Why Rare Earth Elements Have Become Critical

Modern wind turbines increasingly use permanent magnet generators. Unlike traditional gearbox- and electromagnetically excited systems, they are more compact, lighter, and more efficient at low wind speeds. This has made them the standard for offshore installations and onshore turbines with capacities of 5–15 MW.

The key issue is the composition of the magnet. To achieve high magnetic induction, neodymium-based alloys (NdFeB) are used, which are additionally alloyed with dysprosium or terbium to improve heat resistance. Without these elements, the magnets lose their properties under high loads, thereby reducing the generator’s reliability.

As a result, a single large offshore turbine can contain 500-2,000 kg of rare-earth magnets, and scaling up wind farms can require thousands of tons of critical raw materials. What are they?

Geopolitical and Economic Dependence

Approximately 70–80% of global rare earth element production is concentrated in one country, China, with an even larger share in processing and magnet production. For wind energy, this means supply chain vulnerability, especially in the face of trade restrictions, sanctions, or sharp price fluctuations.

During periods of instability, neodymium and dysprosium prices can increase several-fold within months. For turbine manufacturers, this directly impacts installation costs and project timelines. Investors planning wind farms for 20–30-year operational life must consider not only wind and infrastructure but also commodity risks.

Environmental Issues

Rare earth elements are rarely found in their pure form. Their extraction requires extensive ore processing, the use of acids, and the generation of toxic waste. In some regions of China, mining has already led to the degradation of soil and water resources.

Paradoxically, technologies designed to reduce carbon footprints themselves create significant environmental impacts—just at a different stage in the chain. This is why increasing attention is being paid not only to turbine installation but also to the life cycle of materials.

Attempts to Escape Rare Earth Dependency

Engineering and scientific teams have been working on alternatives for several years:

1. Generators without permanent magnets. Traditional asynchronous and synchronous generators with electromagnetic excitation do not require rare earth elements. They are heavier and more difficult to maintain, but allow for the complete elimination of critical raw materials.
2. Reducing the Dysprosium Content. Modern magnet sintering technologies enable the reduction of dysprosium content by optimizing the alloy structure and generator cooling.
3. Magnet Recycling. The recycling of spent turbines is becoming a distinct field. Theoretically, up to 90% of neodymium can be recycled, but in practice, recycling is complex and not always economically feasible.
4. Alternative Materials. Ferrite magnets and new alloys are under investigation, but their magnetic density is currently significantly lower than that of NdFeB, thereby increasing generator size.

Rare earth materials aren’t a “fatal limitation,” but they are forcing the industry to change its approach. In the coming years, wind energy development will move in several directions simultaneously: design optimization, diversification of raw material supplies, and a return to simpler yet more reliable engineering solutions where warranted.

The market will likely split: the most powerful offshore turbines will continue to use permanent magnets, whereas some onshore turbines will revert to generators without rare-earth elements. At the same time, the importance of recycling and secondary raw materials will grow—without them, a large-scale energy transition will become too fragile.

Ultimately, the issue of rare earth materials is a reminder that green energy doesn’t exist in a vacuum. It is directly dependent on resources, technology, and the global economy, and the balance among these factors will determine the long-term sustainability of the energy transition.

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How does height affect energy production?

In practice, the effect looks like this:

A new turbine can generate 2–3 times as much electricity per year as a 20-year-old installation, even without accounting for the increase in rotor diameter. This is why wind energy is increasingly competitive in terms of kilowatt-hour cost with traditional energy sources, including gas-fired power plants. Wind energy supplies entire sectors of regional business—municipal housing, supermarkets, the internet, and even large technology offices, such as online bookmakers senza limiti di puntata in Italy, which must operate around the clock, processing large amounts of data in real time.

Why is higher means more stability

The main reason for the increasing height of turbines is the vertical wind profile. Wind speed increases with height due to reduced friction with the Earth’s surface. Houses, trees, terrain, and even crops “eat up” the flow of energy in the lower layers of the atmosphere. Simply described by a power law:

V(h) = V₀ × (h / h₀)ᵅ,

where ᵅ is the surface roughness coefficient.

