Wind power blades energize composites manufacturing

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The world’s growing appetite for wind energy is transforming wind blades into one of the hottest composite applications around. The huge build-up of wind-power generating capacity — particularly in the U.S, China, and Spain — has raised a bumper crop of new plants for manufacturing these composite parts.

The global wind energy market has grown 23% annually for the last 10 years, says Charles Kazmierski, project manager for Lucintel, a consulting firm in plastics, composites, and other industrial markets. He expects the global wind energy market for composites to be worth about $6 billion by 2012.

The U.S. wind industry has historically experienced a roller-coaster growth cycle dictated largely by the federal governmentÂ’s production tax credit, which subsidizes the industry. Chronic uncertainty over periodic renewals of the tax credit led to costly boom and bust cycles for the industry from 2000 to 2005, according to the American Wind Energy Association (AWEA). Availability of the credit spurred dramatic growth from 2005 to 2007. The market could experience a setback in 2009 if U.S. lawmakers fail to renew the credit by the end of 2008.

Even with the fate of federal tax incentives still unknown, the U.S. wind industry moved forward with new manufacturing installations at breakneck pace in the first quarter of 2008, putting 1400 Megawatts (MW), or about $3 billion worth, of new generating capacity in place, reports AWEA.

This ramp-up in production has put intense pressure on suppliers of resins, reinforcements, and core materials like balsa wood and PVC foam. Suppliers are focused on meeting quality and delivery objectives as wind-turbine makers globalize their operations to meet growing demand. “Until now this was primarily a European business, but now it’s a global business with supply in every major region,” explains Paul Langemeier, director of global market development for epoxy supplier Hexion Specialty Chemicals.

Most observers agree that long-term growth will require technical innovation to make wind more competitive with other forms of energy. One of the key trends is the push to improve productivity. Blade manufacturing via vacuum infusion or prepreg molding is labor intensive and producers are seeking ways to reduce cycle time and cut costs.

Robotic lay-up, enhanced finishing techniques, two-piece or segmented blades, and on-site manufacturing are potential tools to trim labor and logistics costs. New prepreg molding techniques are said to improve surface appearance and facilitate finishing. And resin and prepreg suppliers are introducing materials that cure faster and at lower temperatures.

As wind generating capacity increases, there is also a trend to bigger and lighter blades.

Observers envision greater use of carbon fiber — despite disadvantages of higher cost and tight supplies — due to its higher stiffness and lighter weight than standard E-glass.

Meanwhile, traditional E-glass and specialty glass products are holding off competition from carbon fiber through new chemistry and optimization to meet higher performance requirements.

A wind turbine is composed of several composite parts; but the blades, made of fiber-reinforced epoxy or unsaturated polyester, represent the largest use of material. Other turbine parts made of polyester include the nacelle (housing for the gearbox, generator, and other components) and the hub. The dominant processing method is vacuum resin infusion. It generates low VOCs and can evenly wet out large parts with a controlled amount of resin, thus facilitating production of lighter and less expensive blades.

Prepreg molding with a woven or unidirectional glass fabric is more costly but offers greater consistency because it already contains the matrix material (typically epoxy). Depending on blade size, either vacuum infusion or prepreg molding takes 12 to 24 hours.

Typically composed of 70% to 75% glass by weight, these aerodynamically designed blades must meet very strict mechanical requirements such as high rigidity and resistance to torsion and fatigue. High static and dynamic loads over a wide temperature range are typical during a 20-year service life. A standard 35- to 40-meter blade for a 1.5-MW turbine weighs 6 to 7 tons.

Both epoxy and polyester, and to a lesser extent vinyl ester, shared the wind blade business in the early days but epoxy earned preferred status as blades grew longer. Polyester is easier to process and is less expensive, but epoxy offers stronger mechanical performance — particularly tensile and flexural strength — for blades longer than 26 m (85 ft). Unlike epoxy, polyester needs no post-curing but the blades are generally heavier.

E-glass is by far the most used reinforcement, while more costly carbon fiber is employed on a limited basis for greater stiffness and reduced weight in longer blades.

The barriers to entry for wind blade manufacturing are formidable. They include the physical scale of the parts, the need for competitive technology and manufacturing know-how, a good supply base, global presence, and heavy investment. There are about 12 global wind turbine suppliers and the top four hold about 72% of the market, according to Kazmierski.

Most of these top manufacturers make their own blades, but some, like GE Energy, contract out to firms like Molded Fiber Glass Companies (MFG), Ashtabula, Ohio, and TPI Composites Inc., Scottsdale, Ariz. The worldÂ’s leading wind turbine maker is DenmarkÂ’s Vestas Wind Systems A/S (23% market share), followed by GE Energy, SpainÂ’s Gamesa (17%), GermanyÂ’s Enercon, IndiaÂ’s Suzlon (10.5%), and GermanyÂ’s Siemens.

The worldÂ’s leading blade maker is Danish-based LM Glasfiber A/S, which makes between 8,000 and 9,000 blades/year and has 25% market share. The company started manufacturing in 1978 and has expanded operations worldwide with new U.S. plants in Grand Forks, N.D., and Little Rock, Ark. It claims to have the largest total installed base of blades today: Every third turbine worldwide is fitted with its blades.

LM uses vacuum infusion and what it calls “smart engineering” to produce polyester wind blades that are less costly than epoxy but still boast high performance. The process has been optimized to create a strong, uniform laminate with more rapid hardening, which reduces production time by several hours, according to Steen Broust Nielsen, communications director.

