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    Online Exclusives

    Protective Coatings Leader Hempel Brings Expertise to the Wind Industry

    Protective coatings provide the durability needed to ensure that wind turbines play their part in a sustainable future.

    Protective Coatings Leader Hempel Brings Expertise to the Wind Industry
    Source: Hempel
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    09.22.21
    Renewable energy is becoming increasingly important in our lives. Each of the main types of renewable energy – solar, wind, water and others - have their own unique requirements. In the case of wind power, wind turbines have very specific coating needs, as the turbines need to be protected from harsh environments.

    As one of the world’s leading manufacturers and suppliers of protective coatings, Hempel offers corrosion protection to structures in some of the harshest conditions on the planet.

    “We have been a partner to the wind energy industry since the very beginning and our coatings protect many of the world’s windfarms,” David Heal, global head of renewable energy & performance OEM segments at Hempel, noted.

    Heal pointed out that commercial wind power was pioneered in Denmark in the 1970s and 1980s, and Hempel has been part of its development from the very start.

    “With our headquarters and main R&D center in Copenhagen, we have been in a unique position among coating suppliers, able to immerse ourselves in the wind segment, to understand the needs of our customers and to collaborate with them to develop solutions tailored to the very specific requirements of the industry,” added Heal.

    “This partnership approach continues today and, as the wind industry evolves, we evolve too,” he noted. “We continue to work closely with the key industry players, collaborating on projects to improve efficiency, reduce environmental impact and grow the segment globally.”

    Heal estimates that Hempel’s protective coatings are used on approximately 50% of wind turbines across the globe. There’s more than the blades that need coatings though – Hempel provides coating solutions for the entire wind turbine, including the towers, blades, foundations and nacelles. And there’s more.

    “Asset protection in the wind energy industry isn’t just about the turbine,” Heal observed. “A windfarm is very complex, with a wide range of structures, including substations, buildings and service infrastructure, as well as port equipment and vessels for offshore installations. We provide coatings for all these assets.”

    The wind industry is rapidly growing in size and importance, which Heal noted makes it a very dynamic environment for coatings development.

    “Wind turbine towers, for example, have traditionally been made of steel or concrete,” he added. “However, they are increasingly made from different substrates, including composites. Our experience in other coatings segments, such as the yacht industry, is invaluable in developing coating solutions to protect these substrates from the harsh environment of a working windfarm.

    “The industry is also increasingly global,” Heal continued. “Windfarm projects are often multinational, with different elements constructed in different parts of the world. To ensure consistency in coatings supply and performance, as well as adherence to relevant standards, these projects require a global coatings supplier that understands the complexities and has globally coordinated local teams that can provide products, services and advice, as needed. With our experience and global presence, Hempel is uniquely placed to meet these needs.”

    Key Aspects for Choosing Coatings

    Not surprisingly, durability is the single biggest requirement that customers are looking for in a coating, as windfarms are located in hard-to-access locations, often out at sea or in remote inland areas. The greater the durability, the better.

    “Taking a turbine out of action for repair is extremely costly,” Heal noted. “Therefore, structures in the wind industry are coated to ensure protection against corrosion for the longest possible time. Depending on the environment, a wind turbine is expected to last 25 years – and the coating system should require little or no maintenance during that time. Discussions are now underway to increase this lifetime to 35 years for offshore installations.”

    Heal observed that there is more to “durability” in the wind industry than meets the eye. Downtime is costly, and efficiency is key.

    “The real requirement for wind turbine manufacturers, operators and owners is to find ever-more efficient solutions that bring down the total cost of wind energy per kilowatt hour to become as economically competitive as other energy industries, or more so,” he added. “This means wind turbine manufacturers, operators and owners must increase efficiency across the entire value chain.

    “Durability, therefore, is about extending wind turbine lifetimes and reducing or eliminating maintenance – both of which improve return on investment. At the same time, efficiency gains during application – thanks to the use of lower DFTs, fast-drying systems and easier-to-apply, more tolerant coatings – increase productivity and reduce the production cost per unit. This all brings down the total cost of wind energy per kilowatt hour.”

    Add to this sustainability requirements and standards such as ISO 12944, and choosing the correct coating can be complex.

    “The challenges for onshore and offshore wind turbines also differ, and require specially formulated coating solutions,” Heal said. This is why it’s critical that OEMs work closely with their coatings suppliers to ensure that the most suitable coatings are applied at the point of manufacture. With the right coating applied, application costs and VOC emissions can be reduced during production, and protection against corrosive environments can be provided that will last for the lifetime of the asset.”

    Heal gave two examples of how the right choice of coatings can make a huge difference for wind turbines.

