Weight Optimization of Vertical-Axis Wind Turbine Blades constructed in Swedish Fossil Free Steel : With respect to fatigue life time

Abstract: Wind turbines have been utilized for centuries to harness energy from the wind. Commercial wind turbine blades are typically made from composite materials, which are difficult to recycle, leading to blades ending up in landfills at the end of their lifecycle. Additionally, these materials contribute to microplastic pollution. In response to growing environmental concerns, there has been an increased focus on addressing such issues. The Swedish company SeaTwirl AB develops offshore vertical-axis wind turbines (VAWT), and this study focuses on optimizing the weight of a blade from a new 10-15 MW VAWT concept using steel as the material. Steel has long been recyclable, making it an interesting material for wind turbine blades. The specific steel used in this study is the ultra-high-strength steel "Strenx 1300" from SSAB, which is not only extremely durable but is also expected to be fossil-free by 2026, by implementation of the manufacturing technology HYBRIT. The study found that a single blade made from Strenx 1300, when designed and optimized for 35 years of operational use, would weigh approximately 193.4 tonnes and would require 6016.8 meters of welds with a fatigue class of FAT 125. A rough estimation of the weight of a fiberglass VAWT of the same size resulted in approximately 300 tonnes. Therefore, this study concludes that it may be feasible to construct a commercially competitive VAWT blade using environmentally friendly, fossil-free steel. This approach would make wind energy a more sustainable energy source without the problems of recyclability and microplastic pollution.