LM has adapted its technology to produce the industryÂ’s longest wind blade. The 61.5-m (202-ft) blade, built for a 5-MW turbine from GermanyÂ’s REpower Systems, weighs 17.8 tons. The turbine has a rotor diameter of 126 m (413 ft) and the three blades cover an area almost the size of two football fields. Most remarkable is LMÂ’s ability to use E-glass for stiffness and light weight above the threshold length of 40 m where carbon fiber is generally considered.

LM uses robots and other automation to lay up glass mat in the molds and to glue the blade shells together. To streamline its process and reduce cycle time, LM is investing in new blade technology based on an undisclosed new fiber that reportedly will cut blade production time in half.

Half the $12-million budget of LM’s “Blade King” research program comes from the Danish National Advanced Technology Foundation. New technology is expected to boost efficiency of fiber lay-up and molding. LM is partnering with Denmark’s Aalborg Univ. and Risoe DTU on fiber development and with Comfil, a Danish specialist in thermoplastic composites.

In the U.S, MFG will soon open a new facility in Aberdeen, S.D., to produce blades for GEÂ’s popular 1.5-MW turbines. MFG entered the market by making 9-m blades in the late 1980s and has watched sales climb eight-fold over the last six years, according to Carl LaFrance, wind energy manager.

Like most other blade makers, MFG uses vacuum infusion to mold glass-reinforced blades from 34 to 49 m long. Design and process optimization play a critical role, according to LaFrance.

“It’s all in the details; it’s how you lay up the fabric, charge the mold, and how you get the resin to fill the mold.” Since production volumes are just now providing opportunities for automation, MFG relies on lean manufacturing techniques and 6-Sigma principles to wring out every possible process improvement.

TPI Composites is another strong player in the U.S., with new expansions in the U.S., Mexico, and China. The company is supplying GE Energy from a new 190,000-sq.ft. facility in Taicang, China, and a new 316,000-sq.ft. plant in Newton, Iowa. VienTek, TPIÂ’s joint venture with JapanÂ’s Mitsubishi Power Systems, recently tripled its blade-making capacity in Ciudad Juarez, Mexico, to about 500,000 sq.ft.

TPI uses its patented SCRIMP technology, a form of vacuum infusion available for licensing. Components made with the SCRIMP process are claimed to have higher fiber content than conventionally laid-up components. TPI says glass-to-resin ratios of 70:30 or higher can be achieved, compared with the typical 50:50 ratio, resulting in lighter and stronger parts.

Most turbine makers are globalizing their operations at a rapid pace. GermanyÂ’s Siemens Wind Power opened a wind blade plant in Fort Madison, Iowa, last year. Meanwhile, DenmarkÂ’s Vestas announced plans in August to build a blade plant in Brighton, Colo., to supplement its existing plant in Windsor, Colo. The two facilities are expected to produce 3,600 blades/year when the Brighton plant starts up in 2010.

Siemens has an innovative process that makes blades in one piece, unlike the typical blade that is made in two shells and glued together. SiemensÂ’ IntegralBlade technology uses vacuum infusion to make glass/epoxy blades in a closed process.

The molding system has a closed outer mold and an expanding, flexible inner bladder. Epoxy resin is injected under a vacuum and the blade is cured at high temperature in the mold. After curing, the blade is removed from the outer mold while the inner bladder is collapsed with a vacuum and pulled from the blade. The result is a seamless one-piece blade.

The IntegralBlade system reportedly offers several advantages, including shorter cycles and more efficient use of manpower and space. Only one mold set is required, notes Hendrik Stiesdal, chief technology officer for Siemens Wind Power. Additionally, there are no tolerance issues between the shells and structural spars.

Most important is that the blade is an integral structure with no glued joints that could weaken and potentially expose the structure to cracking, water entry, and lightning strikes. The process is used to make blades 30 to 52 m long.

SpainÂ’s Gamesa, which has blade plants in Ebensburg and Fairless Hills, Pa., molds about 4,500 blades/year. The company is one of only two leading suppliers (Vestas is the other) that utilize epoxy prepreg molding. Resin is distributed more homogeneously and in consistent amounts in prepreg molding, according to Emmanuel Garcia De La Pena, vice president of industrial operations. This ensures consistent thickness, better fiber orientation, and fewer weak points, he says, resulting in better mechanicals and lower weight than with vacuum infusion.

A smaller player in blade manufacturing is Knight & Carver, National City, Calif., a former custom boat builder that transformed itself into a wind blade repair and production specialist almost 10 years ago. The company has found a niche in the blade replacement market, producing 25-m epoxy prepreg blades in Howard, S.D. A unique feature is a pultruded spar cap that provides high strength and stiffness, according to Gary Kanaby, director of business development.

Knight & Carver also made 9-m blades for now-defunct U.S. Wind PowerÂ’s 100-kw wind turbine. These were made of vinyl ester for faster curing, via a one-piece bladder molding process. In a current project with the U.S. Dept. of Energy and Sandia National Laboratories (Albuquerque, N.M.), Knight & Carver developed a 27-m blade to work better at low wind speeds but not increase loads on the turbine in strong winds.

Blade makers struggling to meet burgeoning demand are looking to new materials to help raise overall productivity, reduce cycle time, and cut costs. For example, the new Airstone system of epoxy resins and hardeners from Dow Epoxy Systems expands DowÂ’s offerings for wind blades beyond just resins.

