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Renewable Energy Session

Explore industry-leading protection for wind turbine blades with Belzona products. Learn about testing results, new developments, and case studies showcasing successful applications in the renewable energy sector. Stay ahead in wind energy maintenance and repair.

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Renewable Energy Session

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  1. Renewable Energy Session

  2. Renewable Energy Overview

  3. Renewable Energy Overview Wind Recycling & Biomass Geothermal

  4. Renewable Energy Overview Waste Recycling / Biomass Wind Power Geothermal

  5. Wind Power Industry

  6. Leading Edge Protection • Existing Belzona products used to date • Mostly Successful • Excellent longevity in most instances • Occasionally fast wear rate seen • Feedback from Wind Industry • Colour to match blades • UV resistance • Tested for Rain Erosion resistance After 1 year in high rain

  7. ASTM G73 Liquid Impingement • Industry “benchmark” test • Coated sample on leading edge • of rotating blade • 160 m/s velocity at tip • 90⁰ incidence angle • 3 hour duration

  8. TEST RESULTS - Specimen: Belzona 1341 Erosion occurs primarily at: Duration [hour : min]: 03:00 Root end: X Middle part: X Tip end: X Page 25

  9. Competitor Performance BZ 1341 Specimen: Erosion occurs primarily at: Duration [hour : min]: 03:00 Root end: X Middle part: X Tip end: X Duromar WE-9300 Mankiewicz LEP 9

  10. New Development Product • New product specifically developed for Leading Edge Protection • Goals • Outperform competitor products • No visible damage after 3 hrs rain erosion test • Easier application than competitors • Best competitor 3 coat system • Belzona target 1 coat system

  11. TEST RESULTS LEP 9 Specimen: Erosion occurs primarily at: Duration [hour : min]: 03:00 Root end: X Middle part: X Tip end: X Page 25

  12. TEST RESULTS BZ 2141 Specimen: Erosion occurs primarily at: Duration [hour : min]: 03:00 Root end: X Middle part: X Tip end: X Page 9

  13. Indicative in-house testing; Optimization of PAC10 type coating • Polytech testing time consuming • Need in-house ‘indicative’ test for screening formulations • Belzona 2141 performed very well in rain erosion testing but not U.V. stable • Logical to use CAVITATION testing for screening to optimize PAC10?

  14. Other in-house indicative tests • CAVITATION testing CANNOT be used to predict rain erosion • Need a new test for screening • Currently we are looking at a combination of; • TENSILE STRENGTH and IZOD IMPACT testing • Need to improve on the values exhibited by PAC10 and LEP 9. • Minimum target is no damage in 3 hour rain erosion test • Based on this, we submitted three more candidate formulations for further testing in November

  15. Other in-house indicative tests • GOOD results suggest the new screening method is accurate • Several new formulations produced & submitted for testing in January 2019…

  16. Next Steps • Very Close to Performance Targets! • Optimised formulations to be made and tested within the coming months • Hopeful that one of these will be the final formulation

  17. What now? • Industry expectation extremely high • Existing Belzona coatings not suitable • WAIT for new product before targeting Leading Edge protection • Target other wind opportunities….

  18. Other Wind Opportunities Under Water /Splash Zone (offshore) Mechanical Repairs Base Sealing Concrete Repairs Transformer Leaks

  19. Case Study – Offshore Wind Turbines Problem: On 27 offshore wind turbines, all of them have between one and three hang-off flanges. Option 1: Use of a temporary sealant  Short-term solution Ineffective seal Option 2: Use of Belzona products to seal and protect  Belzona 1161 – (Paste grade) To pack the joint and seal the nuts and bolts (caps filled with the product) Belzona 5831 – (Coating) Applied on the flange for protection and leak prevention  Quick repair / Less downtime  Surface-tolerant products

  20. Case Study – Shaft Rebuilding During Wind Turbine Maintenance Problem: The nacelle had suffered from water ingress. Yaw drive shaft was damaged due to corrosion and wear (lack of lubrification). Belzona solution: Rebuilding with Belzona 1131 using a mould. Self-lubricating properties(low friction surface in the event of lubrication loss) Corrosion resistance / Ideal solution for shaft repair Durable solution  Application still in service since May 2011

  21. Case Study – Wind Turbine Tower Base Sealing Problem: Rain water and moisture infiltration through the turbine base Affect concrete base Propagates cracks and corrosion Option 1: Customer used a protective coating which failed due to UV degradation.  Option 2: Belzona waterproof and weatherproof solution (Belzona 3111 and 3911)Easy to apply / Flexibility Cost-effective / Long Term Solution Micro-porous

  22. Case Study –Oil Leak in Concrete Reservoir in Wind Turbine Tower Problem: Leak on an oil reservoir around a wind turbine tower. Oil loss Concrete loss/damage Option 1: Seal the leaking area with concrete, rebuild damaged are with concrete.  Not feasible according to the customer Option 2: Rebuild and protect with Belzona products Belzona 4141 - (Paste grade) Used to rebuild damaged areas Belzona 1321 – (Coating) Used to seal any leaks Easy concrete repair / Minimal downtime 

  23. Case Study – Oil Leaks onWind Farm Transformer Problem: Oil leaks from flanges and bolts on a wind farm transformer. Option 1: Cover lift of the transformer and fitting a new gasket. Downtime of several weeks  Option 2: Repair on site with Belzona. Stainless steel caps were fitted over the bolts heads and the nuts. Belzona 1161 - (paste grade) - used to fill gaps Belzona 5811 - (coating) - used for protection Belzona solution completed in 5 days.

