All Recyclable Blades Installed At RWE’s 1.4 GW UK Offshore Wind Farm
The title of this post, is the same as that of this article on offshoreWIND.biz.
This is the sub-heading.
All 150 recyclable blades have been installed at the 1.4 GW Sofia offshore wind farm, with more than half of the wind turbines now in place at the UK construction site.
These three paragraphs add more details.
All 150 recyclable blades are now installed, with each turbine utilising 50 sets of three blades, marking the UK’s first large-scale use of this technology at an offshore wind farm, RWE, the developer, said.
The recyclable rotor blades used at Sofia are manufactured by Siemens Gamesa at its Hull factory and use a unique resin that enables easy separation of component materials at the end of each blade’s operational life cycle.
In addition, 62 out of 100 Siemens Gamesa 14 MW turbines have now been installed at the site located 195 kilometres off the UK’s east coast. Each turbine features 108-metre blades and a 222-metre rotor diameter. Cadeler is responsible for the installation of the wind turbines.
Note.
- The Sofia wind farm has a hundred turbines, each with the customary three blades.
- Currently the 13 MW Siemens Gamesa turbines in Dogger Bank A and Dogger Bank B are the largest turbines in British waters.
- Sofia’s at 14 MW will be larger.
- But 15 MW monsters are on their way, with RWE’s Norfolk zone appearing to favour 15 MW Vesta turbines.
At the present time, turbine size seems to be creeping up. I would expect this to happen, as turbines become more affordable.
HMP Highpoint Launches Rail Engineering Apprenticeships To Reduce Reoffending And Address Skills Gap
The title of this post, is the same as that of this article on Railway Gazette.
This is the sub-heading.
A programme of railway engineering apprenticeships has been launched at Highpoint prison in Suffolk in partnership with The Co-operative Group retail and consumer services business and the City & Guilds Foundation.
These first two paragraphs add more detail.
From August, the training programme will allow prisoners to complete full apprenticeships and end-point assessments before release.
The initiative has been set up partly in response to Co-op members’ requests at its AGM for the business to focus on reducing re-offending and supporting prisoner rehabilitation. It is intended to give offenders the chance to earn a Level 2 qualification as Rail Engineering Operatives, with the aim that they can move straight into employment and into trackside roles on release.
I should say, that I know HMP Highpoint well, as it was close to where I lived in Suffolk and I had the occasional drink with some of the prison staff at a local pub. One even encouraged me to apply to be a member of the Internal Monitoring Board for the prison. Sadly, I had the stroke and was unable to follow it through.
I am all for this initiative, especially as it seems to offer employment on release. A similar train and employ policy doesn’t seem to have done Timpsons any commercial harm.
The only problem of running this course at HMP Highpoint, is that the prison, is not near a railway line.
In the selection process for the Internal Monitoring Board, I had a tour of the prison.
One member of staff, who ran a course on recycling told me that his course was the most popular in the prison.
- The main part of the course was about sorting rubbish into what can be recycled and what couldn’t.
- The course was popular, as most companies, who were involved in recycling, needed operatives who do this efficiently, so it helped getting employment on release.
It also had a big side effect, in that the prison was very clear of litter.
This course surely had similar objectives to the new Rail Engineering Operatives course and the Timpsons training.
We need more initiatives like this in our prisons.
My Faithful Servant
The picture shows the plastic shopping bag that I have used to bring my shopping home for at least the last five years.
Note.
- It folds up in my brief case.
- It carries the small amount of shopping, I buy on the odd day.
- My major shopping comes from Ocado and is placed in my hall by a usually cheery van driver.
- It is the right size to carry home dry cleaning.
- Unlike its paper replacement from Marks and Spencer, it doesn’t cut my hand.
Sometimes being 100 % green, isn’t the right way to go.
Redundant Coal Wagons To Be Converted For Construction Traffic
The title of this post is the same as that of this article on Railway Gazette.
These three paragraphs describe the project.
WH Davis is to convert coal wagons owned by leasing company Porterbrook for use by Freightliner to transport aggregates.
