Mobile Generator Set for Wind Turbine Blade Recycling

Genesal Energy promotes sustainability in wind farms with a mobile generator set for the recycling of turbine blades.

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The energy transition and the fight against climate change have boosted the development of wind energy, making it one of the main renewable sources worldwide. However, this progress brings with it a significant challenge: the efficient recycling of wind turbine blades.

With an average lifespan of 20 years – extendable to 25 with proper maintenance – most components of a wind turbine are recyclable. However, blades present a unique challenge due to the composite materials used in their manufacture: glass & carbon fibre and resins. These materials are complex to separate, which raises costs and makes large-scale recycling difficult.

Genesal Energy has taken a step forward in search of sustainable solutions to this challenge. In collaboration with GDES Wind – a company specialised in the maintenance and inspection of blades in wind farms – we designed and installed a 45 kVA mobile generator set to power a machine specialised in the recycling of wind turbine blades. This equipment cuts the blades using diamond wire, offering an efficient and environmentally friendly alternative. The pieces are then efficiently treated as waste, generating mortar or useful pieces for new applications such as planters, canopies or pieces of furniture.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy.

This genset – which complies with Stage V emissions standards – not only ensures a low environmental impact but also provides autonomy of up to 35 hours at 100% load thanks to its 350-litre tank. It is also equipped with a socket panel to power auxiliary tools, extending its functionality and operational efficiency.

A growing challenge in the wind power industry

Although most blades are currently reused in repowering processes or converted into architectural structures such as bridges or bicycle racks, this strategy will not be sufficient in the long term. According to WindEurope, up to 5,700 wind turbines per year will be dismantled in Europe from 2030 onwards, which means an increasing volume of retired blades that will require innovative solutions for recycling.

Grupo electrógeno móvil para eventos con diseño ligero.

Image 1: The trailer-mounted genset inside the customer’s warehouse.

The equipment designed by Genesal Energy to power the GDES Wind solution represents a key step in this direction, aligning with the principles of the circular economy and offering the wind sector an indispensable tool to sustainably manage the dismantling of wind turbines.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy. We continue working to make energy not only cleaner, but also more socially responsible.

Features

  • Supply: 2600mm soundproofed canopy on trailer.
  • Stage V emissions-compliant engine.
  • 350L base frame inserted fuel tank.
  • Control panel: ComAp AMF 25 InteliLite4.
  • Socket panel.

A wind farm in Baja California desert, Genesal Energy’s new commitment to clean energy

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Baja California is one of the Mexican states with a strong focus on renewable energy, and one of the latest examples is a wind farm located in the desert of Baja California Sur.

This large scale project – more than 100 million dollars’ investment – will also entail a revolution in the infrastructures of the area: 20 kilometres of roads and over 20 kilometres of medium voltage overhead and underground networks will be built.

This project is a turning point. It means a before and an after in the lives of the inhabitants of a region with a great tourism potential and a constant growth that for years has needed a robust electricity grid according to an energy demand that does not stop increasing. The future wind farm will respond to this requirement in a clean and sustainable way, avoiding the collapse of the current system.

Genesal Energy participated in this project through the design, manufacture and supply of four generator sets, two of 640 kVA soundproof type, one of 462 kVA open type and one of 125 kVA soundproof type.

Fossil energy sources

Our client needed emergency power for the lifting and switching substations, as well as for the wind farm’s collection network, so the four generator sets were designed as per such requirements.

The wind farm’s commissioning will not only improve the quality of life of Baja California’s people, but will also mean a change in the energy model in the area, as in this state – unlike most of Mexico – power generation comes mainly from fossil sources, which is not usual in other regions.

Besides, this project represents a new challenge for our engineering team, and consolidates the leadership of our subsidiary in Mexico, which is increasingly present in the renewables sector. At Genesal Energy we have recently formalized our commitment to the environment with the achievement of four of the SDS included in the 2030 Agenda.

Over the last years, at Genesal Energy we have reinforced our focus on clean energy, a market in expansion in which we believe. In the case of Mexico, both its privileged climate and the Administration’s support makes the country an ideal place for the development of the renewable energy market. Two representative case studies are ‘San Matías’ (Baja California) and ‘Tres Mesas’ (Tamaulipas) wind farms, along with other international projects we carried out in countries such as Oman, Dominican Republic, Peru and Spain.

A wind turbine, a Genesal generator and a black transformer in an arid Mexico's zone

Features

All the units have been designed according to the CFE W4700-10 standards, and include the below features:

  • RAL 1021 yellow paint, in compliance with CFE norms.
  • DNP 3.0. communication protocol.
  • Third party inspection of the FAT procedure.
  • Spare parts according to CFE specifications.
  • Base frame integrated fuel tank allowing 12h autonomy at full load.
  • Winding heaters.
  • 24V start-up.
  • Space heaters and thermostat in panel.
  • Single mode optical fiber.
  • Dual port fiber switch.
  • Special adaptation of switches for remote opening and closing.

