Periodic Reporting for period 1 - EOLIAN (Bio-based, repairable and recyclable vitrimer composites and advanced sensors for highly reliable and sustainable wind blades)
Berichtszeitraum: 2024-06-01 bis 2025-07-31
In the renewable energy framework, EOLIAN project emerges as a timely and transformative response to a growing environmental and industrial challenge: the sustainable production of wind turbine blades and the management of their end-of-life. EOLIAN proposes a breakthrough solution: the development of a new generation of smart wind turbine blades based on circular, fully recyclable chemistry using bio-based vitrimer resins reinforced with basalt fibres and embedded with in-mould electronics for structural health monitoring and anti-icing functionality.
Vitrimers, with their dynamic covalent bonds, enable circular recycling through both chemical depolymerization and mechanical reshaping, without compromising mechanical performance. The integration of printed sensors and heating elements allows for real-time damage detection and ice prevention, improving safety, reducing downtime, and extending blade lifespan.
The project goes far beyond the current state of the art. While existing recycling methods for composites - mechanical, thermal, or chemical - are limited in efficiency, scalability, and environmental impact, EOLIAN introduces a fundamentally new approach: materials designed from the outset for circularity. The use of basalt fibres, which can potentially outperform glass fibres in durability and recyclability, and bio-based resins derived from vanillin and vegetable oils, reinforces the project’s commitment to sustainability.
The expected impact is substantial. EOLIAN aims to reach a bio-based content of 80%, and at the same time, to obtain materials which can be recycled reused and repurposed, which a cut of CO2 emissions of at least 10%. This will allow the creation of new market opportunities for high-performance recycled materials.
In summary, EOLIAN not only addresses the pressing issues of wind blade end-of-life management but also offers a transformative vision for the sector - one rooted in material innovation, sustainability, and smart functionality.
Vitrimers, with their dynamic covalent bonds, enable circular recycling through both chemical depolymerization and mechanical reshaping, without compromising mechanical performance. The integration of printed sensors and heating elements allows for real-time damage detection and ice prevention, improving safety, reducing downtime, and extending blade lifespan.
The project goes far beyond the current state of the art. While existing recycling methods for composites - mechanical, thermal, or chemical - are limited in efficiency, scalability, and environmental impact, EOLIAN introduces a fundamentally new approach: materials designed from the outset for circularity. The use of basalt fibres, which can potentially outperform glass fibres in durability and recyclability, and bio-based resins derived from vanillin and vegetable oils, reinforces the project’s commitment to sustainability.
The expected impact is substantial. EOLIAN aims to reach a bio-based content of 80%, and at the same time, to obtain materials which can be recycled reused and repurposed, which a cut of CO2 emissions of at least 10%. This will allow the creation of new market opportunities for high-performance recycled materials.
In summary, EOLIAN not only addresses the pressing issues of wind blade end-of-life management but also offers a transformative vision for the sector - one rooted in material innovation, sustainability, and smart functionality.
At M14, several activities have been performed:
Vanillin shift bases (VSB) have been firstly synthetized starting from different amines, in order to tailor viscosity, melting temperature and properties related to the final vitrimer.
Imine-containing vitrimers derived from vanillin-based Schiff bases (VSBs) and DDM have been developed.
In parallel, an alternative vitrimer route based on disulfide bonds (contingency plan) was investigated. Low-viscosity, bio-based and bisphenol-A free vitrimer formulations were developed. The preliminary characterization demonstrated that thermal and mechanical properties close to the requirements were achieved.
A benchmarking with a commercial vitrimer has been carried out, both in terms of vitrimeric properties (mechanical vs repairability) and mechanical.
The produced vitrimers have been used to produce basal fibres base composites, and they have been characterized. In particular, Mode I and Mode II interlaminar fracture tests were conducted to assess the fracture behaviour of vitrimer-based composite laminates, providing valuable insights into their performance in structural applications.
A modelling approach/workflow has been developed in order to simulate the behaviour of epoxy-vitrimer chemistries and their interfaces with fibre, at the atomistic level.
A solubility study was also conducted to assess recyclability. Results confirmed the chemical recyclability of these vitrimer systems under acidic conditions at room temperature, owing to the effective acid-catalysed hydrolysis of imine bonds. This enables potential monomer recovery for vitrimer re-synthesis.
As for SHM technologies and operation and maintenance methodologies, the activity performed so far are related to two key aspects. Demonstrator manufacturing: several demonstrators have been manufactured to analyse the compatibility between the different materials and the performance of the transducers (sensor and actuator). Ice sensor characterization: Ice detection of different transducers has been tested using ice created through a wind tunnel.