The company expects to broaden its market share by offering systems that tailor resin formulations for specific blade performance, according to Bernd Hoevel, global technology leader for wind energy. DowÂ’s new Airstone 780 E line of epoxy infusion materials offers extended pot life, faster curing, and improved cycle time.

Hexion is working with customers to develop new products that reduce weight, improve mechanicals, and deliver “more blades per unit time,” says Langemeier.

Meanwhile, Huntsman Advanced Materials is developing new epoxies that provide better crack and aging resistance for longer blades. Epoxies are also the dominant adhesive for gluing blade halves. Huntsman says its new toughened system is easy to process and offers improved resistance to aging and crack propagation.

Polyester and vinyl ester suppliers are working on new formulations with improved mechanical properties. At Reichhold Inc., a new Dion vinyl ester grade provides 10% to 15% more fatigue resistance and greater overall toughness for longer, lighter blades, according to Bill Schramm, director of global business development.

Ashland Composite Polymers Div. supplies Aropol G300 and M300 polyesters to LM Glasfiber and other blade makers. The companyÂ’s Derakane 601-200 vinyl ester recently won certification from Germanischer Lloyd in Germany, which oversees global standards for safety and performance of wind energy systems. The materialÂ’s physical properties are reportedly better than polyester and approach those of epoxy.

A key advantage over epoxy is shorter post-cure time. And a new polyester from AOC is being used by an undisclosed blade manufacturer. AOC declined to provide further details.

Glass suppliers have responded to the carbon-fiber competition for making longer and lighter blades. OCV Reinforcements came out with WindStrand direct rovings and knitted fabric based on a special glass that is said to be nearly 30% stronger, 15-20% stiffer, and 8-10% lighter than the companyÂ’s current E-glass. This gives blade makers a less costly solution than carbon fiber for blades 40-m long or longer, according to Wisdom Dzotsi, Americas marketing leader. In an exclusive arrangement, a leading blade maker uses WindStrand in a vacuum infusion application.

Chemistry and sizing improvements have resulted in higher-performing glass products like new Hybon 2026 roving from PPG Industries, which boasts 10% greater fatigue resistance than standard products. PPG is also working on stiffer reinforcements that fill the gap between E-glass and more costly carbon fiber.

FinlandÂ’s Ahlstrom Corp. (U.S. office in Windsor, Conn.) has launched CombiFlow, a special E-glass fabric with a PET flow layer for easier and faster resin infusion. The PET is sandwiched between two glass layers. Ahlstrom also announced plans to double capacity for specialty reinforcements in the U.S. by 2011. The capacity, aimed primarily at wind energy, will be added in two phases at Bishopville, S.C.

To reduce the cost of wind energy, developers want to maximize the amount of wind power they can capture. This has spurred demand for turbines with larger MW capacity and a corresponding increase in blade length. Over the last decade, average wind turbine capacity has doubled, thus cutting by 50% the number of turbines and blades necessary to generate a certain amount of power.

The average turbine generating capacity is moving from 1.5 MW to 2 to 2.5 MW. The future holds even larger turbines of 3 MW and up, particularly for offshore use. Today, the largest unit is a 7.5-MW prototype offshore turbine developed by Clipper Windpower Plc, Carpinteria, Calif. It has 50- to 60-m blades.

Many industry observers believe larger turbines will require carbon fiber to provide the necessary stiffness and light weight. Global carbon-fiber use in wind power today is only about 10 million to 12 million lb/yr, vs. over 200 million lb of glass. Vestas and Gamesa are the only top-tier firms using carbon fiber, primarily in the structural spar cap (central spine) of longer blades (40-m and up). Most carbon fiber use is in Europe, and it is applied sparingly with glass.

At a price of $10 to $13/lb, carbon fiber costs 5 to 20 times more than E-glass. So the goal is to use carbon fiber selectively for strength and stiffness without incurring high cost, says Robb Klawonn, president and CEO of Toho Tenax America, a maker of 24K tow product.

In vacuum infusion, carbon fiber is hampered by its inability to wet out efficiently, though more experienced blade makers have learned to overcome this problem. Consequently, more costly prepreg molding is the preferred and most efficient method to utilize carbon fiber. At the same time, carbon fiber historically suffers cost and availability issues.

However, carbon-fiber makers argue that new capacity puts supply more in balance today. Zoltek Inc., the leading carbon-fiber supplier for wind energy, has doubled capacity at its Hungarian plant every year since 2005, reaching 26 million lb this year. Zoltek sells a 50K tow product called Panex 35 for use in wind blades.

Depending on design, the economics of carbon fiber can be favorable in blades longer than 40 m, says Tim McCarthy, Zoltek vice president of marketing and sales. Conversely, other sources point to optimized design and engineering that allow use of E-glass in longer blades like LM Glasfiber’s 61.5-m behemoth. “It will be a long time before carbon fiber is used broadly, due to its cost,” says Siemens’ Stiesdal, whose company is working on 52-m blade made with E-glass.

The other supplier of 50K tow carbon fiber is GermanyÂ’s SGL Group. The company has a strategy of forward integration, which includes the 2007 acquisition of German prepreg maker Epo and the recent purchase of a 51% stake in GermanyÂ’s Abeking & Rasmussen Rotec GmbH Co., a leading independent wind blade maker. SGL also has a majority stake in glass fabric maker SGL Kumpers GmbH, Lathen, Germany. SGL plans to double its carbon fiber capacity to 24 million lb by 2012.

