Electronic supplementary material – Part 2
LCA for Energy Systems
Life cycle assessment of electricity transmission and distribution - Part 2: Transformers and substation equipment
Raquel S. Jorge • Troy R. Hawkins • Edgar G. Hertwich
Received: 11 February 2011 / Accepted: 26 August 2011
© Springer-Verlag 2011
Responsible editor: Wulf-Peter Schmidt
R. S. Jorge (*) • R. R. Hawkins • E. G. Hertwich
Industrial Ecology Programme, Department of Energy and Process Engineering, Norwegian University of Science and Technology (NTNU), Trondheim-7491, Norway
e-mail:
(*) Corresponding author:
Tel. +47 73598957
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Inventory data for components, used for compiling the matrix of foreground processes (foreground matrix A)
Data for the inventories for transformers, switchgear, switch systems, disconnectors, circuit breakers and surge arresters are taken from the ABB’s environmental product declarations and detailed data was obtained from a technical report prepared for the transformers at 9.6, 16 and 20 MVA (ABB 2003e). The power mix assumption for production of components is the Italian power mix, except for components produced in Sweden e.g. transformers of 63, 250 and 500 MVA. Power losses were modeled with the average European power mix (Ecoinvent Centre 2007).
1.1. Transformers
The following life cycle stages of the transformers have been modeled: raw materials production, raw materials transportation, manufacturing of transformer, finished product transportation, use phase (load losses and no load losses are modeled separately), maintenance operations and end of life. The functional unit for all transformers is one transformer operating during lifetime (see table S7). The electricity and heating energy input (natural gas) during manufacturing phase was allocated from total electricity and natural gas used in the manufacturing unit at Monselice (ABB 2003e). The manufacturer uses the assumption that heat and natural gas use in manufacturing increases linearly with the transformer capacity, and the same assumption is used here. The inputs are of energy required are:
Electrical energy = 0.467 kWh/kVA.
Natural gas = 0.1893m3/kVA.
The values for emissions in air and water and solid waste generated were also allocated from the totals for the Monselice factory (ABB 2003e).
Table S1. Emissions and wastes from ABB in Monselice (ABB 2003e).
Emissions and waste in manufacturingAir emissions / kg/kVA / 0.000152
Water emissions
COD
BOD
Susp. solid substances
Hydrocarbons
Ammonia
Nitrate
Nitrite
Phosphorus
Waste / mg/kVA
mg/kVA
mg/kVA
mg/kVA
mg/kVA
mg/kVA
mg/kVA
mg/kVA / 107.9
63.17
120.02
1.89
1.26
8.21
0.31
0.63
Hazardous
Regular / kg/kVA
kg/kVA / 0.00926
0.04939
Table S2. Electrical energy and heat used in manufacturing of transformers, according to their rating.
Transformer rating (MVA) / Electrical energy in manufacturing (kWh) / Heat (natural gas) in manufacturing (kWh)0.315 / 147 / 626
9.6 / 4483 / 19082
16 / 7472 / 31803
20 / 9340 / 39754
40 / 18680 / 79508
50 / 23350 / 99385
63 / 29421 / 125226
250 / 116750 / 496927
500 / 233500 / 993854
The calculation of energy losses in the use phase of transformers is based on a scenario of 50% average load in the transformers. Load losses and no load losses for the different transformers were obtained from ABB.
Table S3. Power losses and lifetime for transformers.
Transformer rating (MVA) / Lifetime(years) / No load losses
(KWh) / Load losses
(KWh) / Total losses
(KWh)
0.315 / 30 / 159000 / 376000 / 535000
9.6 / 30 / 2460000 / 6690000 / 9140000
16 / 30 / 3880000 / 8360000 / 12200000
20 / 30 / 3880000 / 13100000 / 16900000
40 / 35 / 6350000 / 26200000 / 32500000
50 / 35 / 6350000 / 37800000 / 44200000
63 / 35 / 6650000 / 41300000 / 47900000
250 / 35 / 25100000 / 78300000 / 103000000
500 / 35 / 28400000 / 149000000 / 177000000
Since no detailed information about transportation was found, we assumed the required amount of km needed for each transformer type is as in (ABB 2003e), which means a total of 5600 km for the components transportation and 500 km from manufacturing site (gate to gate). For maintenance, again according to (ABB 2003e) the transformer tank is painted once again during the lifetime. Assumptions for end-of-life of all transformers: according to the information in the Environmental Product Declarations, metal parts (copper, steel, and aluminum) should be recycled. Remaining parts are landfill. The recycling rate for the metal parts is 90%. The remaining 10% are assumed to go to landfill. Transformer oil should be disposed according to local regulations. To model this, the Ecoinvent unit process used was ‘Disposal, used mineral oil, to hazardous waste incineration’. Below is the list of raw materials used for each transformer. Transformer oil was modeled as Ecoinvent unit process lubricating oil.
1.1.1. Distribution transformers
a) Distribution transformer 315 kVA
Product description: This type of transformer converts power of 11-22 or 33 kV to 250 or 422 V (ABB unknown). The transformer is mainly used in suburban areas, public supply authorities and industry.
