ReusaBlade: Recyclable materials for rotor blades and their recycling

At a glance

• Rotor blade manufacturers are working on new concepts with dissolvable epoxy resins to allow recycling of the composite materials used. However, there is as yet no established process for such recycling.
• In the ReusaBlade project, the scientists are thus developing and testing different recycling processes for modern fiber composite components. The aim is utilization of the recovered materials on an industrial scale.
• Fraunhofer IWES, which is coordinating the project, is investigating the corresponding process for structures made from a newly developed epoxy resin in a subproject.

The challenge

Although 90% of a wind turbine can be recycled, the sensible use of rotor blades poses a challenge due to the complexity of the composite materials employed, which either cannot be recycled at all or the recycling of which is associated with high energy consumption. In order to counter this problem, rotor blade manufacturers are already working on introducing new materials, in particular new dissolvable resin systems. However, even if these resins are better suited to recycling processes, there are as yet no established processes which would render actual recycling and further use of the recovered materials feasible on an industrial scale too.

The solution

This is where the ReusaBlade joint project comes in. The project partners are working together to develop and test different recycling processes for fiber composite components on a laboratory scale while bearing in mind the possibility of scaling them up to industrial scale. The project demonstrates the recycling cycle using fatigue-stressed rotor blade components with dissolvable matrix systems. Valuable materials such as pultruded carbon fiber components are to be recovered and repurposed by separating fibers and components. The performance of the repurposed materials can be assessed through mechanical and manufacturing testing. In addition, an industrial feasibility study is being conducted to determine the findings for rotor blade production in terms of the costs and the processes to be realized.

In a subproject, Fraunhofer IWES (the project coordinator) is working together closely with Fraunhofer WKI and the project partners to study coupon plates made of solid laminate and sandwich laminate manufactured using the innovative epoxy resin (EP) developed by the company CTP. These coupon boards undergo a complete manufacturing and recycling process, which makes it possible to compare the properties of boards made from new and recycled fibers.

The added value

The project team is developing fundamental insights into the recycling processes of modern rotor blades and thereby delivering a crucial building block for a wind turbine that is 100% recyclable in a sensible way. At the same time, the project will contribute to reducing the costs of dismantling rotor blades and the resources required for wind energy. In addition, ReusaBlade could help to boost the acceptance of wind energy.