Productivity improvements also highlight the latest developments in prepreg molding. Hexcel Composites Ltd. launched a new epoxy prepreg thatÂ’s said to reduce cure time by 15% to 20%. A major advantage of HexPlyM19 is its low risk of uncontrolled exotherm in thick sections.

HexPly M19 reportedly reduces hot spots and allows more aggressive ramp-up rates to reach maximum cure temperature. The dwell is at a higher temperature and for a shorter time than with conventional prepregs. Faster overall cure cuts mold costs by up to 10% because less expensive tooling resins and coatings can be used, along with a less expensive tooling support system. Mold service life can also be increased, Hexcel says.

The company is working on a prepreg system with improved surface appearance to reduce finishing. To meet greater U.S. demand, Hexcel will open a new glass prepreg plant in Colorado in the second half of 2009.

Another leading prepreg supplier, Gurit in the U.K., is focused on optimizing glass content and reducing voids in cured laminates. To solve surface appearance problems, Gurit has developed Sprint IPT, an in-mold primer film that facilitates finishing and painting. Also, Gurit has developed Sprint prepregs, which consist of alternating layers of dry fabric and epoxy film, offering breathability and reduced void content.

A small Spanish manufacturer of wind turbines and blades has developed an automated blade production process that reportedly reduces labor, cuts cycle time by 75%, and produces more consistent blades.

MTorres (U.S. office in Santa Ana, Calif.) devised a patent-pending vacuum infusion process that imposes no limitation on blade length. It infuses the mold with epoxy in one shot, as opposed to multiple infusions with current systems, and also uses cool molds to manage exotherm.

The infusion system has a special head and tackifier that initially adds epoxy in small amounts to stabilize the glass lay-up, according to David Champa, general manager of the U.S. division.

The turnkey system requires just five workers to run five stations for lay-up, bagging, curing, joining, and painting. A gantry system automates glass lay-up. There is also automated bagging, a special bonding fixture to join the two blade halves, and self-powered moving molds.

Champa describes an almost cleanroom environment with extensive temperature-control systems and robotic finishing operations. The company is working with leading turbine makers in the U.S. and Europe and expects to commercialize it next year in the U.S. The processing system will cost between $5 million and $6 million with a two-year return on investment, according to Champa.

An extensive EU-funded research program called Upwind involves more than 40 wind energy specialists who will examine new materials and manufacturing methods for large blades from 70 to 120 m. The project is looking at natural materials like wood and bamboo and cellulose fibers from hemp, flax, and wood. These offer the same stiffness-to-weight ratio as glass and similar strength but are difficult to process, according to Povl Brondsted, head of research programs for the Risoe National Laboratory for Sustainable Energy at the Technical University of Denmark. Thermoplastics like PET and PP and bio-based resins are also being examined.

Upwind is also considering new assembly solutions to build blades in multiple sections. Also under investigation are better process controls and automation.

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Hydropower Plants to Support Solar and Wind Energy

Solar-Wind-Water West Africa integrates hydropower with solar and wind to boost grid flexibility, clean electricity, and decarbonization, leveraging the West African Power Pool and climate data modeling reported in Nature Sustainability.

 

Key Points

A strategy using hydropower to balance solar and wind, enabling reliable, low-carbon electricity across West Africa.

✅ Hydropower dispatch covers solar and wind shortfalls.

✅ Regional interconnection via West African Power Pool.

✅ Cuts CO2 versus gas while limiting new dam projects.

 

Hydropower plants can support solar and wind power, rather unpredictable by nature, in a climate-friendly manner. A new study in the scientific journal Nature Sustainability has now mapped the potential for such "solar-wind-water" strategies for West Africa: an important region where the power sector is still under development, amid IEA investment needs for universal access, and where generation capacity and power grids will be greatly expanded in the coming years. "Countries in West Africa therefore now have the opportunity to plan this expansion according to strategies that rely on modern, climate-friendly energy generation," says Sebastian Sterl, energy and climate scientist at Vrije Universiteit Brussel and KU Leuven and lead author of the study. "A completely different situation from Europe, where power supply has been dependent on polluting power plants for many decades - which many countries now want to rid themselves of."

Solar and wind power generation is increasing worldwide and becoming cheaper and cheaper. This helps to keep climate targets in sight, but also poses challenges. For instance, critics often argue that these energy sources are too unpredictable and variable to be part of a reliable electricity mix on a large scale, though combining multiple resources can enhance project performance.

"Indeed, our electricity systems will have to become much more flexible if we are to feed large amounts of solar and wind power into the grid. Flexibility is currently mostly provided by gas power plants. Unfortunately, these cause a lot of CO2 emissions," says Sebastian Sterl, energy and climate expert at Vrije Universiteit Brussel (VUB) and KU Leuven. "But in many countries, hydropower plants can be a fossil fuel-free alternative to support solar and wind energy. After all, hydropower plants can be dispatched at times when insufficient solar and wind power is available."

The research team, composed of experts from VUB, KU Leuven, the International Renewable Energy Agency (IRENA), and Climate Analytics, designed a new computer model for their study, running on detailed water, weather and climate data. They used this model to investigate how renewable power sources in West Africa could be exploited as effectively as possible for a reliable power supply, even without large-scale storage, in line with World Bank support for wind in developing countries. All this without losing sight of the environmental impact of large hydropower plants.

