Crain's Detroit Business
Keith Cooley, the CEO of NextEnergy, has put together a consortium of industry heavyweights and lined up about $56 million in matching-fund commitments as it awaits word on a $45 million U.S. Department of Energy grant to build an engineering facility on Zug Island that would develop and test drivetrains for what could easily be the world's largest wind turbine.
The facility would be called NextWind and test powertrains that can generate 15-20 megawatts of energy. The world's current most powerful wind turbine, which is in Germany, generates seven megawatts, enough to power about 1,800 U.S. households for a year. The diameter of its rotors is 413 feet. Most commercial wind turbines generate one to 2.5 megawatts.
“Clearly, we'll have a chance to share knowledge, share information, share expertise and share history,” said Cooley of the consortium partners.
Cooley said industry partners already on board with $35 million in commitments include such major turbine manufacturers as Atlanta-based GE Energy, Clipper Windpower Inc. of California, and Belgium-based Hansen Transmissions International NL and such engineering, testing and supplier firms as Ricardo Inc. of Van Buren Township; AVL North America Inc. of Plymouth; LMS of Troy, a business unit of Belgium-based LMS International NV; Munro & Associates Inc. of Troy; and Burke E. Porter Machinery Co. of Grand Rapids.
State of Michigan commitments total $19.2 million, including brownfield remediation help from the Detroit Economic Growth Corp., the Michigan Department of Environmental Quality and Wayne County; infrastructure improvements by the Michigan Department of Transportation; access to bonding from the Michigan Department of Energy, Labor and Economic Growth; and funding from the Michigan Economic Development Corp.
Commitments from the University of Michigan, Michigan State University, Western Michigan University and NextEnergy total about $2 million. Also on board are Sandia National Laboratories in Albuquerque, N.M., the National Renewable Energy Laboratory in Golden, Colo.; and the National Renewable Energy Center in Spain.
Cooley told Crain's he hopes to learn in mid-November if NextEnergy wins the grant against competing bids from organizations in at least six other states.
“While we think we have the best chance, in terms of having sent in the best proposal, you just never know,” he said. He said Michigan's 110-year history of drivetrain testing and development, its roster of partners and matching funds that far exceeded the bid's requirement of $29 million should help.
Cooley is ready to hit the ground running. He said funds should start flowing in January or February, and the project could be up and running in 12-18 months.
He said worldwide demand for 20 megawatt turbines could be in the tens of thousands over the coming decades: “That's enough to keep this area busy for decades.” The DOE grant is for five years.
Cooley said he hopes the testing facility would spark development of an industrial park on the island. He said it would make sense for wind-turbine suppliers to manufacture prototypes in adjacent buildings.
“We hope to attract suppliers and an OEM or two,” he said. “That's an area that's certainly in need of redevelopment.”
Such a move — R&D attracting an OEM — is what's needed to foster a broader impact through creation of a supply chain, said Greg Main, the MEDC's CEO.
“If we bring in a turbine manufacturer, which we don't have right now ... that sets up the opportunity for Michigan suppliers to diversify into those sectors.”
NextEnergy, the Detroit-based nonprofit that aims to accelerate the state's role in clean and alternate energies, hired Albert Kahn Associates Inc., Detroit, to draw up plans for a 50,000-square-foot testing facility, which would house two dynamometers, each capable of generating 10 megawatts of power.
In theory, Cooley said, they could be coupled to test wind-turbine drivetrains capable of producing 20 megawatts of power, though 15 megawatts may be a more realistic target.
“China is working on a 10 megawatt turbine. No one else is doing anything approaching 20 megawatts,” he said.
“The key to wind-turbine scale-up is drivetrain reliability. It needs to last as long as you say it will,” he said. “If you've never seen a wind turbine tear itself apart, it can be spectacular. It just flies apart. No wonder people say, "Not in my backyard.' Manufacturers claim they have 20-year life spans, and they break up in 18 months, so you've got to be able to prove drivetrain reliability.”
In automotive testing facilities, engines or powertrains are connected to dynamometers to test the energy or power created, typically 100-400 horsepower. NextWind's would be dynamometers on steroids.
The goal is for the facility to be used by manufacturers around the U.S. and the world to test drivetrain components, such as gearboxes, hubs, generators and controls.