’This is a fantastic opportunity to demonstrate what can be achieved by giving redundant fleets a purpose for the next 30-plus years’, said WH Davis Managing Director Andy Houghton on December 19. ‘It’s a truly sustainable option that also gives UK manufacturing a boost to enable the creation of UK jobs in the industry. I really can’t wait to see our latest box wagon design in traffic for Freightliner in 2025.’
Mark Wyborn, Head of Freight at Porterbrook, said freight volumes in the construction sector were expected to continue growing, and the deal ’highlights our commitment to investing in the long-term growth of rail freight while providing affordable, innovative and sustainable rolling stock for the UK railway’.
We need more recycling projects like these.
In the article, there is a picture of a Class 66 locomotive like this one.
Except this one, which is named after Benjamin Gimbert GC, is different in that it is running on Hydrotreated Vegetable Oil (HVO). which is a more sustainable fuel.
Unfortunately, there is only so much second-hand vegetable oil from the likes of McDonalds and Burger King and it is also a component of Sustainable Aviation Fuel (SAF).
But in the UK, we have engineers at Cummins, JCB, Ricardo and a number of other companies, research organisations and universities, who could create a conversion for the American two-stroke diesels of the Class 66 locomotive so they could run on hydrogen.
These posts detail attempts to create a zero-carbon or dual-fuel locomotive in the UK and some of my thoughts.
- Dual-Fuel Class 37 And 66 Locomotive Concepts Unveiled
- Could Class 66 Locomotives Be Converted Into Battery-Electric Locomotives?
- Freightliner Secures Government Funding For Dual-Fuel Project
- Grants To Support Low-Carbon Technology Demonstrators
- Thoughts On A Battery/Electric Replacement For A Class 66 Locomotive
- A Hydrogen-Powered Locomotive
- Our Sustainability Journey
The Bi-Mode Class 99 locomotive is coming, but we need action now.
I estimate it would probably cost up to £2million to convert a Class 66 locomotive to hydrogen.
So why not have a competition with a prize of perhaps £10million to see who, can produce the best Class 66 or Class 68 locomotive conversion by the end of 2025?
Conclusion
We need urgent action to cut pollution, noise and emissions from heavy freight locomotives and market forces and government grants don’t seem to have produced a solution, so perhaps a competition with a big prize might do it.
It could even be televised,
UK Breakthrough Could Slash Emissions From Cement
The title of this post. is the same as that of this article on the BBC.
This is the sub-heading.
Scientists say they’ve found a way to recycle cement from demolished concrete buildings.
These five paragraphs outline, why cement is such an environmental problem.
Cement is the modern world’s most common construction material, but it is also a huge source of planet-warming gas emissions.
That is because of the chemical reactions when you heat limestone to high temperatures by burning fossil fuels.
Recycling cement would massively reduce its carbon footprint. Researchers say that if they switched to electric-powered furnaces, and used renewable energy like wind and solar rather than fossil fuels, that could mean no greenhouse gases would be released at all.
And that would be a big deal. Cement forms the foundation of the modern economy, both literally and metaphorically.
It is what binds the sand and aggregate in concrete together, and concrete is the most widely used material on the planet after water.
If cement was a country, it would be the third biggest source of emissions after China and the US, responsible for 7.5% of human-made CO2.
This article shows how by applying chemical magic to two effectively unrelated processes; the recycling of steel and the recycling of concrete to make new cement, very high rewards are possible.
Cambridge University are calling their new product electric cement.
As large amounts of electricity are used in an arc furnace, to produce the two products
These paragraphs outline the innovative Cambridge process.
Cement is made by heating limestone to up 1600 Celsius in giant kilns powered by fossil fuels.
Those emissions are just the start. The heat is used to drive carbon dioxide from the limestone, leaving a residue of cement.
Add both these sources of pollution together and it is estimated that about a tonne of carbon dioxide is produced for every tonne of cement.
The team of scientists,, has found a neat way to sidestep those emissions.
It exploits the fact that you can reactivate used cement by exposing it to high temperatures again.
The chemistry is well-established, and it has been done at scale in cement kilns.
The breakthrough is to prove it can be done by piggybacking on the heat generated by another heavy industry – steel recycling.
