1

TECHNOLOGY PLATFORM

"COMPOSITES & ADVANCED MATERIALS"

CONFERENCE "DISMANTLING AND RECYCLING OF

WIND TURBINES: FROM DESIGN TO END OF LIFE"

BMWi – BERLIN 12 MARCH 2020

EFFIWIND : DEVELOPMENT OF A NEW

GENERATION OF WIND TURBINE BLADES

BASED ON RECYCLABLE ACRYLIC MATERIALS

5 000 M²

45 ENGINEERS/TECH

PRIVATE R&D SERVICE

PUBLIC REGIONAL FUNDING

PUBLIC/PRIVATE COOPERATIVE R&D PROJECT

4,3 M€ ANNUAL TURNOVER

2

3 LOCATIONS IN NEW-AQUITAINE REGIONTHERMOPLASTIC

POLYMER FORMULATION

BIO-BASED CARBON FIBER

SMART MATERIALS

STRUCTURAL HEALTH

MONITORING

ROBOTICS FABRICATION

PROCESS

RECYCLING PROCESS

CANOE PLATFORM : AT A GLANCE

EFFIWIND PROJECT : OVERVIEW

3

PULTRUDED CARBON SPAR CAP

METHACRYLATE BONDING JOINT

LIQUID REACTIVE ACRYLIC RESIN DEVELOPMENT

"NON CRIMP FABRICS" GLASS FIBER

OBJECTIVE : TO DESIGN, TO MANUFACTURE AND TO CERTIFY A NEW GENERATION OF WIND TURBINE BLADES MADE OF RECYCLABLE ACRYLIC COMPOSITE MATERIALS

INFUSION PROCESS DEVELOPMENT

MANUFACTURING OF BLADE SECTIONS (ROOT….)

MANUFACTURING OF FULL-SCALE (25M LONG) WIND BLADE DEMONSTRATOR

DURATION : 2014-2019GLOBAL BUDGET : 10.9 M€

BLADE DESIGN

4

A COMPLEMENTARY VALUE-CHAIN WITH A MULTI-DISCIPLINARY PROJECT TEAM:

MATERIALS DEVELOPER, BLADE MANUFACTURER, WIND FARM USER, ENGINEERING OFFICE….

A BOTTOM-UP APPROACH FROM MATERIALS TO COMPOSITE STRUCTURE:

LIQUID REACTIVE ACRYLIC RESIN DEVELOPED BY ARKEMA (ELIUM©)

NON CRIMP FABRICS GLASS FIBER DEVELOPED BY CHOMARAT (G-PLY)

PULTRUDED CARBON DEVELOPED BY EPSILON-COMPOSITE (CARBOLAM©)

METHACRYLATE STRUCTURAL ADHESIVE DEVELOPED BY BOSTIK (SAF©)

EFFIWIND PROJECT : GLOBAL APPROACH

5

DESIGN OF NEW BLADE :

REDESIGN OF APX48 REFERENCE BLADE FROM NEW MATERIALS (ACRYLIC RESIN, PULTRUDED

CARBON SPAR CAP, METHACRYLATE BONDING JOINT)

EXPECTED WEIGHT GAIN (700 KG) EXTRA LENGTH (2M LONG) PRODUCTIVITY (+ 10-15%)

LOAD CALCULATION PREDESIGN, ASSESSMENT OF LOADS VS. EACH TURBINE COMPONENT

FULL STRUCTURAL VERIFICATION (EXTREME LOADS, BUCKLING, FATIGUE) DNV-GL BLADE C & B

CERTIFICATION

EFFIWIND PROJECT : GLOBAL APPROACH

6

A SCALE-UP APPROACH TOWARDS FULL-SCALE BLADE:

GLASS FIBER REINFORCED ACRYLIC COMPOSITE COUPON

BLADE SECTION (THICK MONOLITHIC COMPOSITE BLADE ROOT….)

