Motion plastics for the hydro energy industry
Machine parts that are used for generating energy via hydropower are exposed to extreme environmental conditions: they have to withstand very high loads, be resistant to saltwater and UV radiation and continuously operate without failure. Downtime due to material wear and frequent maintenance measures can negatively affect the energy output. igus® offers a large variety of customer-specific solutions that fulfil the requirements of these sources of renewable energy, and help improve the technology of the entire system. Whether wave power plants, hydropower turbines or screening plants - there are a lot of application areas for our plain and spherical bearings lead screws and energy guide systems in the hydro energy industry.
Would you like more information about products used in hydro energy? Our experts will be happy to get in touch with you.
Would you like more information about products used in hydro energy? Our experts will be happy to get in touch with you.
Contact an expert
Maintenance-free products for use in hydro energy plants
Rod end bearings
Specifically for adjusting the rotor blades of hydropower turbines- Suitable for use in humid or wet environments
- Extremely low coefficient of friction in dry operation and very low stick-slip tendency
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Plain bearing UW
For use in point absorbers- Extremely wear-resistant under water, tested and maintenance-free
- For fast and constant rotation
- Long service life
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igutex® bearings
Also suitable for underwater use- Heavy-duty bearings for loads up to 200 MPa
- Wear-resistant and dimensionally stable
- Good media resistance
- Specially wound material
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basic flizz system
Complete system for the moving energy supply in screening plants- Low-maintenance, for travels up to 100m
- Protection against weather and dirt exposure
- Cost-effective and fully enclosed system
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High helix lead screws
Higher efficiency for the energy generator specifically in point absorbers- Quiet and vibration-dampening due to rounded tooth geometry
- Longer service life due to asymmetry
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E4.1 e-chain®
Energy chain for wave energy converter- Tough, low-noise, modular
- Hinged lids for fast insertion of cables from both sides
- Cable-friendly interior separation
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Benefits of igus® products in the hydro energy industry
- Suitable for underwater applications
- Resistant to dirt, dust and UV radiation
- Lubrication-free and maintenance-free for 24/7 use
- Extremely low coefficient of friction due to tribo-optimised polymers
- For confined installation spaces and where there is very little room for movement
- Low noise and low vibration
- Long predictable service life
- Low cost
- Customised solutions from prototype to high-volume production
- Large and varied range of products
- Help from a specialist
Frequently asked questions regarding Hydro energy
What is hydro energy?
Hydro energy is a specific form of energy drawn from the power of water or hydro. It is the force of the water that creates the motion and therefore creates the power.
What are the advantages of hydro energy?
One of the key advantages of hydro energy is the fact it is a sustainable source of energy. As the energy is created from the water cycle, which as we all know is fuelled by the sun, it is a clean energy source and therefore renewable.
What are the disadvantages of hydro energy?
Like everything there are a few disadvantages such as limited amounts of water at certain points in the year, it can be a more expensive energy source and we are limited to where these hydro energy plants can be located.
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Successfully in use
Safe energy supply even in high swells
CorPower Ocean, a Swedish company, makes point absorbers that are light and compact and cope well with storms thanks to the innovative Wavespring Phase Control Technology. A cascade gearbox that drives a power generator converts the buoy's up-and-down movement into rotational movement. Energy supply within the buoy is secured by two vertically installed E4.1 series e-chains and chainflex servo, power and control cables.
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Tidal turbine moving safely on rough seas
The OpenHydro tidal turbine generates green electricity in the North Sea. The generator can be moved down 20 metres if necessary, which means that the cables are mostly below the water surface. A conventional metal chain would not work in the aggressive sea conditions. The operator therefore relies on our E4/4 series plastic energy chain, which ensures maintenance-free operation of the turbine.
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Saves space and maintenance costs: basic flizz system on the rake cleaner
The Schlossmühle hydroelectric power plant in Rochlitz, Saxony, has purchased a new rake cleaning system. The H-cleaner made by Muhr, a global specialist for such systems, uses a proven standard for energy supply to traversing carriages: igus' basic flizz system. Completely installed in just 1.5 hours, the compact system safely moves the cables up to 15 metres. Although well hidden, the energy chain is easily accessible for maintenance or when new cables need to be added.
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Uninterruptible power transmission at the tidal turbine
Tocardo's developers were looking for a way to route cables safely from the turbine to the converter in the control cabinet and thus achieve the longest possible service life for the system. igus provided the perfect solution with series E/4 e-chains, which are corrosion-free, completely resistant to persistently damp environments, easy to install, and quick to open if a cable needs to be replaced.