When you recycle steel, you add chemicals that float on the surface of the molten metal to prevent it reacting with the air and creating impurities. This is known as slag.
The Cambridge team spotted the composition of used cement is almost exactly the same as the slag used in electric arc furnaces.
They have been trialling the process at a small-scale electric arc furnace at the Materials Processing Institute in Middlesbrough.
These are my thoughts.
The Only Inputs Are Steel Scrap, Green Electricity And Used Cement
Consider.
- We probably need to increase the percentage of steel scrap we collect.
- Gigawatts of green electricity in a few years, will be available in those places like Port of Ardersier, Port Talbot, Scunthorpe and Teesside, where large amounts of steel will be needed.
- I can envisage large steel users having their own hybrid electric cement/electric arc furnace plants.
- Used cement would be collected and brought to the plants.
- Years ago, I used to live next door to an old World War II airfield. The farmer who owned the airfield, told me, that the concrete was his pension, as when he needed money, he called a company, who crushed it up for aggregate.
I can see a whole new integrated industry being created.
Conclusion
This could be one of the best inventions since sliced bread.
The Problem Of Waste Plastic And Why Pyrolysis Oil Might Just Contain The Answer
The title of this post, is the same as that of this article on the Chemical Engineer.
These three paragraphs introduce the article.
One of the few technologies that can break down unrecyclable post-consumer waste plastic, pyrolysis is fast becoming a potential recycling route for companies trying to reduce their waste output.
The world produces around 450m t/y of plastic, but only 9% is recycled, with most waste ending up in landfill. Pyrolysis, which involves heating the plastic at extremely high temperatures in the absence of oxygen, breaks down the molecules to produce pyrolysis oil or gas. The oil can then be used to develop new products.
George Huber, a professor of chemical engineering at the University of Wisconsin-Madison, is leading a research team that is investigating the chemistry of pyrolysis oil and its use in polyolefin recycling.
This is a quote from George Huber
Waste plastic should be viewed as a resource we can use to make plastics and other chemicals. We should not be landfilling or burning it, we should be reusing the carbon in waste plastics.
I very much agree with what he said.
These are my thoughts.
Pyrolysis
The Wikipedia entry for pyrolysis starts with this paragraph.
The pyrolysis (or devolatilization) process is the thermal decomposition of materials at elevated temperatures, often in an inert atmosphere.
This paragraph describes the technique’s use in the chemical industry.
The process is used heavily in the chemical industry, for example, to produce ethylene, many forms of carbon, and other chemicals from petroleum, coal, and even wood, or to produce coke from coal. It is used also in the conversion of natural gas (primarily methane) into hydrogen gas and solid carbon char, recently introduced on an industrial scale. Aspirational applications of pyrolysis would convert biomass into syngas and biochar, waste plastics back into usable oil, or waste into safely disposable substances.
I came across pyrolysis in my first job after graduating, when I worked at ICI Runcorn.
ICI were trying to make acetylene in a process plant they had bought from BASF. Ethylene was burned in an atmosphere, that didn’t have much oxygen and then quenched in naphtha. This should have produced acetylene , but all it produced was tonnes of black soot, that it spread all over Runcorn.
I shared an office with a guy, who was using a purpose-built instrument to measure acetylene in the off-gas from the burners.
When he discovered that the gas could be in explosive limits, ICI shut the plant down. The Germans didn’t believe this and said, that anyway it was impossible to do the measurement.
ICI gave up on the process and demolished their plant, but sadly the German plant blew up.
I would assume we have progressed with pyrolysis in the intervening fifty years.
University of Wisconsin-Madison
The University of Wisconsin-Madison is a top-ranked American University and is part of my daily life, as the Warfarin, that stops me having another stroke was developed at the University in the 1940s.
Conclusion
The article is a must-read and I feel that my past experience says, that George Huber and his team could be on to something.
I wish them the best of luck.
Cheesecake Energy Collects £9.4m Government Funding
The title of this post, is the same as that of this article on UKTN.
These two paragraphs outline how they will use the grant.
Cheesecake Energy will use the government funding to install its energy storage solution as a microgrid in Colchester to help with local grid limitations.