We continue growing in the renewable energy industry: emergency power for two new wind farms in Mexico

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At Genesal Energy we continue committing ourselves to the renewable energy sector, and one of our latest projects has been in Mexico, where we participated in the construction of two large wind farms.

They are the San Carlos and Santa Cruz wind farms, with more than 100 wind turbines to supply power to the state of Tamaulipas, with more than 3,4 million citizens.

The San Carlos wind farm, now under construction, will generate 198 MW and have 60 AW132 3300 IEC IIB TH120 wind turbines. With an investment of more than 215,7 million dollars and located between Villagrán and San Carlos, it will occupy 171 hectares and will be one of the largest wind farms in Tamaulipas. Genesal Energy is participating through the design, manufacture and supply of three emergency generator sets (two open units of 462 kVA and another 220 kVA soundproof genset) to supply power to various substations.

On the other hand, in the Santa Cruz wind farm – in near proximity to the US border – there will be a total of 42 AW132 TH120 wind turbines. The installation will generate 138 MW. Genesal is supplying a customised emergency genset of 113-125 kVA for the wind farm.

CFE Certification

In both cases, the generator sets have been designed and manufactured by our engineering department following CFE specifications, the Mexican government’s official accreditation which backs foreign companies when opting for great projects and public tenders in the Mexican territory.

Through the participation in the San Carlos and Santa Cruz wind farms, the company’s has reinforced its strategy to aim for renewable energy, especially in strategic markets such as Mexico, Oman and the Dominican Republic, amongst other countries.

GEN462FA and GEN220FI

  • Above-ground approved double-wall 1500L fuel tank in steel-steel, complying with the autonomy required by the client.
  • Alternator anti-condensation heater.
  • Both the generator set and the monoblock have been painted in the colour requested by the client.
  • IB-lite module for Modbus TCP/IP communication, which allows remote monitorization and access through a computer with Internet connection.
  • Analogical voltmeter and ammeter following client’s requests.
  • DNP3 gateway.

GEN125FI

  • Genset prepared for start-up via external command.
  • IB-lite module for Modbus TCP/IP communication, which allows remote monitorization and access through a computer with Internet connection.

 

Supply of generator sets to the Tres Mesas wind farm in Mexico

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Another achievement by one of our distributors.

We have supplied two 82 and 110 kVA units prepared to back-up the auxiliary services of the electrical substations of the Tres Mesas Wind Farm (Phase IV), guaranteeing the correct operation of the electrical systems in response to any eventual failure that may occur.

Features

  • Double-walled 600L fuel tank and automatic fuel transfer system for 48 hours autonomy at 60% load.

 

We designed an ‘anti-hurricane’ generator set for a great wind farm in the Dominican Republic

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Our engineering team has designed and supplied emergency power to the Agua Clara wind farm in the Dominican Republic, a large power station capable of providing power to 250.000 citizens.

The wind farm, whose first phase has already come to a close, has 25 wind turbines, of two megawatts (MW) each, which represents an estimated annual production of 170.000 MW/hour. 

With an initial investment of 100 million dollars, the project produces 50 MW of renewable power and the objective is to install up to 200 MW once the four phases of the project have concluded. Genesal Energy has designed and supplied a special generator set, adapted to face the complicated climate of the región of Monte Cristi, where the wind farm is located.

Agua Clara is in a hurricane-prone area, which means the wind farm’s infrastructure requires special equipment capable of facing this type of phenomena. In order to reduce the pressure exerted on a wind turbine by a potential hurricane, it must direct its nacelle and blades with the help of electric and hydraulic motors in such a way that the wind exerts the least force possible on the structure, avoiding harm.

One hundred percent personalized

At the windfarm, the client needed that, in the event of a hurricane or a cyclone and in consecuence, a mains failure, the wind turbines could position themselves correctly and avoid serious damage through the use o fan alternative source of energy. To achieve this, we manufactured a generator set capable of powering the auxiliary services which drive the positioning of the windmills.

The generator which we’ve designed is 100% customised and can be completely managed, controlled and monitored from the wind park’s control centre (SCADA). Inside the actual container, the local control system was installed, along with a PLC to manage communication with the farm’s SCADA through fiber optics, and a protection relay.

Genesal Energy ha diseñado y suministrado un equipo especial, adaptado para hacer frente a la complicada climatología de Monte Cristi.

The Genesal Energy unit will receive start-up and shut-down commands from the wind farm’s control centre and will start-up and energize a step-up transformer. From that momento onwards, the genset will power the whole wind farm and, therefore, the auxiliary systems needed to position each one of the wind turbines to avoid damages in the event of a hurricane.

To compensate the capacitance of the medium-voltage cable runs to the turbines, of hundreds of metres of height, an inductor bank was also installed in the wind farm’s substation. The generator set must power the bank during the first seconds after the hurricane, while the wind turbines and the medium-voltage cable runs aren’t being powered. In order for the generator set to be able to support this strong inductive load, its alternator was oversized, through the installation of a top of the range 3.000 kVA alternator.

