topic: nmbp-06-2017 type of action: ria...maintenance costs are related to protecting the asset from...

European Commission Research & Innovation - Participant Portal Proposal Submission Forms

of 39H2020-CP-2015-STAGE1.pdf Ver1.00 20160212 Last saved 26/10/2016 16:12:05

Table of contents

Section Title Action

1 General information

2 Participants & contacts

3 Budget

How to fill in the formsThe administrative forms must be filled in for each proposal using the templates available in the submission system. Some data fields in the administrative forms are pre-filled based on the previous steps in the submission wizard.

Horizon 2020Call: H2020-NMBP-2016-2017

(CALL FOR NANOTECHNOLOGIES, ADVANCED MATERIALS, BIOTECHNOLOGY AND PRODUCTION)

Topic: NMBP-06-2017

Type of action: RIA (Research and Innovation action)

Proposal number: 760871-1

Proposal acronym: IDEAL

Deadline Id: H2020-NMBP-2017-two-stage

This proposal version was submitted by Trevor WILLS on 26/10/2016 16:20:13 Brussels Local Time. Issued by the Participant Portal Submission Service.


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Proposal ID 760871-1 Acronym IDEAL

H2020-CP-2015-STAGE1.pdf Ver1.00 20160212 Last saved 26/10/2016 16:12:05

1 - General information

Topic NMBP-06-2017

Call Identifier H2020-NMBP-2016-2017

Type of Action RIA

Deadline Id H2020-NMBP-2017-two-stage

Acronym IDEAL

Proposal title* Increased Durability and Enhancement in Assets Lifetime

Note that for technical reasons, the following characters are not accepted in the Proposal Title and will be removed: < > " &

Duration in months 36

Fixed keyword 1 Add Structural properties of materials

Free keywords adhesion, anti-corrosion performance, mechanical robustness, UV-durability, durability, LCA, modelling, coating, on-line monitoring techniques, asset, nano-materials

Abstract

In the Oil & Gas industry over €1.2 billion is annually spent mitigating the effects of corrosion and 60% of offshore maintenance costs are related to protecting the asset from corrosion. However, improving the anti-corrosion performance of the coating system alone is not enough. Coatings must be able to: remain well-adhered to the metal surface, tolerate significant mechanical impingement and not degrade. Thus, the objective of IDEAL is to develop and demonstrate an innovative coating system for powder and wet paint application, with superior performance to protect assets in extreme environments. The coating system, using an integrated technology approach, will offer superior durability reflected in the 4 key properties: adhesion, anti-corrosion performance, mechanical robustness and UV-durability, whilst maintaining all other performance properties. Coating system performance will be modelled using newly developed predictive tools and measured using both laboratory and field performance monitoring techniques. This real-time virtual testing platform will guide the development, allow quantification of the performance improvement, lead to a more accurate prediction of coating lifetime and reinforce the ability to remove the need of predictive maintenance, which will result in a decrease of the total cost. Furthermore, this project will help Europe to compete better, to extend its technical leadership to win a share of the market growth in Asia. The IDEAL consortium is ideally suited for this development as partners are involved within a broad range of expertise: from experts in developing materials with enhanced properties (Evonik, Olin, University of Manchester (awarded with the Nobel Prize for Physics, 2010), OCAS, University of Sheffield and Arkema), over state of the art coating formulators (AkzoNobel) to specialists in computational modelling (VUB, VTT and MPIE) and on-line monitoring techniques (Rising Blue Star of the Year Zensor).

Remaining characters 28



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Has this proposal (or a very similar one) been submitted in the past 2 years in response to a call for proposals under the 7th Framework Programme, Horizon 2020 or any other EU programme(s)? Yes No

Please give the proposal reference or contract number.

685744-1



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Declarations

1) The coordinator declares to have the explicit consent of all applicants on their participation and on the content of this proposal.

2) The information contained in this proposal is correct and complete.

3) This proposal complies with ethical principles (including the highest standards of research integrity — as set out, for instance, in the European Code of Conduct for Research Integrity — and including, in particular, avoiding fabrication, falsification, plagiarism or other research misconduct).

4) The coordinator confirms:

- to have carried out the self-check of the financial capacity of the organisation on http://ec.europa.eu/research/participants/portal/desktop/en/organisations/lfv.html or to be covered by a financial viability check in an EU project for the last closed financial year. Where the result was “weak” or “insufficient”, the coordinator confirms being aware of the measures that may be imposed in accordance with the H2020 Grants Manual (Chapter on Financial capacity check); or

- is exempt from the financial capacity check being a public body including international organisations, higher or secondary education establishment or a legal entity, whose viability is guaranteed by a Member State or associated country, as defined in the H2020 Grants Manual (Chapter on Financial capacity check); or

- as sole participant in the proposal is exempt from the financial capacity check.

5) The coordinator hereby declares that each applicant has confirmed:

- they are fully eligible in accordance with the criteria set out in the specific call for proposals; and

- they have the financial and operational capacity to carry out the proposed action.

The coordinator is only responsible for the correctness of the information relating to his/her own organisation. Each applicant remains responsible for the correctness of the information related to him/her and declared above. Where the proposal to be retained for EU funding, the coordinator and each beneficiary applicant will be required to present a formal declaration in this respect.

According to Article 131 of the Financial Regulation of 25 October 2012 on the financial rules applicable to the general budget of the Union (Official Journal L 298 of 26.10.2012, p. 1) and Article 145 of its Rules of Application (Official Journal L 362, 31.12.2012, p.1) applicants found guilty of misrepresentation may be subject to administrative and financial penalties under certain conditions.

Personal data protection

Your reply to the grant application will involve the recording and processing of personal data (such as your name, address and CV), which will be processed pursuant to Regulation (EC) No 45/2001 on the protection of individuals with regard to the processing of personal data by the Community institutions and bodies and on the free movement of such data. Unless indicated otherwise, your replies to the questions in this form and any personal data requested are required to assess your grant application in accordance with the specifications of the call for proposals and will be processed solely for that purpose. Details concerning the processing of your personal data are available on the privacy statement. Applicants may lodge a complaint about the processing of their personal data with the European Data Protection Supervisor at any time. Your personal data may be registered in the Early Warning System (EWS) only or both in the EWS and Central Exclusion Database (CED) by the Accounting Officer of the Commission, should you be in one of the situations mentioned in: -the Commission Decision 2008/969 of 16.12.2008 on the Early Warning System (for more information see the Privacy Statement), or -the Commission Regulation 2008/1302 of 17.12.2008 on the Central Exclusion Database (for more information see the Privacy Statement) .



