Lightning No Match for Wind Turbine Blade Protection System
Standing hundreds of feet above ground, wind turbines — like tall trees, buildings, and telephone poles — are easy targets for lightning. Just by virtue of their height, they will get struck.
Lightning protection systems exist for conventional wind turbine blades. But protection was needed for blades made from a new type of material—thermoplastic resin composites — and manufactured using an innovative thermal (heat-based) welding process developed by scientists at the National Renewable Energy Laboratory (NREL).
Thermoplastic materials, like plastic bottles, can be more easily recycled than the thermoset materials commonly used to make wind turbine blades today. While thermoset materials need to be heated to cure, thermoplastics cure at room temperature, which reduces both blade manufacturing times and costs.
NREL’s patent-pending thermal welding process for thermoplastic blades allows for these benefits and even adds to them by replacing the adhesives currently used to bond blade components. The use of welding instead of adhesives eliminates the downsides of added weight and cracking potential.
While thermal welding offers benefits, it also requires adding within the blade a metal heating element — which can attract lightning. As a result, a team of NREL researchers led by Robynne Murray and supported by General Electric (GE) and LM Wind Power (a GE subsidiary) invented a new lightning protection system to keep the novel thermoplastic materials safe.
Thermal Welding Goes for the Patent
In 2018, Robynne Murray, an NREL engineer who specializes in advanced manufacturing methods and materials for wind turbine blades, received a two-year NREL Laboratory Directed Research and Development award to research thermal welding of thermoplastic wind turbine blades.
To make one of these new blades, a vacuum pulls liquid thermoplastic resin into the fiberglass material that is placed in a mold for each blade half. To weld the blade halves together, scientists sandwich a conductive material — such as an expanded metal foil or carbon fiber — between the two blade components and attach a wire to a power source. This creates the heating element. As current flows through this element, the thermoplastic materials melt. Once they are melted, the current is switched off and the bond cools under pressure.
Murray’s research demonstrated that thermal welding can effectively bond thermoplastic wind turbine blade segments. She submitted a patent application on the process in 2018.
A Pathway for Lightning
Thermal welding works. But it leaves the conductive heating element, which can attract lightning, within the blade.
“Thermal welding is an important step in the progression of commercializing thermoplastic materials for wind blades, but what happens when lightning strikes a thermal-welded blade? That was an unanswered question and a big concern,” Murray said. “For thermal welding of thermoplastic blades to become commercially viable, it is critical that the conductive bond lines be protected from a lightning strike.”
Partnering with GE and LM Wind Power, Murray submitted a research proposal to the U.S. Department of Energy’s (DOE’s) Technology Commercialization Fund (TCF). TCF awards are designed to advance technology developed at national laboratories toward commercialization while encouraging lab-industry partnerships.
“With our partnership with GE, a company that can take the thermal welding process to commercialization, our TCF was a strong proposal,” Murray said. “Together, we wanted to determine whether we can protect these blades from lightning strikes and eliminate a big reason to stop us from using the technology.”
In 2019, the team received $150,000 in TCF funding; GE matched that amount.
The research partners set up shop in NREL’s Composites Manufacturing Education and Technology (CoMET) Facility to demonstrate that thermoplastic blades sealed using thermal welding can be protected from lightning strikes.
The team infused an expanded aluminum foil into the blade skin to divert lightning current away from the metal heating elements. They then completed experiments using a simulation that showed that a lightning strike would not cause blade failure with the lightning protection system in place.
Lightning protection To build a lightning shield for their innovative wind turbine blade design, the research team added an expanded aluminum foil layer (left) and a carbon-fiber heating element at the bond lines (right) to enable thermal welding of the blade parts. Photos by NREL
Lightning strike. Researchers used a lightning simulation technique to see where lightning might strike the blade and found that, typically, electricity hit the tip of the blade or one of the edges—but not inside the blade or welded seams where it could cause excessive damage. Photo by NREL
Physical damage tests — which subject the blades to high currents of electricity — demonstrated that about 80% of the electric current went into the expanded aluminum foil layer for lightning protection and not into the blade skin. The carbon fiber beneath the damaged area of the tip was also unscathed.