"This is far from trivial to calculate," says Prof. Wim Thiery, climate scientist at the VUB, who was also involved in the study. "Hydroelectric power stations in West Africa depend on the monsoon; in the dry season they run on their reserves. Both sun and wind, as well as power requirements, have their own typical hourly, daily and seasonal patterns. Solar, wind and hydropower all vary from year to year and may be impacted by climate change, including projections that wind resources shift southward in coming years. In addition, their potential is spatially very unevenly distributed."

West African Power Pool

The study demonstrates that it will be particularly important to create a "West African Power Pool", a regional interconnection of national power grids to serve as a path to universal electricity access across the region. Countries with a tropical climate, such as Ghana and the Ivory Coast, typically have a lot of potential for hydropower and quite high solar radiation, but hardly any wind. The drier and more desert-like countries, such as Senegal and Niger, hardly have any opportunities for hydropower, but receive more sunlight and more wind. The potential for reliable, clean power generation based on solar and wind power, supported by flexibly dispatched hydropower, increases by more than 30% when countries can share their potential regionally, the researchers discovered.

All measures taken together would allow roughly 60% of the current electricity demand in West Africa to be met with complementary renewable sources, despite concerns about slow greening of Africa's electricity, of which roughly half would be solar and wind power and the other half hydropower - without the need for large-scale battery or other storage plants. According to the study, within a few years, the cost of solar and wind power generation in West Africa is also expected to drop to such an extent that the proposed solar-wind-water strategies will provide cheaper electricity than gas-fired power plants, which currently still account for more than half of all electricity supply in West Africa.

Better ecological footprint

Hydropower plants can have a considerable negative impact on local ecology. In many developing countries, piles of controversial plans for new hydropower plants have been proposed. The study can help to make future investments in hydropower more sustainable. "By using existing and planned hydropower plants as optimally as possible to massively support solar and wind energy, one can at the same time make certain new dams superfluous," says Sterl. "This way two birds can be caught with one stone. Simultaneously, one avoids CO2 emissions from gas-fired power stations and the environmental impact of hydropower overexploitation."

Global relevance

The methods developed for the study are easily transferable to other regions, and the research has worldwide relevance, as shown by a US 80% study on high variable renewable shares. Sterl: "Nearly all regions with a lot of hydropower, or hydropower potential, could use it to compensate shortfalls in solar and wind power." Various European countries, with Norway at the front, have shown increased interest in recent years to deploy their hydropower to support solar and wind power in EU countries. Exporting Norwegian hydropower during times when other countries undergo solar and wind power shortfalls, the European energy transition can be advanced.

 

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Electricity turns garbage into graphene

Waste-to-Graphene uses flash joule heating to convert carbon-rich trash into turbostratic graphene for composites, asphalt, concrete, and flexible electronics, delivering scalable, low-cost, high-quality material from food scraps, plastics, and tires with minimal processing.

 

Key Points

A flash heating method converting waste carbon into turbostratic graphene for scalable, low-cost industrial uses.

✅ Converts food scraps, plastics, and tires into graphene

✅ Produces turbostratic flakes that disperse well in composites

✅ Scalable, low-cost process via flash joule heating

 

Science doesn’t usually take after fairy tales. But Rumpelstiltskin, the magical imp who spun straw into gold, would be impressed with the latest chemical wizardry. Researchers at Rice University report today in Nature that they can zap virtually any source of solid carbon, from food scraps to old car tires, and turn it into graphene—sheets of carbon atoms prized for applications ranging from high-strength plastic to flexible electronics, and debates over 5G electricity use continue to evolve. Current techniques yield tiny quantities of picture-perfect graphene or up to tons of less prized graphene chunks; the new method already produces grams per day of near-pristine graphene in the lab, and researchers are now scaling it up to kilograms per day.

“This work is pioneering from a scientific and practical standpoint” as it promises to make graphene cheap enough to use to strengthen asphalt or paint, says Ray Baughman, a chemist at the University of Texas, Dallas. “I wish I had thought of it.” The researchers have already founded a new startup company, Universal Matter, to commercialize their waste-to-graphene process, while others are digitizing the electrical system to modernize infrastructure.

With atom-thin sheets of carbon atoms arranged like chicken wire, graphene is stronger than steel, conducts electricity and heat better than copper, and can serve as an impermeable barrier preventing metals from rusting, while advances such as superconducting cables aim to cut grid losses. But since its 2004 discovery, high-quality graphene—either single sheets or just a few stacked layers—has remained expensive to make and purify on an industrial scale. That’s not a problem for making diminutive devices such as high-speed transistors and efficient light-emitting diodes. But current techniques, which make graphene by depositing it from a vapor, are too costly for many high-volume applications. And higher throughput approaches, such as peeling graphene from chunks of the mineral graphite, produce flecks composed of up to 50 graphene layers that are not ideal for most applications.

Graphene comes in many forms. Single sheets, which are ideal for electronics and optics, can be grown using a method called chemical vapor deposition. But it produces only tiny amounts. For large volumes, companies commonly use a technique called liquid exfoliation. They start with chunks of graphite, which is just myriad stacked graphene layers. Then they use acids and solvents, as well as mechanical grinding, to shear off flakes. This approach typically produces tiny platelets each made up of 20 to 50 layers of graphene.

