GE has repainted the future of sustainable energy through its massive wind turbines and innovative offshore designs. A consortium led by the company has manufactured the world’s largest thermoplastic blade, designed to serve as a full-scale example of a fully recyclable wind turbine blade.
The University of Cambridge study suggests that there will be 43 million tons of blade waste around the world by 2050 from the wind energy industry. The Zero Waste Blade Research (ZEBRA) Project is working on more sustainable materials in the form of thermoplastic composites.
The 62-meter (203-ft) prototype blade is made with Elium resin from materials company Arkema, which is a glass-fiber reinforced thermoplastic. Not only is the material 100 percent recyclable, but it is also claimed to deliver a similar level of performance to thermoset resins that are favored for their lightweight and durability.
Through a chemical recycling method, the material can be depolymerized and turned into a new virgin resin for re-use, acting as a proof-of-concept for a circular economy loop for the wind energy sector. LM Wind Power will start full-scale structural testing to verify the blade’s performance this week.
“With this project, we are addressing two crucial industry challenges,” said John Korsgaard, Senior Director, Engineering Excellence, LM Wind Power. “On one hand, we are progressing on our Zero Waste Blades vision by preventing and recycling manufacturing waste. On the other, we are taking blade recyclability to a new level: the end-of-life thermoplastic composite blade material has a high value and can be readily utilized in other industries as material compounds but can also be depolymerized and the resin reused in the production of new blades.”