FULL-SCALE 25M LONG WIND TURBINE BLADE

EFFIWIND PROJECT : GLOBAL APPROACH

TENSILE AND ILSS TEST ONTO GLASS/ACRYLIC COMPOSITE COUPON

COMPOSITE COUPON, BONDING JOINT

BLADE SECTION

FULL-SCALE BLADE

FATIGUE BEHAVIOR OF GLASS/ACRYLIC COMPOSITE COUPON

MANUFACTURING OF THE BLADE ROOT

(CANOE - LACQ)

INFUSION PROCESS STRATEGY FOR THE BLADE ROOT

FATIGUE BEHAVIOR OF METHACRYLATE BONDING THICK JOINT

FATIGUE BEHAVIOR SIMILAR TO EPOXY

7

A SCALE-UP APPROACH TOWARDS FULL-SCALE BLADE:

GLASS FIBER REINFORCED ACRYLIC COMPOSITE COUPON

BLADE SECTION (BLADE ROOT, PULTRUDED CARBON SPAR-CAP)

FULL-SCALE 25M LONG WIND TURBINE BLADE

EFFIWIND PROJECT : GLOBAL APPROACH

BLADE SECTION

FULL-SCALE BLADE

MANUFACTURING OF THE FULL-SCALE 25M LONG WIND TURBINE BLADE BY

INFUSION PROCESS

TEST AT IWES FRAUNHOFER (BREMENHAVEN)

(NATURAL FREQUENCIES, STATIC TEST FOR ULTIMATE LOADS, 2 YEARS EQUIVALENT FLAPWISE FATIGUE TEST, STATIC TEST FOR RESIDUAL STRENGTH/STIFFNESS)

COMPOSITE COUPON, BONDING JOINT

8

TECHNICAL RESULTS :

MANUFACTURING : INFUSION PROCESS OF A LIQUID REACTIVE ACRYLIC RESIN IN COMBINATION

WITH PULTRUDED CARBON SPAR-CAP, ASSEMBLY PROCESS USING A METHACRYLATE BONDING JOINT

DURABILTY : BETTER OFF-AXIS FATIGUE BEHAVIOR AS COMPARED TO THERMOSET RESIN

GL CERTIFICATION : VALIDATION BY FULL-SCALE STATIC AND FATIGUE TESTING

OTHER TECHNOLOGICAL BENEFITS :

WELDING ABILITY OF THERMOPLASTIC ACRYLIC COMPOSITE PARTS

EASIER TO REPAIR AS COMPARED TO THERMOSET RESIN

EFFIWIND PROJECT : RESULTS AND BENEFITS

9

ENERGETIC AND ECONOMIC RESULTS :

CYCLE TIME REDUCTION DUE TO FASTER LIQUID INFUSION PROCESS AND FASTER POLYMERIZATION

RATE AT ROOM TEMPERATURE AS COMPARED TO THERMOSET RESIN

LESS ENERGY CONSUMPTION BY USING NON-HEATED MOLDS AS COMPARED TO THERMOSET RESIN

PRODUCTIVITY INCREASE : USE OF EXTENDED WIND TURBINE BLADE AT CONSTANT WEIGHT (+2M

LONG AS COMPARED TO THE APX48 REFERENCE BLADE) WITH LIMITED OVERLOADING FOR HIGHER

PRODUCTION INCOME (ESTIMATION OF + 10-15% PRODUCTIVITY)

HEALTH & SAFETY, ENVIRONMENTAL BENEFITS

HAZARDOUS-FREE ACRYLIC RESIN (NO STYRENE, NO BPA…)

SAFER TO MACHINE AND TO DRILL AS COMPARED TO THERMOSET RESIN

EASIER TO RECYCLE AND TO REUSE : CHEMICAL RECYCLING (DEPOLYMERIZATION, DISSOLUTION)

INTO RECYCLED PURIFIED MONOMER – REUSE INTO A RECYCLED ACRYLIC RESIN FOR A SECONF LIFE

EFFIWIND PROJECT : RESULTS AND BENEFITS

PILOT CONTINUOUS CARBONIZATION PROCESS LINE AT CANOE LACQ

LOW COST BIO-BASED CARBON FIBER

BEYOND OF EFFIWIND : PERSPECTIVES

CAPACITY : 1-4 /YEAR

= 2500MPa / E = 250GPa

COST OBJECTIVE : 10-12 €/KG

INNOVATIVE SOLUTION :

LOW COST CARBON FABRIC

HYBRID LOW COST CARBON/GLASS FABRIC

PILOT THERMOPLASTIC IMPREGNATION PROCESS LINE AT CANOE LACQ

FIBER-REINFORCED ACRYLIC TAPE

CAPACITY 1000 T/YEAR

TAPE WIDTH : ¼’’, ½’’, 1’’, … 400MM

INNOVATIVE SOLUTION :