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List of participants# Participant Legal Name Country

1 INTERNATIONAL PAINT LIMITED United Kingdom

2 MAX PLANCK INSTITUT FUR EISENFORSCHUNG GMBH Germany

3 THE UNIVERSITY OF MANCHESTER United Kingdom

4 THE UNIVERSITY OF SHEFFIELD United Kingdom

5 VRIJE UNIVERSITEIT BRUSSEL Belgium

6 Zensor Belgium

7 Evonik Resource Efficiency GmbH Germany

8 ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL NV Belgium

9 Teknologian tutkimuskeskus VTT Oy Finland

10 ARKEMA QUIMICA S.A. Spain

11 Blue Cube Germany Assets GmbH & Co. KG Germany

Please provide the complete list of participants to the project and ensure that the eligibility conditions on the composition of the consortium are complied with. Although successful proposals invited to submit a full proposal for the second stage will be allowed to add partners, this may not have the effect of fundamentally altering the proposal submitted for the first stage. By the complete list of participants, it will be possible to streamline the evaluation process with faster checks for eligibility, and more efficient selection of expert evaluators. The list of participants is pre-filled based on the information given on Step 4 of the application. To add more partners, please save and close the form and go back to Step 4.



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Short name INTERNATIONAL PAINT LIMITED

2 - Administrative data of participating organisations

2 - Administrative data of participating organisationsPIC998482984

Legal nameINTERNATIONAL PAINT LIMITED

Short name: INTERNATIONAL PAINT LIMITED Address of the organisation

Town LONDON

Postcode SW1E 5BG

Street BRESSENDEN PLACE 26TH FLOOR PORT

Country United Kingdom

Webpage

Legal Status of your organisation

Research and Innovation legal statuses

Public body .................................................... no Legal person .............................. yes

Non-profit ...................................................... unknown

International organisation .................................. unknown

International organisation of European interest ...... unknown

Secondary or Higher education establishment ....... unknown

Research organisation ..................................... unknown

SME self-declared status................................... unknown

SME self-assessment ...................................... unknown

SME validation sme.......................................... unknown

Based on the above details of the Beneficiary Registry the organisation is not an SME (small- and medium-sized enterprise) for the call.

NACE Code: 22 - Manufacture of rubber and plastics products

Enterprise Data



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Department(s) carrying out the proposed work

Department name AkzoNobel Performance Coatings

Street Stoneygate Lane

Town Tyne & Wear

Same as organisation address

Department 1

not applicable


Postcode NE10 0JY

Dependencies with other proposal participants

Character of dependence Participant



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Person in charge of the proposal

The name and e-mail of contact persons are read-only in the administrative form, only additional details can be edited here. To give access rights and basic contact details of contact persons, please go back to Step 4 of the submission wizard and save the changes.

Town Tyne & Wear Post code NE10 0JY

Street Stoneygate Lane

Website www.akzonobel.com

First name Trevor Last name WILLS

E-Mail [email protected]

Position in org. Technology Leader Performance Coatings Research

Department AkzoNobel Performance Coatings

Phone 2 +xxx xxxxxxxxx Fax +44 191 7383208

Sex Male FemaleTitle Dr.



Same as organisation

Phone 1 +44 191 4012430



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Short name MPIE


Legal nameMAX PLANCK INSTITUT FUR EISENFORSCHUNG GMBH

Short name: MPIE Address of the organisation

Town DUSSELDORF

Postcode 40237

Street MAX PLANCK STRASSE 1

Country Germany

Webpage http://www.mpie.de




Non-profit ...................................................... yes

International organisation .................................. no

International organisation of European interest ...... no

Secondary or Higher education establishment ....... no

Research organisation ..................................... yes

SME self-declared status................................... 2007 - no


SME validation sme.......................................... 2007 - no


NACE Code: 721 - Research and experimental development on natural sciences and engineering

Enterprise Data



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Short name MPIE


Department name Interface Chemistry and Surface Engineering


Town DUSSELDORF


Department 1

not applicable

Country Germany

Postcode 40237





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Short name MPIE



Town DUSSELDORF Post code 40237


Website http://www.mpie.de/InterfaceChemistry

First name Michael Last name Rohwerder


Position in org. Head of Research group

Department Interface Chemistry and Surface Engineering

Phone 2 +xxx xxxxxxxxx Fax +xxx xxxxxxxxx



Country Germany


Phone 1 +492116792442



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Short name UNIVERSITY OF MANCHESTER


Legal nameTHE UNIVERSITY OF MANCHESTER

Short name: UNIVERSITY OF MANCHESTER Address of the organisation

Town MANCHESTER

Postcode M13 9PL

Street OXFORD ROAD UNIVERSITY OF MANCHEST


Webpage www.manchester.ac.uk



Public body .................................................... yes Legal person .............................. yes

Non-profit ...................................................... yes



Secondary or Higher education establishment ....... yes



SME self-assessment ...................................... 2015 - no



NACE Code: 853 - Higher education

Enterprise Data



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Department name Chemical Engineering & Analytical Science

Street OXFORD ROAD UNIVERSITY OF MANCHESTER OFF

Town MANCHESTER


Department 1

not applicable


Postcode M13 9PL





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Town MANCHESTER Post code M13 9PL

Street OXFORD ROAD UNIVERSITY OF MANCHESTER OFFICE OF DIRECTOR

Website http://www.ceas.manchester.ac.uk/

First name Rahul Last name Raveendran nair


Position in org. Professor of Materials Physics

Department Chemical Engineering & Analytical Science


Sex Male FemaleTitle Prof.




Phone 1 +441613066574

Other contact persons

First Name Last Name E-mail Phone

Amanda Pixton [email protected] +441612758372

Liz Fay [email protected] +441612757114



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Short name USFD


Legal nameTHE UNIVERSITY OF SHEFFIELD

Short name: USFD Address of the organisation

Town SHEFFIELD

Postcode S10 2TN

Street FIRTH COURT WESTERN BANK


Webpage www.shef.ac.uk




Non-profit ...................................................... yes




Research organisation ..................................... no



SME validation sme.......................................... 2007 - no


NACE Code: - - Not applicable

Enterprise Data



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Short name USFD


Department name Mechanical Engineering

Street Mappin Street

Town Sheffield


Department 1

not applicable


Postcode S3 7HQ





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Short name USFD



Town Sheffield Post code S3 7HQ

Street Mappin Street

Website https://www.sheffield.ac.uk/mecheng

First name Patrick Last name Fairclough


Position in org. Professor Mechanical Engineering

Department Mechanical Engineering

Phone 2 +xxx xxxxxxxxx Fax +44 (0) 114 222 7890





Phone 1 +44 (0) 114 222 7798



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Short name VUB


Legal nameVRIJE UNIVERSITEIT BRUSSEL

Short name: VUB Address of the organisation

Town BRUSSEL

Postcode 1050

Street PLEINLAAN 2

Country Belgium

Webpage www.vub.ac.be




Non-profit ...................................................... yes









NACE Code: 853 - Higher education

Enterprise Data



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Short name VUB


Department name Department of Materials and Chemistry

Street PLEINLAAN 2

Town BRUSSEL


Department 1

not applicable

Country Belgium

Postcode 1050





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Short name VUB



Town BRUSSEL Post code 1050

Street PLEINLAAN 2

Website https://www.surfgroup.be/

First name Herman Last name Terryn


Position in org. Reseracher

Department Department of Materials and Chemistry




Country Belgium


Phone 1 +3226293537



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Short name Zensor


Legal nameZensor

Short name: Zensor Address of the organisation

Town Brussels

Postcode 1040

Street Witte Patersstraat 4

Country Belgium

Webpage www.zensor.be




Non-profit ...................................................... no




Research organisation ..................................... no

SME self-declared status................................... 2013 - yes

SME self-assessment ...................................... 2013 - yes


Based on the above details of the Beneficiary Registry the organisation is an SME (small- and medium-sized enterprise) for the call.

