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TPI Sale Delayed By $100M Claims, WindEurope Calls for Unity

Allen, Rosemary, Yolanda, and Matthew discuss highlights from Blades USA including the carbon blade debate. Plus TPI Composites’ bankruptcy sale hits major obstacles as partners dispute over $100M in claims. And Europe’s offshore and onshore wind developers clash over state aid, with WindEurope’s new CEO urging unity.

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[00:00:00] The Uptime Wind Energy Podcast brought to you by Strike Tape, protecting thousands of wind turbines from lightning damage worldwide. Visit strike tape.com. And now your hosts.

Allen Hall 2025: Welcome to the Uptime Wind Energy Podcast. I’m your host Alan Hall, and I’m here with Yolanda Padron, Rosemary Barnes and Matthew Stead.

Yolanda and Matthew have just wrapped up a couple of days at the Blade USA forum in Austin, Texas. Maybe we should start there. Thoughts on the forum this year? Things that were highlights?

Matthew Stead: Yeah. Lightning Root de bond. One positive was that, um, there are a couple of startups there, so, you know, kudos to them for, you know, making the investment.

There was a. There was a startup around, you know, data analytics and, you know, bringing machine learning in. And then there was also another startup looking at recycling. [00:01:00] Um, really trying to get that, that food chain through of, um, you know, grinding and then turning into some sort of valuable product. Um, yeah.

However, I think someone also from EPRI said that, you know, at the moment, you know, the recycling path is, you know, eight times more expensive than the, um, the landfill path. There was a lot of carbon discussion actually. So, and, um, yeah, a lot of discussion about repairs, a lot of discussion about testing, uh, a lot of discussion about, you know, how maybe a carbon blade can last 40 years.

Um, so a lot of discussion about lifetime extensions around carbon. Um, but, but, but, but, you know, really, really hard to repair.

Allen Hall 2025: That goes back to the comments Rosemary and Morton Hanberg made about carbon blades. Should we be making. Carbon blades are not. And I think Morton’s opinion, and maybe Rosemary’s, I don’t wanna speak for her, was carbon blades are okay, but they are really difficult to repair.

Almost impossible to repair. And is it [00:02:00] worth even building them?

Rosemary Barnes: I think if you consider the blade in isolation, then it probably is adding more headaches than it’s worth. But carbon fiber is a bit of an enabler for improvements across the whole system of a, a wind turbine. ’cause when you take, like you can take a lot of weight out of a blade by using carbon fiber.

I mean, it’s never been cheaper to make a blade with carbon fiber than an equivalent blade with glass. You do, you buy the more expensive carbon fiber blade because it’s lighter, a like, a lot lighter, and then you can take, um, weight. It, it reduces the requirements for basically every other component in the wind turbine, but especially stuff like the pitch bearings.

Um, so you solve a lot of other problems, but you create blade problems. So. I think if you ask some of the only works on maintaining blades, then you’re gonna be like, why would you make a carbon fiber blade? It is so much headache. Um, but that’s not the reason why they were ever made in the first place.

[00:03:00] So you’d need to talk to, you know, somebody on, uh, I dunno, front end engineering. Someone from the sales team about why it is that they are going with a more expensive carbon fiber blade. Even acknowledging that they probably underestimate how many problems there are with o and m with, uh, carbon fiber blades.

But even so, like they’re already aware that there are trade offs. Um, and yeah, there’s non blade reasons for, for taking, taking that pain.

Allen Hall 2025: Are there other fibers that could be substituted besides carbon? There, I, I know fiberglass. A, a good, relatively strong fiber and carbon obviously is much stronger. But are there things in the middle that could be substituted that are non-conductive?

Rosemary Barnes: Uh, y yeah, there are, but carbon fibers, it’s not just strong. It’s really stiff. And that’s what its benefit is. Um, like there’s Kevlar but it’s not very stiff. So you would, we would make a really heavy blade if you used Kevlar. It would be probably bulletproof though. So I guess that would be a plus. I, I haven’t looked into it recently, but nothing is [00:04:00] at the, um, like got the performance specs and the cost specs that you would need to, um, make it replace carbon fiber.

Matthew Stead: So one thing that I picked up I thought was pretty, uh, interesting was that by having a stronger, you know, carbon protrusion, you know, the, you know, the backbone of the blade, um, it took a little bit of pressure off the skin. And so therefore, um, you know, the life, life of the blade, um, and the ability to keep running it ’cause the skin is not so critical.

Those seem to be a real, a real plus as well.

Rosemary Barnes: I don’t know, people talk about this in like absolutes, but everything is just a con continuum, right? Like you can make an all glass blade that would last a thousand years if you really wanted to. You just, you know, you just have to make it very, very strong.

’cause it’s, you know, it’s all based on fatigue lifetime. And the smaller that your, um, strain on every component in the blade is, then the less, um, the less fatigue damage is gonna accumulate. Making it a little bit stiffer will actually increase the lifetime by [00:05:00] a a lot. I think the main benefit to protrusions is just that you avoid all of the um, or you avoid a lot of the possibilities for manufacturing defects.

It’s easy to control the manufacture ’cause carbon fiber, like much more so than glass fiber. It’s so, um, it’s so dependent on the fibers being perfectly straight. If you have a little wrinkle, like a little wrinkle is bad in glass fiber, but it’s like really bad in carbon fiber. So protrusions mean that you won’t get wrinkles.

Uh, and you can, you know, control the manufacturing process a lot better, but they are barely repairable, right? So that’s the trade off. You can do some small repairs, but you’re not gonna be just. Um, if you’ve got a, a, a full thickness crack or something, it’s, you know, it’s gonna be game over. You’re not gonna be building that up again.

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Yolanda Padron: will save you millions.

Allen Hall 2025: Well keep going on the, the subject of blades. Imagine if you were selling your house and you told the bank you owe nothing on it.

Then the bank shows up with a bill for over a hundred million dollars. That is essentially what’s happening right now in the TPI composites bankruptcy. Uh, the wind blade manufacturer canceled its [00:07:00] February 17th asset auction after only one bidder came forward. A firm called ECP five LLC, which is, uh, part of Energy Capital Partners, which is based in New Jersey.