For open plains, ᵅ ≈ 0.14; for forests and built-up areas, it is 0.25–0.4. This means that increasing altitude from 80 m to 140 m can increase wind speed by 10–20%, and sometimes more. And here comes the key point of physics: wind power is proportional to the cube of the speed.

If the wind speed increases by just 15%, the potential power increases by approximately 52% (1.15³ ≈ 1.52). This is why engineers are so persistent in raising the rotor ever higher.

What else does height provide besides speed?

Mast height affects more than just average wind speed:

• Less turbulence. The flow becomes smoother, the load on the blades decreases, and the equipment’s service life increases.
• Longer operating periods. The turbine is less likely to be idle due to low wind speeds.
• Better predictability. At higher altitudes, wind is more stable, simplifying generation planning and grid balancing.

Therefore, wind turbine installation height is important for energy systems with a high share of renewable energy sources, where each forecast error entails additional costs.

Why can’t we build infinitely tall wind turbines?

Despite the obvious advantages of increasing height, there are clear physical, engineering, and economic limitations. Every additional meter of mast increases the load on the structure. The bending moment at the base increases nonlinearly, meaning the foundation must be more massive, deeper, and more expensive. On soft or uneven soils, this quickly becomes a critical factor, limiting the project even at the geological survey stage.

Difficulties also arise at the logistical stage. Modern mast sections and blades, 80–90 meters long, require specialized transport, temporary road reconstruction, bridge reinforcement, and approvals from local authorities. In some regions, logistics is the main obstacle to the construction of ultra-tall turbines. The taller the installation, the narrower the range of sites where it can be physically installed.

There are also regulatory restrictions. Airspace, radar zones, and military and civil aviation requirements impose strict height limits on structures. Even in remote areas, a 180-meter-tall turbine may require additional approvals, thereby increasing project timelines and reducing its investment attractiveness.

Finally, the economics of diminishing returns come into play. Above a certain height, the rate of increase in average wind speed slows, and additional capital costs grow faster than the potential benefit. At some point, each additional meter begins to “cost” more than it brings in additional generation. This is why modern projects increasingly seek a balance among height, rotor diameter, and intelligent load management, rather than pursuing unbounded tower growth.

What does this mean for the future of wind energy?

The rise in tower heights has fundamentally changed wind energy. It has transformed a technology that previously only worked in windy coastal areas into a universal generation tool for inland regions with moderate winds. This has expanded the geographic reach of projects and made wind energy less dependent on “perfect” natural conditions.

In the coming years, development will focus on system optimization. Engineers are increasingly focusing on blade aerodynamics, adaptive operating modes, and digital control systems that extract maximum energy from every gust. Height remains an important factor, but it is becoming part of a more complex architecture that accounts for weather-model data, turbulent-flow behavior, and equipment durability.

For power systems, this means more stable and predictable generation. Taller turbines operate for longer throughout the year, experience less downtime, and integrate more effectively into hybrid systems with solar power and storage. As a result, wind energy is no longer perceived as an “add-on” and is increasingly becoming a core element of the regional energy mix.

In the long term, the combination of moderately tall masts, large rotors, and intelligent control will enable the industry to grow further without a sharp increase in costs. Instead of chasing records, a mature engineering logic is emerging, where every meter of height is justified by calculation, not by a flashy presentation figure.

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Wind is a form of solar energy that results from the combination of three simultaneous events:

• The sun heats the atmosphere unevenly;
• Unevenness of the earth’s surface;
• The rotation of the earth.

Wind patterns and speeds vary greatly across the United States and are altered by bodies of water, vegetation, and differences in topography. People use this wind flow, or motion energy, for many purposes: sailing, flying a kite, and even generating electricity.