NACE Code: -

Enterprise Data



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Short name Zensor


Department name

Street Please enter street name and number.

Town


No departement involved

not applicable

Country

Postcode





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Short name Zensor



Town Brussels Post code 1040

Street Witte Patersstraat 4

Website http://zensor.be/

First name Yves Last name Van Ingelgem


Position in org. CEO

Department Zensor




Country Belgium


Phone 1 +32 473 35 89 74



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Short name Evonik Resource Efficiency GmbH


Legal nameEvonik Resource Efficiency GmbH

Short name: Evonik Resource Efficiency GmbH Address of the organisation

Town Essen

Postcode 45127

Street Goldschmidtstraße 100

Country Germany

Webpage www.evonik.de



Public body .................................................... unknown Legal person .............................. yes










NACE Code: -

Enterprise Data



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Department name Evonik Resource Efficiency GmbH


Town Essen


Department 1

not applicable

Country Germany

Postcode 45127





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Town Essen Post code 45127


Website www.evonik.com

First name Michael Last name Fiedel


Position in org. Director R&D Synthesis Additives & Speciality Binders

Department Evonik Resource Efficiency GmbH




Country Germany


Phone 1 +49 201 173 2276



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Short name OCAS


Legal nameONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL NV

Short name: OCAS Address of the organisation

Town ZELZATE

Postcode 9060

Street PRESIDENT JF KENNEDYLAAN 3

Country Belgium

Webpage WWW.OCAS.BE














Enterprise Data



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Short name OCAS


Department name Surfaces


Town ZELZATE


Department 1

not applicable

Country Belgium

Postcode 9060





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Short name OCAS



Town ZELZATE Post code 9060


Website http://www.ocas.be/

First name Krista Last name Van den Bergh


Position in org. Senior Project Engineer Surfaces

Department Surfaces




Country Belgium


Phone 1 +32477026018



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Short name VTT


Legal nameTeknologian tutkimuskeskus VTT Oy

Short name: VTT Address of the organisation

Town Espoo

Postcode 02150

Street VUORIMIEHENTIE 3

Country Finland

Webpage www.vtt.fi




Non-profit ...................................................... yes










Enterprise Data



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Short name VTT


Department name Materials and Manufacturing

Street Kivimiehentie 3 (PO Box 1000)

Town Espoo


Department 1

not applicable

Country Finland

Postcode 02044 VTT





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Short name VTT



Town Espoo Post code 02044 VTT

Street Kivimiehentie 3 (PO Box 1000)

Website http://www.vttresearch.com/

First name Anssi Last name Laukkanen


Position in org. Principal Scientist

Department Smart industry and energy systems




Country Finland


Phone 1 +358408208039

Other contact persons

First Name Last Name E-mail Phone

Irina Granfors [email protected] +358503058009



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Short name ARKEMA QUIMICA S.A.


Legal nameARKEMA QUIMICA S.A.

Short name: ARKEMA QUIMICA S.A. Address of the organisation

Town SANT CELONI

Postcode 08470

Street CTRA OLZINELLES S/N

Country Spain

Webpage













NACE Code: -

Enterprise Data



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Department name Powder Coatings Laboratory


Town SANT CELONI


Department 1

not applicable

Country Spain

Postcode 08470





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Town SANT CELONI Post code 08470


Website www.arkema.com

First name Antoni Last name Nogues


Position in org. Technical Director EMEA

Department Powder Coatings Laboratory


Sex Male FemaleTitle Mr.


Country Spain


Phone 1 0034938484168



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Short name Olin


Legal nameBlue Cube Germany Assets GmbH & Co. KG

Short name: Olin Address of the organisation

Town Stade

Postcode 21683

Street Bützflether Sand 2

Country Germany

Webpage https://www.olinepoxy.com/













NACE Code: -

Enterprise Data



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Short name Olin


Department name Olin Epoxy

Street Schemmerberger Str. 39

Town Mietingen-Baltringen


Department 1

not applicable

Country Germany

Postcode 88487





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Short name Olin



Town Mietingen-Baltringen Post code 88487

Street Schemmerberger Str. 39

Website www.olin.com

First name Markus Last name Schroetz


Position in org. Technology Manager

Department Tech. Service and development




Country Germany


Phone 1 00497356935571



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Acronym IDEAL


Proposal ID 760871-1

3 - Budget for the proposal

Total requested EU contribution for the proposal/ € 6 000 000


IDEAL - Page 1 of 10

Horizon 2020

First stage proposal

for Call: NMBP-06-2017

Research and Innovation actions – stage 1

Improved Durability and Enhancement of Asset Lifetime

IDEAL List of participants

Participant No Participant organisation name Country

1 (coordinator) AkzoNobel UK

2 Evonik Germany

3 Olin Germany

4 Arkema Spain

5 OCAS Belgium

6 Max-Planck-Institut für Eisenforschung GmbH Germany

7 Vrije Universiteit Brussel Belgium

8 Zensor Belgium

9 The University of Manchester UK

10 The University of Sheffield UK

11 VTT, Technical Research Centre of Finland Finland

Table of contents Section 1. Excellence ................................................................................................................................................................ 2

1.1 Objectives ......................................................................................................................................................... 2 1.2 Relation to the work programme ....................................................................................................................... 2 1.3 Concept and methodology ................................................................................................................................ 3

1.3.1 Overall concept ......................................................................................................................................................... 3 1.3.2 Positioning of the project ........................................................................................................................................... 5 1.3.3 Relation to national or international research and innovation activities ..................................................................... 5 1.3.4 Methodology ............................................................................................................................................................. 5

1.4 Ambition ............................................................................................................................................................ 8 1.4.1 Progress beyond the state-of-the-art and innovation potential ................................................................................. 8 1.4.2 Freedom to operate and patent status ...................................................................................................................... 9

Section 2. Impact ....................................................................................................................................................................... 9 2.1 Expected impacts .............................................................................................................................................. 9



Section 1. Excellence

1.1 Objectives

The overall objective is to develop and demonstrate an innovative coating system for both powder and wet paint application, with superior overall performance to protect assets in extreme environments (C5M and C5I) by means of the effective combined integration of novel technologies. The coating system demonstrated will provide a significant improvement in durability reflected in the following 4 key properties: adhesion, anti-corrosion performance, mechanical robustness, and UV-durability, whilst maintaining other relevant coating performance properties (e.g. pot-life, shelf-life, etc.). The performance of these coating systems will be modelled using newly developed predictive tools and measured using both laboratory and field performance monitoring techniques. This innovative coating system will significantly reduce overall life time costs, due to extended maintenance intervals as well as enhancement of the overall assets lifetime.

