Environmental impact of additive manufacturing in the renewable energy industry : case of wind turbine
Lakshmanan, Rohit (2022)
Diplomityö
Lakshmanan, Rohit
2022
School of Energy Systems, Ympäristötekniikka
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi-fe2022062248416
https://urn.fi/URN:NBN:fi-fe2022062248416
Tiivistelmä
Increasing demand for goods and services is growing with the evident rise in population globally. To cater to the needs for the planet, manufacturing methods that are part of industry should be more sustainable, while giving major importance to the environmental performance of the products. The concern of diminishing resources and raw materials is driving scientists, researchers, governments, and industry stakeholders to adopt new technologies that can outperform traditional methods of manufacturing. Additive manufacturing is one such manufacturing method that is on the cusp of being largely integrated into the industries of today. It is a technique that benefits the three pillars of sustainably, namely the environment, economy, and society. It plays a crucial role in reducing waste by efficient resource consumption and reduced manufacturing waste, reduction of emissions during the life cycle of a product, promoting on-demand and localized manufacturing, and offers a high level of design freedom which can help manufacture complex parts. The renewable energy industry has challenges such as system reliability, energy security, environmental impacts, and reliability of the systems. However, with growing technology, these issues can be addressed, specifically by integrating additive manufacturing into the industry. Wind energy is one of the most promising types of renewable energy and it is growing globally in terms of capacity installed per year, and overall capacity available. AM is increasingly being used in the wind energy industry, but it is still yet to be made fully commercial and functional. The main benefits are repairs and remanufacturing, improved supply chain, and reduced environmental issues. Life cycle assessment is a powerful tool to study the environmental impacts for the life cycle of a product. It helps to identify the various impacts caused to the environment by addressing specific indicators such as global warming potential, depletion of resources, water consumption, etc. Life cycle analysis can be then further used to improve the product by developing them further, strategic developments, marketing opportunities, and better legislation.
The results of the thesis firstly indicate the environmental impacts caused by traditionally manufactured a 2 MW wind turbine during its life cycle. The findings were that the products, recurring, and transport stages contributed significantly to the greenhouse gas emissions. Steel, resins and adhesives, and concrete are the materials that contribute maximum to the emissions. Other significant indicators to the environmental performance for the life cycle of the wind turbine are ozone depletion potential, abiotic resource depletion, water footprint, and particulate matter emissions. For each of these indicators, the product and recurring stages contribute the most to the environmental impact. Secondly, a case study has been identified to use additive manufacturing to manufacture a rotating unit, which is a part of the hydraulic pitch system of a wind turbine. The results showed that significant material savings can be achieved by using AM, which can positively impact the environmental performance. The weight reduction and material savings for the assembly was approximately 44% and 72% respectively, in comparison to traditionally manufactured rotating unit. Finally, the results of the thesis from both experimental parts were analyzed and discussed to illustrate the environmental benefits gained by integrating additive manufacturing for the life cycle of the wind turbine.
The results of the thesis firstly indicate the environmental impacts caused by traditionally manufactured a 2 MW wind turbine during its life cycle. The findings were that the products, recurring, and transport stages contributed significantly to the greenhouse gas emissions. Steel, resins and adhesives, and concrete are the materials that contribute maximum to the emissions. Other significant indicators to the environmental performance for the life cycle of the wind turbine are ozone depletion potential, abiotic resource depletion, water footprint, and particulate matter emissions. For each of these indicators, the product and recurring stages contribute the most to the environmental impact. Secondly, a case study has been identified to use additive manufacturing to manufacture a rotating unit, which is a part of the hydraulic pitch system of a wind turbine. The results showed that significant material savings can be achieved by using AM, which can positively impact the environmental performance. The weight reduction and material savings for the assembly was approximately 44% and 72% respectively, in comparison to traditionally manufactured rotating unit. Finally, the results of the thesis from both experimental parts were analyzed and discussed to illustrate the environmental benefits gained by integrating additive manufacturing for the life cycle of the wind turbine.