Multi-lifecycle Assessment of Close-loop Recyclable Wind Turbine Blades

While over 80% of materials in modern wind power installations are recyclable, the sector continues to grapple with the absence of effective, scalable, and environmentally sustainable methods for managing end-of-life wind turbine blades. Addressing the environmental impact of these blades requires not only the integration of lower-impact materials into the manufacturing process but also the advancement of recycling technologies that enable the creation of high-quality secondary materials. Such initiatives are crucial for facilitating the wind energy sector's transition towards a circular economy. This study utilises lifecycle assessment to assess the environmental impact linked with the production of recycled glass fibre and recycled thermoplastic (polymethyl methacrylate, PMMA) products derived from composite wind blade waste. The assessment considers thermolysis recycling of thermoplastic-based blade waste, encompassing the subsequent refinement of recovered organics into usable secondary monomers. The process also involves the production of virgin-quality secondary glass fibre products, by cleaning and remelting of glass fibre recyclates. It was determined that recycled thermoplastic and glass fibre products can reduce most environmental impact indicators compared to virgin counterparts and are able to diminish material production global warming potential by up to 54% and 26% respectively. Consequently, wind blades manufactured using recycled thermoplastic and glass fibres are projected to have a 27% lower cradle-to-grave global warming potential compared to blades made with conventional epoxy resin and virgin glass fibre reinforcements. As such, both material and recycling solutions demonstrate the potential for decarbonising production and progressing toward a circular economy for wind blades. Supplementary Information: The online version contains supplementary material available at 10.1007/s42824-025-00211-7.