From wind turbine blade to new infrastructure application: a breakthrough in composite reuse
What began as an experimental search for a way to process discarded wind turbine blades has evolved into a proven method now used in new infrastructure projects. This marks a crucial step towards solving a global waste problem that is becoming increasingly urgent as wind farms continue to expand. After ten years of intensive research, the breakthrough has been achieved: the circular solution developed by the Research Group of Polymer Engineering is now being applied on an industrial scale.
The challenge: indestructible wind turbine blades
Wind turbine blades are made of exceptionally strong materials: composites. These materials are designed to last for decades. However, many wind turbines have now been in operation for several decades, and an increasing number of rotor blades require replacement. Their removal generates vast quantities of waste. This type of ‘end-of-life composite’ was for a long time almost impossible to process. With the rapid expansion of wind farms, particularly offshore, the problem grew exponentially. A circular solution was urgently needed to prevent this material stream from becoming a new environmental burden.
An innovative approach that harnesses the strength of the material
The Research Group of Polymer Engineering developed a method focused on reusing composites without compromising their mechanical properties. Using this approach, discarded composite material is reduced to robust flakes, which are then used as reinforcement in new composite products. When these flakes are embedded in fresh resin, they form a new, fully fledged and durable material. In this way, old composite is transformed into new composite without any loss of quality.
The research and further development of this method are led by Dr Ir Albert ten Busschen, principal investigator of the Research Group of Plastics Technology. Together with a network of more than 80 partners from industry, government and knowledge institutions, his team developed the technology into a scalable and robust solution.
The breakthrough: from innovation to industry
The technology is now being used to manufacture new products on an industrial scale. At CRC, discarded composite products are processed in large volumes into new raw materials. Compone then uses these materials to produce new composite products. These products are suitable for applications such as infrastructure projects. With this step, the innovation has officially moved from a research project into the marketplace.
Test results that underpin confidence
The move towards industrial-scale application was not taken lightly. To demonstrate the effectiveness of the technology, the materials were subjected to extensive testing over a period of ten years, including tests on strength, stiffness, moisture behaviour and fatigue. Even under a range of extreme conditions, performance remained consistent. The results show that recycled composite delivers the same performance as virgin material.
In addition, an independent research institute (SGS Intron) confirmed that no harmful substances leach from the material. This means the recycled composite is safe for both people and the environment. Life cycle analyses further demonstrate that the method delivers significant environmental benefits, partly due to the long service life of the new products.
As part of the research, the technology has been applied in practical projects, including:
- Bank protection consisting of 80 recycled sheet-pile planks
- Guide rails that safely steer ships into harbour
- A dragline mat for heavy construction traffic
- Deck planks on a road bridge in Friesland, subjected daily to thousands of vehicles
These applications demonstrated that recycled composite not only works in theory, but also proves its value in practice.
International recognition and continued growth
The broad collaboration and technological breakthrough have resulted in several awards, including:
- Deltapremie 2021(opens in new tab)
- RAAK-Award 2021(opens in new tab)
- JEC Innovation Award 2022 (Bouw & Infra)(opens in new tab)
Internationally, the method is recognised as a realistic and scalable solution to the growing composite waste stream from the wind industry. Windesheim actively participates in international working groups focused on shaping the sector’s circular future.
Ten years of research have culminated in a mature, industrial method that is now applied in practice. What began as a challenge surrounding discarded rotor blades has grown into a proven technology.
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