    “A recent inspection was carried out on the Thunoe Knob offshore windfarm outside Aarhus in Denmark, which was coated by Hempel in 1995,” said Heal. “One of the world’s longest serving installations, Thunoe Knob is testament to the importance of using the correct coating system. Four of the 10 turbines were chosen at random and evaluated through visual examination, photographic documentation and dry film measurement. Despite being more than 20 years old at the time, the inspection found that both the interior and exterior coating systems were in good condition and could be expected to remain so for at least another 10 years, demonstrating a practical coating lifetime of more than 30 years.   

    “In the same year, the Horns Rev 1 windfarm, located in the North Sea near the Danish city of Esbjerg, was also inspected. In this hostile location, the environment was classified under the ISO 12944-Part 2 standard as C5 M – a very highly corrosive marine environment with high salinity. Once again four wind turbines were chosen at random and evaluated. The exterior and interior coated surfaces were found to be in prime condition and, from the overall results, it was estimated that the coating system would have a service life of at least 27 years.

    “Both these examples demonstrate that the correct coating system can extend a windfarm’s service life and reduce maintenance, which lowers the overall cost of energy production over the windfarm’s entire lifetime,” Heal concluded.

    Hempel Products for Wind Turbines

    With all of the variety needed for wind turbines, Heal noted that Hempel has bespoke products especially for the wind industry, developed in partnership with leading businesses throughout the wind supply chain.

    These include 4774D, a two-coat wind tower protection system that dries up to 30 percent faster than equivalent three-coat systems. This helps eliminate production bottlenecks, increases throughput and reduces drying hall costs. The two-coat system also means lower VOC emissions and less paint and waste, which all contributes to reducing the overall cost of wind tower production.

    “Since it was first launched in 2008, 4774D has effectively become the industry standard, and today around 80 percent of producers using a two-coat system for wind towers choose Hempel,” said Heal. “The 4774D system has recently been optimised by replacing the existing primer with our industry changing zinc-rich primer, Avantguard. With its unique Triple Activation mechanism and patented Avantguard technology it offers superior corrosion protection.

    “Traditionally, high durability coating systems in the wind industry are based on zinc-rich epoxy primers. However, these coatings are difficult and time-consuming to apply,” Heal added. “This impacts applicator efficiency, resulting in a higher construction cost per unit. Hempel’s Avantguard activated zinc primers overcome these challenges: They have also been proven to deliver the same or better corrosion protection than equivalent zinc-rich epoxies, but are far easier and faster to apply.

    “The superior anti-corrosion performance of Avantguard primers can increase system longevity by up to 50 percent, reducing or eliminating coating maintenance costs and extending asset lifetime,” he noted. “In addition, lower dry film thicknesses are required to deliver the same or higher protection, which means less paint is used. As a result, material costs can be up to 15 percent lower than with systems based on conventional zinc-rich epoxies. At the same time, shorter drying times can reduce application time by as much as 30 percent and better application tolerances improve quality. All this lowers the overall cost per unit, during both construction and operation.”

    Offshore wind foundations hold a different challenge with extremely aggressive conditions in the splash zone (the area that cycles between being submerged and atmospherically exposed due to tides, waves and currents). Heal reported that Hampel’s products for these areas meet the most rigorous NORSOK M501 certification requirements while delivering key attributes that are important to applicators and owners alike.

    “Hempadur 35620 is our solvent-free epoxy system, which provides outstanding corrosion protection but also offers environmental benefits as it is 100% volume solids with almost no volatile organic compounds (VOC),” Heal added. “Hempadur Multi-Strength 45703/45753 is a high solids epoxy system which also provides outstanding corrosion protection and has been applied on over 1 million square metres of offshore structures over the last 20 years. We are continuing to develop new products for all of the wind segments to increase productivity, reduce environmental impact and maximise longevity.”

    Challenges Facing Coatings for the Wind Industry

    The remote location for wind turbines, particularly offshore, is a testing environment for any coating system. Heal noted that as offshore wind technologies developing and wind farms move further out into the oceans from our coastlines, the weather conditions can be more extreme and the access to conduct maintenance becomes more difficult and costly.

    “This in itself demands the most capable and proven products but also can make the introduction of innovative technologies to a conservative market challenging. We are continuing to push this envelope by focusing on developing innovative solutions to drive long term performance whilst optimising process and cost efficiency for the supply chain,” Heal said.

    There is one particular aspect of the wind turbine environment that presents unique challenges to coatings: the leading edge of the turbine blade.

