Breakthrough in Wind Turbine Blade Recycling

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Breakthrough in Wind Turbine Blade Recycling

ZEBRA Project Demonstrates Closed-Loop System
The ZEBRA (Zero waste Blade Research) project marks a significant leap forward in the recycling and circular economy for wind turbine blades. This collaborative effort demonstrates a breakthrough in the complete recycling of thermoplastic blades achieving significant environmental and economic benefits.
A Consortium of Leading Companies Drives Innovation
The ZEBRA project is a unique partnership led by the French Institute for Technological Research, IRT Jules Verne. Joining forces are industry leaders Arkema (resin supplier), Owens Corning (glass fiber supplier), LM Wind Power (blade manufacturer), SUEZ (dismantling and waste processing), CANOE R&D center (recycling technology), and ENGIE (life cycle analysis).

Each company played a crucial role in the development of the closed-loop recycling process:
•Arkema developed and validated the generation of recycled Elium monomer through thermolysis, and, together with its subsidiary Bostik, an innovative adhesive for the blade assembly that is recycled together with Elium paving the way for industrial-scale implementation.
•Owens Corning successfully recovered glass fiber at pilot scale, enabling its reintroduction into the production process for their Sustaina product line.
•LM Wind Power manufactured two wind turbine blades with Arkema’s Elium resin and Owens Corning’s Ultrablade fabrics; one blade including a large structural element made with recycled Elium resin.
•SUEZ provided cutting and grinding expertise for processing the blades.
•CANOE R&D center optimized recycling for production and carbon blade waste, additionally developing methods for repurposing waste streams through mechanical recycling.
•ENGIE conducted a comprehensive life cycle analysis demonstrating the environmental benefits of closed-loop ZEBRA blades and validated their economic viability.

A Sustainable Future for Wind Energy
The ZEBRA project successfully recycled Elium resin and Ultrablade fabrics from wind turbine blades and manufacturing waste, reformulating them back into usable materials. This closed-loop process addresses the growing challenge of end-of-life blade management within the wind energy industry.
•Recycled Elium Monomer: Arkema achieved a yield of over 75% in the thermolysis process, paving the way for industrial-scale production of recycled resin.
•Recovered Glass Fiber: Owens Corning successfully retrieved glass fiber for remelting and reintegration into their Sustaina product line.
•Life Cycle and Cost Analysis: ENGIE’s study confirmed the significant environmental benefits and economic viability of ZEBRA blades when assuming a closed-loop recycling system from production to end-of-life.

ZEBRA blade using Elium thermoplastic resin, Bostik’s highly compatible adhesive and Ultrablade fabrics is bringing the best closed-loop recycling solution compared to traditional thermoset system. The operating cost and investments for recycling facility are significantly lowered. The CO2 emission linked to the recycling operations is reduced as well. All those results are making the closed-loop recycling solution of ZEBRA blades a viable option both on economic and environmental standpoints.
The ZEBRA project is a testament to the power of collaboration in driving sustainable innovation. By demonstrating the feasibility of full wind turbine blade recycling, the project paves the way for a more sustainable future in the wind energy sector.