In 2014, James Tour, a chemist at Rice, and his colleagues found they could make a pure form of graphene—each piece just a few layers thick—by zapping a form of amorphous carbon called carbon black with a laser. Brief pulses heated the carbon to more than 3000 kelvins, snapping the bonds between carbon atoms; for comparison, researchers have also generated electricity from falling snow using triboelectric effects. As the cloud of carbon cooled, it coalesced into the most stable structure possible, graphene. But the approach still produced only tiny qualities and required a lot of energy.

Two years ago, Luong Xuan Duy, one of Tour’s graduate students, read that other researchers had created metal nanoparticles by zapping a material with electricity, creating the same brief blast of heat behind the success of the laser graphene approach. “I wondered if I could use that to heat a carbon source and produce graphene,” Duy says. So, he put a dash of carbon black in a clear glass vial and zapped it with 400 volts, similar in spirit to electrical weed zapping approaches in agriculture, for about 200 milliseconds. Initially he got junk. But after a bit of tweaking, he managed to create a bright yellowish white flash, indicating the temperature inside the vial was reaching about 3000 kelvins. Chemical tests revealed he had produced graphene.

It turned out to be a type of graphene that is ideal for bulk uses. As the carbon atoms condense to form graphene, they don’t have time to stack in a regular pattern, as they do in graphite. The result is a material known as turbostatic graphene, with graphene layers jumbled at all angles atop one another. “That’s a good thing,” Duy says. When added to water or other solvents, turbostatic graphene remains suspended instead of clumping up, allowing each fleck of the material to interact with whatever composite it’s added to.

“This will make it a very good material for applications,” says Monica Craciun, a materials physicist at the University of Exeter. In 2018, she and her colleagues reported that adding graphene to concrete more than doubled its compressive strength. Tour’s team saw much the same result. When they added just 0.05% by weight of their flash-produced graphene to concrete, the compressive strength rose 25%; graphene added to polydimethylsiloxane, a common plastic, boosted its strength by 250%.

As digital control spreads across energy networks, research to counter ransomware-driven blackouts is increasingly important for grid resilience.

Those results could reignite efforts to use graphene in a wide range of composites. Researchers in Italy reported recently that adding graphene to asphalt dramatically reduces its tendency to fracture and more than doubles its life span. Last year, Iterchimica, an Italian company, began to test a 250-meter stretch of road in Milan paved with graphene-spiked asphalt. Tests elsewhere have shown that adding graphene to paint dramatically improves corrosion resistance.

These applications would require high-quality graphene by the ton. Fortunately, the starting point for flash graphene could hardly be cheaper or more abundant: Virtually any organic matter, including coffee grounds, food scraps, old tires, and plastic bottles, can be vaporized to make the material. “We’re turning garbage into graphene,” Duy says.

 

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Nuclear plants produce over half of Illinois electricity, almost faced retirement

Illinois Zero Emission Credits support nuclear plants via tradable credits tied to wholesale electricity prices, carbon costs, created by the Future Energy Jobs Bill to avert Exelon closures and sustain low-carbon power.

 

Key Points

State credits that value nuclear power's zero-carbon output, priced by market and carbon metrics to keep plants running.

✅ Pegged to wholesale prices, carbon costs, and state averages.

✅ Created by Future Energy Jobs Bill to prevent plant retirements.

✅ Supports Exelon Quad Cities and Clinton nuclear facilities.

 

Nuclear plants have produced over half of Illinois electricity generation since 2010, but the states two largest plants would have been retired amid the debate over saving nuclear plants if the state had not created a zero emission credit (ZEC) mechanism to support the facilities.

The two plants, Quad Cities and Clinton, collectively delivered more than 12 percent of the states electricity generation over the past several years. In May 2016, however, Exelon, the owner of the plants, announced that they had together lost over $800 million dollars over the previous six years and revealed plans to retire them in 2017 and 2018, similar to the Three Mile Island closure later announced for 2019 by its owner.

In December 2016, Illinois passed the Future Energy Jobs Bill, which established a zero emission credit (ZEC) mechanism

to support the plants financially. Exelon then cancelled its plans to retire the two facilities.

The ZEC is a tradable credit that represents the environmental attributes of one megawatt-hour of energy produced from the states nuclear plants. Its price is based on a number of factors that include wholesale electricity market prices, nuclear generation costs, state average market prices, and estimated costs of the long-term effects of carbon dioxide emissions.

The bill is set to take effect in June, but faces multiple court challenges as some utilities have expressed concerns that the ZEC violates the commerce clause and affects federal authority to regulate wholesale energy prices, amid gas-fired competition in nearby markets that shapes the revenue outlook.

Illinois ranks first in the United States for both generating capacity and net electricity generation from nuclear power, a resource many see as essential for net-zero emissions goals, and accounts for approximately one-eighth of the nuclear power generation in the nation.

 

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Here are 3 ways to find out where your electricity comes from

US energy mix shows how the electric grid blends renewables, fossil fuels, nuclear, and hydro, varying by ISO/RTO markets, utilities, and state policies, affecting carbon emissions, pricing, reliability, and access.

 

Key Points

The US energy mix is the grid's source breakdown by region: fossil fuels, renewables, nuclear, and hydro.

✅ Check ISO or RTO dashboards for real-time generation by fuel source.

✅ Utilities may offer green power plans or RECs at modest premiums.

✅ Energy mix shifts with policy, pricing, and grid reliability needs.