Table S4. List of raw materials for production of distribution transformer rated 315 kVA (ABB unknown).
Materials / 315 kVA(kg)
Aluminum sheet
Aluminum wire
Insulation mat.
Other
Porcelain
Steel (electrical)
Steel (tank)
Transformer oil
(mineral oil)
Total weight / 86.3
113.51
59.9
9
11
533
324
340
1477
b) Large distribution transformers: 9.6 MVA, 16 and 20 MVA
Product description: The 9.6 MVA transformer transforms power to 6.3 kV and the 16/20 MVA transformer converts power to 22 kV. Raw materials used as inputs are the same for both the 16 and 20 MVA transformers. The difference for the two types is the values for losses.
Table S5. List of materials for production of distribution transformers rated 9.6, 16 and 20 MVA (ABB 2003a, b).
Materials / 9.6 MVA(kg) / 16/20 MVA
(kg)
Aluminum
Brass
Copper
Kraft paper
Paint
Presspan
Porcelain
Resins
Silver
Steel (electrical)
Steel
Steel sheet
Transformer oil (mineral oil)
Tungsten
Wood
Total weight / 65
40
3526
41
180
296
53
44
0.06
6820
3255
5811
6780
2
366
27279 / 94
25
8673
90
210
566
125
58
0.08
10411
4447
5559
10206
2
517
40983
Table S6. List of raw materials for production of distribution transformers rated 40, 50, 63, 250 and 500 MVA (ABBc, d, e, f).
Materials / 40/50 MVA(kg) / 63 MVA
(kg) / 250 MVA
(kg) / 500 MVA
(kg)
Aluminum
Copper, from which
Copper profile
Copper wire
Glass fiber
Insulation material
Kraft paper
Paint
Presspan
Porcelain
Red brass
Resins
Steel (electrical)
Steel
Steel profile
Steel sheet
Transformer oil (mineral oil)
Wood
Other
Total weight / 93
9031
(8788)
(243)
462
421
38
1120
158
41
6
20050
7600
8258
15500
62778 / 18360
1900
277
334
21200
14479
20000
1890
3060
81500 / 1987
24228
(23837)
(391)
1109
1479
95
5294
2009
188
67165
7500
38073
48000
197127 / 39960
6500
2200
2650
99640
53618
63000
15000
8300
290868
2. High voltage components
2.1. Switchgear
For switchgear, the following life cycle phases are modeled: raw materials production, SF6 losses in manufacturing, use and end of life, transport, and heat and power losses in use phase. The following data is obtained from the EPD report for the switchgear (ABB 2003g, unknown b).
Table S7. Power, heat and SF6 losses for switchgear equipment (ABB 2003g, unknown b).
Gas Insulated Switchgear (kV) / Lifetime(years) / Power losses in use phase
(KWh) / Heat loss in use phase
(kWh) / SF6 losses in manufacturing
(kg) / SF6 losses in use phase
(kg) / SF6 losses in end of life
(kg)
300 / 40 / 34164 / 84797 / 0.7 / 6 / 1.5
420 / 40 / 201830 / 84797 / 2.7 / 21.6 / 5.3
Transport of materials is modeled according to the information on the Environmental Product Declaration (EPD) for the devices and it includes 2350 km by lorry and 10500 km by ship. Also according to the EPD, for end of life, copper is recyclable in 95%, steel in 80% and aluminum in 100. The total amount of landfill waste is 1424 kg for the 300 kV Switchgear and 3815 kg for the 420 kV. The EPD mentions that SF6 is recyclable in 99%, but that was not included here since there is no matching process in the database used (Ecoinvent). Material lists are presented below.
Table S8. List of raw materials for production of Gas Insulated Switchgear (GIS) rated at 300 kV (High voltage) (2003 g).
Materials / 300 kV(kg)
Aluminum
Copper
EPDM (rubber)
Epoxy resin
Polyester
SF6
Stainless steel
Steel
Wood
Total weight / 4069
888
25
528
50
147
420
1274
100
7501
Table S9. List of raw materials for production of Gas Insulated Switchgear (GIS) rated at 420 kV (High voltage) (ABB unknown b).
Materials / 420 kV(kg)
Aluminum
Cardboard
Copper
EPDM (rubber)
Epoxy resin
Nickel
Other
Polycarbonate
Polyester resin
SF6
Stainless steel
Steel
Wood
Total weight / 9172
10
1009
65
1096
3
109
5
80
534
362
2057
1000
15502
2.2. Switch system
For the Plug and Switch system, raw materials production, SF6 losses in manufacturing, power and heat losses, SF6 losses in the use phase and end of life were modeled.
Table S10. Power losses and SF6 losses for Plug and Switch system (unknown c).
Plug and switch system / Lifetime(years) / Power losses in use phase
(KWh) / Heat losses in use phase
(kWh) / SF6 losses in manufacturing
(kg) / SF6 losses in use phase
(kg)
40[1] / 69806 / 84797 / 1 / 4
Table S11. List of raw materials for production of Plug and Switch system (unknown c).
