Recyclable Wind Turbine Blades: A Life Cycle Analysis

Abstract

The shift towards renewable energy has highlighted the importance of sustainable practices in wind power development, particularly concerning the end-of-life (EoL) management of wind turbine blades. Conventional blades made from thermoset resins present significant recycling challenges due to their cross-linked structure, which often leads to landfill disposal or energy-intensive recycling processes. This study evaluates the environmental impacts of 45 m wind turbine blades using the Eco Audit approach across four primary life cycle stages: material production, manufacturing, transportation, and operation and maintenance. Six blade models with different fiber and resin configurations are assessed, focusing on a comparison between conventional thermoset resins and Elium, a newly developed liquid thermoplastic resin by Arkema. Elium offers promising recyclability options, including mechanical and chemical processes, which could substantially lower the environmental burden. Compared to composites made with thermoset resins, Elium-based blades demonstrate up to a 22.5% reduction in embodied energy and a 16% decrease in carbon footprint. Additionally, Elium’s compatibility with existing manufacturing processes, room-temperature curing capability, and lower processing energy contribute to its industrial feasibility. Notably, the analysis reveals that the material production phase significantly contributes to the total environmental impact, accounting for up to 98% of the embodied energy and carbon footprint in certain blade models, underscoring the importance of selecting a more sustainable resin, such as Elium, from the outset to reduce the overall environmental load.