Sandia's Twistact Technology: Decarbonization of the Energy Sector in the 2030 Time Frame.\
- Sandia National Laboratories (SNL), Albuquerque, NM, and Livermore, CA (United States)
As of 2018, renewable energy sources such as wind and solar have the lowest unsubsidized levelized cost of energy, and grid-scale storage solutions are being aggressively developed and deployed. However, for a carbon-free energy generation paradigm to be realistic, any impediments to scalability must be addressed. In the wind industry, dependence on rare-earth (RE) magnets in direct-drive generators represents a significant roadblock to widespread technology proliferation. Sandia’s Twistact technology is a fundamentally new rotary electrical contact with only rolling metal-to- metal contact that eliminates the need for RE magnets by enabling a wire-wound generator architecture with no efficiency or cost penalties. This report summarizes work funded by an LDRD in FY16—18, in which we advanced the technology readiness level (TRL) of Twistact technology to TRL 5 and proved the viability of a Twistact-based generator for utility-scale, direct-drive wind turbines. We conducted coupon-level tests of rolling metallic contacts and developed a tribological model that predicts operation in either a low-wear or high-wear regime. We also built device-level testing apparatuses and observed operation of full-scale Twistact devices, which corroborated the predictions of the tribological model and demonstrated over 50 million rotation cycles (30-year lifetime in a direct-drive generator). Indeed, the present work demonstrated that Twistact technology has potential to be an enabling technology that eliminates RE magnet dependence in the wind industry. The next logical step is commercialization of Twistact technology (currently at TRL 5) in partnership with a generator original equipment manufacturer that already has an established presence in the wind power industry.
- Research Organization:
- Sandia National Lab. (SNL-CA), Livermore, CA (United States); Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
- Sponsoring Organization:
- USDOE National Nuclear Security Administration (NNSA)
- DOE Contract Number:
- AC04-94AL85000; NA0003525
- OSTI ID:
- 1761109
- Report Number(s):
- SAND-2018-13646; 670656
- Country of Publication:
- United States
- Language:
- English
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