Röchling launches Pulcap to enhance rotor-blade stability


International plastics processor Röchling Industrial has launched Pulcap, a product made of composites, that enhances the stability of wind-turbine rotor blades. Owing to their extremely high mechanical strength and low weight, the pultruded profiles enable an efficient and safe operation of wind turbines.

By 2030, Germany intends to generate 65 percent of its gross electricity consumption from renewable energy sources. To achieve the intended energy transition, more wind, water, and sun will be used to generate electricity. New, more powerful offshore and onshore wind turbines are being developed or existing turbines are upgraded. Within the scope of repowering, turbine parts are replaced by, for example, larger parts that generate more power. Optimized, longer and more powerful rotor blades are very important in that context.

Röchling has supplied the wind-power industry with glass fiber-reinforced materials for more than 20 years. (Courtesy: Röchling Industrial)

“With our Pulcap pultruded profiles we are contributing to improving the efficiency and performance of wind turbines,” said Franz Lübbers, CEO of Röchling Industrial. “We are very happy to launch this high-quality product to the market.”

The profiles for rotor spar caps are used as reinforcement of rotor blades in wind turbines. In conjunction with the bars, they form the skeleton of a blade and are largely responsible for stability.

Röchling has supplied the wind-power industry with glass fiber-reinforced materials for more than 20 years. The company also offers insulation materials for choke coils, transformers and generators, and inverters.

Röchling Industrial manufactures Pulcaps using the pultrusion process. As part of the continuous process, a composite of glass and carbon fibers is produced with a special resin system that ensures the superior quality of the products.

“The tensile forces during pultrusion straighten the fibres greatly reducing any material defects compared to conventional manufacturing processes,” said Uwe Kasses, who is responsible for the composite business at Röchling Industrial, which also includes the pultrusion process. This reduces any imperfections and considerably decreases the risk of errors during bonding and processing.

At the same time, Pulcaps withstand the highest loads due to their high mechanical properties, so that the profiles reliably reinforce the rotor blade chords.

“Our pultruded profiles for wind turbines comply with the highest requirements. The material is tested in advance according to specified criteria resulting in only approved materials being used,” said Michael Janssen, responsible for Composite developments at Röchling Industrial.

In particular for larger and high-performance wind turbines, aspects such as high strengths play a decisive role due to loads and long service life.

“Our product significantly increases the efficiency of modern systems,” Janssen said. “Using Pulcaps increases service life and improves performance. At the same time, error rates and maintenance times can be reduced, rendering the generation of electricity more economical and sustainable overall.”

More info www.roechling.com/us