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At least 73 records · Page 4

Invertible Neural Networks for Aerodynamic Design of Wind Turbine Blades

The state-of-the-practice methods for aerodynamic design of wind turbine blads use linearized blade element momentum theory (BEM) to optimize the twist and chord profiles from a pre-selected set of 2D airfoil shapes. In this work, we apply invertible neural network (INN) tools to enable the rapid inverse aerodynamic design of wind turbine blades including component airfoils. The INN is trained on data obtained through the use of robust automated mesh generation and the HAMSTR computational fluid dynamics solver with advanced turbulence and transition models validated for turbine applications. Our design technique is a significant improvement over the state-of-the-practice linearized blade element momentum (BEM) techniques in capturing 3D nonlinear aerodynamic effects that are critical for optimal design of the rotors. This is made possible by developing sparse, invertible neural networks (INNs) for inverse design and optimization that realize a 100x cost reduction compared to adjoint-based computational fluid dynamics (CFD) approaches, while enabling increased robustness of the final design. We demonstrate the INN tool for design of a section of the NREL 5-MW blade. All generated shapes satisfy the desired aerodynamic characteristics, demonstrating the success of the INN approach for inverse design of wind turbine blades.

aerodynamic design↗

Infusible Thermoplastic Composites for Wind Turbine Blade Manufacturing: Fatigue Life of Thermoplastic Laminates under Ambient and Low-Temperature Conditions

Traditionally, thermoset resins such as polyesters (PE) and epoxies are used as the polymer matrix for construction of wind turbine blades. However, concern about their end-of-life treatment garners interest to use thermoplastics for increased recyclability. However, the high viscosity of molten thermoplastics inhibits their use in manufacturing wind turbine blades with injection or compression molding. A recently developed, infusible, reactive thermoplastic resin overcomes this technological barrier. Toward verifying that this recyclable resin is suitable for use in wind turbine blades, a dataset of R?=?0.1 and R?=?10 fatigue data for glass fiber-reinforced acrylic composites is provided and equal fatigue life to industry standard epoxy and unsaturated PE resin systems is demonstrated. Specifically, R?=?0.1 fatigue data for acrylic composites at room temperature and -30?degrees C for verification of low-temperature performance are tabulated. To elucidate failure mechanisms, in situ mechanical testing with X-ray computed tomography demonstrates that damage accumulation occurs by crack propagation along the fiber-matrix interface under cyclic loading. Infrared (IR) thermography predicts failure points in composites specimens with porosity defects introduced from nonideal manufacturing processes. Furthermore, these manufacturing defects are shown to compromise the fatigue life of the acrylic laminates by an order of magnitude.

effect of defects↗

Offshore Wind Turbine Blade (85 to120meters ultra-long blade) static and fatigue test

Offshore blades are not just longer, they are wider, heavier and more flexible. These longer blades are a key component of larger wind turbines and for turbines to be more efficient in low wind speeds. These longer blades help reduce the LCOE further and make offshore wind even more competitive. As described earlier, it is essential for the blades to be fully tested to verify and validate the blade designs and manufacturing processes to ensure a reliable product is installed in the field. Through this project WTTC developed and procured new testing equipment required to test longer blades with larger deflections and higher loads. R&D’s BCDA system commissioned was the largest fatigue test exciter system in the world and set the bar for other blade testing facilities worldwide.

17 WIND ENERGY↗

Wind Turbine Materials Recycling Prize Phase 2 (Commercialization of Wind Turbine Blade Waste (WTBW)-Based, Lightweight, Cementitious Composite Materials): Cooperative Research and Development Final Report, CRADA Number CRD-24-31305

The National Laboratory of the Rockies (NLR) and AltiSora, LLC., will develop new lightweight cementitious composite material technologies that will utilize wind turbine blade waste as a raw material to; (1) allow a high value addition (2) at low cost, enabling (3) a significant waste consumption volume; while (4) consuming the entire wind turbine blade, without (5) creating any waste or emissions and to also (6) offer specific benefits to communities involved.

