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STTR Phase I: Preliminary Design and Manufacturing of Mooring Line Connections for 3D Concrete Printed Floating Wind Turbine Anchors

STTR 第一阶段：3D 混凝土打印浮动风力发电机锚系泊线连接的初步设计和制造

基本信息

批准号：
2112072
负责人：
Jason Cotrell
金额：
$ 25.6万
依托单位：
RCAM TECHNOLOGIES
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2021
资助国家：
美国
起止时间：
2021-06-15 至 2022-12-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=2112072&HistoricalAwards=false
关键词：
STTR Phase Preliminary Design Manufacturing

项目摘要

The broader impact of this Small Technology Transfer Research (STTR) Phase I project opens pathways to large-scale domestic manufacturing of low-cost energy infrastructure needed to facilitate the clean energy transition in the United States. The United States has a vast offshore wind energy resource that is nearly four times the nation's current electricity use. This enormous potential presents an opportunity to deliver clean and reliable electricity to the country’s largest population centers while creating hundreds of thousands of jobs to manufacture and service the wind plants. However, approximately 60% of the offshore wind energy resource is in deep waters that require floating wind turbines moored to seafloor anchors. With an installed cost of approximately $1 M each, lower-cost anchor solutions are needed to accelerate the deployment of wind energy. This Phase I project uses advanced additive manufacturing methods to cut the installed costs of wind turbine anchors. The additive manufacturing technology also has strong future market potential in diverse renewable energy technologies beyond anchors, including fixed-bottom offshore substructures, floating wind platforms, wave energy devices, on-shore wind turbine towers, small hydropower, and pumped hydro electric energy storage. This project combines four cost-reducing innovations to create a low cost additively manufactured anchor that will cut installed anchor costs by up to 80% compared to conventional steel suction anchors – saving approximately $3M per floating wind turbine. The proposed project advances the following innovations: (1) the first-ever application of 3D concrete printing to floating wind turbines, (2) an innovative concrete reinforcement system, (3) integrated buoyancy chambers that aid transport and installation of the anchor, and (4) a new mooring line connection method, the development of which is the primary focus of the project. The project goal is to pave the way for the first-ever seafloor embedment of the innovative concrete anchor by de-risking key aspects of a mooring line connection solution capable of resisting extreme mooring line forces of approximately 1,700 metric tons. The Phase I project scope includes comparison and down-selection of mooring line connection concepts, preliminary design of the selected design, fabrication of a section of the concrete anchor using additive manufacturing at a scale of up to 2.5 meters in diameter, and analysis of the cost effectiveness and production rates of the innovative anchor and additive manufacturing process.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这一小型技术转让研究（STTR）第一阶段项目的更广泛影响为促进美国清洁能源转型所需的低成本能源基础设施的大规模国内制造开辟了道路。美国拥有巨大的海上风能资源，几乎是该国目前用电量的四倍。这一巨大的潜力为该国最大的人口中心提供了清洁可靠的电力，同时为风力发电厂的制造和服务创造了数十万个就业机会。然而，大约60%的海上风能资源位于深水沃茨中，这需要系泊到海底锚的浮式风力涡轮机。由于每个风电场的安装成本约为100万美元，因此需要低成本的锚解决方案来加速风能的部署。该一期项目使用先进的增材制造方法来降低风力涡轮机锚的安装成本。增材制造技术在锚以外的各种可再生能源技术中也具有强大的未来市场潜力，包括固定底部海上子结构，浮动风力平台，波浪能设备，岸上风力涡轮机塔，小水电和抽水蓄能。该项目结合了四项降低成本的创新技术，创造了一种低成本的增材制造锚，与传统的钢制吸力锚相比，它将使安装锚的成本降低高达80%-每个浮动风力涡轮机节省约300万美元。该项目推进了以下创新：（1）首次将3D混凝土打印应用于浮动风力涡轮机，（2）创新的混凝土加固系统，（3）集成浮力室，有助于锚的运输和安装，以及（4）新的系泊线连接方法，其开发是该项目的主要重点。该项目的目标是为创新混凝土锚的首次海底嵌入铺平道路，降低能够抵抗约1，700公吨的极端系泊缆力的系泊缆连接解决方案的关键方面的风险。第一阶段项目范围包括系泊缆连接概念的比较和向下选择，选定设计的初步设计，使用增材制造以直径高达2.5米的规模制造混凝土锚的一部分，以及创新锚和增材制造工艺的成本效益和生产率分析。该奖项反映了NSF的法定使命，并已被视为通过使用基金会的知识价值和更广泛的影响审查标准进行评估，