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Electrolube‘s role with renewable sources of energy

Assisting with protection compounds
Electrolube‘s role with renewable sources of energy

Renewable energy is energy collected from renewable resources that are naturally replenished on a human timescale and are projected to account for more than 50 % of global electricity production by 2035. Put another way, this is energy harnessed from the earth’s infinite or non-exhaustible natural resources rather than our traditional reliance upon finite resources of fossil fuels. According to Allied Market Research, the renewable energy market is predicted to grow exponentially by 2025 with biomass representing the leading form of energy within this market. From looking into the applications in more detail, a much wider potential use for all forms of renewable energy sources can be demonstrated.

The discussion commences with a traditional source of renewable energy, water. Water-based power sources, hydropower, tidal power and wave power all rely on hydrokinetic potential; that is, the energy carried by bodies of water. Water-based power is sustainable and has a low carbon footprint. The energy generated by falling or fast-moving water is typically known as hydropower and has been used for centuries for a variety of mechanical applications. In the late 19th century, hydropower was first used for the generation of electricity and has since continued to develop as an important source of renewable power.

Water based renewable energy

Hydroelectricity is produced by passing the flowing water through turbine generators which consist of a number of electronic parts; simply identified as alternators, inverters, control panels and power switches or breakers. This type of power is incredibly versatile, and examples of its application can be seen around the world, one of the most famous being the Hoover Dam in USA. Run-in-river applications can also be utilised to harness the power from flowing water, rather than falling water as seen in a reservoir-dam facility. Whilst the emissions from these plants may be low, they are not totally emission free and their effect on the environment also has to be considered; protection of fish from turbines, appropriate use of the land and evaluation of surrounding wildlife, are just some criteria that must be addressed when developing new sites.

The two remaining water based renewable energy sources sound similar but in fact are very different. Tidal pattern is continuous therefore the energy generation from this is predictable. Tidal generators are placed on suitable shorelines in order to harness the power of this source. Wave power, however, is generated at sea, is unpredictable and currently plays a very minor role in the global mix of energy sources. Consideration in both cases, needs to be placed on the effects of any machinery or movement on the surrounding ecosystem. It is in these demanding electronic applications where Electrolube products assist with protection compounds, such as encapsulation resins and conformal coatings, that aid the efficient and prolonged application of these electronics in challenging environmental conditions. Devices such as sensors and data loggers are important for gathering information both in and out of the plant, providing details such as water depth and wave acceleration to adjust systems and achieve maximum capability. Water protection for these devices is just one example of where an encapsulation resin may make these measurements possible, greatly reducing maintenance requirements and human interaction in data collection.

Solar based renewable energy

Moving on, solar energy has to be one of the most iconic forms of renewable energy, particularly prevalent in the domestic electricity market. Solar cells produce direct current electricity from sunlight via the technology known as photovoltaics (PV), and it is these solar cells that are seen in many different applications globally. However, the technology doesn’t stop at the solar cell alone. Inverters are used to convert the direct current into alternating current electricity so that it can be fed from the solar panel into a home/building to operate standard appliances. In addition, capacitors are used to temporarily store electricity where required, or in off-grid applications batteries may be required to store power for more widespread use. In such cases, these electronic devices will require protection from the elements but will also be required to operate at higher temperatures and offer some form of thermal dissipation, due to the heat emitted during operation. Depending on the design, thermal management products may be used to help dissipate heat away from devices, this could be in the form of thermal gap fillers (Electrolube GF400) for example. However, to offer both protection from the environment and thermal dissipation, specialist encapsulation resins such as the ER2221 may be required.

In addition to capturing and converting the energy, the requirement for measuring the performance or having some control over the solar panel may be required. Measurements such as solar panel temperature, can help to manage solar farms and ensure the most efficient use of the technology is attained. Unfortunately, some of these system electronics can be relatively small and possibly fragile, yet conversely, the average piece of solar equipment must be able to withstand some pretty extreme weather conditions, including direct exposure to the sun, heat and other environmental elements. Electrolube has worked directly with organisations harnessing solar power. In one particular instance, a small device displaying information on the performance and connectivity of the solar panels in an array required protection from the external environment. Some issues had arisen with resins tested, where the hardness and Tg of the material resulted in pressure on the LCD screen, leading to failures in operation. Initially silicone options were tested due to this low stress requirement, but these did not perform to the high level achieved by the company’s UR5044, which showed great stability and low hardness over a wide temperature range. Adhesion of this polyurethane resin was greatly improved compared to the previous silicone resins tested and thus an improved protection from the external conditions was realised.

Devices separate from the solar farm are also very important. Measurements of solar radiation, incoming UV and infrared light spectrums will give data to help correctly position and manage these solar plants. Such data is required to be transmitted, often by GPRS or maybe Bluetooth, and any protection compound used must not interfere with these signals. Encapsulation resins with a low dielectric constant are most suited, such as the UR5118, which also offers excellent water resistance. However, if the unit is well sealed by the outer casing and has a high IP rating, it may also be possible to use a conformal coating (Electrolube AFA) to prevent the effects of condensation on the electronics and also minimise the weight of the device in comparison to a potted unit.

