How zero-waste tech paves the way for sustainable wind turbine manufacturing

Wind power stands as a beacon of hope in the global drive towards renewable energy sources. As the demand for wind power increases, so does the need for efficient manufacturing processes for wind tower turbines. These turbines play a critical role in energy production, especially in the context of a changing world that values eco-friendly power solutions.

According to the IEA, wind electricity generation soared by 14% in 2022, reaching over 2,100 TWh globally, with China leading the way with 37 GW added capacity, including 7 GW in offshore farms. However, to meet the Net Zero Emissions target by 2050, annual capacity additions need to increase from 75 GW in 2022 to 350 GW in 2030, requiring significant policy and private-sector efforts, particularly in permitting for onshore wind and cost reductions for offshore wind.

To meet these demand, advancements in technology have led to the creation of various wind tower designs, each suited for different terrains, wind speeds, and climatic conditions. However, these advancements have added complexity to the production process, particularly for modern wind towers designed for offshore locations. These towers require specialized materials to withstand harsh environmental conditions, posing challenges in securing consistent and quality material supplies for large-scale production.

Transporting massive components from manufacturing facilities to installation sites also presents logistical challenges and can cause delays. Given the critical role of wind towers and the significant investment they represent, there is zero tolerance for defects. 

To address these challenges, non-destructive inspection services, such as those offered by ZDZW, are crucial. These services improve efficiency and reduce costs by detecting and addressing defects in welding and painting during the wind turbine tower manufacturing process.

Furthermore, ZDZW is committed to promoting zero-waste manufacturing in the wind tower turbine manufacturing process. The company believes that reducing waste is not only environmentally responsible but also economically beneficial. By implementing non-destructive inspection techniques and process control feedback, ZDZW aims to minimize defects in welding and painting, thereby reducing the need for reprocessing and the associated costs. 

Additionally, ZDZW’s focus on in-process inspection technology and real-time defect detection allows for adjustments to welding parameters, leading to increased productivity and efficiency. Through their solutions, ZDZW envisions a manufacturing process that not only meets the high-quality standards required for wind towers but also minimizes waste and environmental impact, contributing to a more sustainable future for the wind energy industry.

Context of ZDZW’s zero waste manufacturing process:

Welding Process Control: Detecting defects in the Submerged Arc Welding process (SAW) is crucial, as these defects can lead to elevated reprocessing costs and time. Manual inspection of painting operations is also time-consuming and subjective. However, repairing defects detected in maintenance inspections once the towers are installed offshore can significantly increase costs.

Non-Destructive Inspection Techniques: Non-destructive inspection techniques can detect welding and painting defects during production, providing valuable process control feedback to adjust welding parameters. This adjustment can increase productivity, reduce defective parts, improve efficiency, and decrease the total cost per tower manufactured.

Expected Scenarios:

– Welding Process: The use of electro Magnetic Acoustic Transducer (EMAT) equipment for welding process control offers significant advantages, including non-contact testing and improved in-service applications.

– Painting Process: Mobile robotic systems integrated with inspection suites can provide zero-defect painting manufacturing processes, enhancing inspection precision and speed.

Expected Impact on Key Performance Indicators:

Implementing these technologies can lead to a 15% reduction in repairing costs and time for welding, a 10% decrease in wire/steel/flux scrap per year, and a 10% increase in the first-time right manufacturing rate. 

For painting, it can lead to a 6-hour reduction in inspection time per section, a decrease in inspection costs and operators working in complex conditions, and a 5% reduction in repairing consumables/dissolvent.

The paths to efficiency in wind tower turbine manufacturing

Harnessing wind energy dates back thousands of years, yet it remains a critical component of our modern renewable energy landscape. With increasing concerns over the sustainability of traditional power sources, renewable energy has emerged as a viable and essential alternative. Wind turbines, in particular, have become a symbol of this shift towards sustainable energy production.

Cellular Manufacturing

To improve efficiency in wind tower turbine manufacturing, the concept of cellular manufacturing has proven to be transformative. This approach, rooted in lean manufacturing principles, focuses on eliminating waste and optimizing workflow. By creating dedicated cells for specific manufacturing tasks, such as plate cutting, rolling, welding, and assembly, the distance traveled by components is minimized, reducing inefficiencies and delays.