The objectives can be classified according to 3 blocks of development and/or demonstration (1) the coating system (coating/interface/metal), (2) the supporting modelling tools and (3) LCA and cost-benefit analysis. Commercial coatings on a bare steel plate will be used as reference where relevant:

- minimum 30% improvement in durability of the coating system due to the combined effect of the 4 key properties

o minimum 30% adhesion improvement compared to that of the Intergard 345 (wet paint coating system) and Interpon

PZ790 (powder coating system)

o anti-corrosion performance: minimum 50% improvement in impermeability to aggressive species compared to that

of the Intergard 403 (wet paint coating system) and Interpon PZ790.

o minimum 20% increase in mechanical robustness (i.e. tensile and fracture toughness) compared to that of the

Intergard 403 and the Interpon PZ790.

o minimum 20% improvement in UV-durability compared to that of the Interfine 979 (wet paint coating system) and

Interpon D2525 (powder coating system)

- the coating system is applied by conventional techniques.

- increased performance in the 4 key properties whilst maintaining other performance properties such as pot-life, shelf-life,

cure speed and colour retention.

- an integrated simulation of corrosion, adhesion and mechanical phenomena as a real-time virtual testing platform to guide

the development of new coating system and quantification of the performance improvement

- positive LCA balance and demonstrated cost-benefit of the developed coating system by M36.

IDEAL features: the use of an integrated approach in order to develop and demonstrate a coating system with superior durability

by a combined improvement in the 4 key performance properties. Furthermore, the development of a real-time virtual testing

platform will: guide the development of the new coating system, allow quantification of the performance improvement, lead to a

more accurate prediction of coating lifetime and further reinforce the ability to remove the need of predictive maintenance.

1.2 Relation to the work programme

Durability evaluated theoretically

and in real installation conditions

The durability of the developed system will be evaluated through the theoretical simulation of the anti-corrosion performance, adhesion and mechanical robustness in the real-time developed testing platform. In addition, the durability will be evaluated during the demonstrations on the selected assets (chemical plant, offshore windfarm, oil platform and onshore building located in a highly corrosive environment).

Reduction of overall lifetime

costs/ reduction of costs during

production and installation

The innovative coating system will significantly reduce overall life time costs, due to extended maintenance intervals (from 5 to 10 years) and enhancement of the overall asset lifetime as a result of the overall superior performance of the coating system. In addition, during the course of the project a cost-benefit analysis will guide the selection of technologies and materials to ensure that the developed coating system is not prohibitively expensive. Furthermore, the compatibility with conventional techniques will be evaluated to ensure ultimate cost-effective coating of assets.

Material appropriate for end of life

reuse/recycling

A key consideration during the LCA is the impact of materials choice on reuse/ recycling. The assessment will identify materials of concern and guide the development towards materials appropriate for end of life reuse/recycling, but ensuring that the material has no significant impact on the key properties of the coating system.



Suitable for applications requiring

excellent long term durability and

high reliability

The developed coating system will be suitable for application on onshore and offshore assets in extreme environments, classified as C5M and C5I. The harshness of these environments demand high reliable solutions.

Theoretical understanding of the

factors which affect durability of

materials, including corrosion and

ageing phenomena

The integrated simulation approach combining corrosion simulation with mechanical/adhesion simulation, and setting up screening methodologies for adhesion promoters with the use of buried interface characterisation will allow the IDEAL partners to gain key knowledge on the mechanisms responsible for delamination, corrosion, mechanical robustness and ageing e.g. UV-durability. This will have a significant contribution to overall coating system performance.

Experimental methods to measure and reliably test durability

Experimental methods will be used to evaluate the 4 key performance properties: adhesion (pull off dolly testing, etc.), anti-corrosion performance (Electrochemical impedance, Scanning Kelvin Probe, permeation measurements, exposure to accelerated test chambers, resistance to cathode delamination, etc.), mechanical robustness (tensile testing, fracture toughness, impact testing, abrasion testing, etc.) and UV-durability (weathering chambers and exposure at locations in Florida and Arizona). In addition, ORP-EIS will be used to give insight in the transport processes and the Scanning Kelvin probe technology will be used to study the buried corroding interface. The Zensor PermaZen concept will be used to perform in-line monitoring of the coating performance on the asset.

Non-destructive inspection

procedures and monitoring tools

The Zensor PhermaZen in-line monitoring tool will allow owners/operators of offshore assets to perform a non-destructive inspection. The automated, sensor-based detection also gives access to solid quantified information, removing the need for potentially dangerous or inefficient inspection campaigns.

Development of new and more

durable materials (possibly

multifunctional)

In order to develop the coating system with superior overall performance, technologies were selected which will be further modified into durable materials in order to increase the overall durability with at least 30%.

“fit for purpose” validation of new

materials through testing in the

planned application and

environment

During the third project year, the developed coating system will be demonstrated and validated on a number of offshore and onshore applications: the chemical plant of AkzoNobel in Delfzijl (the Nederlands); the offshore windfarm of Eneco in Luchterduinen (North Sea); an AkzoNobel customer-owned oil platform; and the onshore AkzoNobel Felling Site (UK) located in a highly corrosive environment.

Life cycle assessment analysis During the course of the project a LCA analysis will be performed on the developed coating system itself and when applied on the asset.

Proof of concept, but convincingly

demonstrating scalability towards

industrial needs

This will be addressed by the demonstration of the developed coating system in numerous industrially relevant environments.

1.3 Concept and methodology

1.3.1 Overall concept The cost of corrosion has globally been estimated at over two trillion US Dollars1 and the replacement of corroded steel accounts for over 40% of the annual global production. In the Oil & Gas industry alone over €1.2 billion2 is spent annually mitigating the effects of corrosion and 60% of offshore maintenance costs are related to protecting the asset from the effects of corrosion. Whilst the costs of offshore maintenance are significantly higher than those for onshore structures due to the extreme conditions (C5M3) faced, the latter are also often subjected to highly corrosive conditions (C5I3), and proper protection must also be afforded to these assets – these include chemical production plants, pipes, bridges, and buildings close to the coast. However, improving the anti-corrosion performance of the coating system alone is not enough. The coating must be able to: remain well-adhered to the metal surface, tolerate less than ideally prepared surfaces or to a range of pre-treatments, tolerate significant mechanical impingement and not degrade due to factors such as UV-radiation or suffer from the effects of long-term fatigue. Problems involved in controlling corrosion on offshore oil platforms and infrastructure (wind farms and coastal buildings)4 are:

- factors related to the asset: type, susceptibility to corrosion, shape complexity e.g. curved surfaces, edges, corners and crevices; and surface preparation e.g. roughness, cleanliness (dirt, oil, grease, rust, etc.);

- environmental and operating conditions: degree of exposure to harsh conditions e.g. temperature, corrosive liquids and gases; - consumer specific attributes: cost, colour and ease of application, durability requirements, length warranties, lower

maintenance requirement, increased efficiency for the customer, lower VOCs, reduced energy use and improved hygiene.

