The DecomBlades innovation project has reached a milestone in wind energy sustainability. For the first time, glass fiber retrieved from decommissioned wind turbine blades has been processed and melted into high-quality fibers that meet the standards for use in new turbine blades. Siemens Gamesa, a key partner in the project, has received 40 tons of this advanced material and is now utilizing it to produce 115-meter-long turbine blades for Ørsted’s Greater Changhua 2b and 4 offshore wind farm in Taiwan.
As the wind energy industry addresses the challenge of aging turbines, particularly the composite materials used in blades, sustainability has become a priority. Many turbines from the early days of wind power are reaching the end of their operational lives. DecomBlades has emerged as a collaborative effort among industry leaders and research institutions to establish sustainable value chains for decommissioned turbine blades.
The project’s goal is to reprocess and recycle materials from retired blades into new applications, ultimately creating a circular economy for the wind sector. Siemens Gamesa joined DecomBlades in 2021, driven by its commitment to sustainability and innovation.
In October 2023, DecomBlades achieved a major breakthrough: the successful extraction and processing of glass fibers from old blades into new high-performing fibers. Notably, this process was accomplished at an industrial scale, a critical step toward commercial viability.
According to Energy Cluster Denmark, “we have achieved this important milestone not at laboratory scale, but at an industrial level, and the process has real commercial prospects.”
“This innovation demonstrates that full blade circularity is within reach, marking a significant step towards ending blade landfilling and reducing reliance on virgin materials,” said Ida Krabek, Head of Global Sustainability at Ørsted.
The new fibers underwent rigorous quality control before being incorporated into Siemens Gamesa’s 115-meter-long offshore blades. These blades, set to be installed at Ørsted’s Greater Changhua wind farm, exemplify the success of the circular economy in action.
Jonas Pagh Jensen, Head of Sustainability Value Chain Engagement at Siemens Gamesa, highlighted the significance of the achievement: “Blade recyclability has been a Gordian Knot for the industry. With our RecyclableBlade technology and the strides made in DecomBlades, we’ve proven that glass fibers can be transformed into even better fibers. Glass comprises over 50% of a blade’s mass, making this a vital advancement.”
While this achievement represents a significant leap forward, scaling the innovation remains the next challenge. “We now need to work on making this not only a one-off success but a proven and cost-efficient value chain,” said Johan Schoonhoven, Senior Circularity Advisor at Ørsted.
Collaboration across the value chain is essential for scaling up this innovation. By uniting industry players, DecomBlades aims to refine the process and establish a commercially viable, sustainable solution for turbine blade recycling.
