Wind turbine blade recycling: turning waste into value

Most blades today are made from a plastic and fibre mix known as a fibre-reinforced polymer (FRP). About 60 to 70 per cent of a blade’s weight is made up of glass fibres set in a strong resin binder, while the rest is the plastic that holds it together. Better performing blades use a bit of carbon fibre instead of glass fibre to give strength without adding too much mass, so the blades spin more efficiently.

After 20 to 25 years, blades stop being useful for power generation. Most of them are sent to landfill because they are hard to separate and process. Others are incinerated or used as fuel in energy plants, but that can release harmful emissions.

Extending the useful life of a wind turbine blade is increasingly common. Some companies perform inspections using drones to spot and repair damage early, so blades can continue producing power safely. Projects under Horizon Europe, such as REWIND, aim to boost blade reliability and recyclability through better inspection and design techniques.

Removing and moving turbine blades is a complex, costly and labour‑intensive task. Blades often stretch 20 metres or longer and weigh several metric tons, making dismantling a major undertaking. Special cranes and trained teams are needed to separate blades from the rotor and tower.

Once free, blades are usually cut into smaller segments to assist transport. This step involves heavy equipment such as diamond‑tipped saws and excavators. Transport requires careful planning and often involves special permits.

Can wind turbine blades be recycled? Yes, but only partially. Most of the material in a wind turbine (up to 95 per cent aluminium, steel, copper and concrete) is easily recycled, but until recently composite blades have resisted mainstream recycling. Emerging chemical and thermal separation techniques are enabling the transformation of blades into resources instead of rubbish.

In a method called pyrolysis, blades are heated without oxygen, so the resin burns off and glass fibres are left behind. These fibres lose some strength but can be reused.

This method uses a chemical bath to dissolve the resin under mild heat to free the fibres. It is seen as promising, though it remains at the pilot stage.

Blades are shredded or milled into small flakes that are mixed into concrete building panels or used as concrete fillers. This does not conserve full‑strength fibres but keeps much of the material in reuse.

Blade parts have been used to build objects such as park benches, footbridges and bicycle shelters. While these approaches are creative, they only address a small portion of blade waste.

Composites are not biodegradable; landfill and incineration cause pollution, take up space and may emit greenhouse gases.

Recycling supports EU and global climate strategies by reducing virgin raw material consumption and overall emissions from blade manufacturing.

Some countries (Austria, Finland, Germany and the Netherlands) have landfill bans on composite blades, with Europe aiming for a ban by 2025.

Reprocessed glass fibres and other materials can be sold and reused. For example, the DecomBlades project utilises reclaimed fibre to manufacture new blades.

Wind turbine blade weight makes transport and disposal expensive. Recycling can reduce costs while turning waste into useful materials.

There is growing interest in next‑generation blades built for disassembly or made from materials that break down and can be reshaped more easily. New standards and guidelines on extending turbine life are also being developed. Scaling up both recycling and lifetime extension will help to drive a circular economy in wind energy, from blade production to blade disposal and back again.