1 “The Markets: Corrosion-resistance (2014)”, Composites World, 1st January 2014 2 NACE International, see for example http://www.nace.org/Corrosion-Central/Industries/Oil---Gas-Production/ 3 ISO 12944 Classifications – see for example http://www.international-pc.com/markets/infrastructure/Documents/iso-12944.pdf 4 Features: Corrosion Control, Coatings World February 24th 2015


http://www.nace.org/Corrosion-Central/Industries/Oil---Gas-Production/

http://www.coatingsworld.com/issues/2016-02-01/view_features/corrosion-control


In order to achieve the required increase in durability, an integrated approach will be undertaken to improve the 4 key properties affecting the ability of a coating system to protect the asset: adhesion, anti-corrosion performance, mechanical robustness and UV-durability. Six novel technologies were evaluated for their potential contribution to enhancing coating performance. These selected technologies are currently validated in the lab (TRL4) and within the framework of this project, will be further developed, validated and demonstrated in function of the anticipated coating system for application on assets in extreme environments (C5M and C5I). The methodology that will be employed in this project begins with an individual evaluation of each selected technology in a single coating formulation. In function of the results, various formulations will then be developed incorporating several technologies in coating system with the purpose to demonstrate significantly enhanced performance of the 4 key properties.

Adhesion As a first step towards developing an innovative coating system with superior performance, focus will primarily be paid to adhesion. This is considered the most technically challenging property and good adhesion is fundamental to increasing anti-corrosion performance and mechanical robustness. In order to improve the adhesion properties Evoniks’ state of the art technology based on the incorporation of catechol moieties into coating resins will be further developed and modified in light of the intended coating. The technology will make use of a mussel’s adhesive ability as an archetype for the development. The consortium will also invest in further modification of the conventional epoxy resins by improving the coatings flexibility in order to reduce internal stress causing better adhesion (and increased anti-corrosion performance). As starting point, Olin’s new epoxy resin with improved adhesion by modification of the epoxy backbone will be used.

Anti-corrosion performance In order to enhance the anti-corrosion performance, the incorporation of impermeable graphene technology and the use of metallic coatings will be further examined. To date, the prospect of realistic application using graphene-based coatings has been limited due to the difficulty in growing large and high quality graphene films. However, researchers at the “Home of Graphene” lab at the University of Manchester have recently demonstrated a potential solution to this problem by using multilayer graphite films made by gentle chemical reduction of graphene oxide laminates with hydriodic and ascorbic acids. This results in good adhesion and mechanical robustness. Next to the protective coating system itself, the steel grade and surface preparation of the asset will strongly influence the anti-corrosion performance. This lab builds on their previous work which won them the Nobel Prize for Physics in 20105. Therefore, the consortium will also focus on the application of an additional metallic alloys (i.e. Zn, Zn Al and Zn Al Mg) in order to improve the corrosion resistance of carbon steel in saline environments. OCAS has already developed a range of performance-enhancing solutions, such as pre-treatments and post-treatments, to improve the steel/metallic coating/coating interface. These solutions will be further modified in function of the potential incorporation in the coating system.

Mechanical robustness To address the mechanical robustness associated with performance coatings the inclusion of nanomaterials and the modification of epoxy resins will be considered. The University of Sheffield has recently showed that the inclusion of clay, carbon nanomaterials and (branched, hyperbranched or block) copolymers into coating materials can significantly increase mechanical robustness. Therefore, in order to improve the mechanical robustness of the coating systems, this range of technologies will be further studied and modified. Also, Olin’s epoxy resin with improved adhesion with epoxy backbone modification and incorporation of nanoparticles will be studied as this resin shows, next to an increase in adhesion, an improvement in mechanical robustness.

UV-durability The UV-durability will be addressed by introducing polyester and polyamide resins. The epoxy resins used to date only provide a limited weathering resistance to the coating system as they are not resistant to UV-radiation. The proposed alternative technology of Arkema is based on the well-recognised better exterior exposure resistance of polyester and polyamide resins. These newly developed resins show a very strong adhesion to difficult substrates and will be further modified during the course of this project in order to increase the UV-durability of the coating system.

A combination of the above described most effective technologies will be incorporated into a single coating system in order to significantly enhance the 4 key properties as well as to study synergistic effects. AkzoNobel will employ appropriate designs of experiments to examine the variations in technology combinations, individual concentrations and relative proportions, etc. In order to identify the best performing coating formulation using the relevant commercial coating as a reference, extensive laboratory characterisation and fitness for purpose testing will be executed. Subsequently, the best performing coating systems will be demonstrated on a number of assets in extreme environments.

In addition, the newly developed coating systems will be characterised and modelled under lab conditions as well as in the field in order to gain knowledge on the long-term durability. Therefore, an integrated simulation approach combining VUB’s corrosion simulation, VTT’s mechanical/adhesion simulation, VUB’s fast screening methodologies for adhesion and MPIE’s buried interface characterisation will be used.

5 http://www.graphene.manchester.ac.uk/explore/the-story-of-graphene/2010-nobel-prize/



A key part of the proposal is demonstrating the performance of the coating system in the field, particularly on a chemical plant, an offshore windfarm, an oil platform and onshore building located in a highly corrosive environment, in order to gather key performance information that can be used for further improvement of the coating system, as well as for further optimisation of the predictive modelling tools. Measuring the performance of the coating system in the field will be carried out using the “Rising Blue Star of the Year”6 awarded condition monitoring system of Zensor.

In order to address the 30% cost reduction and a positive LCA balance over the whole life cycle, the AkzoNobel’s Planet Possible philosophy will be applied. This philosophy comprises the continuous improvement throughout the entire value chain. One of AkzoNobel’s latest commitments is to reduce the cradle-to-grave carbon footprint of their products by more than 25% by 2020 (compared with 2012). This means that AkzoNobel’s efforts will also help to create sustainable benefits for their customers: by increased energy efficiency, reduced material losses or improved productivity.

1.3.2 Positioning of the project Technologies for further investigation have already been validated in the lab (TRL4). A combination of the most effective technologies will be formulated into a single coating system and validated under lab conditions, mimicking the real conditions (TRL5). Subsequently, the most promising coating systems will be demonstrated by application on specific assets in C5M and C5I environments (TRL6).

1.3.3 Relation to national or international research and innovation activities Some of the technologies/models/measuring techniques used during this project are linked with other national and EU-projects:

Coating formulation - SEAFRONT: Innovative coating materials for maritime applications

- SUSTICOAT: Sustainable Organic Coatings for Corrosion Protection - MOMIC: Migration of Molecules in Coatings

Multiscale materials mechanical/adhesion simulation

- DIGPOL: development of multiscale modelling approaches for design of nanocomposites

- FUNMODE: development of integrated computational materials engineering solutions for composites

Multi-Ion Transport and Reaction Model (MITReM)

- SICOM: Simulation-based corrosion management for aircraft - CopPer: Copper interconnect for advanced performance and ability - AtCorAS: Dedicated models for atmospheric corrosion linked with changing

electrolyte - SISET: models for flow in presence of naturel convection and vibrating

electrodes (SVET) - µECM: models for pulse ECM by integrating/averaging effect of pulse in time

1.3.4 Methodology The project will be divided in 10 Work Packages (WPs). A schematic view and interdependencies of the WPs and indication of the timing is given in Figure 1 and Figure 2.

