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LET’S LOOK AT THE WIND
ENERGY INDUSTRY.
• It employs over 100,000 people
in Europe. Globally:-• Jan07-Jan08 turnover $20.0bn.
• 20,000MW installed in 12 months.• More than 93,000MW world-wide.
• More than 57,000MW in Europe.
• 22% of Denmark’s electricity.• 34% in Schleswig-Holstein.
• 26.6% pa growth rate.• EU directive targets 22% European
electricity from renewables by 2010.
• EWEA targets 75,000MW by 2010• 172,000MW world-wide by 2010,
turnover over $25bn pa.
From Jan07 to Jan08 that meant over 10000 turbinesin typical sizes of
70m dia. 1.5MW
80m dia. 2.0MW90m dia. 2.5MW
The industry produces 120 blades a day.
Future wind energy growth
I was involved in creating the wind energy industry in the 1980’s. By the mid 1990’s it was becoming clear that the industry was conceptually stuck. For the last decade, my intention has
been to bring through the next generation of wind turbine concepts
and change the cost equation for wind energy so that it is
truly cost competitive with any energy source, without political
support.
The development of technical composites since
1980 (1)
cost
performance
Low cost
glassfibre
Aerospace
composites
Tec
hn
ical
com
pos
ites
The development of technical composites since
1980 (2)New high performance epoxy resins (SP Systems)
New high performance glass and carbon stitched fabrics (Techtextiles)
Wood composites (Composite Technology)
New large scale manufacturing processes
-----------------
All high performance ocean racing yachts
(rewrote the America’s Cup design rules)
Wind turbine rotor technology
(two companies on the Isle of Wight employ 1000 people, turnover £100m)
(European wind turbine rotor industry turnover £2bn)
European wind energy industry employs 100,000 people, turnover £10bn)
(growing at > 25%pa)
The best blades are made of wood
Veneers, glass-cloth and epoxy.
WOOD MICROSTRUCTUREWOOD MICROSTRUCTURE
Ecological PerformanceEcological PerformanceMaterial Energy Stiffness Strength Energy/ Energy/
Stiffness Strength
(GJ/m3) (Gpa) (Mpa) (J/Nm) (kJ/Nm)
Aluminium (Extrusions) 800 70 300 11.4 2.67
Steel (Grade 43 sections) 500 210 275 2.4 1.82
GRP (UD Glass/Polyester) 250 40 300 6.3 0.83
CFRP (UD carbon/Epoxy) 500 125 900 4.0 0.56
Wood (Finnish Birch) 3.8 16 80 0.24 0.048
TYPICAL WOOD COMPOSITE BLADE STRUCTURE
Manufacture of Wood Composite
Blades
Machining root end
WEIGHT BREAKDOWN
Glass
Wood
Resins
Components
Demands for a New Blade Technology
• Production Rate 2 day – 1 day – 12 hour
• Anywhere in world
• Lighter blades for offshore - size
• Improved Health & Safety
Near Term Material OptionsNear Term Material Options
••Glass Polyester, Wet lay upGlass Polyester, Wet lay up - Cheap, heavy, stiff
••Wood Epoxy, Wet lay Vacuum ConsolidatedWood Epoxy, Wet lay Vacuum Consolidated - Cheap,
lighter, stiffer
••Glass Carbon Epoxy,Glass Carbon Epoxy, InfusedInfused - More expensive, light, flexible
••Glass Carbon Epoxy, Glass Carbon Epoxy, Prepreg Prepreg -Most expensive, lightest, most
flexible
••Wood Carbon Epoxy, InfusedWood Carbon Epoxy, Infused-- Cheap, lightest, stiffest
Answer Answer –– Wood Carbon Strip Wood Carbon Strip
InfusionInfusion
• Wood cheap & Carbon (3%) Light
• Vacuum Infusion with strips– Health & Safety – dry materials
– Speed with high solids & low resin volume – shrinkage & distortion
– Low temperature robust tools
• Lower cost materials –than prepreg
Relative Blade WeightsRelative Blade Weights
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
GRP Polyester Wood
Composite
Infused GRE Prepreg GRE Infused Wood
Carbon
Weight
Cost
(achieved)
Process improvementsWood composite
Open moulds
Clean moulds
Gel coat
Cure
Outer glasscloth
Cure
Wood veneers
Vacuum
Cure
Peel and trim
Inner glasscloth
Cure
Trim
Joining adhesive
Place webs
Join moulds
Cure
Drill stud holes
Place studs
Cure
20 steps
2 days
Infused wood carbonOpen moulds
Clean moulds
Gel coat
Cure
Place all dry material
Vacuum
Infuse
Cure
Peel and trim
Joining adhesive
Place webs
Join moulds
Cure
13 steps
1 day
…. And 12 hours is possible
Wood lay-up
Root Fixings built in for infusion
40m Blade Infusing
40m Web placement
Mould closure
This is at 30% overload.