The terms “wind power” and “wind energy” describe the process by which wind is used to produce mechanical power or electricity. This mechanical power can be used for specific tasks (such as grinding grain or pumping water), or a generator can convert this mechanical energy into electricity.

A wind turbine converts wind energy into electricity using aerodynamic force from rotor blades that work like airplane wings or helicopter rotor blades. As the wind flows across the blade, the air pressure on one side of the blade decreases. The difference in air pressure on both sides of the blade creates both lift and drag. The lift force is stronger than the drag force, and this causes the rotor to rotate. The rotor is connected to the generator either directly (if it is a direct-drive turbine) or through a shaft and a series of gears (gearbox) that accelerate the rotation and allow the generator to be physically reduced. This conversion of aerodynamic force into generator rotation creates electricity.

Most wind turbines are divided into two main types:

• Horizontal-axis turbines;
• Vertical-axis turbines.

Wind turbines can be built on land or on the shore of large bodies of water such as oceans and lakes. The U.S. Department of Energy is currently funding projects to promote the deployment of offshore wind turbines in U.S. waters.

Application of wind turbines

Modern wind turbines can be classified according to their installation location and grid connection:

• Onshore wind;
• Offshore wind;
• Distributed wind.

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The molds themselves may have minor imperfections and variations. While composite materials such as fiberglass and carbon fiber offer incredible strength, the process of layering, resin saturation, and curing can create slight differences in the finished blade due to factors such as air bubbles, fiber alignment, and uneven resin distribution. These variations are taken into account during the design phase, but affect the life of the blade.

Regardless of whether the same production process is achieved with the same production conditions and materials, a composite sample will never be completely identical to a previously manufactured composite sample.

Blade accessories such as balancer, grills, spars, etc. are made separately and glued to the housings when the resin has already cured, before closing the blade.

Challenges and opportunities

Making the perfect wind turbine blade requires a balancing act:

• Size vs. weight: Larger blades mean more power, but cause logistical and weight issues;
• Strength vs. durability: blades must withstand enormous loads, including harsh weather, to increase service life;
• Price vs. performance: Finding the best solution involves a trade-off between materials and production methods;
• Environmental impact: recycling issues and production footprint require continuous improvement;
• Manufacturing imperfections: Minimizing small differences between blades is unavoidable, but can increase service life and reliability. Improvements in materials and methods will play an important role.

Through continuous innovation, the future of wind turbine blades will be one of higher efficiency, lower costs, and an even greater impact on our clean energy landscape.

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Design

The first step is to design the wind turbine, taking into account factors such as wind speed, tower height, blade length, and generator power. Engineers use specialized software to optimize the design for maximum efficiency.

Manufacturing of components

The main components of a wind turbine include the tower, blades, nacelle (which houses the generator and other equipment), and control systems. Each component is manufactured separately.

Tower construction

The tower provides structural support for the turbine. It is usually made of steel or concrete. The manufacturing process includes cutting and shaping materials, welding or joining sections together, and applying protective coatings.

Blade manufacturing

Wind turbine blades are typically made of fiberglass reinforced with resin or other composite materials. The manufacturing process includes forming, shaping, curing and finishing the blades to meet the required specifications.

Nacelle assembly

The gondola houses the generator, gearbox, and other components. It is manufactured separately and then carefully assembled. Electrical wiring, control systems, and safety mechanisms are also installed.

Transportation and installation

After the components are manufactured and assembled, they are transported to the wind farm site. The tower sections are erected, and the nacelle with the blades is lifted and placed on top of the tower.

Testing and commissioning

After installation, the wind turbine undergoes various tests to ensure that it is functioning properly, including electrical and mechanical tests as well as performance measurements.

Ongoing maintenance

Wind turbines require regular maintenance and inspections to ensure optimal performance and safety. This includes checking and repairing any damage, lubricating moving parts, and monitoring performance.