17 WIND ENERGY↗

Atmospheric Drivers of Wind Turbine Blade Leading Edge Erosion: Review and Recommendations for Future Research

Leading edge erosion (LEE) of wind turbine blades causes decreased aerodynamic performance leading to lower power production and revenue and increased operations and maintenance costs. LEE is caused primarily by materials stresses when hydrometeors (rain and hail) impact on rotating blades. The kinetic energy transferred by these impacts is a function of the precipitation intensity, droplet size distributions (DSD), hydrometeor phase and the wind turbine rotational speed which in turn depends on the wind speed at hub-height. Hence, there is a need to better understand the hydrometeor properties and the joint probability distributions of precipitation and wind speeds at prospective and operating wind farms in order to quantify the potential for LEE and the financial efficacy of LEE mitigation measures. However, there are relatively few observational datasets of hydrometeor DSD available for such locations. Here, we analyze six observational datasets from spatially dispersed locations and compare them with existing literature and assumed DSD used in laboratory experiments of material fatigue. We show that the so-called Best DSD being recommended for use in whirling arm experiments does not represent the observational data. Neither does the Marshall Palmer approximation. We also use these data to derive and compare joint probability distributions of drivers of LEE; precipitation intensity (and phase) and wind speed. We further review and summarize observational metrologies for hydrometeor DSD, provide information regarding measurement uncertainty in the parameters of critical importance to kinetic energy transfer and closure of data sets from different instruments. A series of recommendations are made about research needed to evolve towards the required fidelity for a priori estimates of LEE potential.

17 WIND ENERGY↗

Design-Space Exploration for Inverse-Design of Wind Turbine Blades Using Data-Driven Methods

The state-of-the-practice aerodynamic design methods for wind turbine blades is typically based on Blade-Element Momentum (BEM) theory using a pre-designed frozen family of airfoils. The airfoils are themselves typically designed using panel methods. The design of the next-generation of large flexible rotors will need to capture the non-linear aerodynamics and three-dimensional flow to reduce the levelized cost of wind energy. Data-driven methods for aerodynamic design using data generated by computational fluid dynamics offer an attractive alternative to BEM-based methods that captures the non-linear aerodynamics of the component airfoils as well as the root and tip sections. In this work, we develop and demonstrate a framework to "smartly" explore the relevant design space in combination with an appropriate automated CFD pipeline to evaluate the aerodynamics of each design. The design-space exploration framework uses appropriate perturbations to the airfoil shape and induction profile from a baseline shape in combination with the inverse-design using BEM. The resulting designs are evaluated using an automated CFD pipeline using the in-house CFD solver framework "Mercury". We perform verification and validation to establish the capability of the Mercury framework to predict the aerodynamic performance of wind turbines. The CFD simulation of the perturbed blade shapes are optimized to restart from the converged baseline simulation to reduce the computational time. Finally, we demonstrate the design-space exploration technique for the design of the outboard section and the full rotor using perturbations to the shape and operating conditions of the NREL 5-MW turbine.

aerodynamic design methods↗

Wind turbine blade material in the United States: Quantities, costs, and end-of-life options

Wind energy has experienced enormous growth in the past few decades; as a result, there are thousands of wind turbines around the world that will reach the end of their design lifetimes in the coming years. Much of the material in those turbines can be recycled using conventional processes, but the composite material that is the main component of the blades is more challenging to recycle. In the United States, turbine blades may be disposed of in landfills, adding a new solid waste stream to the material already being landfilled. This paper presents a spatially resolved estimate of the mass and volume of wind turbine blade waste in each state by 2050 and compares these amounts to estimates of the remaining landfill capacity by state. In this work, we estimate costs for each stage of the disposal process to indicate cost levels for alternatives. Assuming a 20-year turbine lifetime, the cumulative blade waste in 2050 is approximately 2.2 million tons. This value represents approximately 1% of remaining landfill capacity by volume, or 0.2% by mass. We also find that the current cost of disposing of blades in large segments or through grinding is relatively low in comparison to the overall life-cycle cost of energy. Based on these findings, landfill space constraints and disposal costs appear unlikely to motivate a change in waste handling strategies under current policy conditions. Instead, more profound shifts in recycling technologies, blade materials, or policy may be needed to move towards a circular economy for wind turbine blades.

