Creating Sustainable Marine Structures Through the ...

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Creating Sustainable

Marine Structures

Through the Adoption

of Composites

H I P E R C o n f e r e n c e 2 0 2 1

J o n a t h a n E v a n s

Date: 9/29/2021 © Copyright STRUCTeam Ltd Slide: 2

S T R U C Te a m I n t ro d u c t i o n

2010

Material

Supply Chain

Manufacturing

DesignEngineering

STL Formationserving multiple sectors 2025

Mission

Contribute to the challenging

environments of different marine

segments to solve technical challenges

and sustainability objectives with the

CO2 transition in an innovative yet cost

competitive way.

Sectors

Renewable / Wind Energy

Automotive

Marine

Civil

Oil & Gas

Materials Industry

Leading composites engineering services consultancy


S T R U C Te a m I n t ro d u c t i o n

We believe composites will have a key role in achieving much needed innovation for

sustainability goals. Collaboration between expertise is key to trigger great

development with significant impact.

We support our clients to consider and adopt composite materials to benefit their

business.

We help our clients make better decisions, reduce costs, improve efficiency, select

and develop appropriate technologies for their composite business.


‘ C o d e re d fo r h u m a n i t y ’

Ref: https://www.telegraph.co.uk/environment/2021/08/09/paris-15c-climate-goal-set-breached-

within-two-decades/?


D e s i g n D r i ve rs

CAPEX CostWeight

OPEX costs (fuel)

OPEX costs (maintenance)

Industry know-howSustainability (CO2e)

Recyclability

2021 2030+

CAPEX Cost

WeightOPEX costs (fuel)**

OPEX costs (maintenance)Industry know-how

Sustainability (CO2e)**Recyclability

** Driven by future regulations & legislation

CAPEX Cost

WeightOPEX costs (fuel)**

OPEX costs (maintenance)Industry know-how

Sustainability (CO2e)**Recyclability


O p p o r t u n i t i e s fo r C o m p o s i t e s

Material selection, energy efficient production

Trending towards use of recyclable materials

Weight reduction

Corrosion resistance

** Driven by future regulations & legislation

2030+


C a s e S t u d y : Pa t ro l B o a t

Length Overall 18.00 m (60’)Beam 5.00 m

Hull Draught 0.90 m

Displacement 27.5 Tons

Max. Speed 42 Knots

Classification Bureau Veritas

Service life 30 years

10 boats series

50% utilization

Purpose:

¤ Offshore patrol, surveillance and rescue boat

Material options:

¤ Aluminium

¤ Glass fibre, Epoxy resin, PVC core, infusion process

¤ Carbon fibre, Epoxy resin, PVC core, infusion process

¤ Carbon fibre, Epoxy resin, PVC core, prepreg process

Credit: ARES Shipyard Inc.


C o m p o s i t e Ve s s e l M a t e r i a l O p t i o n s

= Mechanical properties

x

x

Fibre

Matrix

(Resin)

Process

Epoxy resin

Glass fibre fabrics Carbon fibre fabrics

Infusion

Dry fabric, resin flow aided by vacuum

Ambient temperature cure

Prepreg

Pre-impregnated

fabrics, elevated

temperature cure

Glass Fibre

/PVC/Infusion

Carbon Fibre

/PVC/Infusion

Carbon Fibre

/PVC/Prepreg

Increasing performance & material cost

Decreasing weight


C O 2e ( C a r b o n D i ox i d e Eq u i va l e n t )

“CO2e signifies the amount of CO2 which would have the equivalent

global warming impact.”

Raw material extraction + processing

Intermediate materials

manufacture (fabric / prepreg…)

Part ManufactureOperation, end of

life, etc…

Scope of analysis

(cradle to factory gate)

Embodied CO2e data

includes extraction and

processing.

Some raw materials can also

store CO2e (e.g. wood).

CO2 Storage

Intermediate material

manufacturing steps

mainly contribute through

energy use.

CO2 Release

Product manufacture

contributions are mainly

caused by energy

expenditure, with some

input from consumables

waste etc… Energy input

(kWh)

Indirect material input

(consumables, etc…)


S t r u c t u ra l We i g h t a n d E m b o d i e d C O 2

Equivalent of 31,400 litres

of diesel saved from CO2e

reduction through material

selection only


Pa t ro l B o a t B u s i n e s s C a s e

Initial cost of composite vessels

can yield a quick ROI after a few

years with moderate utilisation

due to savings on fuel costs

from reduced structural weight.


S t r u c t u ra l We i g h t a n d E m b o d i e d C O 2

Carbon fibre material production is

energy intensive and has higher raw

material CO2e than Aluminium,

however the final product is lighter, so

product’s embodied CO2e is lower

Thermoset resins have high CO2e due to

pre-processing of constituent chemicals

¤ Thermoplastic solutions have 60%

less CO2e, and include the option to

be recycled.


O p e ra t i o n a l C O 2

Estimated equivalent CO2e savings from weight reduction during 30 year operation for single vessel.

9% fuel savings

300,000kg savings of

CO2e, 112t of diesel


I m p a c t o f S av i n g C O 2e U s i n g M a t e r i a l s o n O ve ra l l C O 2

Embodied CO2 is only a small

percentage of the total CO2 emissions

over the vessel’s life.

Operational CO2 reduction is a key

factor in reduction of the greenhouse

gas emissions.

Use of composites can yield emission

reductions of 5-10% for vessel.

Weight reduction opens option for

optimisation using smaller

engines/electric drivetrains, hull shape

optimisation etc..


Pe rc e i ve d B a r r i e rs fo r E n t r y i n M a r i n e S e c t o r

Material properties

Analysis

Regulations

Build, repair and

maintenance

- Characteristic material properties from

previous test data, control during

manufacture

- Plugins for current design tools

- Current curriculum topic in higher

education

- Use of composites in strategic locations

- Service contract provided with new vessels


Re c yc l a b i l i t y

https://www.bloomberg.com/news/features/2020-02-05/wind-turbine-blades-can-t-be-recycled-so-they-re-piling-up-in-landfills


W i n d I n d u s t r y

Ban of landfill by 2030(EC DIRECTIVE 2008/98)

1. Mechanical recycling

(shredding) and re-use of

recyclates in the

concrete/cement industryØrsted led consortium

2. Development of 100%

recyclable blades using

thermoplastic instead of

ThermosetsLM Wind power – Zebra Project

3. Development of chemical

recycling of epoxy based

wind bladesCETEC/Vestas

Short term

solution

Longer term

solution


M a r i n e I n d u s t r y

Marine market is very segmented, wind industry has

fewer large players with resources who join together with

the same goals

Development is lead by wind sector and can be adopted

by marine market as same materials and process are used

Marine industry has significant recycling volume

requirements - half of wind industry volumes

Future mission – Facilitator required to collaborate

between wind and marine sectors – DNV-GL?

Ramboll in partnership with Siemens

Ramboll in partnership with Siemens


C o n c l u s i o n s

Key drivers for projects are set to change from cost dominated decision to sustainability

goals/requirements.

Composites can be used as a method for reducing CO2 emissions by reduction of vessel weight.

“Net zero” emissions target by 2040 from IPCC has to be met by use of renewable based energy production to offset the use of structural materials, but impact can be reduced by reducing weight.

Onboarding of composites can be supported through collaboration to reach common goal of

sustainability.

Current recycling technology developments can be transferred from wind sector – DNV-GL to be

facilitator?


Thank you!

Jonathan Evans

[email protected]

STRUCTeam

www.structeam-ltd.com

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