  24. Wind Energy – Investments • Sales Presentation now available for non-LEP applications

  25. Wind Energy – Investments • Direct Approach to Wind Industry HQs • Most opportunities will be “specification” based • Top down sales approach • Current progress with Orsted

  26. Wind Energy – Investments • Contractor Training Covering highlighted application areas • Practical sessions & demos • “Modular format”, choose relevant applications • Theoretical sessions • Common problems & solutions • Surface preparation • Application standards

  27. Wind Energy – Investments • Attending Wind Europe Bilbao in April 2019 with Rodator

  28. Wind Energy – Investments • LEP product development in progress • Lots of non-LEP opportunities and commercial support • Investment of Belzona in Wind Energy • Contractor training • Head office targeting • Exhibitions

  29. Waste Recycling & Bio fuels

  30. Waste Recycling Processes

  31. Biomass Processes Biofuel Sources & Types • Waste materials, such as used cooking oils • Cleaned and processed to produce biofuels • Broken down or crushed by mechanical means • Processed by “Gasification” or decomposition methods to produce biogas or bio-oils • Broken down or crushed by mechanical means • Pressed to extract oils • Oils refined to produce fuels

  32. Biofuel Energy – Biogas Plants • Over 17,000 Biogas Plants across Europe • Ranging from small to large industrial scale facilities • Often found attached to other types of facilities, such as biorefineries

  33. Biofuel energy - Biorefineries Biorefineries in Europe (2017) List of Facilities w/ location: https://biconsortium.eu/sites/biconsortium.eu/files/downloads/MappingBiorefineriesAppendix_171219.pdf

  34. Waste Recycling & Bio fuels Application Areas • Shaft Repairs • Conveyor repairs • Abrasion resistant systems • Cold bonding • Composite repairs • Pipe Coatings – Internal & External • Linings • Pump repairs • Chocking/Shimming • Concrete repairs – Bunds etc • Roof repairs

  35. Waste Recycling Example Biffa Horsham Waste Recycling plant – North Wales Energy from Waste

  36. Waste Recycling Example • The Process: • Waste delivered to the facility • Shredded before passing over a series of conveyors and other sorting equipment, which separates out biodegradables • Remaining material (mostly paper and plastic) is used to produce Refuse Derived Fuel (RDF) • The biodegradable waste is broken down by anaerobic digestion. This produces two main products: • Biogas • Digestate

  37. Waste Recycling Example • Application on Main sludge Treatment Tank • Corrosion from the internal seams as a result of Microbial attack on the original coating • Required a fast turnaround as fines for dirty water outfall mounting

  38. Waste Recycling Example

  39. Waste Recycling Example • 5 Plate bonding repairs next day Overcoated with Belzona 1321

  40. Existing Case Histories Applications • Biomass/Bioenergy: • https://khia.belzona.com/en/view.aspx?id=7482 • https://khia.belzona.com/en/view.aspx?id=7541 • https://khia.belzona.com/en/view.aspx?id=7486 • Applications at Waste Recycling Plants: • https://khia.belzona.com/en/view.aspx?id=6097https://khia.belzona.com/en/view.aspx?id=6098 • https://khia.belzona.com/en/view.aspx?id=1621 • https://khia.belzona.com/en/view.aspx?id=6407 • https://khia.belzona.com/en/view.aspx?id=1230 • https://khia.belzona.com/en/view.aspx?id=5244 • https://khia.belzona.com/en/view.aspx?id=1141

  41. Waste Recycling & Bio fuels • Complex processes with lots of opportunities • Big potential on lots of territories • Large range of possible applications • Important database on the BEL

  42. Geothermal Energy

  43. GEOTHERMAL POWER Power generated using steam produced by heat coming from the melting center of the earth Belzonasolutions and sales possibilities

  44. Current framework of geothermal production Major producer countries in Europe : Turkey Italy Iceland Butalso : Germany, France, Hungary, Portugal, Austria, Romania, UK

  45. ITALY TUSCANY First geothermal power generator – Larderello / Pisa in 1904 33 geothermalplants 1.8 % of of the total electric energy production in Italy

  46. BELZONA APPLICATIONSBS - Italy CONDENSATE EXTRACTION PUMPS Enel Green Power - renewable energy branch of Enel group - main italian power production company. Condensate extraction pumps : Custom casting items Large scale with internal wet surface from 35 to 45 sqm Placed in underground chambers at 30 m depth

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