University of Nottingham spinout Cheesecake Energy’s installation will collect energy made by a solar farm with a capacity of 8MW and a central heat pump that supplies a district heat pump network.
Cheesecake Energy have been on my list of possible successful energy storage systems for some time and this sounds like a very neat application for energy storage.
Cheesecake Energy bill themselves on their web site as The World’s Greenest Battery, which is a big claim to make.
This outline of their technology is given on their Our Technology page.
Cheesecake Energy’s eTanker energy storage system is a stationary, medium to long-duration energy storage solution which delivers cheap, reliable, efficient energy storage in a modular, containerised package.
The technology stores energy in the form of heat and pressurised air, re-tasking ex-service truck engines to become zero-emission electrical power-conversion machines for putting energy into storage and recovering it from storage. The resulting system does not use diesel or any fuel. It is safe, straightforward to operate, has a lifetime of up to 25 years and can deliver turnaround efficiencies of around 70%.
I like the idea of using recycled truck engines at the heart of the system.
Conclusion
The World’s Greenest Battery could be right!
H&M Move Partners With Lanzatech To Launch Capsule Collection Using Captured Carbon Emissions
The title of this post, is the same as that of this press release from H & M.
This is the sub-heading.
This is the stuff of science fiction: LanzaTech diverts carbon emissions heading for the atmosphere, traps them, and turns them into thread. In a leap towards innovating sportswear, H&M Move partners with the breakthrough material science company for a drop arriving at hm.com/move on April 6.
And this is an H & M image of some of the clothes on a young lady.
Not bad considering that the polyester thread was made using carbon emissions from a steelworks.
Lanzatech’s Process
This paragraph from the H & M press release outlines the process.
Using three simple steps, LanzaTech captures carbon emissions from steel mills, traps them in bioreactors and converts them into the same building blocks that conventional polyester is made of. This revolutionary solution helps reduce pollution and limits the use of virgin fossil resources needed to make new products.
So does this mean that lots of products made from polyester can use the polyester made by Lanzatech?
As I worked for ICI Plastics Division, who had a polyester plant, that was used to make Melinex film, I suspect the answer is yes from the knowledge I picked up at the time.
Out of curiosity, I typed “polyester underwear men’s” into Google and there’s quite a lot of it about. Including some from Marks and Spencer that I own. Marks and Spencer also do a similar product for the ladies. Both products have a high proportion of polyester and could best be described as everyday.
I must find mine comfortable, as I have been buying them for some years now!
So it looks like it might be possible to replace a proportion of the fossil fuel-based polyester with one made from captured carbon dioxide.
And this can this be used in the same way as the fossil fuel-based polyester.
The Wikipedia entry for polyester is full of useful information and is very much a must-read.
This table gives world PET (polyethylene terephthalate) production for 2008 in millions tonnes/year
- Textile – 39
- Resin, bottle – 16
- Film – 1.5
- Special – 2.5
Note.
- Bottle includes, the bottles used for soft drinks, washing up liquid etc.
- Film is high quality and was used as recording tape, but now it’s mainly for packaging.
- Special includes engineering plastics.
Wikipedia has this section on recycling, where this is said.
Recycling of polymers has become very important as the production and use of plastic is continuously rising. Global plastic waste may almost triple by 2060 if this continues. Plastics can be recycled by various means like mechanical recycling, chemical recycling, etc. Among the recyclable polymers, polyester PET is one of the most recycled plastic. The ester bond present in polyesters is susceptible to hydrolysis (acidic or basic conditions), methanolysis and glycolysis which makes this class of polymers suitable for chemical recycling. Enzymatic/biological recycling of PET can be carried out using different enzymes like PETase, cutinase, esterase, lipase, etc. PETase has been also reported for enzymatic degradation of other synthetic polyesters (PBT, PHT, Akestra™, etc) which contains similar aromatic ester bond as that of PET.
Note that PET is one of the most recycled plastics.
So it looks like the LanzaTech process can not only use carbon dioxide, it can also create a product that can be recycled.
Nucor Introduces Elcyon(TM), First Sustainable Steel Product Engineered Specifically For Offshore Wind Energy Applications
The title of this post, is the same as that of this press release from Nucor Corporation.
This is the first paragraph.
