Renewable Remarks: 4 reasons offshore wind projects may benefit plastics processors

are produced with rotor blades as large as possible, improving turbine efficiency and making them more economically feasible.

There are many ways that plastic is used in the creation, assembly and operation of these enormous structures. Here are four reasons plastic manufacturers may benefit from the increase in offshore wind energy projects.


1.  Produce More Blades

High performance rotor blades used in massive offshore turbines are most often made from molded composite materials such as fiberglass/epoxy resin, fiberglass/polyester, or fiberglass/carbon fiber. Some turbine manufacturers outsource blade production to specialty composite manufacturers who work with high strength fiber-reinforced composite materials and have tooling for creating very large parts. It's also important to have experience with resins, pre-impregnated composite sheets, or final molding compounds.

Some blades are produced as single molded parts, but some are made in multiple sections. High transportation costs and difficulties transporting land-based wind turbine rotor blades longer than 165ft have led to the development of sectioned blades that are able to maintain tight tolerances and precise aerodynamic functions when assembled on site.

Successful sectioned blade concepts for land turbines are being adopted for use offshore. As power generating capacity has grown to the 10 megawatt (MW) designs currently under development, blades have increased to 250 feet in length, with cost, strength, and dimensional capabilities being primary drivers for material selection.


2.  Processes New Materials

New, lighter, stiffer materials that show promise for blade construction may benefit from automated processing techniques plastics manufacturers bring to the industry. Advanced composites manufacturers that work or partner with turbine blade research groups at universities or national labs, such as Sandia National Labs or the recently demonstrated blade made from carbon nanotube reinforced polyurethane at Case Western, may help develop next generation processes or intellectual property for new materials leading to advantageous economies of scale and time to market.

Manufacturers who add capabilities with new materials may be able to enter other markets or offer additional services to new or existing customers.

3.  Supply Additional Components

Smaller non-structural parts in wind turbines such as nose cones, cowlings (doors or access panels that open to expose accessories), and other covers could be plastic from non-specialty compression molders.  Nacelles, the outer structure enclosing the entire generator system located on top of the tower, are usually a steel frame with panels which are often plastic, and can be specialized for large turbines. Several plastic components and small brackets inside the nacelle could be supplied, and even manufacturers who create their own blades may outsource other non-structural plastic components.

Despite the fact that 90% of the weight of wind turbines is from metal (American Wind Energy Association Value Chain Report), the main driver to use plastics on non-structural components is to save cost over sheet metal or cast metal.


4.  Integrate Sensors and Advanced Control Technology

The European Wind Energy Association explored the limits of very large scale wind turbine sizes and what it would take to create turbines in the 10-20MW range with rotor blades on the order of 400ft in length in their 2011 Upwind project. Innovations that can enable blade control to improve efficiency or establish feasibility at that length are being tested and developed for use offshore now, such as:

Composites manufacturers with experience integrating electronic controls into large composite molds may offer unique advantages. The experience gained with these types of integration projects may be useful to enter other markets with similar needs, such as in-situ health monitoring of industrial equipment.

Some of these opportunities require specialized skills while others are more general and could be adopted by many plastics manufacturers. An evaluation of your specific abilities can help determine if entering this growing market with many benefits to plastics manufacturers.



For More information:
European Wind Energy Association - Economics of Wind Energy  Report
American Wind Energy Association
    2011 Market report
    Wind Manufacturing Fact Sheet
    Wind Power Value Chain - Turbine Components

About the Author: Debbie Sniderman writes, owns, and consults with VI Ventures (www.vivllc.com), an R&D and manufacturing consulting company for renewable energy products and technologies. She can be contacted at [email protected].