The research confirmed the design can protect wind turbine blades against failure caused by lightning strikes.
“LM Wind Power and GE Research were excited to work with NREL on the development of this technology and appreciated the support by DOE’s Technology Commercialization Fund. Thermal welding technology for thermoplastic, recyclable wind blades offers a significant opportunity to impact the sustainability and carbon footprint of wind blade structures,” said James Martin, director of blade platform deployment for LM Wind Power. “NREL’s focus on mitigating the lightning damage risks associated with the electrically conductive elements in the welded bond is a key challenge to be overcome, and their work has helped mature the technology toward potential commercialization.”
Still More Questions To Answer
The project has already delivered two strikes against lightning. Murray’s work developing a market-ready thermal welding system, however, is still at bat.
“We answered the question about lightning. But there are more questions to answer and more work to be done,” Murray said. “The next step for us is to do structural validation of thermally welded blade bond lines and blade tip segments. I hope we can do this in the next year or so.”
Read more about this project in Wind Engineering.
Article courtesy of NREL.
Arevon Energy has kicked off operations at Vikings Solar-plus-Storage – one of the US’s first utility-scale solar peaker plants.
The $529 million project in Imperial County, California, near Holtville, features 157 megawatts of solar power paired with 150 megawatts/600 megawatt hours of battery storage.
Vikings Solar-plus-Storage is designed to take cheap daytime solar power and store it for use during more expensive peak demand times, like late afternoons and evenings. The battery storage system can quickly respond to changes in demand, helping tackle critical grid needs.
Vikings leverages provisions in the Inflation Reduction Act that support affordable clean energy, strengthen grid resilience, boost US manufacturing, and create good jobs.
The Vikings project has already brought significant benefits to the local area. It employed over 170 people during construction, many local workers, and boosted nearby businesses like restaurants, hotels, and stores. On top of that, Vikings will pay out more than $17 million to local governments over its lifespan.
“Vikings’ advanced design sets the standard for safe and reliable solar-plus-storage configurations,” said Arevon CEO Kevin Smith. “The project incorporates solar panels, trackers, and batteries that showcase the growing strength of US renewable energy manufacturing.”
The project includes Tesla Megapack battery systems made in California, First Solar’s thin-film solar panels, and smart solar trackers from Nextracker. San Diego-based SOLV Energy handled the engineering, procurement, and construction work.
San Diego Community Power (SDCP) will buy the energy from the Vikings project under a long-term deal, helping power nearly 1 million customer accounts. SDCP and Arevon have also signed an agreement for the 200 MW Avocet Energy Storage Project in Carson, California, which will start construction in early 2025.
Vikings is named after the Holtville High School mascot, and Arevon is giving back to the local community by funding scholarships for deserving Holtville High students.
Arevon is a major renewable energy developer across the US and a key player in California, with nearly 2,500 MW in operation and more than 1,250 MW under construction.
Read more: Minnesota’s largest coal plant goes solar: Sherco Solar comes online
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China’s EV giant BYD is aggressively expanding overseas. As it finalizes plans for yet another EV manufacturing plant, this time in Cambodia, BYD will set up shop next to newly opened Ford and Toyota facilities.
BYD’s impressive growth streak is not slowing down. In October, BYD sold over 500,000 new energy vehicles (NEVs), its fifth straight record sales month and the first time it has crossed the half-million mark in a single month.
With China’s auto market becoming flooded with low-cost competitors, BYD is looking to key overseas markets to drive growth.
After opening its first plant in Thailand earlier this year, a booming EV region, BYD plans to open up shop in another major Southeast Asian market.
According to Khmer Times, BYD is nearing a deal to establish a new EV manufacturing plant in Cambodia. Prime Minister Hun Manet said on Wednesday that the Council for the Development of Cambodia (CDC) is in the final stage of negotiations with BYD to build a new electric vehicle facility in the region.
“We may be aware that BYD is a giant Chinese company specialising in EV production, comparable to Tesla, the largest EV manufacturer in the United States,” Mr Hun Manet said at the event.
