Advancing Wisconsin's Green Manufacturing Economy
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Advancing Wisconsin’s Green Manufacturing Economy A COLLABORATIVE REPORT HIGHLIGHTING OPPORTUNITIES FOR WISCONSIN TO GROW OUR MANUFACTURING BASE FOR GREEN ENERGY TECHNOLOGIES. June2020 SPONSORED BY THE TOMMY G. THOMPSON CENTER FOR PUBLIC LEADERSHIP About the authors DR. MATT JEWELL is an associate DR. JUNJIE NIU is an Associate Profes- professor of Materials Science and Engineer- sor in Department of Material Science and En- ing at UW-Eau Claire. His research interests gineering at UW-Milwaukee. Before joining in include materials for advanced supercon- UWM, Dr. Niu worked as a Postdoc Associate ducting magnets and manufacturing process at the Massachusetts Institute of Technology optimization. His professional background (MIT) from 2011 to 2014. He also did interdis- includes three years at ITER, an experi- ciplinary research as a Postdoc Associate at mental nuclear fusion facility being built the Drexel University and the University of in Cadarache, France. He can be reached at Pennsylvania (UPenn) from 2009 to 2011. Dr. [email protected]. Niu’s interdisciplinary research includes un- derstanding fundamental science in physics/ DR. YAN LI is a professor of Economics at chemistry/mechanics, and engineering ma- the UW-Eau Claire. Her current research main- terials in applications of energy storage and ly studies the role of money, credit and bank- energy-water nexus. The areas include but ing in the macroeconomy and the liquidity not limited to, lithium-ion and beyond bat- effects of monetary policy. She is also inter- teries for next-generation EVs, water treat- ested in examining the income inequality and ments and self-cleaning coatings. Dr. Niu has economic growth in emerging markets. She published over 80 papers in peer-reviewed can be reached at [email protected]. journals including 3 Nature series journals with a H-index over 40 and filed over 3 US is Chair and Pro- DR. THOMAS KEMP patents. Dr. Niu also found a start-up com- fessor in the Department of Economics at the pany Niu Energy (http://niu-energy.com) that UW-Eau Claire. His former employers include devotes to develop high energy-density bat- the Department of Transport – Abu Dhabi teries. He can be reached at [email protected]. (2011-2012), The City of Eau Claire, WI (2007- See more details about Dr. Niu’s research at 2011), and Denver University (2001 – 2002). He https://people.uwm.edu/niu/ currently teaches Applied Research Methods, International Trade and Finance, The History BRIAN M. LANGOLF, M.S. has 10 years of Economic Thought, and Macroeconomics. of biogas operations, research and laboratory His ongoing research interests include asset analysis, and interpretation experience. He valuation/hedonic modeling, local economic currently works at the University of Wisconsin development, and public policy design. He Oshkosh serving as the Biogas Program Direc- can be reached at [email protected]. tor. This role involves technical oversight of biogas operations, conduct biogas research is a profes- DR. KEVIN CRAWFORD and provide digester training and consulting sor of Chemistry at UW-Oshkosh. His research services, and internal and external program interests include environmental pollution outreach. This program supports many aca- such as PAHs, heavy metals, and pesticides. demic and sustainability programs on cam- He has recently worked on characterizing pus and in the local community. Brian has liquid fuels produced from biogas, and has also been serving on the on the board of di- consulted for a wide variety of clients mea- rectors for the American Biogas Council since suring low levels of compounds of interest in 2012 working on a number of biogas related complex matrices. He can be reached at craw- initiatives to advance biogas in the United [email protected]. States. Acknowledgements This work was conducted in collaboration with UW-Eau Claire undergraduate researchers Charlotte Cheng, Breanna Fryza, Cameron Johnson, Hannah Johnston, Philip Long, Jens Lund, Emerson Ngu, Megan Roehl, Zoey Tan, and Will Ullrich, UW-Milwaukee graduate student Mingwei Shang, and UW-Oshkosh Director of Biogas Systems & Research Development Brian Langolf. ADVANCING WISCONSIN’S GREEN • 1 • MANUFACTURING ECONOMY Contents About the authors ...............................1 8. Manufacturing Opportunities in Solar Energy ................................37 Acknowledgements .............................1 8.1 Bifacial solar modules ....................37 1. Introduction: Changing Climate, Consumer Preferences, and Producer Preferences. .......4 8.2 Light reflecting technologies for solar modules.................................38 2. Current Green Energy Generation in the United States and Future Projections ..........4 8.3 Processing for half-cut solar cells .........39 3. The Current State of Wisconsin 8.4 End-of-life management . .40 Manufacturing ...............................6 8.5 Additional resources and funding 4. The Current State of Green Energy Manufacture opportunities............................41 in Wisconsin and Neighboring States..........9 9. Analysis of Advanced Lithium-Ion Batteries 5. Methodology and Methodological Challenges Across Wisconsin ............................42 to Estimating Current Capacity to Participate in Green Energy Production .................11 9.1 Development of advanced anode materials . 