Revolutionizing Wave Energy: CorPower Ocean and OPS Solutions Develop Innovative Pre-Tension Cylinder Prototype

Swedish company CorPower Ocean and Norway-based OPS Solutions have joined forces to create a groundbreaking pre-tension cylinder (PTC) prototype, marking a significant milestone in the quest to reduce the cost and mass of wave energy converters (WECs).

The collaboration, known as the COMPACT project, leverages the combined expertise of both companies in wave energy and offshore fabrication. The primary focus of the project was the development of a lightweight pressure casing that could not only cut production costs but also enhance performance.

Utilizing cost-effective composite designs and innovative offshore manufacturing techniques, CorPower Ocean believes that this new approach has the potential to boost efficiency in WEC systems while lowering overall energy generation costs.

The centerpiece of the COMPACT project is the development, testing, and certification of the PTC cylinder, a crucial component of CorPower Ocean’s WEC system. The successful completion of the initial burst test, where the cylinder reached nearly 700 bar (2.3 times the maximum operating pressure), has validated the design philosophy behind the COMPACT project.

According to Ross Harnden, Senior Technical Project Manager at CorPower Ocean and COMPACT Project Lead, “With small modifications to the composite layup, it is expected that it will be possible to reach the 900 bar required to obtain PED certification of the design, which is essential for type certification. The results from the COMPACT project will be instrumental in shaping future design iterations of the CorPower Ocean WEC.”

One of the key challenges faced during the project was finding a suitable cylinder liner material. While testing various polymer combinations, the companies discovered limited cost-effective solutions that could meet the necessary pressure and temperature conditions. Further research, possibly in collaboration with external institutes, will be conducted to address this issue.

Reidar Anderssen, General Manager of OPS Composite Solutions, expressed his enthusiasm for the outcomes of the COMPACT project, stating, “By combining our areas of expertise, we have been able to drive real industry advances that bring wave energy closer to commercialization.”

The financial support for the project came from Iceland, Liechtenstein, and Norway under the EEA Grants “Blue Growth Programme,” which aims to foster innovations in the blue economy.

CorPower Ocean highlighted that the COMPACT project aligns with Portugal’s industrial strategy for ocean renewable energies, projecting that ocean renewable energy could potentially supply 25% of the country’s annual power consumption and generate economic benefits, including €254 million in investment and 1,500 new jobs.

The key developments of the project include advancements in PTC cylinder manufacturing for use in CorPower Ocean’s upcoming C5 device, improvements in winding and flange connection techniques, and strategies to minimize bolt fatigue. Additionally, insights gained from testing fabric-backed high-density polyethylene (HDPE) as a liner material could shape the future iterations of WECs.

In December 2024, CorPower Ocean’s wave energy initiative in Portugal received backing from the European Investment Bank (EIB), recognizing it as an “innovative solution that could revolutionize the renewable energy landscape.”