Wind blade adhesive plant up and running

Dow Formulated Systems has announced the completion of a new wind-blade epoxy adhesive production plant in Roberta, Georgia. The plant, which includes a new reactor and production equipment, is dedicated to the wind sector and will be used to support the U.S. market as well as exports to China and Latin America. The plant is located at Dow’s existing Roberta, Georgia facilities.

Jean-Luc Guillaume, Global Business Leader for Wind Energy for Dow Formulated Systems, said the new plant is part of a global Dow network of production assets that supports clients with local sources for wind blade technology, providing additional supply security and simplified logistics. “We are one of the few blade adhesive suppliers with production in North America,” Guillaume said, adding that, “this investment demonstrates our commitment to the wind energy industry in North America and throughout the world.”

“Epoxy adhesives play a critical role in the fabrication, performance and durability of wind turbine blades where large substructures are bonded together to create the finished blades. Specialized properties are needed for adhesive mixing and application during the fabrication process and cured adhesives must exhibit high levels of toughness and durability to withstand the extreme loads a wind turbine blade is subjected to throughout its service life. The addition of the new U.S. plant helps ensure that, as new adhesives are commercialized, the volume requirements of wind blade clients are met.

Dow Formulated Systems
dow.com

Foam core system for wind blades

The Compaxx 700 foam core for wind turbine blades is the first in a line of new core materials that will help manufacturers extend blade life with high performance sandwich composites. The materials come from Dow Formulated Systems, a business unit of The Dow Chemical Co.

Sandwich-panel fatigue testing following Germanische Lloyd requirements showed the foam core exhibits long-term dynamic behavior and shear-strength properties that build lightweight composites with excellent mechanical strength and fatigue resistance. These properties, coupled with a peel strength about three times higher than the historical reference of core material PVC 60 kg/m³, create a tight core-to-skin bond necessary for blade durability.

In addition, the foam core has a high run-to-run consistency leading to predictable mechanical properties that structural engineers can use to create more precise blades. The Compaxx system is available globally in commercial volumes.

Dow Formulated Systems
www.Dow.com/epoxy

Think Dow Electrical & Telecommunications (not Wire & Cable)

Dow Wire & Cable has decided to change its business name to Dow Electrical & Telecommunications. Because of a growth strategy that moves beyond technology and materials for wire and cable jacketing, insulation, semiconductive and specialty compounds for the power and telecommunications markets. Recent advances in bio-based chemistry have let the business unit play a larger role in personal electronics, appliance, transportation, and building and construction markets.

The Dow Chemical Co. has an R&D and materials science heritage with products made of plastics, composites, additives, and fluids. Combining these with Dow Electrical & Telecommunications knowledge and expertise, along with those of other partners, says the company, creates significant opportunity.

Dow Electrical & Telecommunications
http://www.dow.com/

Building a better wind blade, in Michigan

Dow Chemical Co., Astraeus Wind Energy Inc., and MAG Industrial Automation Systems have announced a wind-energy project funded in part by the state of Michigan. “This joint technology will be built on a solid foundation of MAG’s 30-years in the development of composite processing systems for the manufacture of aircraft components,” said a group spokesman.

The three companies have agreed to develop automated manufacturing equipment focused on improving the manufacture of wind-turbine-blade components, and finished blades, for the wind industry. The need for U.S. energy independence and economic security, coupled with the search for lower impact power sources, is driving demand for clean, alternative energy solutions such as wind energy.

The Michigan Strategic Fund board finalized a Centers of Energy Excellence designation and a $6 million grant for Astraeus to establish operations with an initial focus on the production of spar caps – the “backbone” of a wind turbine blade. The grant will also be used by Dow for material development and optimization, and by MAG for designing, constructing and demonstrating a prototype automated system for manufacturing the spar cap. Designed to help the state diversify into renewable energy technologies, the state funding matches U.S. federal stimulus funds Astraeus previously received.

Dow will use its global skills and experience in advanced-material development and application with the automated manufacturing process and equipment being developed by MAG and Astraeus. The automation will create distinct advantages over the existing manual manufacturing process so wind-turbine-blade manufacturers can increase production rates of higher-quality components with attractive economics.