Figure 1: Schematic view and interrelations of the WPs

6 http://www.offshorewind.biz/2016/09/14/foundation-monitoring-system-brings-zensor-eus-rising-blue-star-of-the-year/



The majority of the activities of WPs 1-4 will be performed in the first project year. Based on the results of WP5, only for selected technologies will additional activities be performed during the second project year.

Figure 2: Indication of the timings of the WPs

WP1: adhesion Aim: To improve the adhesion of the coating system by means of incorporating catechol moieties and/or modification of epoxy resin backbone. Activities:

- Evonik will provide an innovative technology which incorporates catechol moieties into coating resins using the mussel’s adhesive natural ability as an archetype for the development. Using polyamines in combination with catechols, Evonik already obtained coatings with good adhesion and anti-corrosion performance. During this project, Evonik wants to combine co-binders and catechols with amines like triethylenetetramine to develop good adhesive coatings, especially on metal surfaces.

- Olin will modify the epoxy resins and/or crosslinkers to improve overall adhesion. In addition, the influence of the matrix (resin/crosslinker) modification will be further studied, including the interaction of the matrix with other substances in the formulation (fillers, pigments and modifiers) in order to enhance the adhesion properties.

WP2: anti-corrosion performance Aim: To improve the anti-corrosion performance of the coating system by incorporating impermeable graphene technology and/or metallic alloys. Activities:

- The University of Manchester will improve the poor adhesion of graphene-based materials to metallic substrates by crosslinking with other polymers or molecules which bond to graphene or graphene oxide and by encapsulation. Also routes to avoid pin-holes and formation of small defects will be studied and the possibility of using other novel layered or two-dimensional materials for this application will be considered.

- OCAS will modify the performance-enhancing solutions to improve the steel/metallic coating/coating interface. Metallic alloys (i.e. Zn, Zn Al and Zn Al Mg), produced by Rhesca simulation or other metallisation methods will be identified and used alongside selected pre-treatments and post-treatments to build a system with improved adhesion and anti-corrosion resistance. The stability of the interface(s) will be studied using adhesion testing, advanced imaging and chemical analysis tools such as FIB-SEM, TOF-SIMS and APT. Tailor made tests to simulate highly corrosive environments, e.g. seawater and tidal zones, together with high-throughput screening will be used to measure corrosion resistance. Scanning flow cell methodology will be used for localised measurements in damaged areas.

WP3: mechanical robustness Aim: To improve the mechanical robustness of the coating system by inclusion of clay, carbon nanomaterials and (branched, hyperbranched or block) copolymers and/or modification of the epoxy resin backbone. Activities:

- The University of Sheffield will modify the mechanical robustness of the coating materials in function of the coating system by inclusion of carbon nanomaterials into polymer resins and the use of branched, hyperbranched and block copolymers. As these materials operate by creating nanoscale toughening inclusion, an in-house developed measuring process will be used to measure the increase in impact strength and toughness. Following, large scale testing of abrasion and corrosion performance under relevant conditions will be executed.

- Olin will modify the epoxy resins and/or crosslinkers in order to increase the mechanical robustness of the epoxy resins.

WP4: UV-durability Aim: To improve the UV-durability and weathering resistance of the coating system by incorporation of new coating binders.



Activities: Arkema will further modify the polyester and polyamide resins in order to develop a range of new polyester and polyamide grades which can be incorporated in coating formulations. After internal validation, these new grades will be incorporated into the coating formulations. Based on the feedback from WP5 these new grades will be further modified to improve formulation capability and achieve higher performance.

WP5: coating formulation Aim: To combine the most effective technologies of WPs 1-4 and formulate them into single coating systems (wet paint and powder) to enhance the 4 key properties as well as to study synergistic effects. Activities: AkzoNobel will use a design of experiments in order to identify the most promising combinations of technologies formulated in either current epoxy binders and/or in the novel binders developed in WP4. Approximately 200 coating formulations, which differ in combination of technologies, individual concentrations and relative proportions, etc. will be evaluated. Properties such as pot-life, viscosity and cure rate will be tested with suitable formulations and then tested further in WP7. In addition, the compatibility with conventional techniques will be evaluated to ensure ultimate cost-effective coating of assets.

WP6: measurement and modelling Aim: To gain knowledge on the long-term durability of newly developed coating systems by characterising and modelling the lifetime of coating systems under lab conditions as well as in the field. Activities: In order to do this an integrated simulation approach combining corrosion simulation (VUB) with mechanical/adhesion simulation (VTT) will be used. In addition, screening methodologies for adhesion promotors will be set up and buried interface characterisation (MPIE) will be used.

- VUB will simulate the corrosion kinetics and formation of corrosion products under the coating during long-time environmental exposure. VUB has developed the Multi-Ion Transport and Reaction Model7 (MITReM) that is based on the electrochemical physics and chemistries. It calculates the concentration of all relevant chemical species in all subsystems as a function of the exposure time and environmental conditions.

- These calculations will serve as input for the multiscale adhesion simulation by VTT. The adhesion modelling is based on an Integrated Computational Materials Engineering (ICME) approach in which the coating composition is linked to its performance (adhesion, mechanical behaviour (i.e. including wear, impact and cracking) and exposure to UV, aging and hydrophobicity).

- Advanced experimental techniques will also be used to give insight in the transport processes and to deliver input parameters for the simulation tools. VUB will use state of the art Odd Random Phase Electrochemical Impedance Spectroscopy8 (ORP-EIS) to determine reliable input parameters for the corrosion model both at full system and at subsystem level, e.g. dimensions, chemical and electrochemical reaction rate constants and transport parameters (diffusion coefficients).

- MPIE will use their latest developments of the Scanning Kelvin probe technology to study the buried corroding interface (between coating and metal). Since this technique is able to measure the electrode potential at the buried interface through the coating, it enables the detection of very early stages of corrosion. The transformation from a passive stable interface into an active corroding interface goes hand in hand with a change in potential that can be detected much earlier than the later resulting mechanical de-adhesion of the coating.

WP7: lab characterisation and validation Aim: To identify the best performing coating systems by extensive laboratory characterisation and fitness for purpose testing. Activities:

- Adhesion tests by such methods as pull off dolly testing - Anti-corrosion performance electrochemical testing: Electrochemical impedance, Scanning Kelvin Probe, permeation

measurements, exposure in accelerated test chambers, resistance to cathodic delamination etc. - Mechanical robustness testing: tensile testing, fracture toughness, impact testing and bending and abrasion tests. - UV-resistance accelerated tests: weathering chambers e.g. QUV and exposure at locations such as Florida and Arizona.

During the above described tests, changes in surface chemistry will be measured by e.g. FTIR and XPS. The performance of the developed coating systems will be benchmarked against: Intergard 345 (wet paint coating system) and Interpon PZ790 (powder coating system) for adhesion, Intergard 403 (wet paint coating system) and Interpon PZ790 for anti-corrosion performance, Intergard 403 and the Interpon PZ790 for mechanical robustness and Interfine 979 (wet paint coating system) and Interpon D2525 (powder coating system) for UV-durability. A minimum of two coating systems will be selected for the demonstration in a relevant environment (WP8).