 

There are few resources more important than energy. Sure, you may die if you don't eat for days. But your phone will die if you go too long without charging it. Energy feeds tech, the internet, city infrastructure, refrigerators, lights, and has evolved throughout U.S. history in profound ways. You get the idea. Yet unlike our other common needs, such as food, energy sources aren't exactly front of mind for most people. 

"I think a lot of people don't put a lot of bandwidth into thinking about this part of their lives," said Richard McMahon, the SVP of energy supply and finance at Edison Electric Institute, a trade group that represents investor-owned electric companies in the US. 

It makes sense. For most Americans, electricity is always there, and in many locations, there's not much of a choice involved, even as electricity demand is flat across the U.S. today. You sign up with a utility when you move into a new residence and pay your bills when they're due. 

But there's an important reality that indifference eschews: In 2018, a third of the energy-related carbon-dioxide emissions in the US came from the electric power sector, according to the US Energy Information Administration (EIA). 

A good chunk of that is from the residential sector, which consistently uses more energy than commercial customers, per EIA data.

Just as many people exercise choice when they eat, you typically also have a choice when it comes to your energy supply. That's not to say your current offering isn't what you want, or that switching will be easy or affordable, but "if you're a customer and want power with a certain attribute," McMahon said, "you can pretty much get it wherever you are." 

But first, you need to know the energy mix you have right now. As it turns out, it's not so straightforward. At all.

This brief guide may help. 

For some utility providers, you can find out if it publishes the energy mix online. Dominion Energy, which serves Idaho, North Carolina, Ohio, South Carolina, Utah, Virginia, West Virginia, and Wyoming, provides this information in a colored graphic. 

"Once you figure out who your utility is you can figure out what mix of resources they use," said Heidi Ratz, an electricity markets researcher at the World Resources Institute.

But not all utilities publish this information.

It has to do with their role in the grid and reflects utility industry trends in structure and markets. Some utility companies are vertically integrated; they generate power through nuclear plants or wind farms and distribute those electrons directly to their customers. Other utilities just distribute the power that different companies produce. 

Consider Consolidated Edison, or Con Ed, which distributes energy to parts of New York City. While reporting this story, Business Insider could not find information about the utility's energy mix online. When reached for comment, a spokesperson said, "we're indifferent to where it comes from."

That's because, in New York, distribution utilities like Con Ed often buy energy through a wholesale marketplace.

Take a look at this map. If you live in one of the colored regions, your electricity is sold on a wholesale market regulated by an organization called a regional transmission organization (RTO) or independent system operator (ISO). Distribution utilities like Con Ed often buy their energy through these markets, based on availability and cost, while raising questions about future utility revenue models as prices shift. 

Still, it's pretty easy to figure out where your energy comes from. Just look up the ISO or RTO website (such as NYISO or CAISO). Usually, these organizations will provide energy supply information in near-real time. 

That's exactly what Con Edison (which buys energy on the NYISO marketplace) suggested. As of Friday morning, roughly 40% of the energy on the market place was natural gas or other fossil fuels, 34% was nuclear, and about 22% was hydro. 

If you live in another region governed by an ISO or RTO, such as in most of California, you can do the same thing. Like NYISO, CAISO has a dashboard that shows (again, as of Friday morning) about 36% of the energy on the market comes from natural gas and more than 20% comes from renewables. 

In the map linked above, you'll notice that some of the ISOs and RTOs like MISO encompass enormous regions. That means that even if you figure out where the energy in your market comes from, it's not going to be geographically specific. But there are a couple of ways to drill down even further. 

The Environmental Protection Agency has a straightforward tool called Power Profiler. You can enter your zip code to see the fuel mix in your area. But it's not perfect. The data are from 2016 and, in some regions of the country like the upper Midwest, they aren't much more localized, and some import dirty electricity due to regional trading. 

The World Resources Institute also has a tool that allows you to see the electricity mix by state, based on 2017 data from EIA. These numbers represent power generation, not the electricity actually flowing into your sockets, but they offer a rough idea of what energy resources are operating in your state. 

One option is to check with your utility to see if it has a "green power" offering. Over 600 utilities across the country have one, according to the Climate Reality Project, though they often come at a slightly higher cost. It's typically on the scale of just a few more cents per kilowatt-hour. 

There are also independent, consumer-facing companies like Arcadia and Green Mountain Energy that allow you to source renewable energy, by virtually connecting you to community solar projects or purchasing Renewable Energy Certificates, or RECs, on your behalf, as America goes electric and more options emerge. 

"RECs measure an investment in a clean energy resource," Ratz said, in an email. "The goal of putting that resource on the grid is to push out the need for dirtier resources."

The good news: Even if you do nothing, your energy mix will get cleaner. Coal production has fallen to lows not seen since the 1980s, amid disruptions in coal and nuclear sectors that affect reliability and costs, while renewable electricity generation has doubled since 2008. So whether you like it or not, you'll be roped into the clean energy boom one way or another. 

 

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The Phillipines wants nuclear power to be included in the country's energy mix as the demand for electricity is expected to rise.

Philippines Nuclear Energy Policy aims to add nuclear power to the energy mix via executive order, meeting rising electricity demand with 24/7 baseload while balancing safety, renewables, and imported fuel dependence in the Philippines.

 

Key Points

A government plan to include nuclear power in the energy mix to meet demand, ensure baseload, and uphold safety.