    “A wind turbine will remain in situ for up to 25 years with some parts requiring no maintenance at all,” Heal said. “By comparison, the leading edge can need repair as often as every one to two years as it continuously cuts though rain, salt spray, insects and ice – at speeds up to 600 km per hour. A poor surface on the leading edge can have a huge impact on turbine performance, as airflow is impacted and less energy is created.

    “In addition, maintenance and asset downtime are costly. A high-quality LEP coating therefore is key to windfarm efficiency, in terms of production, maintenance and energy generation. This is why Hempel is developing solutions specifically for blades,” Heal noted.

    Of course, there is much more to consider when specifying coatings in the wind energy industry than the windfarm itself. Like all industries, wind energy is working very hard to improve its overall sustainability. As well as the increased durability offered by a Hempel coating system – which extends asset lifetime and reduces emissions associated with maintenance – wind energy customers are looking to lower VOC emissions during application. Lowering VOC emissions while also maintaining durability is a key technical challenge that we are constantly working on across all our segments, including marine, power generation and infrastructure.

    Lowering VOCs during application can be achieved by adjusting work processes. In relation to this, our technical services have proven invaluable for many customers. We provide a range of Services focused on increasing efficiency during both production and maintenance. These including working with customers to optimise application processes in order to reduce costs, waste and emissions. Our services also help improve application quality, which extends asset uptime and maintenance intervals.

    The Importance of Partnerships

    Heal noted that Hempel recently launched a strategy to double its revenue by 2025, and the company sees partnerships as key to achieving this goal.

    “For years, we’ve earned our customers’ trust by delivering reliable products and services. We’re now taking this to another level by partnering with customers to pioneer new services, digital technologies and products together. We will share knowledge and experiences with our partners as we gain them, and work together to develop new solutions that add deep value to their businesses, in terms of both sustainability and profitability,” Heal added.

    The latest strategic partnership with GRI Renewable Industries is an excellent example. GRI Renewable Industries is a leading manufacturer of towers and flanges for the wind sector and the partnership will strengthen the two companies’ long-term cooperation.

    “The strategic partnership is focused on improving sustainability, reducing costs and prolonging the lifetime of wind towers – for the better of GRI Renewable Industries and the industry as a whole,” said Heal. “The ambition is to reduce surface treatment cost by 10 percent and lower VOC emissions during application by up to 50 percent. Both sides bring unique knowledge and experience to the partnership – not just in technical terms, but also business knowledge.

    “We entered into a similar strategic partnership with Vestas last year, with the ambition of reducing surface treatment costs and developing more sustainable coating solutions,” added Heal. “At the same time, we will help Vestas remain competitive as it delivers on its ambition to become CO2 neutral by 2030.

    “As a part of the partnership, we have identified multiple initiatives that can reduce both CO2 and waste at Vestas’ site in Pueblo, Colorado, which is one of the largest wind tower manufacturing facilities in the world. Here, we will take the first steps in the partnership by collaborating with Vestas to explore new digital solutions. Initial calculations demonstrate the potential to reduce surface treatment costs at the factory, while also cutting CO2 emissions related to surface treatment by around 60 percent (equal to 1,100 tonnes of CO2e per year),” Heal concluded.

    Preparing for the Future

    Ultimately, Hempel wants to shape a brighter future with sustainable coating solutions.

    “This is our goal as a company,” Heal said. “Not just because it’s the right thing to do, but because it makes good business sense and our customers, employees and other stakeholders demand it.

    “Earlier this year, we launched a Futureproof framework, which clearly lays out our positions and ambitions within all aspects of sustainability,” Heal continued. “To name a few, our goals include becoming carbon neutral, achieving zero waste to landfill and helping our customers reduce their CO2e emissions by up to 30 million tons, all by 2025. We have also committed to the Science Based Targets initiative in accordance with the 1.5-degree pathway.”

    According to the International Renewable Energy Agency (IRENA), achieving the Paris Climate Agreement 1.5-degree temperature rise target will require significant acceleration across a range of renewable sectors and technology. To meet 2050 targets, onshore and offshore wind would need to generate more than one-third (35 percent) of total electricity needs worldwide, becoming the prominent generation source. According to the International Energy Agency (IEA), theoretically, there is enough offshore wind resource alone to meet total global electricity demand 18 times over.

    “Harnessing this potential, however, remains a challenge,” Heal observed. “To provide some context, while a smaller share of the wind market, offshore wind today accounts for only 0.3 percent of power generation globally. This is from a total installed capacity of 29GW. Current forecasts, according to the IEA, are for offshore wind capacity to reach 190GW by 2030, and 350 GW by 2040. As the numbers suggest, there is a lot of work to be done. But, as the leading provider of coatings solutions for the wind industry, we’re determined to play our part by helping make renewable energy installations as cost-effective and sustainable as possible.”

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