The MAREWIND project as leader towards a more sustainable and circular offshore wind sector

During the last months, the MAREWIND project has made great strides towards the validation of the developed samples. At present, the natural step is the validation in a real environment where formal controlled testing will be performed to ensure that the materials developed satisfy the expected requirements.

The consortium has started the work in real exposure and also with samples with real materials and morphologies, enabling relevant validation.

On the one hand, for bigger pieces, TECNAN has defined key parameters – such as flow rate, speed or distance – of spray gun application, and characterised the resulting samples with the aim to compare its properties versus the ones previously validated in the laboratory. Several application tests were carried out in order to adapt the procedure to complex and more realistic morphologies. More in detail, real pieces of mooring lines and inter array cables have been coated with the antifouling solution via spray gun, maintaining all the expected repellence properties, as in previous tests. The anticorrosion coating was also applied on samples around 1m2 and with curved and complex geometries with no imperfections observed. Besides, TECNAN has optimised strategies for removing the excess of product and curing conditions for real fastening elements regarding dip-coating application.

 On the other hand, TWI for its side is improving the application of the superhydrophobic coating for blades for improved control and for having higher resistance to mechanical impact.

Additionally, as advanced concrete-based materials concerned, ACCIONA has made preliminary UHPC floating prototypes, focused on the relevant scale prototype design that will be tested in more realistic environments such as wave basin for offshore application studies (EUMER facilities), at the same time, real exposure durability testing will be performed at ACCIONA Habour demo-site. Furthermore, for the Alkali Activated Concretes (AAC), CETMA carried out a small-scale prototype with a complex geometry to evaluate the ability of the AAC to flow within the mould. They have also designed the final prototype indicating the number and position of SMART reinforcing rebars.

Advances concerning the blade prototype, imply that EIRE has been working on the validation demonstrator, testing the 5m wind blade spar box, as representative section of the main structural component of the 13 m blade.

Figure 1. Bigger and real samples: real fastening elements coated with anticorrosion protection or non-coated, samples of real structures being coated with antifouling and new concretes developed.
           

As part of the validation activities, final optimisations of the selected formulations are being carried out in order to maximise the properties of the novel solutions developed.

More in detail, TWI has started the optimisation of the best performing coating formulation, working on the 3rd generation of antierosion coatings adjustment. After several tests, TWI has adjusted the level of functionalized microparticles in the formulation, showing an increased wear resistance of the coating.  For the reinforced composites formulations for blades, the contemplated strategies by TWI and CETMA, are progressing properly. Respecting the work of TWI, the final material test campaign for GF/epoxy-SiO2 as the new blade material was completed. The results are compared with conventional GF/epoxy, showing that the modified epoxy-SiO2 resin outperforms the conventional epoxy resin in the majority of property tests. CETMA for its side, is working on the infusion process of the TPR (thermoplastic reactive resin), as a new recyclable resins. The results of testing campaign for GF/TPR as the new blade material, has showed that properties of recyclable composite are  comparable with conventional GF/epoxy laminates. They have defined the final composition, layup and geometry of the full TPR demonstrator, and as regards TPR matrix, CETMA has selected a specific recyclable resin to be used in scale up activities with low exothermic properties to produce large parts with thick sections.

Figure 2. Fine-tuning of reinforced composite materials.
       

The scale-up of formulations includes the progress regarding liquid nanocoating production as well as novel concrete or composite fabrication.

On the one hand, production of the anticorrosion and antifouling coatings started with first batches of 20 liters with suitable results, having the focus on the 100 liters target of production. The spray gun application and the monitorization of the key parameters (viscosity, particle size…) showed that the larger batches have the same tendency as the product made at laboratory scale. As a result, TECNAN will produce larger batches following the same parameters. In addition, INL is producing the self-healing active material for the anticorrosion system, and studying what is the most suitable format for the scalability.

Also, the preparation of pilot batches of SiO2 mixed with epoxy infusion resin (epoxy-SiO2) has already started by TWI side, in order to supply EIRE for the production of the new blade reinforced composites

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Figure 3. 20L reactor of antifouling coating and EIRE-epoxy demonstrator webs.

After having performed all laboratory tests, the MAREWIND project is currently gradually moving to a real environment.

Currently, TECNAN is testing the bigger pieces in saline mist chamber before preparing the ones to be exposed to real conditions.  Specific and bigger samples coated with the anticorrosion system are envisaged to be tested by ENEROCEAN in the upcoming months in real marine environment using TECNALIA’s HarshLab floating laboratory. On the other hand, ENEROCEAN is currently testing the antifouling coatings on flat panels, both partially submerged and in total immersion, as well as on real samples (moorings and cables) in real marine environment. These antifouling coatings tests are being performed at the Oceanic Platform of the Canary Islands (PLOCAN) facilities.

Figure 4. Real Samples with antifouling coating in real exposure tests located in PLOCAN, floating design of UHPC structure validation for the manufacturing of the relevant scale prototype for its testing in the wave basin at EUMER facilities and real environment durability testing of UHPC at ACCIONA Harbour demosite.
             
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On 16th and 17th November, the MAREWIND consortium met in the headquarters of Lurederra Centro Tecnológico in Los Arcos (Navarra, Spain) to discuss the 2-year progress of the project.

The first day, the meeting started with the review of the work done and the achievements reached so far on the activities related to the predictive modelling and the SHM tools for preventive maintenance of wind energy. The discussion continued with the latest updates on the technology validation and the manufacturing activities performed during the last months, including upscaling of nanocoating formulations, the generation of floating concrete prototypes and advanced composite testing among others. To wrap the first day of the meeting, the last topic addressed the preparatory actions for the future demonstration of the technologies in relevant environments.

The second day was dedicated to the presentation of the upcoming steps in the technical validation of the results such as the baseline for LCA analysis. Then, the meeting followed by a summary of all the communication and dissemination results achieved from the beginning of the project. To conclude the meeting, the consortium presented the next steps which will be followed to face the upcoming exploitation and standardisation challenges.

 Next steps

The consortium is preparing its fourth newsletter. Stay tuned for more details about the progress achieved so far.

You can subscribe for the latest MAREWIND news and events, here.

 

Progress achieved after 18th months

It has been a busy and productive first phase of the project MAREWIND project. Since its launch in December 2020, the MAREWIND team has been working hard on progressing to achieve the ambitious goals of the project. The project addresses the main aspects related to materials durability and maintenance in offshore structures which have the potential to reduce imply failure, misfunctioning, loss of efficiency in energy generation and which have a major repercussion on O&M and CAPEX. MAREWIND aims to develop durable materials and recyclable solutions for the offshore wind industry, while extending the service life of the wind facilities. In addition, the project outcomes will also contribute to meeting the EU climate targets and create new job opportunities within the wind industry.  

MAREWIND project has achieved its second milestone!

Second milestone of the project has been successfully achieved! During the first year and a half, most of the technical work done by the partners has focused on the fabrication and testing elements individually. Specific formulations have been selected after testing and checking accelerated essays which comply with technical requirements. A great progress has been done thanks to the close collaboration between the partners of MAREWIND consortium. We are looking forward to sharing the outcomes we will achieve in the upcoming years!

Next steps

The consortium is preparing its third newsletter, so stay tuned for more details about the progress achieved so far. You can subscribe for the latest MAREWIND news and events, here.