Periodic Reporting for period 2 - Carbo4Power (New generation of offshore turbine blades with intelligent architectures of hybrid, nano-enabled multi-materials via advanced manufacturing)
Okres sprawozdawczy: 2022-05-01 do 2023-10-31
Carbo4Power is targeting to develop a new generation of lightweight, high strength, multifunctional, digitalised multi-materials for offshore wind and tidal turbine rotor blades that will increase their operational performance and durability while reducing the cost of energy production (below 10ct€/kWh for wind turbines and 15ct€/kWh for tidal), maintenance and their environmental impact. The innovative concept is based on nano-engineered hybrid (multi)materials and their intelligent architectures which breaks down as follows:
-Nanocomposites based on dynamic thermosets with inherent recyclability and repairability and tailored nano-reinforcements to enhance mechanical properties.
-Multifunctional nano-enabled coatings to improve turbine protection (e.g. against lightning and biofouling (e.g. 50% fouling release).
-Blade segments will be designed and fabricated by advanced net-shape automated multi-material composite technologies that will allow ca. 20% scrap reduction.
-The approach for WTB is to deliver innovative design of modular rotor blade, while the approach for TTB is aimed towards an optimal design for ‘one-shot’ manufacture.
-Recycling of blade materials will be increased up to 95% due to the advanced functionalities of 3R resins and adhesives with debonding on demand properties.
The strategic goal is to provide the frame which will create new pathways for manufacturing of FRPs for multiple processing life cycles, and explore the emerging valorisation opportunities in offshore energy sector.
-Nanocomposites based on dynamic thermosets with inherent recyclability and repairability and tailored nano-reinforcements to enhance mechanical properties.
-Multifunctional nano-enabled coatings to improve turbine protection (e.g. against lightning and biofouling (e.g. 50% fouling release).
-Blade segments will be designed and fabricated by advanced net-shape automated multi-material composite technologies that will allow ca. 20% scrap reduction.
-The approach for WTB is to deliver innovative design of modular rotor blade, while the approach for TTB is aimed towards an optimal design for ‘one-shot’ manufacture.
-Recycling of blade materials will be increased up to 95% due to the advanced functionalities of 3R resins and adhesives with debonding on demand properties.
The strategic goal is to provide the frame which will create new pathways for manufacturing of FRPs for multiple processing life cycles, and explore the emerging valorisation opportunities in offshore energy sector.
Up to 36 months of implementation, the development of the materials to be used for WTB and TTB manufacturing have been completed. The main 3R resin formulation for vacuum infusion, 3R resin formulation for manufacturing prepregs for ATL/AFP process have been defined and are being evaluated in intermediate scale. Furthermore, 3R resin based pre-pregs, NE 3R resins for prepregs (lightning protection application), NE inks and thermal heaters based on NE inks for de-icing applications, non-intrusive QR sensors based on 3R resin and carbon-based nanoparticles to monitor strain, humidity, temperature in composite materials, smart adhesives (triggered DoD, functionally graded). Furthermore, most of the simulation activities have been completed until M36 providing information in different systems design, supporting some of the material and bonded joints solutions developments, and helping in the definition of manufacturing, joining and repairing processes. Intermediate and relevant environmental testing is being performed on the selected materials. Regarding the demonstrators manufacturing, the tooling for modular WTB have been defined, and QRS sensors were successfully integrated during AFP and TTB One-shot demonstrator infusion manufacturing processes. The damage analysis using QRS sensors has been performed in coupons level to be then used in demonstrators’ validation testing. Also, the IoT system has been completed. The risk assessment and sustainability are being continuously updated, and the technoeconomical analysis on manufacturing processes has been completed. Dissemination and Communication actions have been constantly monitored and updated. The individual BMCs have been created and the 1st Open Day of the project has been realised.
The expected potential impact of the project includes:
-Reduction of operational and maintenance costs by development of durable and multifunctional materials. The employment of advanced techniques for fibre modification and introduction of nanomaterials, can lead to lighter and stiffer blades and increase their durability. Furthermore, Carbo4Power´s multi-functional coatings with high wear resistance, (super) hydrophobic/omniphobic properties and lightning protection will reduce potential damage by lightning strikes, erosion and biofouling, consequently reducing the maintenance requirements.
