Hot Dip Galvanizing in Renewable Energy Applications

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1 Hot Dip Galvanizing in Renewable Energy Applications Frank E. Goodwin

2 Renewable energy is experiencing rapid growth Global statistics Start 2004 End 2012 End 2013 New Investment in Renewable Power and Fuels Billion USD Renewable Power Capacity (not including hydro) Gwe Renewable Power Capacity (including hydro) GWe Hydropower Capacity GWe Solar Photovoltaic Capacity (PV) GWe Wind Power, Onshore and Offshore GWe Biomass Power Capacity GWe < Concentrating Solar Thermal Power (CSP) GWe Geothermal Power Capacity GWe Solar Hot Water Capacity GWt

3 Recent developments In the EU-27 plus Norway and Switzerland during 2013, 72% of new electric generating capacity was based on renewable energy. Renewables have been the majority of new electric generating capacity installed in these countries since This is a significant change from as late as 2003, when conventional fossil fuel generation accounted for 80% of new capacity in these countries. Throughout the year 2013, wind power met 33% of electricity demand in Denmark and 21% in Spain In Italy, solar photovoltaic met 8% of annual electricity demand. The forecast for capacity growth is such that Denmark has banned the use of fossil fuel-fired boilers in new buildings as of 2013 and expects renewables to provide at least 40% of total heat supply by In China, new renewable power capacity surpassed new fossil fuel and nuclear capacity for the first time in 2013.

4 Renewable energy is a growing opportunity for galvanizing Expected project life normally >20 years Projects often in remote areas, requiring damage-resistant coating and limited access for maintenance Assembly on site is normal, no further surface treatment is desirable Steel s strength increasingly important as components increase in size

5 Revenue from sale of electricity from the renewable energy sources Billions USD

6 Concentrating Solar Thermal Power (CSP) Capacity Growth

7 CSP: electric power produced by concentrating solar energy into heat using mirrors that direct it toward a tower that typically contains a molten salt circulation loop. The heat of the molten salt is exchanged to mechanical and then electrical energy using turbines or Stirling engines. Abnegoa Solucar CSP site near Seville, Europe s largest CSP plant 183 MW on 1000 hectares

8 Galvanized Heliostat Support of Titan Tracker, Toledo, Spain Parabolic Mirror, CSP Site in Spain Stirling Solar Array, Tooele Amy Depot USA (courtesy American Galvanizers Assn.) 98 tons HDG

9 Solar PV 2012 Capacity and 2013 Additions, Top 10 Countries (Total 2013 capacity 139 GW)

10 Solar PV Projects Using HDG (1) Royalla, ACT Australia solar PV site, 37 MW capacity. (courtesy of Michael Ainsley) 9.14 MW 1000 tons HDG Koshimizu solar PV site, Hokkaido, Japan (courtesy Japan Lead Zinc Development Center)

11 Solar PV Projects Using HDG (2) 32.5 MW 134,000 panels 3000 tons HDG 5 MW 28,000 panels 960 tons HDG Shiranuka solar PV site of Hokkaido Electric Power Corp. (courtesy Japan Lead Zinc Development Center) Wakkanani, Hokkaido solar PV site of Hokkaido Electric Power Corp. (courtesy Japan Lead Zinc Development Center)

12 Solar PV Projects Using HDG (3) 55 tons HDG 150 tons HDG Bergen County, NJ, USA Parking Garage Solar Canopy (courtesy American Galvanizers Assn.) The first McDonald s restaurant solar canopy, Garfield Heights, OH, USA, incorporating electric vehicle charging stations. (courtesy American Galvanizers Assn.)

13 Solar PV Projects Using HDG (4) Metropolitan Tea Canadian distribution hub rooftop solar PV array, Toronto, Ontario. 70 tons HDG for legs and support rails and also 100 s of meters of steel cable tray for electrical runs. 702 KW. (courtesy American Galvanizers Assn.)

