North-C Blade: from end-of-life wind turbine blades to new raw materials for industry

Wind turbines play a crucial role in the energy transition. But as more and more wind farms are built, a new challenge is emerging: what happens to the wind turbine blades when they reach the end of their service life? It was precisely this question that was at the heart of the North-C Blade project, a collaboration between research institutions, industry and port partners, supported by the Belgian Energy Transition Fund.

The processing of end-of-life wind turbine blades remains a challenge. Due to their complex composition, high-quality, large-scale recycling is not yet a given.

Through the North-C Blade project, the partners investigated how end-of-life wind turbine blades can be converted into valuable raw materials for industry.

An end-to-end value chain approach

The project brought together partners from across the entire value chain, transcending sector boundaries. ENGIE Laborelec analysed the composition of the wind turbine blades, carried out material analyses and provided the expertise and materials required for further processing within the research. Ghent University investigated how the ground material could be converted into syngas using an innovative vortex reactor and plasma gasification. Among other things, the research focused on the optimal processing of the complex composite materials. INEOS Inovyn contributed expertise in syngas purification and chlorine removal. ArcelorMittal investigated potential applications of syngas within industrial processes. Commissioned by Smart Delta Resources and North Sea Port, SWECO carried out the techno-economic feasibility study. To this end, Smart Delta Resources brought together the various partners from the value chain and supported the development of industrial synergies. North Sea Port provided the perspective of the port and industrial cluster and helped to identify future application opportunities within the region.

Schematic representation of the circular value chain investigated within the North-C Blade project. Through chemical recycling, end-of-life wind turbine blades are processed into valuable material streams and raw materials for the steel, energy and chemical industries.
 

From wind turbine blade to industrial raw material

The main focus of the research was the development of a process for the chemical recycling of wind turbine blades. Following mechanical pre-treatment, Ghent University investigated how the material could be converted, via plasma gasification, into syngas, a gas mixture that can serve as an energy carrier or as a raw material for new chemical products.

In addition to the production of syngas, the recovery of valuable materials from wind turbine blades was also investigated. The research clearly showed that the quality of the recovered fibres is a decisive factor in the economic viability of the entire concept.

Particular attention was also paid to the composition of the gas streams. Some wind turbine blades contain chlorine-containing components (PVC). INEOS Inovyn therefore investigated how chlorine can be efficiently removed so that the syngas can be used safely and to a high standard in industrial applications.
 

Links with industry and feasibility

A key strength of North-C Blade is its integration into existing industrial value chains in the region.

The syngas produced could potentially be used as an alternative to fossil raw materials in various industries. As part of the project, ArcelorMittal investigated how syngas could be used in steel production processes, for example to replace part of the fossil carbon. Applications are also conceivable in the chemical sector for the production of, amongst other things, methanol and ethanol. This creates a circular chain in which materials from decommissioned wind turbines are reused in new industrial products.

The study also examined how such processes can be integrated into existing industrial infrastructure. By making use of existing facilities, logistics networks and industrial installations, significant synergy benefits can be realised.

To evaluate the concept in its entirety, Sweco, commissioned by Smart Delta Resources and North Sea Port, developed a process model covering the entire supply chain: from end-of-life wind turbine blades to new raw materials and end products. The assessment looked not only at technical feasibility, but also at investment costs, operational costs and opportunities for industrial integration.

The main conclusion is that the process has great potential, but that the ultimate business case depends heavily on the quality and market value of the recovered fibres. That is precisely why further testing and validation of these material streams are an important next step.

Collaboration as the key to success

The project brought together expertise from the fields of research, energy, chemistry, steel, engineering and industrial symbiosis to tackle a single common challenge.

The North Sea Port harbour and industrial cluster offers a unique environment for this. Within a limited geographical area, it is home to knowledge institutions, port infrastructure, energy companies, chemical firms, recycling companies and the steel industry. This combination makes it possible not only to research new circular value chains, but also to develop them effectively on an industrial scale.
 

Carl De Maré, Smart Delta Resources Flanders: 

“Projects such as North-C Blade demonstrate the unique strength of the North Sea Port region. The entire supply chain, from offshore wind and recycling to chemicals and steel, is present here. Thanks to this unique combination of port infrastructure, research institutions and industries, we can develop and scale up complex circular value chains in a way that you don’t find just anywhere.”

Project details North-C Blade

• Focus: circular processing of end-of-life wind turbine blades
• Funding: Energy Transition Fund (Flemish fund for innovative projects that accelerate the energy transition)
• Partners: Smart Delta Resources, North Sea Port, Ghent University, ENGIE Laborelec, INEOS Inovyn, ArcelorMittal
• Technical and economic feasibility study: Sweco

Process chain studied: dismantling → pre-treatment → syngas production → syngas purification → material recovery → industrial valorisation

Key findings:
•    technical feasibility demonstrated;
•    the quality of the recovered fibres is crucial to the business case;
•    promising applications for the steel, energy and chemical industries;
•    potential for integration into existing industrial infrastructure;
•    further validation and pilot-scale testing required.