A new report from the U.S. Department of Energy (DOE) offers a roadmap for a more sustainable wind energy industry through increased recycling and reuse of decommissioned wind turbine components. The report, "Recycling Wind Energy Systems in the United States," reveals that while existing infrastructure can handle 90% of the mass of decommissioned turbines, innovative solutions are needed for the remaining 10%, primarily blades, generators, and nacelle covers. This research will inform over $20 million in Bipartisan Infrastructure Law investments aimed at bridging this gap.

"The U.S. already has the ability to recycle most wind turbine materials, so achieving a fully sustainable domestic wind energy industry is well within reach," stated Jeff Marootian, principal deputy assistant secretary for the Office of Energy Efficiency and Renewable Energy. "Innovation is key to closing the loop, and this research will help guide national investments and strategies aimed at advancing technologies that can solve the remaining challenges."

The report, compiled by a team of researchers from the National Renewable Energy Laboratory, Oak Ridge National Laboratory, and Sandia National Laboratories, outlines short, medium, and long-term research and development priorities. It emphasizes the need for improved decommissioning practices, strategic siting of recycling facilities, expanded infrastructure, and the development of more easily recyclable materials and component designs. Recovering critical materials like nickel, cobalt, and zinc from generators and power electronics is also highlighted as crucial for a circular economy.

Current recycling efforts focus on easily recyclable components like towers, foundations, and steel subcomponents. However, the report identifies blades (made of composite materials), generators, and nacelle covers as more challenging. Short-term strategies include promoting thermoplastic resins in blade production and reusing these resins in cement. Medium and long-term solutions include pyrolysis and chemical dissolution for blades, high-yield separation techniques for power electronics, and hybrid methods for recycling permanent magnets. Regional factors, such as material demand and transportation costs, will play a significant role in the economic viability of recycling.

The DOE is actively supporting this transition through several initiatives:

$20 Million Investment: The Bipartisan Infrastructure Law is funding a Wind Energy Recycling Research, Development, and Demonstration program focused on sustainable components, material recycling, and qualifying recycled materials.

$3.6 Million Prize Competition: The Wind Turbine Materials Recycling Prize has awarded six winners to advance their recycling technologies toward commercialization.

The DOE's research draws from its Renewable Energy Materials Properties Database (REMPD) and incorporates life cycle and techno-economic assessments of various recycling pathways. The goal is to develop efficient, cost-effective, and environmentally responsible methods for managing decommissioned wind turbine materials. This includes evaluating current industry practices, assessing the research landscape, and identifying opportunities for emerging technologies.

By promoting a circular economy in the wind energy sector, the DOE aims to reduce material supply chain vulnerabilities, conserve resources, and enhance the sustainability of wind power, contributing to a cleaner energy future.

Companies like RWE and Siemens Gamesa are also taking steps towards circularity. RWE's Sofia offshore wind farm in the UK will deploy 132 recyclable turbine blades (44 of its 100 turbines), supplied by Siemens Gamesa. This follows a successful pilot of the technology at RWE's Kaskasi wind farm in Germany. These recyclable blades utilize a new resin that allows for material separation and reuse in various applications, marking a significant advancement in wind turbine sustainability. While other blade recycling methods are in development, these "designed-for-recycling" blades represent a major step forward. Sofia, a 1.4 GW project, is slated for completion in 2026 and underscores RWE's commitment to innovation and sustainability in offshore wind.

Credit:

U.S. Department of Energy (DOE)