Manufacturing of a sustainable wind turbine blade with the recovery materials from original blade

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Abstract
While most components of wind turbines (WTs) can be recycled, the blades present a significant challenge. Made from thermoset resin composites, these blades are difficult to recycle at the end of their service life. Although several recycling methods are under development, none allows for the recovery of the resin, and the reclaimed fibres exhibit lower mechanical performance compared to virgin materials. Certain thermoplastic resins offer a more sustainable alternative due to their inherent recyclability, enabling not only the thermoforming of composites but also the recovery of both resin and fibres for reuse in future manufacturing processes. This study demonstrates the manufacturing process of a small wind turbine blade using Akelite, a high-performance liquid acrylic resin with excellent mechanical properties and thermal stability. After undergoing fatigue testing, the blade was successfully recycled, and its constituent materials were reused to manufacture a new WT blade. This process significantly enhances the sustainability of wind energy systems by enabling the full recovery of blade materials at the end of their operational life. Moreover, it aligns with Sustainable Development Goal 12 (SDG-12), by promoting responsible consumption and production, and establishes a circular economy model that could transform blade manufacturing practices across the renewable energy sector.