WP8: demonstration in relevant environment Aim: To identify the best performing coating system demonstrated in a relevant industrial environment. Activities: These demonstrations will be performed in extreme environments (C5M and C5I). These are: the chemical plant of AkzoNobel in Delfzijl (the Nederlands), the offshore windfarm of Eneco in Luchterduinen (North Sea), an AkzoNobel customer-

7 An integrated modelling approach for atmospheric corrosion in presence of varying electrolyte film; Van den Steen, N., Simillion, H., Dolgikh, O., Terryn, H. & Deconinck, J.; Electrochimica Acta, 2016, 187, 714-723 8 Investigation of the self-healing properties of shape memory polyurethane coatings with the ‘odd random phase multisine’ electrochemical impedance spectroscopy; Jorcin, J., Scheltjens, G., Van Ingelgem, Y., Tourwé E., Van Assche, G., De Graeve I., Van Mele B., Terryn H. & Hubin A.; Electrochimica Acta A, 2010, 55, 6195-6203



owned oil platform and the onshore AkzoNobel Felling (UK) located in a highly corrosive environment. A minimum of two coating systems (WP7) will be selected for the demonstrations. These demonstrations will consist of the exposure of both laboratory prepared test panels and test patches of the candidate coating systems applied directly to the asset. Monitoring will be carried out by visual observation, return of test panels to the laboratory for more detailed analysis and using Zensor’s PermaZen corrosion detection system. It has been demonstrated that this detection system can track corrosion activity on uncoated surfaces in the field and on coated surfaces in the laboratory. Within this WP the detection system will be further optimised to detect corrosion of coated test panels exposed in the demanding locations where the field trials will be carried out to provide robust, in-line monitoring.

WP9: LCA and cost-benefit analysis Aim: To develop a coating system with a positive LCA balance over the whole life cycle and a reduced cost of at least 30%. Activities: Sustainability will be addressed through the application of AkzoNobel’s Planet Possible philosophy9 which will serve to optimise the environmental gain of the coating system through consideration of the lifecycle of the coating system itself and the coated asset. This will ensure delivery of overall resource efficient solutions. In addition, a fully assessment will be performed on the chemical plant of AkzoNobel. This plant was selected as it is located in a C5I environment and AkzoNobel has a lot of knowledge on the properties of this plant (e.g. lifetime, etc.). In this work package 4 key elements will be addressed:

- ensuring that materials produced in the project for use in coating systems are of an acceptable cost such that their incorporation into paint formulations is not prohibitively expensive;

- ensuring that fully formulated coating systems produced in WP5 are of acceptable cost to the customers and their customers, considering not just ingredient and production costs but also the application method(s) required;

- carrying out a detailed cost-benefit analysis throughout the project taking into account the factors referred to in the previous points together with the performance improvements provided by the new coating systems during validation and demonstration; and

- carrying out a LCA on AkzoNobel’s chemical plant to demonstrate the environmental gain from the developed coating system.

WP10: communication and dissemination Aim: To promote project visibility and to guarantee that the knowledge obtained through the project becomes available to the widest audience to enhance its exploitation potential. Activities:

- An IDEAL website will be developed and continuously updated. This will serve as a communication and dissemination hub, containing a technical description of the project approach. Furthermore, reports and news will be published. Full access will be used for dissemination of non-confidential updates, results and new highlights. Restricted access will be granted only to project partners to facilitate information exchange and to upload data, reports and publication drafts.

- Promotion material will be developed and will consist of the IDEAL logo, fact sheet, brochure and standardised project presentation templates.

- The IDEAL partners will disseminate findings in leading national and international conferences and tradeshows, such as: Coatings Science International, EuroCorr, International Conference on Multifunctional, Hybrid and Nanomaterials, European Coatings Show, NACE Corrosion, Application of Electrochemical Techniques of Organic Coatings (AETOC), The Society of Protective Coatings (SSPC), The American Coating Show, American Coatings Conference, Coatings Tech Conference, Advanced Polymers via Macromolecular Engineering (APME), High Performance Polymers for Oil & Gas and BIT Congress on Nanoscience.

- A dedicated IDEAL workshop is foreseen to take place during EuroCorr 2017.

WP11: project management Aim: To ensure the successful completion of this project by ensuring the delivery of qualitative results within time and budget, managing potential risks and managing the administrative, financial and contractual responsibilities of the project, including reporting to the European Commission. Activities: AkzoNobel will organise regular project meetings to follow-up on overall project progress and performance, and will ensure open and effective communication between the consortium partners. AkzoNobel will also manage the interaction with the European Commission and the submission of the required documentation, deliverables and reports.

1.4 Ambition

1.4.1 Progress beyond the state-of-the-art and innovation potential Current coating systems are limited in lifetime because it is technologically very challenging to achieve maximum combined performance of the 4 key properties required to ensure long-term protection of assets, especially in extreme environments (C5M and C5I).

9https://www.akzonobel.com/nl/system/images/AkzoNobel_Planet_Possible%20brochure_Buildings_Infrastructure%20_tcm11-84357.pdf



Epoxy coatings are today widely regarded as being the most cost-effective anti-corrosion coating systems, but suffer from being relatively brittle and susceptible to mechanical damage because of their low fracture toughness10 and susceptibility to UV-degradation11. Furthermore, whilst toughened bulk epoxy materials12 have been produced, success in producing toughened thin coating systems has to-date been limited. Finally, success with self-healing coatings is to-date very limited and restricted to the hiding and protection of small scratches or release of inhibitors into relatively small damaged areas13. It is unlikely that the routes towards self-healing coatings currently being progressed will be able to cover large scale damage. Producing more mechanically durable coatings less prone to damage in the first instance is potentially a better route to pursue.

Another limitation of current systems is their adhesion capability when applied over non-ideally prepared substrates i.e. those with significant amounts of aged coatings, rust, moisture, salts, grease etc. on their surfaces. In order to improve coating adhesion, a range of adhesion promotors is available. These adhesion promotors exist of polyesters from dibasic acid and are used especially for heavy duty corrosion protection and when the substrate cannot be fully cleaned from salt, water or paint residues e.g. while painting offshore installations. For these applications the performance of the adhesion promotors is too weak and therefore cracks under the top occur frequently. These cracks soak water and as a result the whole coating peels off. Total removal of aged coatings, rust, moisture, salts, grease etc., in offshore conditions is either too expensive or cannot be accomplished safely. For instance, coating repair or replacement on an oil platform can typically cost as much as €100.000 per day, and whereby safety measures prove difficult. As a consequence, coatings must either provide longer maintenance intervals and/or be tolerant to application over such surfaces. Maintenance intervals are typically five years. Although these are often influenced by economic factors and other reasons, the performance of the coating is the key determinant.