17 WIND ENERGY↗

Development of wind turbine blade recycling baselines in the United States

Over the past several years, the wind energy industry has received scrutiny regarding wind turbine blade (WTB) recycling due to the landfilling of WTBs caused by a lack of industrially viable recycling solutions. The amount of WTBs that will need to be recycled is set to increase in the United States as the deployment of wind energy is expected to rapidly grow to meet the nation's energy goals by 2035. While significant progress has been made worldwide, it is still unclear which WTB recycling solutions would be the most cost and energy effective within the United States for the existing fleet of wind turbines. To guide researchers and industry with a clear path forward, a range of options for WTB recycling in the United States are modeled through development of baseline scenarios and the use of formal life cycle assessment (LCA). Model data have been collected through literature review, industry engagement, and expert opinion regarding current end of life practices and considerations surrounding equipment, labor, and logistics. A detailed baseline for WTB decommissioning processes has been developed and used to assess alternative approaches, such as on-site shredding to compare the impacts on greenhouse gas (GHG) emissions. The developed LCA model and baseline scenarios for WTB recycling is used to assess the current WTB decommissioning practices in the United States along with emerging recycling pathways, including cement kiln co-processing and pyrolysis. Initial findings indicate that there are different approaches to decommissioning WTBs in the United States, each of which has unique implications for recycling. In light of this finding, additional results from the modeling will be used to better understand decommissioning practices and assist in making educated decisions on recycling pathways for the future. Throughout the analysis, focus was given to where international efforts might differ from the United States. WTB recycling is occurring worldwide, and different countries have different drivers for creating markets for recycled WTB materials. The contrasts and similarities between the United States and other countries offer insight to areas of opportunity that the United States could investigate and areas that can be readily transferred from existing solutions. By modeling and characterizing the current decommissioning practices and potential recycling solutions for the United States, a clearer vision will be created for pathways forward as to how to handle end of life WTBs to enable more efficient and cost-effective opportunities for material recovery from end-of-life WTBs.

Korey, Matt↗

VitriEdge: Repairable & Durable Vitrimer Coatings for Wind Turbine Blade Leading Edges

The primary goal of this Level 1b incubator project was to explore the use of vitrimer coatings for repair of leading-edge erosion on end-of-life wind turbine blade surfaces, beyond coating strength of adhesion which has previously been demonstrated in the Level 1a project. Uniform vitrimer coatings (thickness: 400 µm) were applied to two end-of-life wind turbine blades for flexural, fatigue, and laminate tensile testing where the addition of the coating did not produce any statistical variation in tensile properties with minor drops in flexural strength for some laminate formulations. However, a <2% variation in storage modulus was measured for laminate structures (i.e., blade samples with vitrimer coatings) across 100,000 flexural cycles and upon laminate tensile failure, the vitrimer coatings displayed no visible signs of delamination. In addition, three methods to heal vitrimer coating damage was displayed: oven heating, addition of hot water, and a forced convection heat gun. All three heating and healing mechanisms demonstrated significant healing with scratch depths decreasing between 79-91% at healing times ranging between 1-min and 10-minutes. Finally, a water jet machine was used to simulate rain erosion for both the blade surfaces and vitrimer-coated blade surfaces where the diameter and depth of the damage was recorded as a function of exposure time, water pressure, height of exposure, and angle of exposure. Of interest, while the vitrimer coating did not significantly lessen the damage experienced during rain erosion, the addition of vitrimer composite coatings(5 wt.% mica addition) did result in a crack-resistant, durable coating capable of self-healing behavior and in all cases the angle of rain exposure was the most critical parameter explored. It is crucial to continue exploring this space where vitrimer coatings are of interest for both their self-healing properties and potential use as reversible adhesives.

