Optimation and GE Renewable Energy: Disrupting Conventional Windmill Wisdom By Steven Beyer GE Renewable Energy Additive Manufacturing is developing skyscrapersized wind turbines using massive 3D-printed concrete bases, made right at each wind farm site. Optimation Technology Inc. (Optimation. us) in Rush, NY outside Rochester, is working with GE to engineer the equipment and support the printer and process, and the materials development that will eventually be deployed around the world. Together at the wind farm site, the partners plan to use 3D-printing and customdeveloped high-performance concrete to manufacture turbine bases that could add as much as 80 meters — and possibly more — to the turbines’ height. The technology will print bases up to 20 meters high with additional steel tower sections to be installed to bring total height to 150200 meters (over 650 feet). Traditionally built in steel or precast concrete, wind turbine towers have typically been limited to a height of under 100 meters, as the width of the base cannot exceed a 4.5-meter diameter so that it can be transported by road without excessive additional costs. To date smaller scale platforms have been printed and tested. Full scale units are planned for the near future. Taller turbines can capitalize on stronger winds at higher altitudes, and the structures support larger blades that generate more power. But building bigger turbines makes transporting the pieces needed to put it together a logistical nightmare.
Cover photo: Prototype GE Cypress system
The major benefits of the proposed tall tower are that it enables bypassing the logistical limitations for steel tower dimensions (diameter < 4.6 m); it decreases the levelized cost of energy (LCOE) compared with the Department Of Energy’s 5MW baseline turbine; it allows the integration of the tower door to the concrete pedestal rather than requiring a penetration of the steel tube section, which further reduces cost; the use of additive concrete technology eliminates formworks, saves labor, reduces construction duration, and allows the tower geometry to be optimized for maximum structural efficiency. The success of this project will pave the path for using additive concrete technology to achieve future ultra-tall wind towers.
The Mobile Concrete Factory This article describes GE and Optimation’s efforts to develop a mobile concrete factory for efficient deployment/ setup with the ability to produce on-demand concrete for printing operations. As part of this, Optimation is developing equipment requirements for material handling, mixing, pumping, and horizontal rebar assembly and integration, and providing procurement activities. Since Optimation's start in 1985, its multidiscipline engineers, designers and skilled tradespeople have worked together with clients to successfully deliver thousands of projects throughout the U.S. and the world. Optimation provides mechanical and process engineering and design, automation and systems integration, skilled trades fabrication and maintenance services for a variety of industries. This combination of skills and experience make for a strong partner. “Optimation is seen as a strategic partner for GE Renewable Energy’s Additive Concrete Technology Development 10 | The ROCHESTER ENGINEER FEBRUARY 2021
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