43 6. Current Industry Assessment ................12 9.2 Wisconsin LIBs manufacturers . 44 7. Manufacturing Opportunities in Wind Energy ................................31 9.3 Development of advanced lithium ion batteries ............................45 7.1 Advanced composite materials for wind turbine blades ...........................31 9.4 Wisconsin LIBs recycling..................45 7.2 3D printing of molds for turbine blades ...32 9.5 Summary ................................46 7.3 Drivetrain advances......................33 9.6 Additional resources and funding opportunities............................48 7.4 End of life management..................34 10. Manufacturing Opportunities in Biogas ......50 7.5 Additional resources and funding opportunities............................34 11. Project Findings and Recommendations .....53 COVER IMAGE TOP: (CC BY) Photo by Tony Webster | White Water / Palm Springs, Riverside County, California https://commons.wikimedia.org/wiki/File:Dillon_Wind_Power_Project_(15990721656).jpg COVER IMAGE BOTTOM: (CC BY) Photo by Tu | https://www.flickr.com/photos/tuey/332361446 ADVANCING WISCONSIN’S GREEN • 2 • MANUFACTURING ECONOMY Executive summary The transition from fossil fuel energy sources to advanced renewable sources is well underway in Wisconsin, but at present Wisconsin manufacturers are not optimally positioned to integrate themselves into the supply chain for advanced energy generation technologies such as wind, solar, and biogas, along with energy storage tech- nologies such as lithium-based batteries. In this report we evaluate the market conditions for existing Wisconsin manufacturers to further develop prod- ucts and processes to support green energy industries, and we identify specific R&D opportunities to leverage existing capacity and capabilities to meet the current development requirements of the wind, solar, biogas, and lithium battery industries. Global climate change will require changes in how we produce energy. At the same time, recent geopolitical events combined with the COVID-19 outbreak is certain to lead to a reevaluation of global supply chains. Taken in combination it is likely that market and policy changes will create significant opportunities for the domestic manufacture of the components associated with the production of ‘green’ energy. Using a combination of NAICS industrial data and proprietary firm data, that is scalable to the national level, we determine the real capacity for Wisconsin State manufacturers to participate in the component supply chain associated with wind and so- lar power. We find that there exists significant untapped manufacturing capacity that could be utilized in the relatively short term if required and if opportunity costs are deemed appropriate. We also address bridgeable capacity gaps and workforce-related issues. IMAGE ABOVE: (CC BY-SA) Photo by Peter Rood | https://commons.wikimedia.org/wiki/File:Stately_Wind_Turbine_(8295293053).jpg ADVANCING WISCONSIN’S GREEN • 3 • MANUFACTURING ECONOMY 1. Introduction: Changing Climate, Consumer Preferences, and Producer Preferences. A growing consensus regarding the policy significance of global climate change is likely to require relatively swift changes to how we produce energy. This change, as with all changes, will bring both challenges and op- portunities. With this study, we hope to provide assistance to Wisconsin manufacturers to minimize the former while enabling us to more fully exploit the latter. The broad manufacturing base of the state, combined with a solid transportation network, and a strong educational system is well placed to become a significant component to the supply chains of so-called green technologies. Countries worldwide are now facing dual challenges of combating climate change while fueling economic growth. Renewable energy is one of the most viable solutions to control and reduce the impact of greenhouse gases produced by conventional fossil fuels. The transition to renewable energy is well underway both in Wis- consin and nationally, and in this report we intend to identify Wisconsin firms that are well-suited and well-po- sitioned to shift into the manufacture of components for green industries. Due to the nature