Electric permanent magnet lifting magnet

Electro-permanent lifting magnets can play an important role in wind turbine manufacturing by facilitating the handling and placement of metal components. These magnets are designed to safely lift and move heavy metal objects, offering advantages in terms of efficiency, safety and ease of use.

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History

Vestas can trace its roots back to 1898, when Hand Smith Hansen bought a blacksmith shop in Lem, West Jutland, which was operating as a family business. After the Second World War, Vestas was founded in 1945 by his son Peder Hansen as “Vestjysk Stålteknik A/S” (West Jutland Steel Technology). Initially, the company manufactured household appliances, shifting its focus to agricultural equipment in 1950, intercoolers in 1956, and hydraulic cranes in 1968. It entered the wind turbine industry in 1979 and has produced wind turbines exclusively since 1989. In 1997, the company launched the NTK 1500/60. The product was designed by Timothy Jacob Jensen and won the German IF Award and the Red Dot Award. The North American headquarters of the company was moved in 2002 from Palm Springs, California to Portland, Oregon.

In 2003, the company merged with Danish wind turbine manufacturer NEG Micon to create the world’s largest wind turbine manufacturer under the Vestas Wind Systems brand. After a decline in sales and operating losses in 2005, Vestas recovered in 2006 with a market share of 28% and increased production, although the market share declined between 12.5% and 14%.

“Vestas launched an awareness program in 2007, among the first in Denmark.

On December 1, 2008, Vestas announced plans to expand its North American headquarters in Portland by constructing a new 600,000 square foot (56,000 m2) building, but this plan was scrapped in 2009 due to the economic downturn, and in August 2010, the company announced a revised plan, scaled down to scale, to expand its Portland headquarters by renovating an existing but vacant 172,000 square foot (16,000 m2) building. At the time, Vestas employed about 400 in Portland and committed to adding at least another 100 workers there within five years; the new building would have room for up to 600 workers. In May 2012, the company moved its Portland offices to a new headquarters building, a restored historic building.

In February 2009, the company announced the production of two new types of turbines, the 3-megawatt V112 and the 1.8-megawatt V100. The new models were to be available in 2010.

In July 2009, Vestas announced that its production operations on the Isle of Wight in England would be closed due to lack of demand in the UK, affecting 525 jobs there and 100 in Southampton. About 25 workers at the wind turbine plant on the island occupied the administrative offices in protest on July 20, 2009, demanding nationalization to save their jobs.

In August 2009, Vestas hired more than 5,000 additional workers for its new plants in China, the US and Spain. The company stated that it is “expanding strongly in China and the US as these markets are growing the fastest, in contrast to the sluggish pace of wind farm development in the UK”. As part of this gradual shift in production from Europe to China and the US, in October 2010 the company announced that it was closing five plants in Denmark and Sweden, with the loss of 3,000 jobs.

In November 2010, Vestas discontinued the 70-person Vestas Excellence advisory department responsible for competitiveness, supplier services, quality assurance and globalization.

In May 2013, Marika Fredriksson became the company’s new Executive Vice President and Chief Financial Officer after her predecessor, Dag Andresen, resigned for personal reasons. Her strategy is to return Vestas to higher earnings after the significant losses the company has faced: from a €166 million loss in 2011 and increasing to €963 million in 2012.

In September 2013, Vestas formed an offshore wind joint venture with Mitsubishi Heavy Industries, creating MHI-Vestas, including the 7-9 MW Vestas V164, the most powerful turbine on Earth.

In May 2014, Vestas announced that it would add hundreds of jobs to its Colorado facilities in Windsor and Brighton, and after a rough 2012, called 2013 one of its “best years ever.” Vestas also added employees in Pueblo and expected the tower to eventually exceed 500. “Vestas stated that it planned to employ 2,800 workers in Colorado by the end of 2014. As of 2016, Vestas has a nacelle production capacity of 2.6 GW in the US.