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First plastic WEC reliably moved with iglidur
The Volta wave energy converter made by PolyGen Ltd in Chesterfield is the world's first device for generating renewable energy from ocean waves and is made predominantly of plastic. For the flap axles, the developers were looking for bearings that could withstand the high mechanical loads and corrosive saltwater for as long as possible. They found the perfect solution at igus: iglidur flange bearings made of H370, a material developed specifically for wet environments.
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Further applications
Screening plant, rake cleaner
In order for hydropower plants to produce electricity reliably, the flow of water to the turbine must be guaranteed at all times. Any floating debris that collects on the protective screens of the water supply must therefore be removed regularly. This task is performed by screen cleaning systems, for example mobile horizontal/crosswise cleaners. As an alternative to trailing cables/festoons and busbar systems, we offer low-maintenance energy chain systems to reliably supply the travelling carriage with energy, in particular the basic flizz system, our standard for rake cleaners and scrapers.
basic flizz energy supply system
- Cost-effective complete system consisting of energy chain, chainflex cables and stainless steel housing
- Protection against weather and dirt exposure
- Low-maintenance, for travels up to 100m
Find out more about basic flizz
Water turbines
In Kaplan and Francis turbines, the water flow to the rotor blades and thus the turbine output can be regulated with the aid of adjustable, pivoting guide vanes. The adjustment mechanism consists of adjustment rings on the outside of the housing, which act on the rotary axes of the guide vanes via articulated levers. We offer the right plain bearings and rod ends for this purpose, which are robust, maintenance-free and corrosion-free.
Plain and spherical bearings
- Lubrication-free flanged bushings made of the all-round material iglidur G or iglidur H especially for underwater applications
- Rod ends igubal KBRM: corrosion-free, suitable for liquid media, with robust, long fibre-reinforced polymer spherical ball
Wave energy converter
Point absorber
Buoys anchored to the seabed with an integrated generator that converts the kinetic energy into electrical energy as the waves move up and down: point absorbers are considered a particularly promising wave energy converter technology. To guide the movement of the floating body and stabilise it even under adverse conditions, robust, maintenance-free linear guides are required, which we offer alongside sliding plates and compact, lightweight energy chains for safe cable guidance.
Bearing technology and e-chain
- Bar stock plates made of iglidur JB: highly wear-resistant with a low coefficient of friction
- Heavy-duty lead screw nut dryspin JGRM + high helix lead screw dryspin stainless steel AISI 304 with right-hand thread
- Pillow block drylin RJUM + round shaft EEWM in stainless steel AISI 420C
- Energy chain Series E4.1: light, robust, modular
Oscillating wave converters
An OWSC (Oscillating Wave Surge Converter) utilises the amplified liquid particle movement of waves in the near-shore zone. The conversion principle is based on a horizontal (more rarely vertical) pendulum movement of a flap that drives a high-pressure fluid in a secondary hydraulic system by means of a piston. We have the right plain bearings for the outer bearing points and for guiding the piston - high-strength, media-resistant and, as always, lubrication-free and maintenance-free.
Plain bearings
- For guiding the piston:
Sleeve bearings iglidur H370 for high loads, with very good wear resistance under water - For fixing the water column and the main pivoting movement:
High-strength wound slide bearings igutex X1 or igutex TX2, very wear-resistant under extreme loads
Plain bearings
- For guidance of the piston:
Sleeve bearings iglidur Q for high loads, wear-resistant on many shafts - For supporting the main axis:
High-strength wound slide bearings igutex X1 or igutex TX2, very wear-resistant under extreme loads
Seawater pump
The wave energy converter (WEC) "Searaser" is a pump consisting of two floats arranged one above the other and connected by a piston. As the waves rise and fall, seawater is pumped to a higher level on land so that it can be stored in large ponds and generate electricity with a turbine and generator when required. To guide the pump piston, we offer suitable plain bearings with particularly high wear resistance for underwater applications.
Plain bearings
Cylindrical bushings iglidur UW: extremely wear-resistant underwater endurance runner, the first choice for pump applicationsAttenuator
This is another way to generate electricity from wave movements: with a long, modular series of floats connected via lever arms to a chain of electric generators. Placed in the direction of the waves, a serpentine movement is created as soon as the waves pass under the floats, and the levers drive the generators. We recommend our heavy-duty underwater plain bearings with flange for the many bearing points on both sides of the levers.
