Wind ind Tec echnolog hnology y Ar Area ea Derek Berry June - - PowerPoint PPT Presentation

Wind ind Tec echnolog hnology y Ar Area ea

Derek Berry

June 17, 2015

2 Wind Technology Area

• 30 year history of collaboration with every major

wind turbine OEM and US blade manufacturer

• Extensive university-based composite material and

manufacturing research at Colorado School of Mines, Colorado State University, and University of Colorado-Boulder

• Largest US university-based turbine blade manufacturing

prototyping facility at Iowa State University

• Wind composite manufacturing scale−up facility

Wind Technology Area

Wind turbine manufacturing

Automation (Viper)

• Fast resin

infusion and curing

Models for

• Preforming

− Infusion

• Cure kinetics
• Performance

Automation

• Fast resin

infusion and curing

Low-cost carbon fiber

• Pultrusion

− Nondestructive Evaluation

• Blade recyclability

3 Wind Technology Area

• High-performance simulation tools
• Wind resource assessment
• Wind forecasting
• Utility grid connectivity
• Economic analysis of turbine technology
• Full-scale structural testing

− Blades − Dynamometer − Field testing

National Wind Technology Center (NWTC)

4 Wind Technology Area

Colorado has more blade facilities (factories plus technical centers) than any other state

The State of Colorado has

• 22 wind industry manufacturing plants
• 29 operating wind farms
• 3 wind research and workforce

development institutions

Source: Winds of Change, E2 Environmental Entrepreneurs

Core Partners Are Capable and Strategically Located

5 Wind Technology Area

Wind

Top 3 US OEMs with >70% share

• f installed US wind

generation capacity US #1 blade manufacturer

Fibers

World’s largest PAN fiber source and leading US furnace manufacturer for Carbon Fiber Top 3 US glass fiber producers

Resins

World leading thermoplastic and thermoset resin providers

Wind Turbine Assembly and Market Leaders

6 Wind Technology Area

IACMI Goals As Stated in the Funding Opportunity Announcement

Focus Areas

• Vehicles
• Wind turbine blades
• Compressed gas storage (Compressed natural gas, hydrogen)

Five Year Technical Goals

• 25% lower carbon fiber-reinforced polymer cost
• 50% reduction in CFRP embodied energy
• 80% composite recyclability into useful products

Impact Goals

• Enhanced energy productivity
• Reduced life cycle energy consumption
• Increased domestic production capacity
• Job growth and economic development

TRL 4 TRL 4 - 7

FOA-driven goal for wind turbine blades Wind turbine market driven by derivatives

• f these goals

7 Wind Technology Area

Historic Growth of Wind Capacity

• Global growth from 6 GW

(1996) to 318 GW (2013)

• About 3% of global electricity

supply in 2013

• US growth from 1.4 GW

(1996) to 61 GW (2013)

Source: Wind Vision: A New Era for Wind Power in the United States, US Department of Energy 2015

Active wind-related manufacturing facilities and wind projects in 2013

8 Wind Technology Area

• Average wind levelized cost
• f energy (LCOE) is a major

factor in driving installed wind capacity in the United States

Source: Wind Vision: A New Era for Wind Power in the United States, US Department of Energy 2015

Average wind LCOE and wind technology scale-up trends Average wind LCOE and US annual installed wind capacity

• Ability to scale wind turbine

technology is a driving force in reducing the average wind LCOE in the United States

Drivers of Wind Capacity Growth

9 Wind Technology Area

• Composite materials
• Composite manufacturing

process innovation

• Large blade transportation

logistics

• Blade reliability

Source: Wind Vision: A New Era for Wind Power in the United States, US Department of Energy 2015 Wind turbine blade components (Wind Power Monthly, July 2012) Challenges of blade transport (SSP Technology)

Challenges of Continued Blade Growth

10 Wind Technology Area

• Wind blade molding cycle time
• Labor content
• Material costs
• Lightweighting of wind turbine components
• Recyclability
• Quality/reliability of structural components

Courtesy of TPI Composites

Drivers for Composites in the Wind Industry

11 Wind Technology Area Sandia/TPI BSDS 9 m blade

Shared Goals for Turbine Composite Structures

• Improve the manufacturing quality
• f structural composite components
• Decrease the cost of composite raw

materials

• Increase the recyclability of composite

wind turbine components at the end of life

• Decrease the embodied energy
• f the manufacturing process for

blades, towers, nacelles, and nose cones

• Reduce the production cycle time
• f turbine composite components
• Enhance the lifetime reliability of

composite parts

12 Wind Technology Area

Wind Blade Challenges and Opportunities

• Reduction in hands-on labor

− Automated fabric laying − Automated tape laying

• Transportation logistics

− Segmented blades

• Recyclability

− Thermoplastics

• Field reliability of blades

− In-process nondestructive evaluation − Structural testing

• Blade structural properties

− Pultruded spar caps

• Time to market

− Additive manufacturing―molds

13 Wind Technology Area Complex automotive structural composite part using injection molding TPI/Sandia CX-100 Blade Infusion

Potential Project Areas for Wind Technology Composite Components

• Thermoset/thermoplastic matrix

development

• Automated fabric placement during

laminate layup

• Automated nondestructive evaluation

during the composite production process

• Pultruded blade and tower sections
• Pultruded structural spar caps
• Additive manufacturing of composite

tooling and components

• Possible overlap with the automotive

technology area of IACMI in the area

• f compression molding, resin transfer

molding, and injection molding

14 Wind Technology Area

Reduce Labor Content

• Fabric placement

automation

• Pultruded carbon fiber

spar caps

Increase Blade Quality

• Nondestructive

Evaluation automation

• Fabric placement

automation

• Pultruded carbon fiber

spar caps

• Fiber manipulation

during layup

Reduce Energy Content

• End-of-life recyclability of

thermoplastic resins

• Higher energy capture of

longer blades

• Lower transportation costs
• f segmented blades

Reduce Cycle Time

• Advanced thermoplastic

resins

• Pultruded carbon fiber

spar caps

• Nondestructive

evaluation automation

IACMI Colorado Technology Area Wind Blade Manufacturing

15 Wind Technology Area

Opportunities Challenges

• Blade joint design challenges
• Load transfer
• Weight penalty
• Increased manufacturing costs
• Reliable field assembly

Potential Wind Turbine Assembly Project: Segmented Blade

• Reduce shipping size of blade segments
• Reduce cost of blade shipping logistics
• Potentially decrease cost of turbine

assembly

• Lower levelized cost of energy

16 Wind Technology Area

Industry and Workforce Development Partners

Source: Winds of Change, E2 Environmental Entrepreneurs, AWEA

Colorado Partners

In 2014, wind energy provided 13.6% of all of Colorado’s in-state electricity production. The wind industry in Colorado has created between 6,000 and 7,000 jobs total as of 2014―which is nearly 10% of the nation’s wind industry workforce.

17 Wind Technology Area

Derek Berry (303) 717-8416 derek.berry@nrel.gov Ron Schoon (303) 275-4644 ron.schoon@nrel.gov

NREL Contact Information