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DOE OSTI2024

OpenFAST Modeling of the T-Omega Wind Floating Offshore Wind Turbine System: Preprint

To reduce the cost of offshore wind energy through a more efficient design of the floating support structure, T-Omega Wind developed a novel lightweight and shallow-draft platform concept that aims to achieve a wave-following behavior without resonance amplification. The rotor and generator are carried by four tower legs with each leg supported by a shallow-draft float at the base. In preparation for a more detailed analysis, a coupled aero-hydro-elastic model of the proposed concept is developed in OpenFAST. The detailed modeling approach is presented, including a novel application of the SubDyn substructure dynamics module of OpenFAST to approximate the loads on the axle tube at the tower top from the rotor hub bearings. Preliminary results obtained with the OpenFAST model by rigidifying the substructure and blades indicate that the original sizing of the design can lead to large hub acceleration in the axial/surge direction and in the pitch direction due to platform-pitch motion. The high hub acceleration also potentially leads to large bending moments in the four tower legs. To address the issue identified, an updated design is developed with, among other changes, increased float spacing at the tower base and improved geometry of the tower legs. The new design suggests significantly reduced extreme platform pitch angles under the same conditions and will be further analyzed in the future through full aero-hydro-servo-elastic simulations.

FOWT↗
DOE OSTI2021

Land-Based Wind Market Report: 2021 Edition

The U.S. Department of Energy's 2021 edition of its land-based wind market report provides an overview of key trends in the U.S. wind power market, with a focus on 2020. You can find a report, data file and presentation on the Files tab, below. Additionally, several data visualizations are available on the Visualizations tab. Highlights of this year’s update include: -Wind comprises a growing share of electricity supply: U.S. wind power capacity grew at a record pace in 2020, with 25 billion dollars invested in 16.8 GW of capacity. Wind energy output rose to account for more than 8% of the entire nation’s electricity supply, and is more than 20% in 10 states. At least 209 GW of wind are seeking transmission interconnection; 61 GW of this capacity are offshore wind and 13 GW are hybrid plants that pair wind with storage or PV. -Wind project performance has increased over time: The average capacity factor among recently built projects was over 40%, considerably higher than projects built earlier. The highest capacity factors are seen in the interior ‘wind belt’ of the country. -Turbines continue to get larger: Improved plant performance has been driven by larger turbines mounted on taller towers and featuring longer blades. In 2010, no turbines employed blades that were 115 meters in diameter or larger, but in 2020, 91% of newly installed turbines featured such rotors. Proposed projects indicate that total turbine height will continue to rise. -Low wind turbine pricing has pushed down installed project costs over the last decade: Wind turbine prices are averaging 775–850 dollars/kW. The average installed cost of wind projects in 2020 was 1,460 dollars/kW, down more than 40% since the peak in 2010, though stable for the last three years. The lowest costs were found in Texas and the (non-ISO) West. -Wind energy prices remain low, around 20 dollars/MWh in the interior of the country: After topping out at 70 dollars/MWh for power purchase agreements (PPAs) executed in 2009, the national average price of wind PPAs has dropped. In the interior ‘wind belt’ of the country, recent pricing is around 20 dollars/MWh. In the West and East, prices tend to average 30 dollars/MWh or more. These prices, which are possible in part due to federal tax support, fall below the projected future fuel costs of gas-fired generation. -Wind PPA prices are often attractive compared to wind’s grid-system market value: The value of wind in wholesale power markets is affected by the location of wind plants, their hourly output profiles, and how those characteristics correlate with real-time electricity prices and capacity markets. The market value of wind declined in 2020, following natural gas prices lower and averaging under 15 dolalrs/MWh in ERCOT, MISO, NYISO and SPP; higher values were seen in CAISO, ISO-NE and PJM. -The average levelized cost of wind energy is down to 33 dollars/MWh: Levelized costs, which exclude the impacts of federal tax incentives, vary across time and geography, but the national average stood at 33 dollars/MWh in 2020—down substantially historically, though consistent with the previous two years. Levelized costs were lowest in ERCOT, SPP, and the (non-ISO) West. -The health and climate benefits of wind in 2020 were larger than its grid-system value, and the combination of all three far exceeds the current levelized cost of wind: Wind generation reduces power-sector emissions of carbon dioxide, nitrogen oxides, and sulfur dioxide. These reductions, in turn, provide public health and climate benefits that vary regionally, but together are economically valued at an average of 76 dollars/MWh-wind nationwide in 2020. -The domestic supply chain for wind equipment is diverse: For wind projects recently installed in the U.S., domestically manufactured content is highest for nacelle assembly (>85%), towers (60-75%), and blades and hubs (30-50%), but is much lower for most components internal to the nacelle.