Furthermore, the development of new coatings is proven to be difficult because within the current state of the art there is no proven relationship between laboratory testing data and field performance data. Particularly in the area of corrosion it is difficult to relate laboratory tests to long term in-field performance. This is particularly due to (1) a lack of data from the field in which the key performance affecting properties are measured, (2) a lack of understanding of the mechanisms of failure and (3) the absence of a detailed model that allows prediction of coating performance from laboratory test data.

Substantial innovation potential: The ambitious objectives for the proposed coating system with superior overall performance will represent a major breakthrough in performance coatings beyond the currently available solutions and simulation models. The single coating system leads to an improvement in the 4 key performance properties which results in improved overall durability and reduced costs by extending the maintenance intervals and enhancement of asset lifetime. The introduction of the organic coating in the current corrosion model and the introduction of all key properties (adhesion, mechanical robustness and UV-durability) represent a major step beyond the current state of corrosion modelling. The developed simulation tool will be a major step forward in the realisation of a real-time virtual testing platform for prediction lifetime of strategic material used in e.g. offshore wind and aeronautic applications. Furthermore, this model will allow to establish a proven relationship between laboratory testing data and field performance data.

1.4.2 Freedom to operate and patent status All IDEAL partners performed a freedom to operate study for their specific technology, formulation, model or measuring technique. Based on the results of these individual studies, it can be concluded that they all have freedom to operate. The University of Manchester has filed a patent application relating to barrier materials comprising reduced graphene oxide, methods of making reduced graphene oxide materials and their uses (PCT/GB2015/050900). OCAS has a patent on the metallic coating Magnelis, one of the proposed technologies (WO 201412173 A1). These patents will be taken into account in the background IP and agreed upon in the consortium agreement to enable optimum execution of activity.

Section 2. Impact

2.1 Expected impacts This project will impact on the following:

30% increase in overall durability of the coating system compared to the commercially available coating systems This translates to the combined improvement of the following properties:

- Adhesion: at least 30% improvement compared to the selected benchmark coating systems by using an innovative approach based on mimicking the mussel’s adhesion ability by incorporating catechol moieties.

- Anti-corrosion performance: at least 50% improvement in permeability to the selected benchmark coating systems by the implementation on an impermeable layer of graphene, preventing the transport of water, oxygen and ions, combined with innovative systems of metallic (i.e. Zn, Al Zn, Al Zn Mg) and organic coatings layers.

10 B Ramezanzadeh, M M Attar, Progress in Organic Coatings, 71 (2011), 242-248 11 V C Malshe, G Waghoo, Progress in Organic Coatings, 51 (2004), 267-272 12 H Yahjaie et al, Progress in Organic Coatings, 76 (2013), 286-292 13 S J Garcia et al, Progress in Organic Coatings, 72 (2011), 211-221



- Mechanical robustness: at least 20% increase in tensile strength and fracture toughness compared to the selected benchmarks by incorporation of specialist synthesis of block copolymers, creating nanoscale inclusions and modification of the epoxy resin backbone.

- UV-durability: at least 20% improvement by integration of new grades of polyester and polyamide resins with improved UV-resistance.

At least equivalent level for all other properties - wet paint coating system: overall superior performance and improved durability, whilst maintaining low viscosity for application,

appropriate pot-life and low VOCs. - powder coating system: overall superior performance and improved durability, whilst maintaining low viscosity for application,

suitable flow and levelling and cure speed.

At least 30% lower cost The current protective coating systems meet the following challenges: limited accessibility, high repair- and maintenance costs for coating offshore and maintenance free for the entire lifetime of the coated asset (25 years)14. Therefore, there is a need to develop cost-effective coating systems with a longer lifetime and minimum need for maintenance. Cost for paint applications in extreme environments (C5M and C5I) can be two orders of magnitude higher than the costs in onshore environments. For instance, coating repair or replacement on an oil platform can typically cost as much as €100.000 per day. The coating system developed and demonstrated during this project will offer significantly higher performance than current coating systems. This will enable an extension of the maintenance period of 5 years to 10 years, without compromising corrosion protection. As a result, the total cost of applying or repairing coating systems will be reduced with at least 30%.

Positive LCA balance over the whole life cycle Sustainability will be addressed through the application of AkzoNobel’s Planet Possible philosophy which will serve to optimise the environmental gain of the coating system through consideration of the lifecycle of the coating system itself and the coated asset. Based on 20 years of experience of life cycle assessments of performance coatings, AkzoNobel’s Global Sustainability Group will also contribute a summary of the entire asset lifecycle to identify which parameters are most important in controlling the environmental performance of coatings (impacts and benefits) used for asset protection. This knowledge will be beneficial to guide development focus in the project onto environmental critical areas. As guidance to choices made in the coating system development, intermediate comparisons of the environmental performance of different alternatives will be carried out. Achieving a positive LCA will increase the chance of successful commercialisation as this factor is gaining importance in steering product choice, to such extent that companies as AkzoNobel specifically advertise new products as EcoPremium, i.e. meaning that the new product is more environmentally friendly than the previous equivalent product as demonstrated by a positive LCA balance. Furthermore, the presence of the entire supply chain allows a full system LCA analysis which will resonate stronger with the asset owners.

Relevant to several applications The developed coating system during this project will already have been demonstrated on offshore and onshore applications: a chemical plant, an offshore windfarm, an oil platform and an onshore building. As this developed coating will be formulated into a wet paint coating as well as in a powder coating, it also opens up the opportunity for manufacturing of pre-powder coated parts. This will also introduce further diversity into the coating product portfolio, thereby expanding customer based potential and innovation potential. Furthermore, the developed technologies will have a broader application in other coating segments, which are less demanding, such as coil coating for the exterior of commercial buildings. The IDEAL consortium is ideally suited for subsequent further adaptation of the developed coating systems through their broad corporate market reach.

Contribution to strengthening competitiveness of the European Industry The market of performance coating systems is a global market. Europe’s market is a mature one and growth potential is mainly in Asia. This project will help Europe to compete better, to extend its technical leadership ahead of inevitable consolidation, to expand its revenue stream for the global market and to win a share of the market growth in Asia. The growing competitiveness of Asian suppliers of protective coatings supported by rapidly expanding academic and technical competence should not be underestimated. In addition, the Maintenance, Modifications and Operations market (MMO-market) has felt the impact of the lower oil price which has resulted in a delay in non-critical maintenance. To comply with legislative standards the industry has seen operators working on a “fix on failure” attitude. Therefore, the market is demanding new coating systems which result in a significant extension of the maintenance period. Furthermore, the operators of offshore structures are under legal pressure to justify the presence of personnel on the offshore (EU Directive 2004/35/EC and 2013.30/EU), resulting in a market willingness to adopt new coating systems, which by delaying maintenance operations require less offshore maintenance time.

14 Corrosion protection of offshore wind structures Astrid J. Bjorgum (SINTEF Materials and Chemistry) / Ole Øystein Knudsen (SINTEF Materials and Chemistry) / Hanno Schnars (Fraunhofer-Institute for Wind Energy and Energy System Technology IWES Northwest) / Sibo Buter (Endures) / Harald van der Mijle Meijer (TNO) Presentation EUROCORR 2016 EUROPEAN CORROSION CONGRESS Montpellier 12th September 2016 France


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