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11. July 2019

Covestro: Efficient manufacture of rotor blades with polyurethanes

Covestro announced that power generation from renewable sources is a key part of its sustainability concept and underlines its commitment to achieving the UN Sustainable Development Goals, in particular goal number 7 for renewable energy (UN-SDG 7). This applies above all to wind power, which is one of the most promising renewable energy sources due to its global availability and the technical progress already made, said the company.

Covestro said this is also reflected in the development of wind power capacity, which is seeing double-digit annual growth across the globe. China is the world’s largest wind power market with 221 GW of installed capacity at the end of 2018, according to the World Wind Energy Association.

However, cost-efficient processes for manufacturing wind power plants are in greater demand than ever to enable further expansion and for competing with traditional energy resources. Once in operation, the aim is for turbines to be used over a lengthy period with the lowest possible maintenance requirements.

Together with global industry partners, Covestro has developed a solution for an efficient production of rotor blades for wind power plants (Source: Covestro)

Together with global industry partners, Covestro has developed a solution for an efficient production of rotor blades for wind power plants (Source: Covestro)

In order to meet this challenge, Covestro has joined forces with partners and developed a polyurethane resin and a manufacturing technology, which – in conjunction with glass fibre mats and an efficient production process – enables shorter cycle times. “This is a clear cost advantage for manufacturers,” said Dirk Soontjens, who coordinates the global wind power activities of Covestro. “Its advantage over epoxy resins used so far is that it flows more easily and ensures better wetting of the glass fibre mats used for reinforcement.” The resin also exhibits very good mechanical properties and meets many regulatory and industry performance standards, said the manufacturer.

Only recently, Covestro has processed the first commercial order for utilisation of the PU resin for production of eighteen wind rotor blades with a length of 59.5 meters each, together with the respective spar caps and shear webs, all manufactured by Zhuzhou Times New Material Technology (TMT), one of the largest wind blade manufacturers in China. The blades were delivered to Envision, a global wind turbine technology company, and are scheduled to be installed in a wind farm in Eastern China in July 2019.

Also in Europe, Covestro collaborates with leading players of the wind power industry and intends to commercialise its technology shortly. Besides that, the company operates a new wind power laboratory in Leverkusen, which expands its global lab capacities in Asia and Europe to support customers and innovation.

Furthermore, Covestro said that it has also developed coating solutions with higher cost efficiency. For instance, protective coatings based on Pasquick technology for steel towers as well as gel coatings for blades of wind power plants can significantly increase productivity and ensure a long lasting performance without maintenance. This is due to the fact that the use of Pasquick requires one layer less than conventional corrosion protection and that the coatings have a lower curing time, said the company.

Besides that, waterborne topcoats based on Bayhydur and Bayhydrol provide long-lasting performance with low solvent emissions. Last but not least, Covestro also offers protection for rotor blades based on products of the Desmodur line, providing long lasting protection against abrasion.


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