New generation of offshore turbine blades with intelligent architectures of hybrid, nano-enabled multi-materials via advanced manufacturing

Project Information

Carbo4Power

Grant agreement ID: 953192

DOI

10.3030/953192

Project closed

EC signature date 4 December 2020

Start date 1 November 2020

End date 31 October 2024

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced materials

Total cost

€ 7 831 707,49

EU contribution

€ 6 996 860,75

Coordinated by

ETHNICON METSOVION POLYTECHNION
Greece

Periodic Reporting for period 3 - Carbo4Power (New generation of offshore turbine blades with intelligent architectures of hybrid, nano-enabled multi-materials via advanced manufacturing)

Reporting period: 2023-11-01 to 2024-10-31

Summary of the context and overall objectives of the project

The Carbo4Power project addresses key challenges in offshore wind and tidal energy, focusing on durable, lightweight, and multifunctional materials to enhance turbine performance and reduce costs. It tackles inefficiencies in manufacturing due to material waste and lack of automation, high energy production, transport and assembly costs, high maintenance costs, and the limited recyclability and environmental impact of turbine blades through innovative materials and design solutions. Key Objectives:
-Develop novel 3R (repairable, reprocessable, recyclable) multifunctional thermoset epoxy composites with dynamic covalent networks, nano-reinforcements, and functionalized fibers to enhance mechanical properties, electrical/thermal conductivity, and SHM capabilities using embedded Quantum Resistive Sensors (QRS).
-Multifunctional, protective coating systems including coatings with improved aero-/hydrodynamic performance, self-cleaning, anti-icing, anti-fouling, corrosion resistance, and self-healing properties.
-Implement advanced automated composite manufacturing technologies (ATL, AFP, NCF, DFP, 3D printing) in a flexible digital eco-design environment to reduce waste, improve efficiency, and lower costs.
-Develop segmented rotor blades for WTB to enable scalable designs, cost-effective transport, and on-site assembly.
-Innovative joining technologies: advanced adhesives, thermoplastic welding, and hybrid joints to enhance durability, modularity, and recyclability.
-Efficient SHM system using non-intrusive QRS sensors for real-time monitoring, improving safety and reducing maintenance needs.
-Digital validation pipeline by leveraging AI, machine learning, and multi-scale modeling for optimized material validation and robust mechanical/hydrodynamic designs.
-Validate innovations through rigorous testing, including 1:20 scale modular wind turbine blades and tidal blade prototypes, ensuring market readiness.
-Reduce environmental impact by 35% with 3R materials, debondable adhesives, and eco-friendly designs, supported by LCA and LCC analyses.
-Enhanced Recycling and Reparability by implementing dynamic bonding, debonding-on-demand, and advanced repair techniques to extend blade lifespan and reduce costs.
-Effective dissemination and exploitation to promote innovations to foster industry adoption and competitiveness.
The project monitored progress using 24 Key Performance Indicators (KPIs), achieving 100% completion for 20 KPIs and over 80% for the remaining four, demonstrating its success in meeting ambitious objectives.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project successfully designed, manufactured, validated, and demonstrated innovative offshore turbine blades tailored for wind and tidal energy applications. The significant advancements in material innovation, manufacturing processes, and turbine performance, were achived offering a substantial contribution to renewable energy technologies. Key outcomes include new sustainable and nano-engineered materials: two 3R resin formulations optimized for WTB/TTB manufacturing, NE resin formulations incorporating CNTs and graphene enhanced electrical conductivity, enabling advanced lightning protection systems; functionalized graphene-based resistive inks demonstrated excellent thermal outputs for active de-icing; QRS developed for pressure, strain, flow, moisture, and temperature monitoring, integrated and validated for SHM; scalable CF sizing solutions improved fibre-matrix interfacial strength; Functionally Graded (FGAJ) and Multiple Adhesive Joints (MAJ) enhanced joint strength and recyclability, with debonding-on-demand capabilities. Multi-functional coating solutions, including riblet, erosion protection, and antifouling coatings, were developed for W/TTB, enhancing durability, hydrophobicity, and drag reduction.Twenty digital models were created to support de-icing systems, material property predictions, infusion processes, bladelet design, optimization of bi-adhesive and scarf-bonded solutions, validating their accuracy for turbine applications. Intermediate validation confirmed the suitability of 3R composites and joint solutions for demanding conditions, with successful NDT techniques, omniphobic coatings, active de-icing systems, lightning protection, biofouling resistance and underwater cleanability demonstrated for WTB and TTB components. Repairability of 3R composites achieved over 90% recovery in mechanical properties. Two modular 1:20 scale WTB (5.8 m length) and TTB (MADRAS, one-shot) demo validated advanced manufacturing methods, structural integrity and performance, while process monitoring proved reduced waste and improved production efficiency. SHM systems with embedded sensors detected damage modes and provided real-time monitoring for turbine blades, validated through laboratory and field tests. AI-driven models predicted damage evolution and enhanced maintenance strategies. Circular economy principles were successfully integrated into turbine blade design with 3R materials, modular segmentation, and advanced recycling methods. Comprehensive LCA and LCC studies highlighted reduced environmental impact and cost-effectiveness. Risk and safety assessments ensured safe handling of materials and processes. Project results outreached >10 workshops,>17 scientific articles, >32 conferences, 6 exhibitions, 10 workshops. 27 Key Exploitable Results were delivered, supported by business models, commercialization strategies, and synergies with related projects. The Carbo4Power project advanced renewable energy technology, achieving critical innovations in materials, design, and manufacturing while emphasizing sustainability, recyclability, and economic viability.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project advances renewable energy technologies and sustainability through innovative materials and manufacturing processes for W/TTB, enabling efficient, cost-effective energy generation while integrating circular economy principles, including recyclability, reprocessability, and repairability, to reduce environmental footprints and support climate change mitigation goals. Modular designs, reversible bonding, AI integration, and real-time monitoring enhance operational efficiency, predictive maintenance, and cost reductions. A comprehensive LCA and LCC analysis evaluated the environmental and economic impacts of the materials and components across production, operation, and EoL stages. TEA demonstrated reduced LCoE and manufacturing costs via automation and innovative materials, supported by a Tier 1 risk assessment addressing safety and occupational exposure. Advanced modeling tools and AI-driven algorithms simulated blade behaviors, optimized designs, and predicted aerodynamic/hydrodynamic loads, enabling technology transfer to other applications. Durable, multifunctional materials with wear-resistant coatings, lightning protection, and hydrophobic properties mitigate damage, reduce maintenance needs, and enhance turbine blade lifespans. The project fosters economic growth by supporting industrial innovation, creating skilled jobs, and enhancing EU competitiveness in the global renewable energy sector. Public engagement through exhibitions and workshops raises awareness of renewable energy technologies. By delivering 27 KERs, the project accelerates the transition to sustainable energy systems while addressing climate challenges and promoting societal benefits.

Carbo4Power schematic concept