17 WIND ENERGY↗
DOE OSTI2020

WRF Modelling of Deep Convection and Hail for Wind Power Applications

Deep convection and the related occurrence of hail, intense precipitation and wind gusts represent a hazard to a range of energy infrastructure including wind turbine blades. Wind turbine blade leading edge erosion (LEE) is caused by the impact of falling hydrometeors onto rotating wind turbine blades. It is a major source of wind turbine maintenance costs and energy losses from wind farms. In the United States Southern Great Plains (SGP), where there is widespread wind energy development, deep convection and hail events are common, increasing the potential for precipitation-driven LEE. A 25-day Weather Research and Forecasting (WRF) model simulation conducted at convection-permitting resolution and using a detailed microphysics scheme is carried out for the SGP to evaluate the effectiveness in modelling the wind and precipitation conditions relevant to LEE potential. WRF output for these properties is evaluated using radar observations of precipitation (including hail) and reflectivity, in situ wind speed measurements and wind power generation. This research demonstrates some skill for the primary drivers of LEE. Wind speeds, rainfall rates and precipitation totals show good agreement with observations. Here, the occurrence of precipitation during power producing wind speeds is also shown to exhibit fidelity. Hail events frequently occur during periods when wind turbines are rotating and are especially important to LEE in the SGP. The presence of hail is modelled with a mean proportion correct of 0.77 and an odds ratio 4.55. Further research is needed to demonstrate sufficient model performance to be actionable for the wind energy industry and there is evidence for positive model bias in cloud reflectivity.

17 WIND ENERGY↗
DOE OSTI2022

Interregional Renewable Energy Zones in National Transmission Analysis

This report describes the interregional renewable energy zone (IREZ) methodology for national application in the United States. The aim is to develop a data-driven, replicable methodology for use in long-term regional and interregional transmission planning. An IREZ is best understood as a conceptual transmission collection point that is easily accessible to a very high volume of low-cost developable wind and solar energy potential. The objective is to identify opportunities for new high-volume long-distance interregional transmission corridors: a limited number of lines with higher voltages, with reduced total cost per megawatt of transfer capability.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

American WAKE experimeNt (AWAKEN)

The American WAKE experimeNt (AWAKEN) is an international multi-institutional wind energy field campaign to better understand wake losses within operational wind farms. Wake interactions are among the least understood physical interactions in wind plants today, leading to unexpected power and profit losses. For example, Ørsted, the world’s largest offshore wind farm developer, recently announced a downward revision in energy estimates across their energy generation portfolio, primarily caused by underprediction of energy losses from wind farm blockage and wakes. In their announcement, they noted that the standard industry models used for their original energy estimates were inaccurate, and this was likely an industry-wide issue. To help further improve and validate wind plant models across scales from individual turbines as well as interfarm interactions between plants, new observations, such as those planned for AWAKEN, are critical. These model improvements will enable both improved layout and more optimal operation of wind farms with greater power production and improved reliability, ultimately leading to lower wind energy costs.