-Increase of market capacity regarding the cost for energy/per capita and therefore reduction of the cost in the life cycle of an OE. Specifically, Carbo4Power will develop materials that can be employed in automated processes to enable high deposition rates, scrap reduction and reduction of investments that will directly impact the production cost of Wind and Tidal turbine blades.
- Promoting safety and nanosafety approaches and contributing towards the framework of EU nano-safety and regulatory strategies.
- Reduction of Installation and Commissioning costs, by investigating modularity (segmental) designs of blades that will provide easier transportation and installation, compared to conventional blades manufactured in only-one piece, such as blades larger than 80 m long and weighting more than 25 tonnes. A Structural Health Monitoring (SHM) prototype system will also be developed for the efficient and effective monitoring of offshore turbine blades. Combined with machine learning and artificial intelligence techniques based on artificial neural networks (ANNs) coupled with appropriate algorithms, advanced data processing will be enabled to allow reduction of repairing costs.
-Reduction of CO2 emissions and decommissioning of blades, by developing materials that can be repaired, recycled and repurposed. Furthermore, the investigation of materials with smart debonding properties will allow the bonding of blades for operation, and debonding on demand for maintenance or decommissioning. This way the environmental impact, which occurs from off-shore energy sector, will be reduced and the project outcomes will have positive impact to the society.
- Improved understanding of materials behaviour and manufacturing processes based on theoretical materials models. The modelling tools and computational algorithms will simulate the whole structural behaviours of blades targeting by topology optimization and aerodynamic/ hydrodynamic modelling to give load values. The proposed modelling techniques will impact the in depth understanding of the material properties from atomistic to continuum and they will be especially helpful for the export of the technology to other applications. To export the technology, focus will be given on data-driven artificial intelligence (AI) to help manufacturers
select the ideal blade material from the outset.
-With the establishment of an Offshore Energy Board (OEB) which is comprised of experts from offshore energy sector, a techno-economical assessment of the current industrial requirements will be realised and provide guidelines to address increased market needs occurred from unforeseen events such as COVID19.
-Reduction of operational and maintenance costs by development of durable and multifunctional materials. The employment of advanced techniques for fibre modification and introduction of nanomaterials, can lead to lighter and stiffer blades and increase their durability. Furthermore, Carbo4Power´s multi-functional coatings with high wear resistance, (super) hydrophobic/omniphobic properties and lightning protection will reduce potential damage by lightning strikes, erosion and biofouling, consequently reducing the maintenance requirements.
-Increase of market capacity regarding the cost for energy/per capita and therefore reduction of the cost in the life cycle of an OE. Specifically, Carbo4Power will develop materials that can be employed in automated processes to enable high deposition rates, scrap reduction and reduction of investments that will directly impact the production cost of Wind and Tidal turbine blades.
- Promoting safety and nanosafety approaches and contributing towards the framework of EU nano-safety and regulatory strategies.
- Reduction of Installation and Commissioning costs, by investigating modularity (segmental) designs of blades that will provide easier transportation and installation, compared to conventional blades manufactured in only-one piece, such as blades larger than 80 m long and weighting more than 25 tonnes. A Structural Health Monitoring (SHM) prototype system will also be developed for the efficient and effective monitoring of offshore turbine blades. Combined with machine learning and artificial intelligence techniques based on artificial neural networks (ANNs) coupled with appropriate algorithms, advanced data processing will be enabled to allow reduction of repairing costs.
-Reduction of CO2 emissions and decommissioning of blades, by developing materials that can be repaired, recycled and repurposed. Furthermore, the investigation of materials with smart debonding properties will allow the bonding of blades for operation, and debonding on demand for maintenance or decommissioning. This way the environmental impact, which occurs from off-shore energy sector, will be reduced and the project outcomes will have positive impact to the society.
- Improved understanding of materials behaviour and manufacturing processes based on theoretical materials models. The modelling tools and computational algorithms will simulate the whole structural behaviours of blades targeting by topology optimization and aerodynamic/ hydrodynamic modelling to give load values. The proposed modelling techniques will impact the in depth understanding of the material properties from atomistic to continuum and they will be especially helpful for the export of the technology to other applications. To export the technology, focus will be given on data-driven artificial intelligence (AI) to help manufacturers
select the ideal blade material from the outset.
-With the establishment of an Offshore Energy Board (OEB) which is comprised of experts from offshore energy sector, a techno-economical assessment of the current industrial requirements will be realised and provide guidelines to address increased market needs occurred from unforeseen events such as COVID19.