Developing better wind
turbines
(capture more energy)
(use less material)
Developing better blade
shapes
Comparing two blades
Old blade, 23.5m, 3.2 tonnes
New blade, 25m, 2.7 tonnes
Thickness and twist
Power Curves
Thrust
Bending Moment
Typical current cost
distribution
Rotor 29%
Drive train 10%
Generator 25%
E-system/converter 15%
Tower 12%
Nacelle 3%
Yaw mechanism 3%
Transformer 2%
Hydraulics 1%
Are there things you can do to the rotor at no cost, to get more out of
it and out of the generator/electrical system and the tower?
Yes! We haven’t finished yet. If you really want
To get them Ryle’d, you do what Professor Sir
Martin Ryle, Astronomer Royal, was doing in
Cambridge in 1980. He said it was far more
Efficient to survive highWinds like a palm tree
Than like an oak tree.So you let the blades
Hinge. And you can
Capture 50% moreEnergy using 2/3 of
The material.Like this….
Coning rotors
0
200
400
600
800
1000
1200
1400
1600
0.0 5.0 10.0 15.0 20.0 25.0
U (m/s)
V80 (scaled) CONE-1500 LS
A coning rotor produces a very favourably shaped power curve.
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25
U (m/s)
0
200
400
600
800
1000
1200
1400
1600
Pe
lec (
kW
), T
hru
st
(kN
),
To
rqu
e (
kN
m)
Cone angle Pelec Thrust Torque
The thrust and torque are well controlled by the coning.
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
2.0 4.0 6.0 8.0 10.0 12.0
Vavg (m/s)
0
20
40
60
80
100
120
140
CONE-1500 LS V80 (scaled) % Advantage
It gives a higher energy capture than a
similarly rated conventional machine.
The blade bending moment curve is
greatly reduced by the coning.
Optimising wind turbine designs in China
Design machines with high capacity factors and
Use cost-effective Chinese materials
Long transmission
distancesSmooth wind
conditions
Blade material
Ecological PerformanceEcological PerformanceMaterial Energy Stiffness Strength Energy/ Energy/
Stiffness Strength
(GJ/m3) (Gpa) (Mpa) (J/Nm) (kJ/Nm)
Aluminium (Extrusions) 800 70 300 11.4 2.67
Steel (Grade 43 sections) 500 210 275 2.4 1.82
GRP (UD Glass/Polyester) 250 40 300 6.3 0.83
CFRP (UD carbon/Epoxy) 500 125 900 4.0 0.56
Wood (Finnish Birch) 3.8 16 80 0.24 0.048
Bamboo 3.8 25 120 0.15 0.032
Typical current cost
distribution
Rotor 29%
Drive train 10%
Generator 25%
E-system/converter 15%
Tower 12%
Nacelle 3%
Yaw mechanism 3%
Transformer 2%
Hydraulics 1%
Are there things you can do to the drive train and generator at no cost,
to get more out of them and out of the rotor and the tower?
Rare Earth Permanent Magnet Air
cooled direct drive generators
Generator efficiency
The Fray-Farthing-Chen Cambridge Process, developed by the materials science group at
Cambridge University and now being commercialised by a spin-off company called
Metalysis, is a simple one-step electrochemical technology in which metal oxide is directly reduced to metal powder in the solid state, using no exotic
chemicals. This will greatly reduce the cost of Rare Earth material extraction for permanent magnet
generators
Performance of the FFC Cambridge Process
Inner Mongolian wind conditions
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.0 5.0 10.0 15.0 20.0 25.0V (m/s)
6.76 m/s , k = 2
6.76 m/s , k = 2.26.76 m/s , k = 2.52
8.57 m/s , k = 2
8.57 m/s , k = 2.28.57 m/s , k = 2.52
Wind speeds for a Northern Chinese site through the year/day.
Hourly average Coned 1500 rotor power output from this site.
CONE-1500
China wind data @ 40m height
Diurnal averages across winter (Dec 20 - March 20) and summer (June 20 - Sept 20)
Vavg (m/s) k Eann (GWh) CF Vavg (m/s) k Eann (GWh) CF
100
Summer 7.21 5.47 0.42 7.31 5.60 0.43
Winter 9.18 7.84 0.60 9.12 7.74 0.59
80
Summer 6.99 5.15 0.39 7.08 5.29 0.40
Winter 8.90 7.55 0.57 8.84 7.45 0.57
40
Summer 6.34 2.55 4.21 0.32 6.43 2.42 4.37 0.33
Winter 8.08 2.52 6.61 0.50 8.02 2.47 6.52 0.50
Day is from 07:00 - 19:00 averaged throughout the year (+- 1hr variation)
Tower height (m)
Day Night
Average capacity factor 0.51 (0.42 Summer, 0.59 Winter).
(Typical European capacity factors are 0.2 - 0.25.)
Next GenerationWind Turbine Development -
in China
Advanced, high tip speed
Composites rotor technology
Rare Earth permanent magnet
Direct drive generators
R y l e T e c h n o l o g y
The intention is to produce the best wind turbines in the world
- in China
And change the cost equation for wind energy so that it is
truly cost competitive with any energy source, without political
support.
Ryle Technology Company Structure
60% of gross profits reinvested in further development of the company
10% of gross profit distributed as bonus to all staff
30% declared as profit and distributed to shareholders
2 founder shareholders 4% and 6%
90% of shares held in trust by the Ryle Foundation