17 WIND ENERGY↗
DOE OSTI2022

Land-Based Wind Market Report: 2022 Edition

The U.S. Department of Energy's 2022 edition of its Land-Based Wind Market Report provides an overview of key trends in the U.S. wind power market, with a focus on 2021. You can find a report, data file and presentation on the Files tab, below. Additionally, several data visualizations are available on the Visualizations tab. Despite ongoing supply chain challenges, wind energy in 2021 continued to see strong growth, technology improvements, and low prices in the U.S. Key highlights include: Wind comprises a growing share of electricity supply: U.S. wind power capacity grew at a strong pace in 2021, with the 13.4 GW of new additions representing a $\$20$ billion investment and 32% of all newly added U.S. generation capacity. Wind energy output rose to account for more than 9% of the entire nation’s electricity supply. At least 247 GW of wind are seeking transmission interconnection; 77 GW of this capacity are offshore wind and 19 GW are hybrid plants that pair wind with storage or solar PV. Wind project performance has increased over the decades: The average capacity factor among recently built projects was nearly 40%, considerably higher than projects built earlier. The highest capacity factors are seen in the interior ‘wind belt’ of the country. Turbines continue to get larger: Improved plant performance has been driven by larger turbines mounted on taller towers and featuring longer blades. In 2011, no turbines employed blades that were 115 meters in diameter or larger, but in 2021, 89% of newly installed turbines featured such rotors. Proposed projects indicate that total turbine height will continue to rise. Low wind turbine pricing has pushed down installed project costs over the last decade: Wind turbine prices averaged $\$800$–$\$950$/kW in 2021, a 5% to 10% increase from the year prior but substantially lower than in 2010. The average installed cost of wind projects in 2021 was $\$1,500$/kW, down more than 40% since the peak in 2010, though relatively stable in recent years. The lowest costs were found in Texas and the (non-ISO) West. Wind energy prices are on the rise, but generally remain low, around $\$20$/MWh in the interior of the country with higher prices in the West and East. After topping out above $\$75$/MWh for power purchase agreements (PPAs) executed in 2009, the national average price of wind PPAs has dropped—though supply-chain pressures have resulted in increased prices in recent years. In the interior ‘wind belt’ of the country, recent pricing is around $\$20$/MWh. In the West and East, prices tend to average above $\$30$/MWh. These prices, which are possible in part due to federal tax support, fall below the projected future fuel costs of gas-fired generation. Wind PPA prices are often attractive compared to wind’s grid-system market value: The value of wind in wholesale power markets is affected by the location of wind plants, their hourly output profiles, and how those characteristics correlate with real-time electricity prices and capacity markets. The market value of wind increased in 2021, averaging $\$16$/MWh in MISO, $\$19$/MWh in SPP, $\$23$/MWh in NYISO, $\$31$/MWh in ERCOT, $\$33$/MWh in PJM, $\$44$/MWh in ISO-NE, and $\$48$/MWh in CAISO. The average levelized cost of wind energy was $\$32$/MWh for plants built in 2021: Levelized costs, which exclude the impacts of federal tax incentives, vary across time and geography. The national average stood at $\$32$/MWh in 2021—down substantially historically, though relatively stable in recent years. Levelized costs were lowest in ERCOT, SPP, and the (non-ISO) West. The health and climate benefits of wind in 2021 were larger than its grid-system value, and the combination of all three far exceeds the current levelized cost of wind: Wind generation reduces power-sector emissions of carbon dioxide, nitrogen oxides, and sulfur dioxide. These reductions, in turn, provide public health and climate benefits that vary regionally, but together are economically valued at an average of over $\$90$/MWh-wind for plants built in 2021.

17 WIND ENERGY↗
DOE OSTI2023

A Sustainable Wind–Biogas Hybrid System for Remote Areas in Jordan: A Case Study of Mobile Hospital for a Zaatari Syrian Refugee Camp

Access to reliable and sustainable energy in remote areas remains a pressing global challenge, significantly affecting economic development and the quality of life. This study focuses on the implementation of fully off-grid wind–biogas hybrid power systems to address this issue, with a focus on remote healthcare camp facilities. This paper investigates the performance of a hybrid renewable energy system within the context of one of Jordan’s northern remote areas, the Zaatari Syrian Refugee Camp, assessing its efficiency and environmental impact by taking the Zaatari hospital as the case study. Simulations were conducted to evaluate system components, including wind turbines, biogas generators, and diesel generators. A comprehensive evaluation was conducted, encompassing both the operational efficiency of the system and its impact on the environment. This study also considered various scenarios (SC#), including grid availability and autonomy levels, to optimize system configurations. The techno-economic assessment employed the levelized cost of energy (LCOE) as a key performance indicator, and sensitivity analyses explored the impact of diesel costs and wind power fluctuations on the system. Additionally, environmental assessment was conducted to evaluate the environmental effects of hybrid systems, with a specific focus on reducing greenhouse gas emissions. This investigation involved an examination of emissions in three different scenarios. The results indicate that the lowest LCOE that could be achieved was 0.0734 USD/kWh in SC#1 with 72.42% autonomy, whereas achieving 100% autonomy increased the LCOE to 0.1756 USD/kWh. Additionally, the results reveal that in scenarios SC#2 and SC#3, which have a higher proportion of diesel generator usage, there were elevated levels of NO x and CO 2 emissions. Conversely, in SC#1, which lacks diesel generators, emissions were notably lower. The proposed hybrid system demonstrates its potential to provide a reliable energy supply to healthcare facilities in remote regions, emphasizing both economic feasibility and environmental benefits. These findings contribute to informed decision making for sustainable energy solutions in similar contexts, promoting healthcare accessibility and environmental sustainability.

