05.12.2023 – Aluminium Association

Low-carbon power generation accounts for about 40% of Russia’s power generation. And this figure is set to increase with the advancement of wind power. Growth will be facilitated, in part, by the use of aluminium in wind turbines. Micron Design from Krasnoyarsk has developed a unique solution for incorporating aluminium alloys into wind turbines.

An aluminium blade 40-50 metres long weighs just 3 tonnes, whereas a fibreglass one weighs around 11 tonnes, while the production costs are similar.

GIGAWATTS OF GREEN ENERGY
Renewable energy sources are highly regarded today, attracting more attention and substantial investments. China, India, and the United States firmly hold the lead in this field, with China accounting for nearly a quarter of the world’s renewable energy capacity: over 500 gigawatts. The leaders in Europe are Germany, Spain, and Denmark.

In Russia, where the green energy sector is just starting to gain traction, the total capacity of all such facilities is about 300 MW. According to the Renewable Energy Association (REA), 482 MW in 2024 and 1.25 GW in 2025 will be added. It is expected that over the next two years, the total capacity will reach 2.17 GW, and the installed renewable capacity will be 6.17 GW.

By 2035, an additional 4,500 wind turbines are planned to be installed in Russia.

The leaders in terms of green energy generation are the Stavropol Territory (775.3 MW), the Astrakhan Region (625.2 MW), the Rostov Region (607.3 MW), the Republic of Kalmykia (450.7 MW), and the Orenburg Region (372.7 MW). Currently, there are approximately 1,200 wind turbines in Russia. By 2035, Russia will see an additional 4,500 wind turbines.

FACING THE WIND
However, as the renewable energy sector expands, the demand for wind turbine maintenance, spare parts, and disposal inevitably grows. For instance, in recent years, the disposal of wind turbine blades, which are the most challenging components in terms of recycling in the alternative energy sector, has become a worldwide issue.

Currently, blades are predominantly made from fibreglass composites, and recycling is a real challenge. The urgency of this issue will only increase over time, both globally and in Russia. By 2025, it is projected that the total weight of expired blades will reach 25,000 tonnes. The majority of decommissioned blades will be found in European wind energy leaders such as Germany, Spain, and Denmark. By 2050, wind turbine blades could become the primary issue, as their total number is expected to reach 200,000 or 40 million tonnes of composites.

This issue will not spare us, either. Over the next 10 to 20 years, more than 300 wind turbines in Russia (approximately a quarter of the total fleet) will require the replacement of components, including large blades. According to the Aluminium Association’s experts, we will need to address the issue of blade disposal within the next five years.

So far, the best solution humanity has come up with is to simply bury used wind turbine blades. Many countries have landfills for blades. However, the land used for disposal has been removed from economic use for over a century due to the slow decomposition of fibreglass composites in the soil.

Market leaders and researchers are working on new composite disposal processes. Proposed alternative technologies for recycling composite blades include mechanical recirculation, solvolysis and pyrolysis, and high-voltage pulse fragmentation, among others.

ALTERNATIVE TO COMPOSITES
Micron Design in Krasnoyarsk has found a solution to this pressing issue. The company’s flagship project, TeRUS is about the design and manufacturing of unique wind farms for combined electricity and heat generation.

Considering the environmental aspect, the company proposed a manufacturing technology for wind turbine blades made from lightweight, durable, and 100% recyclable aluminium alloys. Aluminium blades eliminate the disposal problems at the end of their lifecycle, as the metal can be immediately recycled. The project received backing from the Aluminium Association, primarily as the access to the materials.

From an economic perspective, this Russian project is also noteworthy. The Micron team studied the characteristics of internationally available wind turbine blades and concluded that the cost of fibreglass blades is higher than those made from duralumin. Consider this: a 40-50m long fibreglass blade weighs about 11 tonnes, while its aluminium counterpart weighs only three tonnes, with almost equal production costs. So, why not manufacture wind turbine blades from duralumin, using technologies borrowed from aerospace engineering? The cost of energy generated by the TheRUS turbines is RUB 4.5 per 1 kW/h at a 7 m/s wind speed. The Krasnoyarsk aluminium-based project is highly innovative and patented in Russia, Germany, and Finland. Indeed, it differs from conventional wind turbines in numerous ways.

For instance, the majority of wind generators are installed in the southern regions of Russia. The equipment from Krasnoyarsk can operate in remote northern regions with low wind speeds. The generator starts at a wind speed of 2 m/s. Naturally, there is a demand for such systems in the remote regions. For example, compact wind power plants can provide electricity for geologists, builders, maintenance crews, temporary facilities and settlements in remote areas.

It is noteworthy that the Krasnoyarsk team has considered the logistical challenges and focused on reducing the equipment weight, rapid assembly and erection. Previously, the market lacked such solutions. Looking ahead, Micron will start the manufacturing of full-sized blades. This will be a fundamentally new solution on a global scale.

THREE ALLOYS, ONE BLADE
The Krasnoyarsk company has already started the project. Raw materials and equipment are already available while pilot manufacturing and testing still require effort, time, and meticulous work. The 65 kW TeRUS FVTS-20 mobile wind turbine is a prototype for testing the design and manufacturing process of aluminium blades.

The capacity of the TerUS FVTS-20 turbine developed in Krasnoyarsk is 65 kW.

Each blade is made from three aluminium alloys: 2xxx, 5xxx, and 6xxx. The manufacturing process includes extrusion, pressing, and finishing. For instance, the blade tip made from the 6xxx series alloy will be extruded at the Krasnoyarsk SEGAL plant (a SIAL Group company). They are working on the design. Micron Design, with its unique equipment in Russia, will do the machining.

Three aluminium alloys (2xxx, 5xxx and 6xxx) are used to make each wind turbine blade.

The blades have a complex structure. These huge components can be disassembled and shipped by regular cargo vehicles. Such a structure does not lead to a significant increase in the weight. This design significantly broadens the geographical coverage of wind turbines.

The TerUS combined power and heat generation equipment can be easily delivered to even the most remote areas and rapidly assembled on-site.

Besides the five aluminium blades, the TerUS plant includes a mast, a generator, and thermal energy storage, all having aluminium components.

The first pilot wind generator of the TerUS project is scheduled to be installed in 2024 in Krasnoyarsk, at the site of Micron Design. The company site is outside the city limits and on a small hill. It is a perfect testing ground for the prototype.

The cost of electricity generated by TeRUS FVTS-20 plants is RUB 4.5 per 1 kW/h at a wind speed of 7 m/s.

The successful completion of the project will enable the use of aluminium blades not only in the TeRUS wind power plants but also as replacements for fibreglass composite blades in existing wind turbines, with plans to enter the global market.