The goal of the collaboration between GE Renewable Energy, COBOD, and LafargeHolcim is to build a 200-meter-high wind turbine tower and a 3D printed concrete base.
These towers are up to twice the height of current wind turbine towers and are usually constructed of steel or precast concrete with a height limit of fewer than 100 meters. These towers are designed to capture stronger winds and produce them at a lower cost More energy.
Years of cooperation will see COBOD’s concrete 3D printing technology, which is used to build one of the first additive manufacturing buildings in Europe, namely BOD, together with LafargeHolcim’s tailor-made materials for the site Produce larger concrete foundations, thereby eliminating logistics challenges and the cost of generally prohibiting the use of precast concrete foundations over 4.5 meters. A prototype base of 10 meters was created in October last year.
Henrik Lund-Nielsen, founder of COBOD International A/S said: “With our groundbreaking 3D printing technology combined with the competence and resources of our partners, we are convinced that this disruptive move within the wind turbines industry will help drive lower costs and faster execution times, to benefit customers and lower the CO2 footprint from the production of energy.”
GE is using COBOD’s concrete 3D printing with LafargeHolcim’s custom materials.
Edelio Bermejo, head of research and development at LafargeHolcim, added: “Concrete 3D printing is a very promising technology for us, as its incredible design flexibility expands the realm of construction possibilities. Being both a user and promoter of clean energy, we are delighted to be putting our material and design expertise to work in this groundbreaking project, enabling cost-efficient construction of tall wind turbine towers and accelerating access to renewable energy.”
The overall goal is to optimize the production and construction costs of renewable energy, while reducing the average energy cost (LCOE). Generally, it is said that the 80-meter 5 MW turbine produces 15.1 GWh per year. In contrast, twice the height of the same turbine will generate 20.2 GWh, or more than 33% of additional power.
Matteo Bellucci, head of advanced manufacturing technology for GE’s renewable energy, commented: “3D printing has been integrated into GE’s DNA, and we believe that large-format additive manufacturing will bring disruptive potential to the wind energy industry. Concrete printing has achieved over the past five years With great progress, we believe that it will be closer to the actual application in the industry. We are committed to making full use of this technology, in terms of the design flexibility it allows and the logic simplification achieved on such a large component.”