carbon fibre – challenges and benefits for use in wind ...€¦ · carbon fibre – challenges...
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Carbon F ibre – Cha l lenges and Benef i ts for use in Wind Turbine B lade Des ign
1 ©Copyright STRUCTeam Ltd
Christopher Monk
Engineering Manager
STRUCTeam Ltd
Your composite Business lifecycle is our expertise
We can help you make better decisions, reduce costs, improve efficiency and develop appropriate technologies for your composite business.
2 © Copyright STRUCTeam Ltd
STRUCTeam Introduction
Independent Composite Consultancy
70+ Projects Completed since 2010 across various market sectors
We enable composite applications!
P ro j e c t I n t ro d u c t i o n
3 Copyright STRUCTeam Ltd
Key Partners ¤ Holding Company Composites - HCC
• Experts in Development and Supply of Carbon Materials and Product Forms across Industry Areas
¤ DNV-GL
• Experts in Turbine Development & Certification
Overall Objective ¤ Establish Baseline Blade Design for our
Wind Clients
• Blade design is scalable +/-5m and ‘tunable’ for given turbine data
• Decision Making Tool based upon Sound Business Case Assessment
• Understand and Quantify Benefits associated with Carbon Material use
C a r b o n F i b re u s e i n W i n d B l a d e s
4 © Copyright STRUCTeam Ltd
Carbon Fibre is the material of choice for many Wind Energy OEMs when it comes to the development of large wind blades.
¤ Vestas, Gamesa, Enercon, AREVA and GE are all using Carbon fibre in Wind Blades
¤ Carbon allows
• Better Turbine Performance
• Reduction in Turbine Loads
¤ Wind OEMs need to
• Understand the business case
• Have Confidence in Quality
B l a d e S u p p l y C h a i n I n f l u e n c e
5 Copyright STRUCTeam Ltd
Blade Manufacturer 1
Blade Manufacturer 2
Blade Manufacturer n
Turbine manufacturer
Blade Designer
Integrated System Design to fully realise the value
This is not always structured in this way!
M a t e r i a l C h o i c e fo r W i n d B l a d e s
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Typical Structural Architecture for Wind Blade
Choice between Carbon and Glass in Sparcaps and on Trailing Edge
Structurally Critical Areas – Confidence in Quality Essential
Trailing
Edge
Ro t o r B l a d e D e s i g n P ro c e s s
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Aero Design
Structural Design
Component Surface Areas and
Bill of Materials
Carbon Material Commercial Data
Carbon Material Technical Data
Tooling Cost and Manufacturing
Cost Assessment
Glass Material Technical Data
Materials Cost and Supply
Chain Feasibility
Aero Performance Assessment
Overall Business Case Assessment
Turbine Data
STL HCC
Client
Turbine Load Assessment
Re s u l t s o f t h e S t u d y
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Glass vs. Carbon Blade Comparison
Geometry Comparison ¤ Better Aero Performance
¤ Lower overall turbine loads
Glass Blade Carbon Blade Difference
Mass (tonnes) 35 26 -25%
Cost (k€) 190 244 +28%
C a r b o n v s G l a s s B l a d e – C A P E X C o s t s
10 © Copyright STRUCTeam Ltd
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
Glass BladeRotor
Carbon BladeRotor
Turbine Component Cost Estimates (k€)
Comparison of Overall System Costs
Rotor Costs Nacelle Structure Balance of System Drive Train Tower Substructure
Overall Saving of 115k
€ per turbine (1-2%)
+16% -9% +1% -2% -7% -3%
C a r b o n v s G l a s s B l a d e – E n e r g y Y i e l d
11 © Copyright STRUCTeam Ltd
Aero Benefit from Carbon vs Glass Blade:
¤ Thinner more slender blade gives overall lower loads on Turbine
¤ AEP is maintained or even slightly better than for glass (1.1% benefit at TSR=10)
Lower CAPEX + Increased AEP =
LOWER COST OF ENERGY
TSR Carbon Cp Annual mean Wind Speed
Carbon AEP (MWh)
Glass AEP (MWh)
% AEP Benefit
10 0.506 8 26476 26193 1.1%
C a r b o n v s G l a s s B l a d e B e n e f i t s – Fa r m L e ve l
© Copyright STRUCTeam Ltd 12
Reduced CAPEX + Higher Energy Yield = Lower Cost of Energy
¤ Apply Representative Cost Model to a 500MW Offshore Farm (83 Turbines)
¤ 33.7M € over 25 year life or 1.3M €/year saving for typical farm
-15000
-10000
-5000
0
5000
10000
15000
20000
25000
30000
35000
Carbon BladesCost Premium
(3 Blades)
Direct Cost BenefitsFor Turbine fitted with
Carbon Blade(Includes premium of
Carbon Blades)
Estimated Operationalbenefits
For Turbine fitted withCarbon Blade
Pe
r W
ind
Far
m B
en
efit
(M€
)
CoE Benefit (Yr 21-24)
CoE Benefit (Yr 16-20)
CoE Benefit (Yr 11-15)
CoE Benefit (Yr 6-10)
CoE Benefit (Yr 1-5)
Turbine Cost Saving
Carbon Investment
9.5M €
33.7M €
Overall benefit is 43.2M €
C a r b o n v s G l a s s B l a d e - D e s i g n F l ex i b i l i t y
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Blades are often designed as a Hybrid Glass/Carbon solution
Tune the overall rotor mass and blade price point to exact turbine capacity
Client to take the
decision on
where to draw
this line
C a r b o n v s G l a s s B l a d e – E n a b l i n g L a rge r Ro t o r
© Copyright STRUCTeam Ltd 14
Keep rotor mass same but increase size
10% load reduction allows 3% larger rotor
1.5% overall increase energy production
Much more competitive product offering ¤ Lower CoE from higher energy output per turbine
¤ Fewer turbines per farm
A c h i e v i n g C o n f i d e n c e i n Q u a l i t y
© Copyright STRUCTeam Ltd 15
Design for Manufacture to ensure quality
Repeatable and Robustness product and process:
¤ Material format
¤ Ability to inspect/control the finished product
Very large volume due to sheer scale of the product
¤ Supply chain robustness and longevity
C o n c l u s i o n s
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There are opportunities for further use of carbon fibre in wind
Enabling the Application requires ¤ Thorough Examination of Business Case
¤ Adaptable Designs considered as integrated system
Confidence In Quality ¤ Product Forms Developed With Manufacturing Process Engineers and
Blade Designers
Q u e st i o n s a n d C o m m e n t s
17 © Copyright STRUCTeam Ltd
Christopher Monk
Engineering Manager
00 44 1983 240 534
00 44 7718 425 240