The NextWind project dovetails with one of NextEnergy's big thrusts. Cooley said that over the past two years, NextEnergy officials have talked with more than 1,000 auto suppliers in Michigan about getting into wind energy.
The facility would be called NextWind and test powertrains that can generate 15-20 megawatts of energy. The world's current most powerful wind turbine, which is in Germany, generates seven megawatts, enough to power about 1,800 U.S. households for a year. The diameter of its rotors is 413 feet. Most commercial wind turbines generate one to 2.5 megawatts.
“Clearly, we'll have a chance to share knowledge, share information, share expertise and share history,” said Cooley of the consortium partners.
Cooley said industry partners already on board with $35 million in commitments include such major turbine manufacturers as Atlanta-based GE Energy, Clipper Windpower Inc. of California, and Belgium-based Hansen Transmissions International NL and such engineering, testing and supplier firms as Ricardo Inc. of Van Buren Township; AVL North America Inc. of Plymouth; LMS of Troy, a business unit of Belgium-based LMS International NV; Munro & Associates Inc. of Troy; and Burke E. Porter Machinery Co. of Grand Rapids.
State of Michigan commitments total $19.2 million, including brownfield remediation help from the Detroit Economic Growth Corp., the Michigan Department of Environmental Quality and Wayne County; infrastructure improvements by the Michigan Department of Transportation; access to bonding from the Michigan Department of Energy, Labor and Economic Growth; and funding from the Michigan Economic Development Corp.
Commitments from the University of Michigan, Michigan State University, Western Michigan University and NextEnergy total about $2 million. Also on board are Sandia National Laboratories in Albuquerque, N.M., the National Renewable Energy Laboratory in Golden, Colo.; and the National Renewable Energy Center in Spain.
Cooley told Crain's he hopes to learn in mid-November if NextEnergy wins the grant against competing bids from organizations in at least six other states.
“While we think we have the best chance, in terms of having sent in the best proposal, you just never know,” he said. He said Michigan's 110-year history of drivetrain testing and development, its roster of partners and matching funds that far exceeded the bid's requirement of $29 million should help.
Cooley is ready to hit the ground running. He said funds should start flowing in January or February, and the project could be up and running in 12-18 months.
He said worldwide demand for 20 megawatt turbines could be in the tens of thousands over the coming decades: “That's enough to keep this area busy for decades.” The DOE grant is for five years.
Cooley said he hopes the testing facility would spark development of an industrial park on the island. He said it would make sense for wind-turbine suppliers to manufacture prototypes in adjacent buildings.
“We hope to attract suppliers and an OEM or two,” he said. “That's an area that's certainly in need of redevelopment.”
Such a move — R&D attracting an OEM — is what's needed to foster a broader impact through creation of a supply chain, said Greg Main, the MEDC's CEO.
“If we bring in a turbine manufacturer, which we don't have right now ... that sets up the opportunity for Michigan suppliers to diversify into those sectors.”
NextEnergy, the Detroit-based nonprofit that aims to accelerate the state's role in clean and alternate energies, hired Albert Kahn Associates Inc., Detroit, to draw up plans for a 50,000-square-foot testing facility, which would house two dynamometers, each capable of generating 10 megawatts of power.
In theory, Cooley said, they could be coupled to test wind-turbine drivetrains capable of producing 20 megawatts of power, though 15 megawatts may be a more realistic target.
“China is working on a 10 megawatt turbine. No one else is doing anything approaching 20 megawatts,” he said.
“The key to wind-turbine scale-up is drivetrain reliability. It needs to last as long as you say it will,” he said. “If you've never seen a wind turbine tear itself apart, it can be spectacular. It just flies apart. No wonder people say, "Not in my backyard.' Manufacturers claim they have 20-year life spans, and they break up in 18 months, so you've got to be able to prove drivetrain reliability.”
In automotive testing facilities, engines or powertrains are connected to dynamometers to test the energy or power created, typically 100-400 horsepower. NextWind's would be dynamometers on steroids.
The goal is for the facility to be used by manufacturers around the U.S. and the world to test drivetrain components, such as gearboxes, hubs, generators and controls.
The NextWind project dovetails with one of NextEnergy's big thrusts. Cooley said that over the past two years, NextEnergy officials have talked with more than 1,000 auto suppliers in Michigan about getting into wind energy.
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