When on a road trip, you may have come across a long trailer carrying a massive wind turbine blade. You might have wondered how such a large component is transported to challenging locations, like the top of a mountain, and installed at significant heights. This task used to require extensive logistical efforts and sometimes even alterations to access roads, often steep and winding. Imagine the difficulty of moving a large cabinet up a narrow staircase to get a sense of the challenge. Thankfully, the introduction of blade lifter technology has made previously deemed unfeasible projects possible due to their inaccessible locations.
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The challenge of transporting a blade
In the mid-2010s, wind turbine blades, composed of fiberglass, carbon fiber, wood, and aluminum, weighed up to seven tons and were forty meters long. Today, these figures are surpassed by current standards as wind turbines become more powerful and efficient, leading to exponentially longer blades. Helicopters were once used for short-distance transport, but now road transport is the primary option.
Maritime transport and locating factories near wind farms can manage part of the journey. However, large trucks with extendable trailers are essential for the final stages. Bridges, roundabouts, and intersections along the route must be considered, and sometimes adjustments to the road surface are needed when navigating uphill curves on mountainous roads.
Blade lifter technology takes over
To address this challenge, blade lifter technology has been developed, featuring a blade-lifting mechanism installed on trailers. The blade is secured to a hydraulic system that can adjust its orientation up to approximately 65 degrees, with some models reaching 90 degrees. This allows the blade to maneuver around obstacles and reduces the necessity for large trailers. Additionally, the platform where each blade is mounted can, in certain cases, rotate 180 degrees to counteract wind gusts. Some models can lift up to 1,000 metric tons.
The system was initially tested in 2012 for a wind farm installation in Switzerland. While the adoption has been gradual, with countries like Spain not incorporating it until 2019, it has now become a mature technology with impressive applications. The success is driven by various advantages, including:
- Facilitating the installation of wind farms in previously inaccessible locations, expanding the scope of renewable projects.
- Reducing costs associated with civil engineering works, as major road modifications are no longer necessary.
- Minimizing environmental impact by preserving existing vegetation and reducing earthworks.
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The case of the MacIntyre wind farm
ACCIONA EnergÃa is leading the way with this system in countries like Australia. At the MacIntyre wind farm, they showcased its effectiveness in one of the largest installations in the southern hemisphere. By utilizing existing roads, they decreased the required earthworks by 250,000 cubic meters. Furthermore, by keeping the surrounding land undisturbed, the impact on vegetation was minimized by 20,000 square meters—equivalent to three times the size of Manchester United’s stadium in the UK.
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Overall, wind energy is becoming more efficient. This is partly due to the increasing size of wind turbines and the focus on offshore wind farms, but also thanks to advancements in manufacturing and transport systems. If you’re interested in learning about the lifecycle and recycling of a blade, we recommend reading this article on how a blade can be reincarnated as a sneaker.
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