09 BIOMASS FUELS↗
DOE OSTI2022

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↗
DOE OSTI2020

Accomplishments and Mid-Year Performance Report: Wind Energy Program Fiscal Year 2020

Through transformative science and innovation, the U.S. Department of Energy's (DOE's) National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory's (NREL's) Flatirons Campus helps lead the way to a sustainable energy future that powers America with significant levels of reliable, low-cost, and accessible wind energy. Since 1976, NREL has provided an ideal environment for the research and development (R&D) of advanced energy technologies through: Wind energy resource assessments, World-class research facilities, High-performance computing and modeling, Data and technology analysis, Manufacturing breakthroughs, Environmental analysis and wildlife conservation efforts, Education and training programs for a future workforce. These activities enable the innovations needed to advance U.S. wind systems, address market and deployment barriers, and drive down the cost of wind energy with more efficient, more reliable, and more predictable wind energy systems. This report provides an overview of the achievements NREL delivered on behalf of DOE's Wind Energy Technologies Office (WETO) and other partners during the first and second quarters of Fiscal Year (FY) 2020.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2022

Interregional Renewable Energy Zones

Interregional Renewable Energy Zones (IREZs) are a component of the National Transmission Planning Study (NTPS), which analyzes strategies for building out transmission infrastructure to support decarbonizing the electricity sector by 2035. In particular, IREZs envision long-distance transmission corridors for moving large amounts of low-cost renewable energy. An IREZ is a transmission collection point that is easily accessible to a very high volume of low-cost developable wind and solar energy potential. This dataset includes 155 IREZs identified across the continental United States where each IREZ is characterized by its primary and secondary resource.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Circular Economy Modeling Efforts at NREL: Circular Economy Lifecycle Analysis and Visualization (CELAVI) and the Circular Economy Agent-Based Model (ABM)

Circular Economy (CE) aims at decoupling human activities from economic growth and resource use. While CE economic and environmental benefits are often touted by its proponents, increased circularity and improved sustainability do not necessarily go hand-in-hand. The Circular Economy Lifecycle Assessment and Visualization (CELAVI) framework simulates the transition of renewable energy technology supply chains towards circularity and quantifies spatially explicit environmental impacts and supply chain costs. Using wind blade end-of-life (EOL) management as a case study, this presentation will highlight CELAVI's features. Furthermore, envisioned extension to the framework could improve the stakeholder decision model by accounting for logistical and other factors. The CELAVI framework could be leveraged to answer crucial questions regarding renewables EOL management.

circular economy↗
DOE OSTI2021

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↗
DOE OSTI2022

2021 Component Innovation Project Awardee: Bergey Windpower

In recent years, the cost of small wind turbines for homes, farms, and small businesses has decreased dramatically thanks to advances in American technology made possible by research and development support from the U.S. Department of Energy. But further reductions are needed to realize the gigawatt-scale potential of distributed wind energy to help electrify rural America, reduce carbon emissions, and create jobs. Currently, for residential- and farm-scale wind turbines with direct-drive, permanent-magnet alternators, the alternator is the highest-cost component of the wind turbine (excluding the tower). The Bergey Windpower Excel 15 wind turbine incorporates advanced technology in its rotor and controls and will soon incorporate advanced power electronics - but its alternator is based on technology that is more than a decade old. To help reduce capital expenditures of the Excel 15 wind turbine, Bergey Windpower is developing an advanced, lower- cost, permanent-magnet alternator.

CIP↗
DOE OSTI2021

Design of a 3.4-MW wind turbine with integrated plasma actuator-based load control

Historically, cost reduction in wind energy has been accomplished by increasing hub heights and rotor diameters to capture more energy per turbine. The growth in rotor and turbine costs with increasing turbine sizes is also driven by the additional structure that must be added to withstand unsteady aerodynamic loads caused by turbulence, gusts, wind shear, misaligned yaw, upwind wakes, and the tower shadow. In this paper, we present a holistic design solution to integrate active load control using a controllable Gurney flap based on plasma actuators. We illustrate the design solution for a land-based 3.4-MW wind turbine rotor. Comparisons to a baseline reference 3.4-MW wind turbine show significant load reduction (15–18% DEL reduction for flap-wise blade root moments), rotor mass reduction (5–8%), and LCOE reduction (1.16–3.11%). To achieve these results, a comprehensive sequential-iterative design procedure is introduced to integrate the controllable Gurney flap into the turbine design and to drive the design solution toward the best LCOE reduction solution. Results are presented for mapping fatigue load reductions into cost reductions. In addition, an evaluation of active load control extended from Region-III to also include Region-II showed a further 34% reduction in DEL.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Interconnection Cost Analysis in ISO-New England

