CARTER WIND TURBINES LLC — Department of Energy SBIR Phase I: C56-17a

Description

C56-17a-273450This project will support key objectives for wind energy to minimize environmental impacts and innovate complex terrain installation technologies for large emerging global wind power markets, namely: 1) distributed industrial/infrastructure applications, and 2) deep-water offshore. Both markets need more reliable, resilient, lower cost technologies and greater functionality to scale rapidly. Most oil and gas facilities, water and food processing plants, EV charging stations, and other large energy users do not have access to on-site wind power, particularly installed without mobilizing heavy equipment. A novel flexible two-bladed, downwind, low-cost design can solve logistics challenges faced at vast numbers of remote U.S. and global sites including new offshore lease areas with modularity, ultra-lightweight strength, and a large swept area to power ratio. Confirming feasibility of a new prototype midsize wind turbine, SBIR funding will validate and fast-track equitable deployment of the market’s largest tilt-up modernized wind generator along with stand-alone storage and onsite charging. Evaluating ground-breaking prototypes will accelerate significantly lower LCOE at distributed sites for later offshore scaling, advancing stronger lightweight downwind approaches as identified “Grand Challenges.” This SBIR project will quantify increased energy production, dynamic power system integration for the rapidly evolving grid, and resulting >40% LCOE reductions expected to achieve $45/MWh for this proven wind turbine design. This project will install prototype turbines on 60 m guyed freestanding towers with integrated energy storage and validate innovations including functionality, performance, design and safety, and durability. The project will compare savings of concrete and costs for cranes, excavators, and other materials as well as GHG impacts and embedded energy to conventional wind turbines. Building on previous development and field operation, Phase 1 will complete the certification design review package, including control/safety system, integrated battery storage, loads document, component specifications and analyses, and prepare for field testing of new prototypes to be installed and evaluated in Phase 2. An accelerated commercialization plan for this improved pioneering design demonstrates near-term commercial viability. Working with established U.S. wind industry leaders, Phase I will substantially advance TRL/MRL and reduce energy costs, improve access to remote locations, and create 300+ new U.S. manufacturing jobs. SBIR funding leverages on three previous federal awards for tower component innovation, variable speed electrical system optimization, and rotor expansion to 36 meters. The Oklahoma Commerce Department and Lawton-Fort Sill have offered large incentives to locate a new manufacturing facility 50 miles north of its current Texas location. Orders are pending for 100 units representing >$40M including interest from utilities and a leading U.S. construction equipment distributor. Despite little marketing and media outreach, inquiries represent hundreds more sales. Successfully scaling design innovations will enable critical cost reductions for U.S. offshore wind as well as underserved remote land-based applications.