Solar panels can be seen powering devices from decorative garden lighting to streetlights and road signs. Smart streetlights and solar benches are amongst the newest products to fully integrate numerous technologies, such as remote management control, wireless charging and Wi-Fi hotspots all built in, and again, all requiring protection for the electronics used. The chemical industry is playing a strong part in these novel developments, right up the development of solar paint. The possibilities here are seemingly endless.

Wind based renewable energy

The third renewable source for discussion is wind power, one of our most predominant sources, with the UK currently ranking as the 6th largest producer of wind power in the world. Wind farms capture the energy of wind flow by the use of turbines and convert it into electricity. Commercially positioned wind systems can power many alternative organisations whereas single wind turbines are predominantly used as a method to supplement pre-existing energy sources.

The traditional turbines are huge with very large blades driven by wind power which in turn powers a rotor. This rotor spins the shaft within the tall upright of the turbine and this powers a generator for harnessing electricity. Almost all wind turbines can contain up to 8,000 separate parts including gearboxes, power systems, generators, sensors and devices for electronic control. One of the huge challenges is to assemble these enormous devices, enable a long life and trouble-free operation. All electronics and components mounted in the tower must also be able to withstand constant vibration, temperature changes (extremes), environmental conditions (these can change depending upon the location but can include salt mist/spray and limited accessibility). Longevity of component life, reduced maintenance and long-term cost are all key drivers prompting reliable protection systems in the form of either conformal coatings, encapsulation resins or sometimes a combination of both.

There are also requirements for thermal management materials within the use of wind turbines and the company was faced with a particularly tricky problem when a ‘greener’ version of a standard thermal interface material was required. It is encouraging that green energy developers are considering all aspects of environmental impact, including the materials used with the manufacture of their products. In this case, the thermal interface material had to be classed as completely non-hazardous and as traditional TIMs contain zinc oxide they were deemed completely unsuitable. Presented with the problem, Electrolube developed a solution specifically for the purpose, HTCX_ZF. This was developed using alternative thermally conductive fillers which removed the zinc oxide and the corresponding H410 hazard phrase, representing toxicity to aquatic life. The product also offered an increased thermal conductivity compared to the standard material and thus offered greater efficiency of heat dissipation in customer testing.

The location of the wind farm is as important as the location of any other renewable energy sites. In offshore wind farms, the conditions are much more extreme and corrosive elements such as salt mist can have a detrimental effect on both mechanical and electrical parts. With experience in electronic devices for marine applications, the company can offer support and advice on suitable protection compounds for such applications. Like the developers of integrated technology, Electrolube strives to utilise experience gained from multiple industries and from the varying types of products offered in our range. Combining the understanding of protection levels required, with correct thermal management and suitability for applications such as LED technology, assists in the correct selection of products for complex and critical applications. For example, the use of the company’s products to protect lighting arrays in outdoor applications, such as shopping centres, sports arenas and even aircraft runways, gives confidence and understanding of the potential use of these products to protect the warning lights used on the top of wind turbines. Combine that with their understanding of products in applications where wireless data transfer is required, the smart management of such lighting technology can be successfully achieved, even in such harsh external conditions.

The most used form of renewable power in the UK however is carbon-neutral and comes from bio-waste, making use of the unwanted by-products of today’s way of life. Biomass is an alternative fuel made from organic materials, including wood, crops and plants, animal waste and more. Biomass products are burned within a boiler, generating a source of steam to turn a turbine thereby producing electricity. Traditional coal-fired power stations can be converted to run entirely on biomass fuel. Biomass, hydroelectricity and wind power are the three resources on which we depend the most on, in order to achieve cleaner energy goals and reduction of carbon footprint.

Whilst the most reliable and productive sources of renewable energy have a heavy reliance on harvesting equipment with a myriad of moving parts, it is clear that electronic developments have been key in the development and integration of these sources into our everyday lives. Over time, the harvesting of energy is likely to become even more automated and entwined with the IoT as trees are being fitted with PV cells and pressure power sensors can now be found underneath high traffic roads. Efficiency and reliability will increase as the level of AI builds. Thermal management materials, conformal coatings and encapsulation resins all have a vital part to play in the protection, reliability and lifetime of devices throughout the planning and maintenance of energy generation and harvesting technologies.

Company contact

Ashby Park
Coalfield Way
Ashby de la Zouch
LE65 1JR, United Kingdom
Tel.: +44 1 530 419600
E-mail: info@hkw.us.com
Website: www.electrolube.com


Wärmemanagementmaterialien, konforme Beschichtungen sowie Harze zur Verkapselung spielen bei der Planung und Wartung von Energieerzeugungs- und Energiegewinnungstechnologien eine entscheidende Rolle für den Schutz, die Zuverlässigkeit und die Lebensdauer der Geräte.


Les matériaux de gestion thermique, les revêtements conformes ainsi que les résines destinées à l’encapsulation jouent un rôle essentiel pour la protection, la fiabilité et la durée de vie des équipements lors de la conception et de la maintenance des technologies de production d’énergie et de collecte d’énergie.


Терморегулирующие материалы, конформные покрытия, а также герметизирующие смолы играют решающую роль при проектировании и обслуживании энергогенерирующих и энергодобывающих технологий для защиты оборудования, обеспечения его работоспособности и срока эксплуатации.

Jade Bridges is the Technical Manager with Electrolube.




Also of interest:

Electrolube improves electrical performance with the correct connectors

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