Periodic Reporting for period 2 - Modvion (Reducing wind energy costs with a stronger, taller wind turbine towers made from wood modules)
Reporting period: 2021-10-01 to 2023-09-30
Founded in 2016, Modvion is a wood technology company with patented technology for high-altitude wind power towers, using a modular design and constructed from laminated veneer lumber (LVL). During spring 2020, Modvion installed a 1st pilot tower, 30m tall, near Gothenburg. The EIC Accelerator project enabled the first commercial LVL wind tower to be installed, close to the urban area Skara in Sweden, during the autumn 2022. The carbon dioxide absorbed by the trees during their growth period remains stored in the LVL wind tower, enabling climate neutral wind energy.
In the next ten years, wind power capacity in Europe is expected to double. To maximize energy output and efficiency, one of the most promising innovations are high-altitude wind power plants. When the height of a tower doubles, the effect from the turbine quadruples and thus lower the cost of energy. Current high-altitude tower components are difficult to transport due to their size – the tower base diameter can’t exceed 4.3 meters due to road infrastructure limits (e.g. tunnels), meaning that special infrastructure would have to be built or other longer routes are chosen. Therefore, a strong, yet modular design, could further advance the production of tall wind power plants and consequently speed up Europe’s transition into greener energy.
Modvion brings to market the next generation of wind turbine towers in laminated wood. Our unique technology, demonstrated in an 30m tall earlier prototype and in the more recent 105 m installation, allows us to create a modular tower, which is large in diameter, easy to assemble, and carbon negative since it stores more carbon than is produced during production. Based on industry data, calculations show that one 150-meter tower built with Modvion’s technology can avoid emissions of 2,000 tons of CO2 when replacing a similar steel tower. In the light of the latest IPCC reports, and that all 27 EU Member States committed to turning the EU into the first climate neutral continent by 2050, the innovations like Modvion’s are much needed.
Current solutions are designed simply to provide sufficient support for a wind turbine and its installed capacity. For a turbine to be cost-effective, it must be available to produce electricity 24 hours per day. At higher altitudes, wind velocity is higher and has less turbulence, which gives wind turbines access to more continuous airflow, thus producing more electricity. There are multiple tall wind tower types, 150 m and above, currently available or under development, each offering various advantages. Modvion’s uniqueness comes from being built from wood and being able to cut CO2-emissions when replacing a steel-based wind turbine tower. Furthermore, a modular tower has a huge advantage when come to transport on public roads.
Thanks to laminated wood having 55% higher specific strength than steel per weight, our towers typically weigh 30% less than steel towers. This gives a huge advantage when coming to site assembly where an extensive cost carrier comes from the time large cranes are needed at site. The cranes hour rate can significantly be reduced when using a less weighty material and modular towers. The total cost of the towers will also be reduced when using a less expensive material, and since the tower construction having 55% higher specific strength reduces the total need of materials in the even higher wind power towers to be constructed.
The EIC Accelerator project enabled the first commercial LVL wind tower to be erected, including development methodology, factory build up and installation at site.
In the next ten years, wind power capacity in Europe is expected to double. To maximize energy output and efficiency, one of the most promising innovations are high-altitude wind power plants. When the height of a tower doubles, the effect from the turbine quadruples and thus lower the cost of energy. Current high-altitude tower components are difficult to transport due to their size – the tower base diameter can’t exceed 4.3 meters due to road infrastructure limits (e.g. tunnels), meaning that special infrastructure would have to be built or other longer routes are chosen. Therefore, a strong, yet modular design, could further advance the production of tall wind power plants and consequently speed up Europe’s transition into greener energy.
Modvion brings to market the next generation of wind turbine towers in laminated wood. Our unique technology, demonstrated in an 30m tall earlier prototype and in the more recent 105 m installation, allows us to create a modular tower, which is large in diameter, easy to assemble, and carbon negative since it stores more carbon than is produced during production. Based on industry data, calculations show that one 150-meter tower built with Modvion’s technology can avoid emissions of 2,000 tons of CO2 when replacing a similar steel tower. In the light of the latest IPCC reports, and that all 27 EU Member States committed to turning the EU into the first climate neutral continent by 2050, the innovations like Modvion’s are much needed.
Current solutions are designed simply to provide sufficient support for a wind turbine and its installed capacity. For a turbine to be cost-effective, it must be available to produce electricity 24 hours per day. At higher altitudes, wind velocity is higher and has less turbulence, which gives wind turbines access to more continuous airflow, thus producing more electricity. There are multiple tall wind tower types, 150 m and above, currently available or under development, each offering various advantages. Modvion’s uniqueness comes from being built from wood and being able to cut CO2-emissions when replacing a steel-based wind turbine tower. Furthermore, a modular tower has a huge advantage when come to transport on public roads.
Thanks to laminated wood having 55% higher specific strength than steel per weight, our towers typically weigh 30% less than steel towers. This gives a huge advantage when coming to site assembly where an extensive cost carrier comes from the time large cranes are needed at site. The cranes hour rate can significantly be reduced when using a less weighty material and modular towers. The total cost of the towers will also be reduced when using a less expensive material, and since the tower construction having 55% higher specific strength reduces the total need of materials in the even higher wind power towers to be constructed.