“Dow is committed to identifying and developing innovative technologies and solutions to improve the viability of alternative energy sources,” said Monty Bayer, global business director, Dow Ventures & Business Development, Licensing and Venture Capital. “This collaboration will create enhanced and innovative solutions that we believe will assist in transforming the growing wind energy industry.”  The demand for wind-generated power is growing, driven by a U.S. Department of Energy goal to increase domestic electricity production from wind power by 20%  over the next 20 years requiring aggressive turbine volume production.  “The state incentive package will let Astraeus accelerate production plans of high quality wind turbine components,” said company President Jeff Metts.

Dow and MAG will focus on advanced materials and automating manufacturing for Astraeus to produce spar caps, with a long-term vision for the technology to be used for the fabrication of other wind turbine components and assembly of those components into finished wind-turbine blades. Oak Ridge National Laboratory, the U.S. Department of Energy’s largest science and energy laboratory, will assist Dow with evaluation of the advanced materials. Dow and MAG expect to have a material-enabled automation technology solution available in 2012

“This joint technology will be built on a foundation of MAG’s 30-years of leadership in the development of composite processing systems for the manufacture of aircraft components,” said Joe Jones, Executive Vice President of MAG’s Renewable Energy Group. “Combining our high-tech manufacturing system with Dow’s advanced materials will result in a superior manufacturing solution.”

Dow Chemical Co.
www.dow.com

Astraeus Wind Energy Inc.
astraeuswind.com

MAG Industrial Automation Systems
mag-ias.com/en

Gearbox lube for wind turbines

One way to improve wind-turbine efficiency is with proper gearbox lubricant. Dow recently introduced the UCON GL-320 lubricant for wind turbine gearboxes and those in other applications. The high viscosity index of the lube, addresses the issue of cold weather causing high lubricant viscosity without the need for additional VI improvers. It has higher heat capacity than hydrocarbon oils, which allows it to move more heat, forestalling a shutdown when turbine output is at the maximum. The lubricant has better lubricity at ambient conditions, so it has potential to shift the power-versus-wind-speed curve to the left, leading to greater power output when the production is less than the maximum design output.

This lubricant also addresses the issue of micropitting, which can lead to wearing and changes in gear teeth shape, reducing gear accuracy, and increasing vibrations and noise. It can also lead to other problems such as misalignment and fatigue failure. High viscosity lubricants like UCON GL-320 are a thicker lubricant film that can help to reduce the debris and worn particles that often accompany less well-lubricated gears.

DOW

www.dow.com

Dow lubricant brochure for wind turbine gearboxes

The Dow UCON™ GL-320 lubricant was developed for wind turbines, though it can also be used for other types of gearboxes.

Turbines can shut down in cold weather because of filter failures resulting from high lubricant viscosity. UCON™ GL-320 has a higher viscosity index to address this issue without needing additional VI improvers.  The lubricant also has a higher heat capacity than hydrocarbon oils, which allows it to move more heat, reducing shutdowns. It’s polyalkylene glycol based and has the potential to shift the power vs. wind speed curve to the left, resulting in greater power output.

The brochure is available for download at www.ucon.com.

The Dow Chemical Company
dow.com

Research center for carbon fiber blades

Low-cost carbon fiber for industrial applications, including advanced wind turbine blades, is the goal for an expanding chemical company. Dow Chemical Co., Midland, Mich., says it will expand its renewable and alternative energy reach in the state thanks to more than $108 million in business tax credits and grants. In addition, the Michigan Economic Growth Authority is expected to approve $103 million in tax credits and incentives for Dow’s Powerhouse Solar Shingle project and Kokam advanced battery manufacturing facility.
A $20 million carbon-fiber project will create a center focused on developing low-cost carbon fiber for use in the production of advanced wind turbine blades and in transportation applications. The company is partnering with Oak Ridge National Laboratory to develop the material over about three years, said Steve Bakkal, the Wind Energy Sector Development director for the Michigan Economic Development Corp. The project will be sited in one of Dow’s existing facilities. And while it won’t immediately create jobs, it will have job creation potential later, drawing wind turbine blade manufacturers and other companies who can use the carbon fiber to the Great Lakes Bay Region, he said.