportation. The assessments focus on the identification and evaluation of potential environmental improvements.
In this case, after successful analysis of the Life Cycle resource usage as well as the direct & indirect costs related to the environmental impacts, the most important improvement areas were instantly determined and prioritized:
The most important issue being the SF-6 gas containing switch gears, which the industry uses to safeguard against fire and electrical discharges in the wind turbine's high-voltage system. Main reason for its dramatic environmental impact being that one kilogram of SF-6 has the same greenhouse effect as 22,800 kilograms of CO
2, making it the most potent Greenhaouse Gas. And since a wind turbine contains about 7 kilograms SF-6 on average, this amount would correspond to 10% of the CO
2 emitted in connection with manufacture, transport, application and dismantling of a wind turbine during its total lifetime – if this SF-6 gas were to be emitted to the atmosphere.
Proposal
A two-step approach to resolve the issue:
- Long-term research and technology development to replace the SF-6 gas in switchgears by sustainable alternatives like gas mixtures or even air - but since this might take another decade,
- immediate design, simulation, test and implementation of a unique return system for SF-6 gas containing switch gears to ensure that all SF-6 worldwide is under systematic and professional management control, being salvaged by specialists during maintenance as well as at end-of-life and then either recycled or destroyed.
Result
The world's first and by the same time global SF-6 Gas Management and Take-Back-Scheme for an entire industry, in partnership with the supply chain and SF-6 specialists worldwide - hence a global Carbon Footprint reduction of 10% for the Wind Turbine Manufacturer alone, officially reviewed and agreed as in compliance with the current best LCA practices and in accordance with the ISO 14044 standard as to Arpad Horvath, Ph.D. Berkeley, California and reported in the publicly available Sustainability Reports.
Therefore, the intelligent interpretation of the Life Cycle Analysis results enabled
the design of a competitive advantage
taking the lead in the industry,
avoiding future liability cost, and even
safeguarding future legal compliance for the manufacturer of more than 40.000 wind turbines as well as the respective customers worldwide.
Another case study example: End-of-Life and Cradle-to-Cradle Projects such as Carbon Fiber and Glass Fiber Recycling as well as the application of these Recyclates with different organizations, Florida, USA, 2013
Challenge
Another important improvement area determined and prioritized by the wind turbine Life Cycle Assessment mentioned earlier on is the missing recycling solution to the massive amount of glass fiber and carbon fiber materials from the wing technology applied for the last 25-30 years, as well as in other appliances such as the e.g. machine houses.
These composite materials are currently on the rise in worldwide production due to their low weight as well as high strength and elasticity – in the wind, but also in the aerospace, marine and automotive industry.
However, partly due to the long lifetime of the respective products, the question of dismantling and recycling of these composites remains unresolved so far – currently available are only disposal via more and more scarce landfill sites, and in some places incineration or pyrolysis.
To showcase the rising urgency: The wind industry alone calculates about 42,000 wind turbines to be dismantled by 2020, accounting for about 270,000 tons of composite material to be disposed of – equaling a possible saving of about 13.000.000 GJ of energy, 540.200 tons of CO
2, 2.431 tons of SO
x and 810 tons of NO
x in the next ten years if recycling is applied.
Since 13.000.000 GJ of energy don't tell a lot, here some equations: This amount of energy equals 8h of primary energy supply for Germany, or 173 days of primary energy supply to Munich - or 1334 years of primary energy supply to the Munich Oktoberfest.
Proposal
Research into alternatives to the costly and very energy-consuming pyrolysis, as well as the low-recycling incineration or non-recycling disposal of compound materials,
A row of Cradle-to-Cradle recycling tests to see whether newly developed mechanical recycling technologies can cope with Glass Fiber as well as Carbon Fiber,
Assessment how the resulting recyclates compare to the common disposal solutions in landfill or incineration/pyrolysis with regard to:
their physical performance indicators regarding the re-application in different products and industries
their environmental performance via Live Cycle Analysis as well as
their economical performance through a comparison of the respective business cases.
Result
First of all we delivered proof that the newly developed mechanical recycling technologies for Glass Fiber can cope with Carbon Fiber also. Hence making mechanical recycling possible not only for Carbon Fiber products, but even for the ever more often applied amalgamated products made of Glass and Carbon Fiber.
Furthermore the new recyclate products made from recycled Carbon Fiber showed the highest tensile strenght test results ever measured. This presents a sensation in itself: A recyclate product delivering better strength test results than the same product made from virgin fiber material, hence better performance of a product made from cheaper waste material compared to the same product made from expensive raw material. A win-win in the ecological as well as the economical discipline.
Based on these encouraging results three scenarios were developed and are currently under examination with the customers to improve the environmental as well as the economical performance of the related products:
- replacement of virgin fibers by recyclate fiber materials including recycled fiber content up to 80%,
- replacement of metal parts by recyclate fiber materials of the same recycled fiber content of up to 80% and
- replacement of concrete materials by recyclate fiber materials including recycled fibers up to 15% recycling fiber content.
Besides the clarification of these facts re: material, environmental as well as economical performance also the examination of other important "deal makers" for potential customers in wind and automotive industry is currently ongoing:
investments in a service organization delivering the necessary volumes of high quality composite waste from different sources to make recycling viable,
investments in the necessary process operations and infrastructure as well as
investments in marketing for possible end-users of recovered composite fibers, as well as in the development of new recycling products to open new markets.