wind technology area - iacmiwind technology area 2 •30 year history of collaboration with every...

Wind Technology Area

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


• 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)


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


Wind Top 3 US OEMs with

>70% share

of 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


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 - 7

FOA-driven goal for wind turbine blades

Wind turbine market driven by derivatives

of these goals


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


• Average wind levelized cost of energy (LCOE) is a major factor in driving installed wind capacity in the United States


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


• Composite materials

• Composite manufacturing process innovation

• Large blade transportation logistics

• Blade reliability


Department of Energy 2015

Wind turbine blade components (Wind Power Monthly, July 2012)

Challenges of blade transport (SSP Technology)

Challenges of Continued Blade Growth


• 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


Sandia/TPI BSDS 9 m blade

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 composite parts


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


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 of compression molding, resin transfer molding, and injection molding


Reduce Labor Content

• Fabric placement automation

• Pultruded carbon fiber spar caps

Increase Blade Quality

• Nondestructive Evaluation automation

• Fabric placement automation


• Fiber manipulation during layup

Reduce Energy Content

• End-of-life recyclability of thermoplastic resins

• Higher energy capture of longer blades

• Lower transportation costs of segmented blades

Reduce Cycle Time

• Advanced thermoplastic resins


• Nondestructive evaluation automation

IACMI Colorado Technology Area

Wind Blade Manufacturing


Op

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rtun

itie

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Ch

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• 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


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.


Derek Berry (303) 717-8416

[email protected]

Ron Schoon (303) 275-4644

[email protected]

NREL Contact Information

wind technology area - iacmiwind technology area 2 •30 year history of collaboration with every...

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