Case Study

Implementing a cellular process in our wind tower manufacturing has streamlined our operations, reducing inefficiencies and wasted time. Organizing our plate cutting station into a U-shape layout decreased material movement, introducing materials on one side, processing in the center, and removing from the opposite side to reduce transportation time. 

The rolling station positioned next to the cutting station further minimised transportation times, with roller conveyors and sliding tables expediting plate movement to welding. Specific jigs and fixtures ensured consistency in welding processes.

Sections moved directly from linear welding to circular welding to maintain production momentum. Post-welding, sections were directed to sandblasting and painting stations, either in the same cell to maintain momentum or employing quick-drying paint techniques to expedite the process. The final assembly station was set up for rapid movement of freshly painted sections using cranes and heavy lifting equipment.

Before cellular implementation, the lead time to produce one wind tower was 10 days, allowing for approximately 3 towers in a month. After implementing the cellular process, lead time was reduced by 30%, with a new lead time of 7 days, allowing for approximately 4.3 towers in a month, a 43.33% increase in monthly productivity.

From a human resources perspective, cellular manufacturing boosts morale and productivity by providing clear roles and cross-training opportunities. It fosters a sense of ownership and accountability, leading to elevated job satisfaction and productivity. The cost benefits include reduced transportation and handling costs, less storage demands, and lower inventory costs.

Key Benefits

Cellular manufacturing offers several key benefits to wind tower manufacturing. By breaking down the production process into specific activities within cells, transportation time is reduced, leading to lower work-in-progress inventory and cost savings. The U-shape configuration of cells optimizes material flow, while the ability to provide rapid feedback during anomalies ensures quality control. Additionally, the flexibility of cellular manufacturing allows for easy reconfiguration of cells to accommodate varying tower designs or specifications.

Materials and Features of Wind Turbine Towers

Wind turbine manufacturers are exploring new materials and designs to reduce costs and increase efficiency. Towers are being built with materials such as concrete to reduce steel usage and hedge against steel price volatility. Despite the potential cost savings, challenges such as increased labour requirements for on-site manufacturing need to be addressed. Steel towers, particularly tubular steel towers, remain the dominant choice for large wind turbines, with concrete towers emerging as a cost-effective alternative.

Lubrication for Wind Turbines

Efficient lubrication is crucial for the optimal performance and longevity of wind turbines. Various components require specific lubrication to withstand the demanding conditions they operate in. 

Bearings, gearboxes, generators, and braking systems all benefit from specialized greases that offer high load resistance, vibration resistance, and compatibility with sealing materials. The proper lubrication not only reduces wear and tear but also ensures smooth operation, ultimately improving the efficiency of the wind turbine.

Advanced materials enhancing efficiency

The use of advanced materials is revolutionizing the wind turbine manufacturing process, making turbines lighter, stronger, and more durable. Composite materials like carbon fiber reinforced plastics (CFRP) are increasingly used in turbine blades due to their high strength-to-weight ratio. These materials allow for larger, more efficient blades, resulting in increased energy generation. Additionally, advanced materials are resistant to corrosion, reducing maintenance costs and improving the lifespan of wind turbines.

Smart Blade Technology

Integrating smart technologies into turbine blades has led to the development of smart blades that can adapt their shape and angle in response to changing wind conditions. These blades are equipped with sensors and actuators that optimize energy capture, reduce loads, and mitigate fatigue. By dynamically adjusting their shape, smart blades ensure optimal performance, improving efficiency and reliability while reducing the risk of structural damage.

Aerodynamic Design Innovations

Recent advancements in aerodynamic design have led to innovations that minimize drag and enhance energy capture. Features like serrated trailing edges disrupt the formation of turbulent vortices, reducing drag and improving efficiency. Streamlined shapes and vortex generators further enhance turbine performance, ensuring maximum energy extraction from the wind.

Advanced Control Systems

Advanced control systems play a vital role in optimizing power generation and reducing loads on turbine components. These systems continuously monitor wind conditions and turbine performance, adjusting rotor speed, pitch angle, and yaw control to maximize energy production. Machine learning algorithms enable adaptive control, dynamically optimizing turbine operations based on real-time data.

Ensuring each wind tower meets stringent quality criteria while speeding up production is essential to meet the growing demand for wind power. By implementing non-destructive inspection services and advanced technologies, manufacturers can improve efficiency, reduce costs, and enhance the reliability of wind tower turbines, contributing to a more sustainable energy future.