Features

  • Engine and alternator pre-heaters.
  • ModBus TCP/IP communicaition.
  • Tailor-made control logic carried out through PLC & DEIF AGC4 controller.
  • Dedicated electrical protection relay.
  • Oversized alternator to support high inductive currents.
  • Automatic fuel transfer system.
  • Special application for an anti-hurricane system in a wind farm.

 

Emergency power for the Los Llanos wind farm, a new source of renewable power

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The first wind park to be raised in the province of Malaga was in the Casares municipality and since then the offer for this type of renewable power has not stopped growing.

Genesal Energy’s focus on alternative and sustainable power has also increased considerably in the last decade, with an ever-growing market, and Andalucía is no exception in our line of business.

This way, one of our latest projects has taken us to the Los Llanos wind park, one of the pioneers in this autonomous community, through the manufacturing and supply of a “turnkey” generator set, made-to-measure for the client, which amongst other requirements, asked that the genset be prepared for remote start-up and that it could provide power to the primary loads in the substation facing a possible mains failure.

The generator set, which will operate in Los Llanos, will start-up remotely when the control system of the substation detects a mains failure because precision is vital in this type of installation where wind is the basic power source.

Features

  • Approved double-walled 1.000L fuel tank for outdoors
  • Baseframe fuel tank prepared as leakage tray
  • Electronic engine speed regulation
  • Signal and alarm remote expansion module
  • Remote start-up

 

A wind farm in Baja California, key in Genesal’s efforts towards clean energy

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Baja California is one of the Mexican states with a strong focus on renewable energy, and the San Matías wind farm is one of the latest examples.

The installation, now in its construction phase, will generate 30 MW, and include eight wind turbines of 2,5 MW and 20 MW. Its comissioning, expected in 2021, will improve the lives of Baja California’s inhabitants, including the kiliwas, an indigenous tribe living in Baja California.

At Genesal Energy we participated in the project though the design, manufacturing and supply of two 200-220 kVA gensets. At Genesal Energy, renewable energy is a market in expansion in which we believe, and we position ourselves in the first positions in the ranking with international projects such as those carried out in Mexico, Oman and the Dominican Republic.

Features

  • Engine with electronic speed regulation.
  • Approved, double-walled 2.000L fuel tank for the GEN220F and 3.000L for the GEN220FI.
  • 24V start-up, to comply with CFE standards.
  • Yellow 17 paint, in compliance with CFE standards.
  • Alternator anti-condensation heater.
  • Excitation current and voltage measurement.
  • Control panel heater.
  • DNP 3.0. communication gateway.

We increase our reach in the national market with the supply of emergency power for wind farms in Castilla-La Mancha, Aragón and Galicia

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Emergency power for wind farms

Providing power to the primary loads of the electrical substation (wind farm) in the event of a mains failure is the main objective of the gensets designed by Genesal Energy to operate in the Oriche and Venta Vieja substations in Teruel, Montilla del Palancar in Cuenca, and Serra das Penas in Lugo.

In each case, the client asked for an especially low noise level, 75 dB at 7 metres, and oversized fuel tanks. The solution provided by Genesal Energy consisted in manufacturing made-to-measure gensets, each personalised to adapt to each one of the installations.

This way, each one of the four generator sets was designed following the client’s needs and complying with their requests, such as the noise level. The gensets are extremely silent thanks to the installation of attenuation systems in the air inlet and outlet of each one.

Furthermore, each unit includes the necessary binary signals in order for the client to integrate it in the substation without any issues.

Features

  • Oversized fuel tank.
  • Leakage tray.
  • Recirculation and heating system for the engine’s cooling liquid needed to provide an adequate temperature for the unit’s start-up.
  • Air inlet and outlet sound attenuators to achieve the required dB’s.
  • Redundant battery system to guarantee availability of start-up power.
  • Dry contacts for the control and monitorization of each genset’s status.

We continue to reinforce our presence in the Middle East

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Oman has inmense potential in the field of renewable energies, especially solar and wind.

One of our latest projects in this country consisted in the supply of a 500 kVA made-to-measure generator set for a great wind farm.

It’s designed to operate in parallel with the mains, to withstand elevated temperatures and to guarantee the farm’s auxiliary services based on the characteristics of the site itself, installation and operation. At Genesal Energy, we’re able to grow in the Middle East thanks to new projects in countries such as Oman, Qatar and Saudi Arabia.

Features

  • Generator set prepared to operate in parallel with the mains, equipped with a motorized thermal-magnetic breaker for the genset.
  • Alternator with Class B temperature rise and anti-condensation heating.
  • 800L fuel tank integrated in the base frame with leakage tray.
  • Independent, approved, double-walled 4000L with an automatic fuel transfer system.
  • Neutral earthing resistor to limit the earth fault current.
  • Control panel heating system.