October 24, 2023, FL New Energy Limited, a pioneer of the hybrid tower industry, has successfully completed the world’s first 180-meter-high hybrid wind tower with whole structure using UHPC150 (ultra-high performance concrete 150) in Lianshui Jushi Wind Power Project.

On December 29, 2024, the research achievement of the project, namely, the ultra-high performance concrete onshore wind turbine internal prestressed hybrid tower system, passed the evaluation of scientific and technological achievements by the China Concrete and Cement-based Products Association.

• Innovative application of ultra-high performance concrete (UHPC) materials in the field of wind power hybrid tower structures

With the continuous growth of global demand for renewable energy, wind power as one of the clean energy sources, has the advantages of environmental protection, low cost, and significant economies of scale. Its development is increasingly valued worldwide. With the high-quality and rapid development of the wind power industry, larger megawatt level, longer blade, and higher hub wind turbines have become a major trend in the development of the wind power industry. The wind turbine tower is an important component that must have sufficient load-bearing capacity, stiffness, and stability. Currently, there is a lack of wind turbine tower technology solutions in the market that balance safety and economy within the hub height range of 100-140 meters. The cost of wind turbine hybrid towers is high and the economy is insufficient, making it difficult to achieve market application. The all concrete tower is difficult to meet the relevant requirements of the host frequency. As the power of wind turbines continues to increase, the maximum hub height of wind turbines gradually rises to 185 meters, placing higher demands on the tower's load-bearing capacity, stiffness, and stability within limited dimensions. This project has developed a complete set of internal prestressed technology system suitable for UHPC onshore wind turbine towers over 100 meters. Tower from 120 meters to 180 meters have been successfully applied in actual wind power projects, and can be expanded to wind power projects above 180 meters in the future, covering the full range of height applications for wind turbine towers. This system can be applied to large-scale wind power base projects, such as those in the Three North regions with a height range of 100 meters to 140 meters. It can also be applied to dispersed projects of 150m and above in the central and southeastern regions, with significant advantages in high shear wind speed areas and low wind speed high tower scenarios.

• Large scale, low-cost, and efficient application of UHPC

A major highlight of this project is the world's first large-scale, low-cost, and efficient application of UHPC wind power hybrid tower. In order to reduce the production cost of UHPC and broaden its application fields, the R&D team adopted locally produced machine-made sand, greatly reducing raw material costs. In the process of designing and preparing UHPC, the R&D team developed a professional software to quickly optimize the particle size distribution and morphology parameters of the mechanism sand, ensuring the theoretical effect of achieving the densest packing. In addition, the R&D team has proposed an innovative UHPC dense optimization design method, which integrates dry stacking and free water wet stacking technologies, significantly shortening the mix design cycle of different projects. In the preparation process of UHPC, the R&D team has successfully overcome technical challenges such as ultra-fine powder conveying and uniform dispersion of steel fibers, making it possible to prepare ultra-high performance concrete on a large scale, at low cost, and with high efficiency.

• Hybrid tower technology in complex future application scenarios

The R&D team has completed the technical reserve for hybrid tower technology in future complex application scenarios through the development of this project. The future wind power tower will inevitably develop towards higher hub height, lighter structure, higher strength and durability; Require higher manufacturing performance and lower production costs for hybrid towers; With the advancement of offshore wind power generation, the construction and working environment of tower structures will become more complex. For this purpose, the R&D team developed a segmented internal prestressed system and designed and adopted a segmented internal bonded prestressed system, which improved the overall integrity and safety of the tower. This innovative design enhances the stability of the tower, enabling it to withstand various harsh environmental conditions and is completely maintenance free. In order to ensure the flexibility and safety of the lifting process, the research and development team has adopted a new tower crane technology that has the ability to stand on its own and support walls. This lifting method is not only safer, but also can be lifted simultaneously with the tower without being limited by lifting height and weight.

Yu Sun, Director of FL New Energy, emphasized the significance of this achievement: “FL New Energy is extremely proud to be the first company to build the UHPC hybrid tower which reaches the height of 180 meters around the world. This project is of great significance for the development and large-scale successful application of UHPC materials, as well as for further improving the height of onshore wind turbine hubs, enhancing wind energy utilization efficiency, expanding wind farm construction areas, and even large-scale development of offshore wind power in the future.”

Shanghai FL New Energy Co., Ltd. was established on July 7, 2020, with its headquarters located in Huangpu District, Shanghai. It is a high-tech enterprise specializing in the research and development as well as application of new energy technologies. As a pioneer in the wind power concrete tower industry, FL New Energy is committed to providing customers with full life cycle smart energy solutions, ranging from equipment research and development, design, production, and installation to operation and maintenance. The company's main concrete tower products cover heights from 120 to 300 meters and are compatible with mainstream market models ranging from 2MW to 40MW. In addition, FL New Energy is actively expanding its presence in the upstream and downstream new energy industries. It has put into operation 11 production bases globally and is developing an integrated new energy project combining wind, solar, hydrogen, and storage in Serbia.

The company boasts strong technical capabilities, with over 180 invention patents to its name. It has also led the formulation of national standards such as the "Technical Specification for Prestressed Cast-in-Place Concrete Towers of Wind Turbine Generating Sets." Its products have passed the German TÜV Rheinland certification, demonstrating advanced technology and excellent quality.

FL New Energy has achieved remarkable success in both domestic and international markets, with a domestic market share exceeding 40% and multiple records for the highest hub height in the world. The company is also actively involved in international cooperation to promote the global application of new energy technologies.

If interested, please contact CCPA Science and Technology Department at chenyu@ccpa.com.cn for further information.