✅ Executive order proposed by Energy Secretary Alfonso Cusi

✅ Targets 24/7 baseload, rising electricity demand

✅ Balances safety, renewables, and energy security

 

Phillipines Presidential spokesman Salvador Panelo said Energy Secretary Alfonso Cusi made the proposal during last Monday's Cabinet meeting in Malacaaang. "Secretary Cusi likewise sought the approval of the issuance of a proposed executive order for the inclusion of nuclear power, including next-gen nuclear options in the country's energy mix as the Philippines is expected to the rapid growth in electricity and electricity demand, in which, 24/7 power is essential and necessary," Panelo said in a statement.

Panelo said Duterte would study the energy chief's proposal, as China's nuclear development underscores regional momentum. In the 1960s until the mid 80s, the late president Ferdinand Marcos adopted a nuclear energy program and built the Bataan Nuclear Plant.

The nuclear plant was mothballed after Corazon Aquino became president in 1986. There have been calls to revive the nuclear plant, saying it would help address the Philippines' energy supply issues. Some groups, however, said such move would be expensive and would endanger the lives of people living near the facility, citing Three Mile Island as a cautionary example.

Panelo said proposals to revive the Bataan Nuclear Plant were not discussed during the Cabinet meeting, even as debates like California's renewable classification continue to shape perceptions. Indigenous energy sources natural gas, hydro, coal, oil, geothermal, wind, solar, biomassand ethanol constitute more than half or 59.6%of the Philippines' energy mix.

Imported oil make up 31.7% while imported coal, reflecting the country's coal dependency, contribute about 8.7%.

Imported ethanol make up 0.1% of the energy mix, even as interest in atomic energy rises globally.

In 2018, Duterte said safety should be the priority when deciding whether to tap nuclear energy for the country's power needs, as countries like India's nuclear restart proceed with their own safeguards.

 

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EPA, New Taipei spar over power plant

Shenao Power Plant Controversy intensifies as the EPA, Taipower, and New Taipei officials clash over EIA findings, a marine conservation area, fisheries, public health risks, and protests against a coal-fired plant in Rueifang.

 

Key Points

Dispute over coal plant EIA, marine overlap, and health risks, pitting EPA and Taipower against New Taipei and residents.

✅ EPA approved EIA changes; city cites marine conservation conflict

✅ Rueifang residents protest; 400+ signatures, wardens oppose

✅ Debate centers on fisheries, public health, and coal plant impacts

 

The controversy over the Shenao Power Plant heated up yesterday as Environmental Protection Administration (EPA) and New Taipei City Government officials quibbled over the project’s potential impact on a fisheries conservation area and other issues, mirroring New Hampshire hydropower clashes seen elsewhere.

State-run Taiwan Power Co (Taipower) wants to build a coal-fired plant on the site of the old Shenao plant, which was near Rueifang District’s (瑞芳) Shenao Harbor.

The company’s original plan to build a new plant on the site passed an environmental impact assessment (EIA) in 2006, similar to how NEPA rules function in the US, and the EPA on March 14 approved the firm’s environmental impact difference analysis report covering proposed changes to the project.

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That decision triggered widespread controversy and protests by local residents, environmental groups and lawmakers, echoing enforcement disputes such as renewable energy pollution cases reported in Maryland.

The controversy reached a new peak after New Taipei City Mayor Eric Chu on Tuesday last week posted on Facebook that construction of wave breakers for the project would overlap with a marine conservation area that was established in November 2014.

The EPA and Taipower chose to ignore the demarcation lines of the conservation area, Chu wrote.

Dozens of residents from Rueifang and other New Taipei City districts yesterday launched a protest at 9am in front of the Legislative Yuan in Taipei, amid debates similar to the Maine power line proposal in the US, where the Health, Environment and Labor Committee was scheduled to review government reports on the project.

More than 400 Rueifang residents have signed a petition against the project, including 17 of the district’s 34 borough wardens, Anti-Shenao Plant Self-Help Group director Chen Chih-chiang said.

Ruifang residents have limited access to information, and many only became aware of the construction project after the EPA’s March 14 decision attracted widespread media coverage, Chen said,

Most residents do not support the project, despite Taipower’s claims to the contrary, Chen said.

New Power Party Executive Chairman Huang Kuo-chang, who represents Rueifang and adjacent districts, said the EPA has shown an “arrogance of power” by neglecting the potential impact on public health and the local ecology of a new coal-fired power plant, even as it moves to revise coal wastewater limits elsewhere.

Huang urged residents in Taipei, Keelung, Taoyaun and Yilan County to reject the project.

If the New Taipei City Government was really concerned about the marine conservation area, it should have spoken up at earlier EIA meetings, rather than criticizing the EIA decision after it was passed, Environmental Protection Administration Deputy Minister Chan Shun-kuei told lawmakers at yesterday’s meeting.

Chan said he wondered if Chu was using the Shenao project for political gain.

However, New Taipei City Environmental Protection Department specialist Sun Chung-wei  told lawmakers that the Fisheries Agency and other experts voiced concerns about the conservation area during the first EIA committee meeting on the proposed changes to the Shenao project on June 15 last year.

Sun was invited to speak to the legislative committee by Chinese Nationalist Party (KMT) Legislator Arthur Chen.

While the New Taipei City Fisheries and Fishing Port Affairs Management Office did not present a “new” opinion during later EIA committee meetings, that did not mean it agreed to the project, Sun said.

However, Chan said that Sun was using a fallacious argument and trying to evade responsibility, as the conservation area had been demarcated by the city government.

 

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