17 WIND ENERGY↗

The inclusion of uncertainty in circularity transition modeling: A case study on wind turbine blade end-of-life management

The transition to a more circular economy (CE) is complex and hard to predict, including in sustainable energy technologies. Many sources of uncertainty make it challenging to model CE scenarios and their potential benefits. As an example, the high variability in costs and revenues of different recycling options makes future wind turbine blade recycling highly uncertain. To better understand this challenge, the circular economy, life cycle assessment and visualization (CELAVI) framework - a discrete event simulation and life cycle assessment framework - is modified to incorporate uncertainty analysis capabilities. Moreover, a 3-step procedure that covers different aspects of uncertainty in CE studies and includes a Monte-Carlo analysis is proposed. The procedure is tested in a case study on wind turbine blade recycling using CELAVI. Results highlight that grinding and landfilling costs are the most influential parameters for wind power circularity. The model's output coefficients of variation (when input parameter uncertainties are propagated) are between 92% and 384% depending on the indicator. The approach developed in this study may help researchers and decision-makers who study circularity prioritize their data collection effort. Finally, our method contributes to a mounting yet critical body of research: the measurement of uncertainty in circularity transitions.

17 WIND ENERGY↗

High temporal frequency data from a four turbine, blade-resolved wind farm simulation with ExaWind

The data was generated with ExaWind (https://github.com/Exawind) which couples AMR-Wind (https://github.com/Exawind/amr-wind/), Nalu-Wind (https://github.com/Exawind/nalu-wind), TIOGA (https://github.com/Exawind/tioga), and OpenFAST (https://github.com/OpenFAST/openfast). This is a large-scale simulation of a blade-resolved wind farm using the ExaWind software stack. ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. Another application, OpenFAST, handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. This particular simulation includes four blade-resolved wind turbines operating in a turbulent atmospheric boundary layer. The AMR-Wind solver uses 500 million cells and is being solved on 256 AMD GPUs of the Oakridge Leadership Computing Facility Frontier supercomputer. Each turbine is assigned its own Nalu-Wind solver with over 13 million elements per turbine and solved using 448 CPU cores, for a total of 1792 CPU cores. For each node, 56 cores contain Nalu-Wind, while 8 cores correspond to AMR-Wind operations on the GPUs. Consequently, ExaWind is entirely utilizing the CPUs and the GPUs of the nodes concurrently. The data used in the visualization is full flow field data output from the simulation. It is lossy-compressed to a specific accuracy using ZFP and written to disk every 16 time-steps to enable real-time flow visualization. The flow fields are sampled at a high temporal frequency to enable real-time, 24fps visualization. The flow fields are sampled every 12 simulation time steps (every 0.04132s).

17 WIND ENERGY↗

Numerical simulation of vortex-induced vibration response of a single IEA 10-MW wind turbine blade

Three-dimensional simulation of vortex-induced vibration (VIV) of a single International Energy Agency (IEA) 10-MW reference wind turbine blade with a length of 97.325 m is performed using the ExaWind stack, an open-source suite of codes. This study aims to illustrate the spanwise VIV response characteristics and cross-validate the results with an existing commercial framework. Five near-body meshes and three time steps are selected for the convergence study. To improve computational efficiency, several VIV triggering methods are also compared to shorten the VIV development period. The ExaWind-based VIV simulation strategy for a single IEA 10-MW blade is determined. First, the modal shape is validated against published results. Then, spanwise VIV responses of four blade configurations under a fixed and varied incoming flow velocity are analyzed. Results show that the VIV response is dominated by the first edgewise (second overall) mode. Little first-mode contributions appear near the second-mode node, producing a pi phase jump, and a higher harmonics response occurs near the blade root. Rotational degrees of freedom are minor compared with translational motion. The response versus reduced velocity is analyzed, showing a two-branch behavior similar to that of VIV for a bluff cylinder. Across all tested cases, the dominant frequency remains locked to the natural frequency of the second mode with no observed desynchronization. A mild deviation is observed for the case of 90-degree pitch and 310-degree azimuth rotation near a reduced velocity of 6, which will be examined with additional cases in future work. These findings indicate that severe VIV responses can arise under specific configurations and flow conditions, thereby increasing the potential for VIV fatigue damage and requiring greater attention during operation.