Materials / Plug and Switch(kg)
Aluminum
Copper
EPDM (rubber)
Iron
Other
Resins
SF6
Stainless steel
Steel
Total weight / 785
138
83
614
2
206
36
160
135
2159
The end of life is modeled according to the scenario described in the EPD.
2.3. Disconnectors and circuit breakers
For disconnectors, processes modeled are raw materials production, waste generated in use phase, power losses and end of life.
Table S12. Power losses and SF6 losses for disconnectors and circuit breakers (ABB 2002, ABB 2002b, ABB unknown d, ABB 2004).
Disconnector / Lifetime(years) / Power losses in use phase
(kWh)
Double Break Disconnector type SDB range 123-420 kV
Center Breaker Disconnector type SGF range 123-245 kV
Power Generator Circuit-Breaker, Type HECS
Live Tank Circuit Breaker, Type LTB 145D / 20
20
40
40 / 61615.76
46412.2
182208
121944
Power losses are calculated with the assumption that the average load is 50% of the nominal current.
Table S13. List of raw materials for the production of Double Break Disconnector type SDB range 123-420 kV (245p) (ABB 2002).
Materials / Double Break Disconnector(kg)
Aluminum
Copper
Porcelain
Steel
Mineral oil
Wood
Total weight / 259
63
810
818
0.7
190
2140.7
Table S14. List of raw materials for the production of Center Breaker Disconnector type SGF range 123-245 kV (ABB 2002b).
Materials / Center Breaker Disconnector(kg)
Aluminum
Copper
Plastic
Porcelain
Steel
Wood
Total weight / 91.62
23.16
8.41
420
438.02
165
1146.21
Table S15. List of raw materials for the production of Power Generator Circuit Breaker, Type HECS (ABB unknown d).
Materials / Power Generator Circuit breaker(kg)
Aluminum
Copper
Epoxy Resin
Iron
SF6
Steel
Other
Total weight / 1837
190
239
25
37.4
1377
19.6
3725
Table S16. List of raw materials for the production of a Live Tank Circuit Breaker, type LTB 145D (ABB 2004).
Materials / Live Tank Circuit Breaker(kg)
Aluminum
Copper
Epoxy
Other polymers
Porcelain
PFTE (polymer)
SF6
Silver
Steel
Tungsten
Zinc
Total weight / 166.68
55.56
4.2
4.2
680.6
6.95
4.2
0.0833
458.37
0.1389
6.95
1388
The amount of waste generated during manufacturing, after usage and end of life can be found on the EPD.
2.4. Surge arrester
Only raw materials production, power losses and end of life were modeled for this equipment.
Table S17. List of raw materials for the production of a surge arrester (ABB unknown e).
Materials / Surge arrester(kg)
Aluminum
Cardboard
EPDM (rubber)
Epoxy resin
Steel
Zinc
Total weight / 0.56
1.5
0.36
0.01
0.01
0.58
3.02
In the use phase, 26.31 kWh are accounted for power losses. The equipment is disposed in a landfill site.
3. Medium voltage components
Table S18. Raw materials for production of the Uniswitch (ABB unknown f).
Materials / Uniswitch(kg)
Aluminum
Brass
Copper
EPDM (rubber)
Epoxy resin
Glass
Paint
Polycarbonate
Polyester
Polypropene
SF6
Stainless steel
Steel
Zinc
Total weight / 1.1
0.4
7.6
0.7
22.6
0.1
0.8
0.9
0.1
0.1
0.2
6
89.7
0.5
130.8
The recycling rate for the materials can be found at (ABB unknown f).
References
ABB (unknown) Environmental Product Declaration, Distribution Transformer 315 kVA (ONAN). ABB Distribution Transformers, Australia
ABB (2003 a) Environmental Product Declaration, Large Distribution Transformer 10 MVA (ONAN). ABB T&D: Monselice, Italy
ABB (2003b) Environmental Product Declaration, Large Distribution Transformer 16/20MVA (ONAN; ONAF); ABB T&D Monselice, Italy
ABB (2003c) Environmental Product Declaration, Large Distribution Transformer 40/50MVA (ONAN/ONAF). ABB T&D Unità Operativa Transformatori: Milano, Italy
ABB (2003d) Environmental Product Declaration, Power Transformer 250 MVA. ABB T&D Unità Operativa Transformatori: Milano, Italy
ABB (2003e) Environmental Product Declaration, Power Transformer TrafoStar 63 MVA. ABB Transformers AB: Ludvika, Sweden
ABB (2003f) Environmental Product Declaration, Power Transformer TrafoStar 500 MVA. ABB Transformers AB: Ludvika, Sweden
ABB (2003g) Environmental Product Declaration, GIS Type ELK-14 for 300 kV. ABB Switzerland Ltd, High Voltage products: Zurich, Switzerland
ABB (unknownb) Environmental Product Declaration, GIS Type ELK-3 for 420 kV. ABB Switzerland Ltd, High Voltage products: Zurich, Switzerland
ABB (unknownc) Environmental Product Declaration, Pass MO. ABB T&D SpA – ADDA: Lodi, Italy