Electric transmission system operators (ISOs, RTOs, or utilities) require new large generators seeking to connect to the grid to undergo a series of impact studies before they can be built. This process establishes what new transmission equipment or upgrades may be needed before a project can connect to the system and assigns the costs of that equipment. Berkeley Lab has collected interconnection cost data for 194 projects in New England from interconnection studies performed between 2010 and 2021. Project-level cost summary data are available for download on this page. We find: -Interconnection costs have grown over time, especially for projects that withdraw. -Interconnection costs are highest for onshore wind, followed by solar and storage. Natural gas and offshore wind projects tend to cost less to interconnect, in comparison. -Economies of scale exist for solar and possibly storage projects, but not for other resource types. -Wind and solar projects requesting capacity network resource interconnection service have higher interconnection costs, despite being evaluated using the same interconnection standard in the analyzed studies. -Low and high interconnection costs can be found throughout the ISO-NE footprint. -Costs are split fairly evenly between investments at the point of interconnection and within the broader network for active and withdrawn projects, while complete projects incur most costs at the point of interconnection.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Development of a Lower Cost, High Volume, Commercially Available, Precursor for Lower Cost Carbon Fiber for Automotive and Wind Blade Applications

Essentially all carbon fibers used in structural applications are presently manufactured from solution spun polyacrylonitrile (PAN) precursor. Solution spinning is accomplished at relatively low temperatures using very large amounts of environmentally unfriendly solvents that impart major impact to line speed and costs involved with handling and reclaiming the solvents and associated “waste streams” required in spinning and extracting those solvents. Dralon and others have demonstrated the dry spinning of PAN in the production of some acrylic fibers for textile applications, but to this point it has not been demonstrated in the production of carbon fibers. In dry spinning, the PAN polymer is also dissolved into similar solvents, although typically less solvent is utilized to maintain a somewhat higher solids content of 20-50%. The use of lower overall solvent quantities and elimination of the need for solvent/water separation simplifies and reduces the cost of solvent recovery operations. Other portions of the precursor production and carbon fiber manufacturing processes are quite similar. The work described in this report demonstrated that dry spun acrylic fiber can be an attractive candidate for carbon fiber precursor of potential interest to applications looking to capture the specific stiffness (stiffness per unit mass) and specific strength (strength per unit mass) of carbon fiber when produced at a discount relative to commercial carbon fibers in the market today. Dralon has determined that the dry spinning process utilized for producing fibers used as precursors in this project requires 27% less energy versus producing comparable fibers via the industry standard wet spinning process. Identification of carbon fiber manufacturers, as well as applications development and targeted marketing, will be required to achieve significant in-roads into mission areas of interest to DOE, such as automotive applications and wind turbine blades. In support of that activity, initial data produced in this project indicate the innovative approach as described in this report can meet at least the baseline property requirements identified for these applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8

In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.

17 WIND ENERGY↗
DOE OSTI2020

Low cost carbon fiber as potential lightning strike protection for wind turbine blades

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP have become the integral part of load bearing structures in the blade. In this work, we are proposing to utilize the low cost carbon fiber (LCCF), manufactured at Carbon Fiber Technology Facility (CFTF) of Oak Ridge National Laboratory (ORNL) as not only the cost effective alternative to the currently used carbon fiber (CF) but also as the lightning strike protection of the wind turbine blades. Wind turbines often get hit by lightning strikes due to their operating locations. LCCF can provide structural integrity to these gigantic structures and mitigate the effect of lightning strike on them by effectively dissipating the current. Two composite panels made of LCCF were tested against artificial lightning strikes of 100 kA and 200 kA (component A of lightning waveform SAE ARP 5412-B). The results showed very high resilience of LCCF composite due to their high electrical conductivity both in-plane and in through-thickness directions. There was no significant damage (fiber breakage, resin evaporation or delamination) in both the cases.

Kumar, Vipin↗