The design specifications for the blade, has been defined. The aerodynamic design to define the outer geometry of the blade is in progress and a preliminary structural topology with a classical layout has been selected: dedicated spar cap, one shear web and sandwich laminates for the shell structure.
As for risk assessment, a scoping questionnaire was circulated among the technical partners allowed the inhalation risk assessment of the vitrimer synthesis processes. Next steps will focus on the finalization of the exposure analysis, the analysis of the fibre enhancement process of the vitrimers and coupling these results with the hazard banding of the materials involved, to identify potential health related hot spots of the processes.
A preliminary LCC was presented based on the initial trials of vitrimers manufacturing and for the manufacturing of the conventional 14 meters blade based on data provided by Norvento. The next steps include updating the completed LCA/LCC questionnaires and their preliminary analyses, as well as finalizing the ongoing questionnaires and completing their corresponding LCA/LCC assessments.
Vanillin shift bases (VSB) have been firstly synthetized starting from different amines, in order to tailor viscosity, melting temperature and properties related to the final vitrimer.
Imine-containing vitrimers derived from vanillin-based Schiff bases (VSBs) and DDM have been developed.
In parallel, an alternative vitrimer route based on disulfide bonds (contingency plan) was investigated. Low-viscosity, bio-based and bisphenol-A free vitrimer formulations were developed. The preliminary characterization demonstrated that thermal and mechanical properties close to the requirements were achieved.
A benchmarking with a commercial vitrimer has been carried out, both in terms of vitrimeric properties (mechanical vs repairability) and mechanical.
The produced vitrimers have been used to produce basal fibres base composites, and they have been characterized. In particular, Mode I and Mode II interlaminar fracture tests were conducted to assess the fracture behaviour of vitrimer-based composite laminates, providing valuable insights into their performance in structural applications.
A modelling approach/workflow has been developed in order to simulate the behaviour of epoxy-vitrimer chemistries and their interfaces with fibre, at the atomistic level.
A solubility study was also conducted to assess recyclability. Results confirmed the chemical recyclability of these vitrimer systems under acidic conditions at room temperature, owing to the effective acid-catalysed hydrolysis of imine bonds. This enables potential monomer recovery for vitrimer re-synthesis.
As for SHM technologies and operation and maintenance methodologies, the activity performed so far are related to two key aspects. Demonstrator manufacturing: several demonstrators have been manufactured to analyse the compatibility between the different materials and the performance of the transducers (sensor and actuator). Ice sensor characterization: Ice detection of different transducers has been tested using ice created through a wind tunnel.
The design specifications for the blade, has been defined. The aerodynamic design to define the outer geometry of the blade is in progress and a preliminary structural topology with a classical layout has been selected: dedicated spar cap, one shear web and sandwich laminates for the shell structure.
As for risk assessment, a scoping questionnaire was circulated among the technical partners allowed the inhalation risk assessment of the vitrimer synthesis processes. Next steps will focus on the finalization of the exposure analysis, the analysis of the fibre enhancement process of the vitrimers and coupling these results with the hazard banding of the materials involved, to identify potential health related hot spots of the processes.
A preliminary LCC was presented based on the initial trials of vitrimers manufacturing and for the manufacturing of the conventional 14 meters blade based on data provided by Norvento. The next steps include updating the completed LCA/LCC questionnaires and their preliminary analyses, as well as finalizing the ongoing questionnaires and completing their corresponding LCA/LCC assessments.
Imine-containing vitrimers derived from vanillin-based Schiff bases (VSBs) are promising polymer matrices for composites, ensuring high bio-based content and recyclability. Despite being reported in several scientific papers, they are not yet fully on the market: one of the reasons could be the limited workability (high viscosity and reactivity). The technical activities of EOLIAN are specifically focused on these aspects, trying to reduce viscosity without compromising the thermal properties (Tg), in order to have a vitrimer which is suitable to be used with vacuum infusion.
The use of basalt fibres for the manufacturing of wind blades is barely reported. They have very good mechanical properties and can increase the bio-based content. The use of basalt fibres with vitrimer matrices is barely reported in literature.
As for SHM technologies and operation and maintenance methodologies, the manufacturing of the demonstrator with these new materials is challenging, as the compatibility between the different materials and the performance of the transducers (sensor and actuator) has not been investigated so far.
The use of basalt fibres for the manufacturing of wind blades is barely reported. They have very good mechanical properties and can increase the bio-based content. The use of basalt fibres with vitrimer matrices is barely reported in literature.
As for SHM technologies and operation and maintenance methodologies, the manufacturing of the demonstrator with these new materials is challenging, as the compatibility between the different materials and the performance of the transducers (sensor and actuator) has not been investigated so far.