BYD closes in on deal for a new EV plant in Cambodia
BYD will follow Toyota, which opened an assembly plant in Cambodia in May, and Ford’s first assembly plant in the region, which opened in June 2022.
Cambodia’s prime minister stressed the importance of attracting new investments. With geopolitical tensions rising, many companies are looking to new locations.
Southeast Asia is expected to become a major electric vehicle hub. The Cambodian government unveiled plans earlier this year to raise automotive and electronics exports to over $2 billion while creating more than 22,000 new jobs.
BYD opening a new EV plant would be “excellent news” for Cambodia, Natharoun Ngo Son, Country Director of EnergyLab, told Khmer Times.
An EV manufacturing plant will “provide an excellent opportunity to reskill or upskill the Cambodian workforce” for new higher-paying jobs. EnergyLab is launching a new skills development program early next year to prepare the Cambodian workforce for the auto industry’s shift to EVs.
The news comes after BYD launched its first electric pickup, the Shark PHEV (BYD Shark 6), in Cambodia last month.
BYD is also planning to open EV plants in Mexico, Brazil, Pakistan, Hungary, and Turkey as it competes with Ford and Toyota in the global auto market.
Electrek’s Take
According to a recent Bloomberg report, BYD is quickly catching up to Ford in global deliveries. BYD outsold Ford in the third quarter by around 40,000 units.
While Ford is cutting more jobs in Europe as part of its restructuring, BYD has been on a major hiring spree as it ramps up production to meet the higher demand.
BYD is known for its low-cost EV models, like the Seagull, Dolphin, and Atto 3, but the Chinese auto giant is expanding into pickup trucks, midsize smart SUVs, and luxury EVs.
Ford is well aware of BYD’s rise in the global auto ranks. CEO Jim Farley has warned rivals in the past about losing significant revenue if they cannot keep up with China. Farley said he was shocked by the advanced tech he saw after a trip to China in early 2023.
Although Ford is shifting gears to focus on smaller, lower-cost EVs, it may be too little too late. Ford is developing what’s promised to be one of the most efficient EV platforms in California, but its first model based on it, a midsize electric pickup, isn’t due out until 2027.
Will BYD overtake Ford in the global auto ranks? Let us know what you think in the comments below.
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Researchers at Canada’s University of Waterloo have developed a new lithium-ion EV battery design that can charge from zero to 80% in just 15 minutes and has a longer lifespan.
The new design also allows batteries to handle up to 800 charging cycles, significantly increasing their lifespan.
Yverick Rangom, a professor in Waterloo’s Department of Chemical Engineering, said, “If we can make batteries smaller, charge faster, and last longer, we reduce the overall cost of the vehicle. That makes EVs a viable option for more people, including those who don’t have home charging stations or who live in apartments. It would also increase the value of second-hand EVs, making electric transportation more accessible.”
The secret sauce here is in the anode, which traditionally relies on graphite. The researchers designed a method to fuse graphite particles together to improve conductivity. This tweak enables lithium ions to move fast without causing typical degradation or safety hazards associated with fast charging.
What’s cool is that they didn’t reinvent the wheel in terms of materials; the team worked with the same lithium-ion components already used in EV batteries today.
“We’re just finding a better way to arrange the particles and providing new functions to the binders that hold them together such as state-of the-art electron, ion, and heat transfer properties,” explained Michael Pope, co-lead of the research and professor at Waterloo’s Ontario Battery and Electrochemistry Research Centre. “This approach ensures that the technology can be scalable and implemented using current production lines, offering a low-cost solution to battery manufacturers.”
The next step? The research team is optimizing the manufacturing process and putting prototypes to the test to gauge industry interest. The goal is to make sure this new battery design isn’t just effective – it has to be scalable and ready for widespread industry adoption.
“It’s crucial that it can be implemented within the existing infrastructure for both battery production and charging stations,” added Rangom, lead researcher for the Battery Workforce Challenge.
The University of Waterloo researchers’ findings are published in the journal Advanced Science.
Read more: North Dakota is ramping up its EV charger installations
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