In March 2015, Vestas announced that it would increase the number of jobs by 400 at its Windsor blade manufacturing plant and stated: “We had a very successful 2014”. In 2015, almost half of all Vestas turbines went to the US market (almost 3 GW for the US out of 7.5 GW worldwide). Vestas intends to build a blade factory in India in 2016.

In 2014 and 2015, 26 unscrupulous employees were reported under the company’s whistleblower program (the first in Denmark) and were penalized.

In February 2016, Vestas received the largest order of 1000 MW (278 x 3.6 MW) for the Fosen project near Trondheim in Norway. This is worth DKK 11 billion and should deliver 3.4 TWW per year.

In Q1 2016, the average price of a wind turbine was €0.83 million per MW, compared to €0.91 a year earlier.

In 2016, Vestas was recognized as number 7 in the Clean200 list.

In 2019, MHI-Vestas received a supply and operation vessel for the Deutsche Bucht offshore wind project, with two more ships planned for other projects.

In June 2022, during the full-scale invasion of Ukraine by Russian troops, the company terminated the investment contract with Russia. The shipyard fulfilled its plan for 2022 and had no contract for 2023.

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Shanghai Electric was founded in 2004 and has since grown rapidly to become one of the largest wind turbine manufacturers in the world. The company actively invests in research and development, striving for excellence in renewable energy.

Shanghai Electric applies advanced technology in the production of wind turbines, which enables them to provide high efficiency and reliability of their products. They are constantly introducing new developments and improvements to ensure optimal utilization of wind energy.

The company offers a wide range of wind turbines in various capacities and configurations to meet the needs of customers around the world. Their products are used in both large wind farms and decentralized power supply systems.

Shanghai Electric is actively expanding its presence in global markets by establishing strategic partnerships and collaborating with key players in the industry. They aim to become a leader in wind energy and facilitate the transition to a more sustainable energy future.

Shanghai Electric adheres to high standards of environmental responsibility in all aspects of their business. Their products help to reduce greenhouse gas emissions and protect the environment, making an important contribution to the fight against climate change.

Shanghai Electric continues on their path to success with innovative and reliable wind energy solutions. Their commitment to excellence and sustainability makes them a key player in the global alternative energy market, and their products play an important role in achieving global climate change and sustainability goals.

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CSIC Haizhuang Windpower Equipment Co., Ltd. was founded in 2004 as a high-tech industrial firm specializing in the development and production of large wind power equipment and related major components. It was established through the merger of related enterprises and research institutions of CSIC.

As a leader in shipbuilding and equipment manufacturing, CSIC Haizhuang Windpower is able to conduct excellent research, produce high-quality products and provide excellent customer service. With annual revenue of 100 billion yuan (16 billion US dollars), it is one of the top 100 Chinese companies.

Up to this point, CSIC has developed professional manufacturing competence for the wind turbine industrial chain and manufacturing capabilities for ships, motors, tools, electrical, computer control and other major components. The supply of WECS components through CSIC’s affiliates is considered a huge advantage in this market.

To provide blades for its recently introduced H151-5.0MW platform, LM Wind Power announced a strategic partnership with Chinese wind turbine manufacturer CSIC (China Shipbuilding Industry Corporation) HZ Windpower.

Additionally, they provided information at the product launch ceremony for CWP 2016 in Beijing, where CSIC HZ Windpower acquired the type certificate for the new offshore turbine. Marc de Jong, CEO of LM Wind Power, stated that it is a great joy to help CSIC HZ Windpower launch its latest offshore wind farm. They are a pioneer and a significant player in the development of offshore wind business in China.

CSIC HZ Windpower is looking for information to take the lead in offshore wind energy development in China by utilizing the advanced technology of LM Wind Power, a highly reliable manufacturer with respect to wind speed and a long history of successful offshore blade supply. Because reliability, respect and quality are critical to the offshore industry, they chose to use LM Wind Power blades.

In 2013, they installed two wind turbine prototypes linked to LM Wind Power blades in Rudong, Jiangsu Province, China. The successful operation of the prototypes and exceptional performance led to a long-term target agreement between LM Wind Power and CSIC HZ Windpower.