14 Solar PV Projects Using HDG (5) 60 unit housing settlement in Freiburg, Germany utilizing solar PV panels. (Courtesy Industrieverband Feuerverzinken)

15 Solar PV Projects Using HDG (6) Turkish solar PV projects utilizing galvanized structurals (courtesy Alka Group)

16 Solar PV Projects Using HDG (7) Nzema Project Ghana 155MW the third largest solar project in the world $400m on budget 2 year building program scheduled for completion in October 2015 (courtesy Rob White) S.Africa 50 MW package plant (courtesy Rob White)

17 Why is HDG chosen for Solar PV projects? Quick assembly Toughness of the galvanized coating allowed it to be handled without damage or touch-up hostile environments Requirement of very durable coating Requirement that project be maintenance-free for many years in highly visible location Only minimal touchup of exposed steel required during construction Damage resistance and sustainable construction value

18 Solar Water Heating Collector Additions in 2012 Only, Top 10 Countries (total 2013 Capacity 326 GWt)

19 Solar Water Heating Materials Competition Many systems are located on rooftops, a market dominated by aluminum. Rooftop installations do not usually involve welding, a weak point for aluminum fabrication, but depend upon ease of cutting and forming, which, together with the light weight of aluminum structurals, result in its overwhelming choice for rooftop structures. The availability of solar thermal panels that use aluminum structurals in pre-assembled kits is a marketing advantage for aluminum. Hot dip structurals for rooftop solar collectors are only used under conditions of severe wind loads or when long spans are required, allowing steel s higher strength to work in their favor. There may be a marketing opportunity to work with a solar thermal collector manufacturer in producing pre-assembled kits. The durability and galvanic compatibility of galvanized structurals would also be key selling points to promote

20 Wind Energy 2014

21 Wind Energy Projects (1) Wind energy tower at Barton Wind Farm, Shenandoah, PA, USA. 30 tons HDG. (courtesy American Galvanizers Assn.) Wind Energy tower of Keuka Energy, Ainsworth, IA, USA. 8 tons HDG. (courtesy American Galvanizers Assn.)

22 The Manufacturing Base Solar PV and Wind Solar PV Wind Energy Number of Number of Market Companies Market Companies Country Share, % in Top 15 Country Share, % in Top 10 China China USA Denmark Japan USA Canada 4 1 Spain Norway Germany Other 51 1 India Other Installed Wind Energy 2013: 9 GW Offshore 360 GW Onshore There are 100 s of manufacturers of wind towers supporting 100 KW or less

23 Wind Energy Projects (2) Wind Energy Tower of Safaricom mobile telephone carrier, Laisamis, Kenya. 7.5 KW, 24m high tower

24 Offshore Wind Towers Example 50m long, 7.5m max diameter, weight 420 tons Thermal Spraying/ Painting Hall at Titan Wind, Esbjerg, DK

25 Biomass Electric Power Wood Pellet Production

26 Biomass Projects (1) Biomass Fuel Storage Facility, Liverpool, UK. 1,200 tons of galvanized structurals, accommodating 65,000 tons of wood pellets (courtesy UK Galvanizers Assn.) American Renewables Biomass Power Plant, Gainesville, FL, USA. 450 tons of galvanized steel in conveyors, angle and structural members and connections (courtesy American Galvanizers Assn.)

27 Biomass Projects (2) Staffordshire Waste-to-Energy Recovery Facility, Wolverhampton. 23 MW, includes spans of HDG structurals up to 43m (courtesy UK Galvanizers Assn.)

28 Bolzano Waste-to-Energy Plant EGGA 2015 Global Galvanizing Awardee Provides heat and hot water for 8000 inhabitants Reduces CO 2 emissions by 80,000 tons/y

29 Marine And Hydrokinetic Hydrokinetic power generator mounted on submersible pontoon craft for use in rivers or tidal areas. Turbines are mounted on galvanized supports and protected by galvanized grates. The entire electrical package is waterproofed and a power cable is connected to shore. (Alaska Industrial Development and Export Authority)

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31 Summary Renewable energy is a growing market for which general galvanized structurals offer many advantages Many architects and contractors are already familiar with general galvanized work, it is seen as a familiar and reliable material. The main challenge for growth lies with solar thermal and onshore wind energy projects where competitors have established strong positions. Technical and marketing initiatives will be required to ensure further growth.