720094FalconClosedGRD Development of PrototypeInnovate UKProject 'Falcon' will develop an innovative pultrusion tape manufacturing process from which prototype high integrity monolithic pipes will be produced. The tape will be a unique matrix of polyaryletherketone (PEEK) and T700 carbon fibre. The resultant pipe will have significantly higher performance characteristics an order of magnitude above what is currently practical when used in the manufacturing of subsea risers, flow-lines and jumpers (see diagram in Appendix A) for hydrocarbon extraction in the Oil & Gas industry and Carbon Sequestration. The innovation will create a high performance advanced material and demonstrate the resulting pipe structure will withstand corrosive hydrocarbon products, at significantly higher temperatures and increasing pressures, as demanded by the Industry’s roadmap for subsea production technologies. Existing formulations of PEEK/Carbon are used for Aerospace and Automotive applications but utilise less viscous, lower quality, polymer matrices to encapsulate the carbon fibre. The resulting formulations and manufacturing processes are unable to deliver the material consolidation, process control, production speed and PEEK stratification that will be necessary to manufacture pipes capable of withstanding ultra-deep water environments and operating conditions. A reformulated material structure combined with a unique pultrusion process is required to counteract the high viscosity and high melt temperature of a higher specification of PEEK. The innovations required to address this challenge must encompass: a) fundamental changes to material composition/structure; b) novel forming/extrusion methodologies (particularly die configuration and the introduction/application of higher temperatures and increased pressure); and c) novel cooling techniques to retain desired crystalinity. A successful project will also provide spin off opportunities for high performance PEEK/carbon tape in the Aerospace, Automotive and Defence sectors.