Current research shows that the generator is likely to produce approximately 43,400 kWh of electricity per year. However, let’s assume that you have the exact capacity in mind when making a purchase. In this case, experts do not advise using the generator as the deciding factor.

However, in terms of functionality, power information is important. A power of 1 to 10 kW is optimal for wind-powered electrical systems. But a 20 kW wind turbine is perfect if you want something more domestic. It will generate just enough power to provide your home with electricity.

Based on power, onshore turbines are often rated at kW or MW. This is the maximum power output of the turbine, not the amount of electricity it continuously generates like other energy sources. For example, a 100 kW wind turbine has a maximum output of 100 kWh per hour (100 kW x 1 hour = 100 kWh).

Over the coming years, CSIC HZ Windpower will actively continue to expand and access its service business, as well as onshore, offshore and international markets.

Overall, the industry is trying to continue and achieve the key development goals of “One Center, Three Enterprises”, such as the importance of sustainable growth and the mobilization of important sectors of the wind industry for the coming years.

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Wind energy is one of the leading alternative energy sources because it has a number of advantages. The advantages of wind power plants include

• they do not pollute the environment, do not emit harmful emissions into the atmosphere, i.e. they are environmentally safe;
• wind energy is inexhaustible and free, meaning that only the installation of the windmill needs to be financed;
• the possibility of installation in hard-to-reach areas;
• autonomy in functioning, i.e. does not depend on the operation of the power grid;
• no need for a large area to install wind turbines.

However, among the obvious advantages of wind power plants, there are also disadvantages, namely

• long payback period for the cost of installing wind turbines;
• although wind is an inexhaustible natural source of energy, it is characterized by the instability of the wind flow, so wind farms should be installed in places where the average annual wind speed exceeds 3 m/s;
• danger to birds and animals living underground;
• noise and vibration from the operation of wind turbines.

Wind power plants (WPPs), or as they are also called Wind Farms, are a complex of wind turbines or wind generators consisting of a charge controller, rotor, voltage inverter and batteries. The rotor consists of three blades, the length of which determines the capture of the wind flow. The rotor converts the energy of the incoming wind flow into mechanical energy of the turbine rotation and its further conversion into electricity. The wind turbine blades are covered with insulating material to protect against lightning.

“There are two types of wind turbines: with a horizontal and vertical axis. To date, 95% of wind energy is generated by horizontal wind turbines, as their productivity is three times higher than vertical ones. Wind power plants are controlled remotely through a control room: start/stop of wind turbines, analysis of each wind turbine and the entire station, monitoring of meteorological indicators, and generation of a report on wind turbine performance.

In order to determine the location of a wind farm, it is important to take into account the optimal meteorological conditions (wind potential of the area), the stability of the soil for installing wind turbines, and bird migration routes.

The EIA for a wind farm, as well as the development of a project for the establishment of a sanitary protection zone, including the necessary calculations and measurements, should be entrusted to experienced specialists in the field of environmental protection and environmental permitting. Our specialists are able to provide a high level of services for the operation of wind farms within the framework of environmental legislation. In addition, MCL’s specialists are competent in conducting social and environmental impact assessments at the international level. Choosing MCL, you will get a reliable business partner in the field of ecology, management and law!

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• a unit that converts wind power into energy;
• storage battery;
• inverter;
• charge controller.

Equipment that converts wind energy into electricity includes

• a turbine, i.e. a rotor that converts the energy of a straight-line wind flow;
• a generator that converts mechanical energy into electrical energy;
• mast (this structural element can be of the “truss” type or tubular);
• turbine control system;
• multiplier (depending on the model);
• tail or azimuth drive system;
• rectifier, which is necessary when using alternators for proper battery charging.

In terms of power, all wind generator equipment is classified as household, which is characterized by a power of 1-10 kW and industrial – from 500 kW.

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