CARBON SPAR-CAP

AUTOMATED ACRYLIC TAPE PLACEMENT

ACRYLIC PATCH REPAIR

SENSOR INTEGRATION FOR IN-SITU MONITORING OFTHE MANUFACTURING PROCESS

SENSOR INTEGRATION

INNOVATIVE SOLUTION :

PIEZOELECTRIC FIBER

PIEZORESISTIVE FIBER

OPTICAL FIBER

SENSOR INTEGRATION FOR IN-SERVICE COMPOSITESTRUCTURAL HEALTH MONITORING (MAINTENANCE,DURABILITY)

10

ROBOTIZED ADDITIVE MANUFACTURING

DEVELOPMENT OF ROBOTIZED MANUFACTURING PROCESS FOR LARGE

COMPOSITE PART (CANOE ATELIER 6.4 LACQ)

ROBOT EQUIPPED WITH MULTI END-EFFECTOR

COST-EFFECTIVE PROCESS

NEW DESIGN (HONEYCOMB…)

SENSOR INTEGRATION

POLYMER COMPOUNDINGBY TWIN-SCREW EXTRUDER

ROUTE A : NO ACRYLIC/FIBER SEPARATION

• REUSE OF RECYCLED ACRYLIC/FIBER COMPOSITE INTO THERMOPLASTIC MATRIX (PMMA, ABS)ADDITIVE MANUFACTURING APPLICATION

• REUSE OF RECYCLED ACRYLIC/FIBER COMPOSITE INTO CONCRETE MATERIALSFOUNDATION AND TOWER APPLICATION

SHREDDED ACRYLIC-BASED FIBER-REINFORCED COMPOSITE

SHREDDED ACRYLIC-BASED FIBER-REINFORCED COMPOSITE

BEYOND OF EFFIWIND : RECYCLING PERSPECTIVES

11

• REUSE OF RECYCLED MMA MONOMER INTO ACRYLIC COMPOSITE FORWIND BLADE APPLICATION

FILLERS

N2SHREDDED ACRYLIC-BASED FIBER-REINFORCED COMPOSITE

N2

CONDENSATION UNIT

MONOMER

• REUSE OF RECYCLED CHOPPED FIBER INTO CONCRETE MATERIALS FOR

FOUNDATION, TOWER APPLICATION

ROUTE B : CRACKING BY EXTRUSION

BEYOND OF EFFIWIND : RECYCLING PERSPECTIVES

12

ROUTE B : CRACKING BY EXTRUSION

BEYOND OF EFFIWIND : RECYCLING PERSPECTIVES

13

HIGH-PRESSURE WATER JET CUTTING (ON SITE) 65 PARTS

GRINDING / CRUSHINGDEPOLYMERIZATION

PURIFICATION OF RECYCLED MONOMER

FEW TENS KG OF PURIFIED RECYCLED MONOMER

MANUFACTURING OF FEW TENS KG OF RECYCLED ELIUM ACRYLIC RESIN

INFUSION PROCESS FOR A SECOND LIFE

CANOE

FORMULATION ADJUSTMENT TO REGENERATE ELIUM RESIN

RECYCLED CARBON OR GLASS FABRICS

METHACRYLIC SYRUP FORMULATION INTO THERMOPLASTICSFOR THERMOMOLDED SHEETS

ROUTE C : SEPARATION BY DISSOLUTION

BEYOND OF EFFIWIND : RECYCLING PERSPECTIVES

MAM

MAM + POLYMERS

PULVERIZED MAM

BASKET

ADDITIVES

REGENERATED ELIUM RESIN

WIND TURBINE COMPOSITE PARTS

RECYCLED CARBON OR GLASS FABRICS

APPLICATION :THERMOMOLDED SHEETS

ROUTE C : SEPARATION BY DISSOLUTION

BEYOND OF EFFIWIND : RECYCLING PERSPECTIVES

15

16

ACKNOWLEDGMENTS

THE EFFIWIND CONSORTIUM REALLY THANKS THE NEW-AQUITAINE REGION AND THE ADEME

FOR THEIR TECHNICAL AND ADMINISTRATIVE SUPPORT AND ALSO FOR THE FUNDING AS PART

OF THE PROGRAM "INVESTMENT FOR THE FUTURE"

TECHNOLOGY PLATFORM

"COMPOSITES AND ADVANCED MATERIALS"

THANKS FOR YOUR ATTENTION