Nucor today introduced Elcyon™, the Company’s new sustainable heavy gauge steel plate product made specifically to meet the growing demands of America’s offshore wind energy producers building the green economy and its necessary infrastructure. Nucor will manufacture Elcyon at the company’s new, $1.7 billion state-of-the-art Nucor Brandenburg steel mill in Kentucky , which produced its first steel plate at the end of December 2022.
It sounds impressive, but it should be if $1.7 billion has been spent.
This paragraph, says more about the process.
Elcyon is a clean, advanced steel product made using Nucor’s recycled scrap-based electric arc furnace manufacturing process. Nucor’s circular steelmaking route has a greenhouse gas emissions intensity that is one fifth the global blast furnace extractive steelmaking average, based on Scope 1 and 2 emissions. Utilizing Thermo-Mechanical Controlled Processing (TMCP) at the new mill, Elcyon, the only steel of its kind in the United States was created specifically to meet the rigorous quality standards of offshore wind energy designers, manufacturers and fabricators. Along with meeting Euronorm specs, Elcyon is characterized by larger plate dimensions, improved weldability and excellent fracture toughness, as compared to competing products.
What more can a steelmaker want?
- It uses steel scrap to make new steel.
- The process could be powered by green electricity.
- The process cuts emissions to twenty per cent.
- The steel is what customers want.
- The steel has better properties than competing products.
These two paragraphs talk about the prospects for Elcyon.
Nucor Steel Brandenburg is the first steel plant in the world to pursue certification under LEED v4 from the U.S. Green Building Council, the highest standard for sustainable building design, construction, and operation. The new mill is located in the middle of the largest steel plate-consuming region in the country and will be able to produce 97% of plate products consumed domestically, with a potential output of 1.2 million tons of steel annually.
Elcyon and the Brandenburg mill both draw upon Nucor’s 50 years of industry leadership in sustainable steel production. From last year’s launch of Econiq™, the world’s first net-zero steel available at scale, to recently becoming the first major industrial company to join the United Nations 24/7 Carbon-Free Energy Global Compact, Nucor has consistently worked to meet the needs of its customers and other stakeholders while protecting the well-being of our planet.
Nucor have certainly done their market research and appear to be very scientifically green.
In the About Nucor section of the press release, this is the last sentence.
Nucor is North America’s largest recycler.
This is some statement to make, if it weren’t true! Wikipedia says this about the company.
Nucor operates 23 scrap-based steel production mills. In 2019, the company produced and sold approximately 18.6 million tons of steel and recycled 17.8 million tons of scrap.
The home page of the Nucor web site also makes this claim.
North America’s Most Sustainable Steel And Steel Products Company
Perhaps, the UK government needs to ask Nucor to build one or more of their scrap-based steel production mills in the country to produce all the steel plate we will need for our growing offshore wind industry.
We certainly have the GW to power the arc furnaces.
Conclusion
Nucor is a big beast to watch!
European Company To Make All Wind Turbine Blades 100 % Recyclable, Plans To Build Six Recycling Factories
The title of this post, is the same as that, of this article on offshoreWIND.biz.
This sub-heading outlines what the company plans to do.
A Denmark-based company Continuum plans to make all wind turbine blades fully recyclable and stop landfilling and their emissions-intensive processing into cement with six industrial-scale recycling factories across Europe, backed by investment from the Danish venture capital firm Climentum Capital and a grant from the UK’s Offshore Wind Growth Partnership (OWGP).
Other points in the article include.
- Continuum plan six factories.
- The first factory will open at Esbjerg in Denmark in 2024 and will be able to accept end-of-life blades this year.
- The second factory will be in the UK and it will be followed by others in France, Germany, Spain, and Turkey.
- Each factory will have the capacity to recycle a minimum of 36,000 tonnes of end-of-life turbine blades per year.
This paragraph describes, what will happen to the recycled turbine blades.
The company will recycle wind turbine blades into composite panels for the construction industry and the manufacture of day-to-day products such as facades, industrial doors, and kitchen countertops.
Looking at their description of their mechanical separation process, I suspect that they could recycle other products and manufacture lots of others.
The Anonymous Widower 