The EIC Accelerator project enabled the first commercial LVL wind tower to be erected, including development methodology, factory build up and installation at site.
To fulfil the project objectives, Modvion has expanded the project team from 6 to 27 dedicated employees. The expansion needed have required a new office building in the same building as the new tower factory. The team have together designed and built an assembly line in a factory to produce wooden tower modules, developed groundbreaking installation methods and designed the first wooden wind turbine tower made of LVL.
The project management work ensured fulfilment of the objectives and keep track of the time, budget and resources needed. The risk mitigation and the quality work are in progress throughout the total project and the risk register and quality assurance plan are continuously updated.
Early stages of the project focused on the design and development with simulations and thorough testing. The first two years resulted in a well-developed product design that met expectations and requirements set for the tower. This work secures the durability of construction and enables manufacturing of the tower parts.
The manufacturing of tower modules started in late 2022 and continued in 2023. During the manufacturing process several valuable lessons was learned, and the process was tuned accordingly, to reduce the manufacturing time per module. A total of 28 modules was produced and these were transported to the build site for tower assembly.
The tower is erected at a site outside Skara in Sweden. Work have been performed to secure the site, including building permits and landlord agreements. In parallel with the preparation of the site, the installation processes for the site erection work are developed, including HSE manuals and safety requirements. During late 2022 and early 2023 the tower foundation was cast in concrete and site presence was established with a site office and tool containers. The assembly of tower modules to tower sections started during spring and tower erection (section stacking) continued shortly thereafter through the summer of 2023. After the final tower section was lifted during autumn only the wind turbine nacelle and blades needed to be installed to finalize the wind power plant, which was done shortly thereafter.
The project management work ensured fulfilment of the objectives and keep track of the time, budget and resources needed. The risk mitigation and the quality work are in progress throughout the total project and the risk register and quality assurance plan are continuously updated.
Early stages of the project focused on the design and development with simulations and thorough testing. The first two years resulted in a well-developed product design that met expectations and requirements set for the tower. This work secures the durability of construction and enables manufacturing of the tower parts.
The manufacturing of tower modules started in late 2022 and continued in 2023. During the manufacturing process several valuable lessons was learned, and the process was tuned accordingly, to reduce the manufacturing time per module. A total of 28 modules was produced and these were transported to the build site for tower assembly.
The tower is erected at a site outside Skara in Sweden. Work have been performed to secure the site, including building permits and landlord agreements. In parallel with the preparation of the site, the installation processes for the site erection work are developed, including HSE manuals and safety requirements. During late 2022 and early 2023 the tower foundation was cast in concrete and site presence was established with a site office and tool containers. The assembly of tower modules to tower sections started during spring and tower erection (section stacking) continued shortly thereafter through the summer of 2023. After the final tower section was lifted during autumn only the wind turbine nacelle and blades needed to be installed to finalize the wind power plant, which was done shortly thereafter.
The project has so far:
- contributed with 21 new permanent employees within the green energy sector. The project team consists of a good mix of dedicated and highly qualified persons who will bring the first commercial LVL wind tower to the market, meet the three project objectives and thereby contribute towards the goal of a climate neutral continent by 2050.
- rent and renovate an office facility in connection with the factory unit. The factory unit has also been renovated and have been populated with all the equipment needed for the production.
- secured a 20-year Lease Agreement for the erection site and have offered several work opportunities in connection with the production and construction work during 2022-2023.
- achieved construction results which supports the goal that Modvion’s will be the first to install a LVL Wind Power tower which store CO2 instead of emit CO2, since the carbon dioxide absorbed by the trees during their growth period remains stored in the LVL wind tower. This together with many other innovative technologies will hopefully help us prevent the climate crisis.
- a design which are modular which gives the benefit of an easy logistics as the modules do not exceed the physical/legal limits for the transport roads.
- results that support the goal that wind tower in laminated wood can be used to reach higher heights while reducing weight, in comparison with steel towers.
- built a 105-meter wooden wind turbine tower to show the market that a climate neutral and circular alternative is feasible.
- contributed with 21 new permanent employees within the green energy sector. The project team consists of a good mix of dedicated and highly qualified persons who will bring the first commercial LVL wind tower to the market, meet the three project objectives and thereby contribute towards the goal of a climate neutral continent by 2050.
- rent and renovate an office facility in connection with the factory unit. The factory unit has also been renovated and have been populated with all the equipment needed for the production.
- secured a 20-year Lease Agreement for the erection site and have offered several work opportunities in connection with the production and construction work during 2022-2023.
- achieved construction results which supports the goal that Modvion’s will be the first to install a LVL Wind Power tower which store CO2 instead of emit CO2, since the carbon dioxide absorbed by the trees during their growth period remains stored in the LVL wind tower. This together with many other innovative technologies will hopefully help us prevent the climate crisis.
- a design which are modular which gives the benefit of an easy logistics as the modules do not exceed the physical/legal limits for the transport roads.
- results that support the goal that wind tower in laminated wood can be used to reach higher heights while reducing weight, in comparison with steel towers.
- built a 105-meter wooden wind turbine tower to show the market that a climate neutral and circular alternative is feasible.