Wind ind Tec echnolog hnology y Ar Area ea Derek Berry June 17, 2015
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 turbine manufacturing Automation Models for Automation Low-cost (Viper) • carbon fiber Preforming • Fast resin − Infusion • infusion • Fast resin Pultrusion • and curing infusion Cure kinetics − Nondestructive and curing • Performance Evaluation • Blade recyclability Wind Technology Area 2
National Wind Technology Center (NWTC) • 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 Wind Technology Area 3
Core Partners Are Capable and Strategically Located 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 Source: Winds of Change, E2 Environmental Entrepreneurs development institutions Wind Technology Area 4
Wind Turbine Assembly and Market Leaders Wind Fibers Resins World’s largest PAN World leading Top 3 US OEMs with fiber source and leading thermoplastic and >70% share US furnace thermoset resin of installed US wind manufacturer for providers generation capacity Carbon Fiber US #1 blade Top 3 US glass fiber manufacturer producers Wind Technology Area 5
IACMI Goals As Stated in the Funding Opportunity Announcement Focus Areas TRL 4 - 7 TRL 4 • Vehicles • Wind turbine blades • Compressed gas storage (Compressed natural gas, hydrogen) Five Year Technical Goals FOA-driven goal for wind turbine blades • 25% lower carbon fiber-reinforced polymer cost • 50% reduction in CFRP embodied energy • 80% composite recyclability into useful products Impact Goals Wind turbine market • Enhanced energy productivity driven by derivatives • Reduced life cycle energy consumption of these goals • Increased domestic production capacity • Job growth and economic development Wind Technology Area 6
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 Active wind-related manufacturing facilities and wind projects in 2013 Department of Energy 2015 Wind Technology Area 7
Drivers of Wind Capacity Growth • Average wind levelized cost of energy (LCOE) is a major factor in driving installed wind capacity in the United States 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 Source: Wind Vision: A New Era for Average wind LCOE and wind technology scale-up trends Wind Power in the United States, US Department of Energy 2015 Wind Technology Area 8
Challenges of Continued Blade Growth • Composite materials • Composite manufacturing process innovation • Large blade transportation logistics • Blade reliability Challenges of blade transport (SSP Technology) Source: Wind Vision: A New Era for Wind turbine blade components (Wind Power Monthly, July 2012) Wind Power in the United States, US Department of Energy 2015 Wind Technology Area 9
Drivers for Composites in the Wind Industry • Wind blade molding cycle time • Labor content • Material costs • Lightweighting of wind turbine components • Recyclability • Quality/reliability of structural components Courtesy of TPI Composites Wind Technology Area 10
Shared Goals for Turbine Composite Structures • Improve the manufacturing quality of 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 of the manufacturing process for blades, towers, nacelles, and nose cones • Reduce the production cycle time of turbine composite components • Enhance the lifetime reliability of Sandia/TPI BSDS 9 m blade composite parts Wind Technology Area 11
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 Wind Technology Area 12
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 TPI/Sandia CX-100 Blade Infusion • Additive manufacturing of composite tooling and components • Possible overlap with the automotive technology area of IACMI in the area of compression molding, resin transfer molding, and injection molding Complex automotive structural composite part using injection molding Wind Technology Area 13
IACMI Colorado Technology Area Wind Blade Manufacturing Reduce Cycle Time Increase Blade Quality • Advanced thermoplastic • Nondestructive resins Evaluation automation • Pultruded carbon fiber • Fabric placement spar caps automation • Nondestructive • Pultruded carbon fiber evaluation automation spar caps • Fiber manipulation during layup Reduce Energy Content Reduce Labor Content • End-of-life recyclability of • Fabric placement thermoplastic resins automation • Higher energy capture of • Pultruded carbon fiber longer blades spar caps • Lower transportation costs of segmented blades Wind Technology Area 14
Potential Wind Turbine Assembly Project: Segmented Blade Opportunities • Reduce shipping size of blade segments • Reduce cost of blade shipping logistics • Potentially decrease cost of turbine assembly • Lower levelized cost of energy Challenges • Blade joint design challenges • Load transfer • Weight penalty • Increased manufacturing costs • Reliable field assembly Wind Technology Area 15
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. Industry and Workforce Development Partners Source: Winds of Change, E2 Environmental Entrepreneurs, AWEA Wind Technology Area 16
NREL Contact Information Derek Berry (303) 717-8416 derek.berry@nrel.gov Ron Schoon (303) 275-4644 ron.schoon@nrel.gov Wind Technology Area 17
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