A collaborative initiative involving Renewable Parts Limited (RPL), SSE Renewables, and the National Manufacturing Institute Scotland (NMIS), has showcased an innovative approach to remanufacturing critical components of onshore wind turbines using advanced additive manufacturing techniques. This initiative aims to restore worn and damaged pinion shafts from wind turbine yaw gearboxes, a vital component that ensures turbines align optimally with wind direction to maximise energy capture.

Pinion shaft failures often necessitate the replacement of these components, resulting in significant waste—up to 42 kilograms of steel per shaft discarded and subsequently leading to turbine downtime. The project’s early trials have demonstrated that remanufactured shafts can meet original specifications following appropriate machining and non-destructive testing. Remarkably, this process could save up to 84 kilograms of CO2 equivalent emissions for each component remanufactured—significantly enhancing the sustainability of wind energy operations.

According to Ryan McCuaig, a Product Development Engineer at Renewable Parts, the collaboration has propelled the concept of remanufacturing forward, providing the necessary facilities and expertise to ensure these essential components do not end up in waste. “Working with NMIS and SSE Renewables has allowed us to prove that these critical components don’t need to end up in a skip—they can be given a second life,” he remarked.

The initiative is rooted in Glasgow’s ReMake programme, which emphasises circular manufacturing techniques aimed at reducing waste and carbon footprints in sectors like energy, aerospace, and transportation. As it stands, fewer than 2% of products in the UK are designed for reuse, underlining a significant opportunity for improvement. The project aspires to achieve up to a 99% reduction in CO2 emissions compared to the production of new parts, thus reinforcing the critical nature of adopting circular economy principles in the wind sector.

Andreas Reimer, Senior ReMake Theme Lead at NMIS, stated that mainstreaming repair and remanufacturing practices is crucial for reducing environmental impacts and fostering economic opportunities across high-integrity sectors, including renewable energy. He highlighted that if remanufacturing were to gain widespread industry acceptance, it could not only mitigate substantial steel waste but also lower emissions associated with transporting replacement parts from abroad, fostering local job creation and preserving specialist manufacturing skills within the UK.

The project has benefitted from funding through the Glasgow City Region Innovation Accelerator programme, which operates under the auspices of Innovate UK. With a one-year extension currently in progress, the ReMake programme continues to facilitate manufacturers in adopting circular practices that promote sustainable growth.

Parallel to this effort, NMIS launched the £5.5 million ReMake Value Retention Centre (RVRC), collaborating with the Universities of Strathclyde, Exeter, and Sheffield. This centre aims to foster multidisciplinary innovation in circular practices, focusing on everything from advanced repair methods to developing new business models that can extend product life and dramatically reduce emissions at scale.

Further advancements in sustainability within the wind energy sector can be seen globally. For instance, researchers at the University of Maine are examining ways to recycle wind turbine blades into 3D printing feedstock, a move that promises to diminish landfill waste while simultaneously benefiting the construction industry through cost savings. Concurrently, projects in Denmark have harnessed 3D printing to enhance component design and performance, yielding significant reductions in weight and material use.

Such initiatives underscore a broader trend toward integrating circularity principles in renewable energy production, with various companies striving to optimise their products and supply chains. As the industry evolves, the collective expertise and commitment seen in projects like RPL’s remanufacturing initiative may well be the blueprint for a more sustainable wind energy future.

Source: Noah Wire Services