17 WIND ENERGY↗

Toward the Advanced Manufacturing of Land-Based Wind Turbine Blades: Preprint

The National Renewable Energy Laboratory (NREL) and General Electric (GE) are partners within the Additive and Modular Enabled Rotor Blades and Integrated Composites Assembly (AMERICA) project. AMERICA aims to develop advanced manufacturing solutions to reduce labor and cycle time while increasing recyclability of wind turbine blades. The project is funded by the Advanced Manufacturing Office (AMO) of the U.S. Department of Energy (DOE). This paper describes the techno-economic analysis of the novel manufacturing process applied to the tip of the blade of a representative land-based wind turbine. A comparison to a standard manufacturing process is established, highlighting challenges and opportunities. Several uncertainties affect the analysis, but with the current set of assumptions, the tip adopting advanced manufacturing is predicted to lower labor by 21%, cycle time by 39%, and total blade tip costs by 15% while simultaneously increasing production quality and adopting recyclable thermoplastic resin.

3D printing↗

A Methodology for Robust Load Reduction in Wind Turbine Blades Using Flow Control Devices

Decades of wind turbine research, development and installation have demonstrated reductions in levelized cost of energy (LCOE) resulting from turbines with larger rotor diameters and increased hub heights. Further reductions in LCOE by up-scaling turbine size can be challenged by practical limitations such as the square-cube law: where the power scales with the square of the blade length and the added mass scales with the volume (the cube). Active blade load control can disrupt this trend, allowing longer blades with less mass. This paper presents the details of the development of a robust load control system to reduce blade fatigue loads. The control system, which we coined sectional lift control or SLC, uses a lift actuator model to emulate an active flow control device. The main contributions of this paper are: (1) Methodology for SLC design to reduce dynamic blade root moments in a neighborhood of the rotor angular frequency (1P). (2) Analysis and numerical evidence supporting the use of a single robust SLC for all wind speeds, without the need for scheduling on wind speed or readily available measurements such as collective pitch or generator angular speed. (3) Intuition and numerical evidence to demonstrate that the SLC and the turbine controller do not interact. (4) Evaluation of the SLC using a full suite of fatigue and turbine performance metrics.

17 WIND ENERGY↗

Autonomous Sensor System for Wind Turbine Blade Collision Detection

This paper presents an automated blade collision detection system for use on wind turbines, toward the goal of supporting monitoring and quantitative assessment of wind energy impacts on wildlife. A wireless, multisensor module mounted at the blade root measures surface vibrations, and a blade-mounted camera provides image capture of colliding objects. Using sensor data recorded during field testing of the system on an operational wind turbine, we present the development, training, and testing of automated detection algorithms for collision detection using machine-learning approaches. In particular, we compare the use of a new two-step, anomaly-based classification algorithm with conventional adaptive boosting and amplitude-based detection techniques, where the two-step approach improves average precision for the experimental data set. This integrated sensor and classification systems demonstrates a new approach for automated, on-blade collision detection for wind turbines, with broad utility across structural health monitoring applications.

17 WIND ENERGY↗

Design for Recycling Principles Applicable to Selected Clean Energy Technologies: Crystalline-Silicon Photovoltaic Modules, Electric Vehicle Batteries, and Wind Turbine Blades

Abstract The global growth of clean energy technology deployment will be followed by parallel growth in end-of-life (EOL) products, bringing both challenges and opportunities. Cumulatively, by 2050, estimates project 78 million tonnes of raw materials embodied in the mass of EOL photovoltaic (PV) modules, 12 billion tonnes of wind turbine blades, and by 2030, 11 million tonnes of lithium-ion batteries. Owing partly to concern that the projected growth of these technologies could become constrained by raw material availability, processes for recycling them at EOL continue to be developed. However, none of these technologies are typically designed with recycling in mind, and all of them present challenges to efficient recycling. This article synthesizes and extends design for recycling (DfR) principles based on a review of published industrial and academic best practices as well as consultation with experts in the field. Specific principles developed herein apply to crystalline-silicon PV modules, batteries like those used in electric vehicles, and wind turbine blades, while a set of broader principles applies to all three of these technologies and potentially others. These principles are meant to be useful for stakeholders—such as research and development managers, analysts, and policymakers—in informing and promoting decisions that facilitate DfR and, ultimately, increase recycling rates as a way to enhance the circularity of the clean energy economy. The article also discusses some commercial implications of DfR. Graphical Abstract

36 MATERIALS SCIENCE↗