Mobile Wind Turbine Blade Recycling With Sectioning And Grinding
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Solution Overview
Problem
The existing methods for recycling wind turbine blades are not cost-effective due to high transportation and processing costs, especially for offshore wind farms, and the recycled fibers lack organization and orientation, requiring further processing.
Innovation Solution
A mobile recycling system composed of individual processing units that can be transported and assembled on-site, including a first unit for sectioning blades into parts and a second unit for crushing and grinding, followed by optional chemical and thermal recycling to produce uniform granulates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wind turbine blades are transported to distant recycling plants for processing, then comprehensive recycling can be achieved, but transportation costs and environmental impact increase significantly
Solution Approach 1:
The recycling system is divided into separate mobile processing units that can be transported independently to the wind farm site. Each unit performs a specific function (sectioning, crushing, grinding, chemical recycling), allowing the system to be assembled on-site without requiring long-distance transportation of entire blade assemblies.
Solution Approach 2:
The mobile recycling system is transported and assembled at the wind farm location before the actual recycling process begins. This preliminary setup eliminates the need for subsequent transportation of processed materials, as all recycling operations are performed in-situ at the decommissioning location.
2Length of moving object
If blades are sectioned into smaller pieces for transport, then transportation becomes feasible, but handling costs and processing complexity increase
Solution Approach 1:
The blade recycling process is segmented into distinct operational stages (sectioning, crushing, grinding, chemical treatment) performed by separate mobile units. This segmentation allows each unit to handle materials at appropriate size scales without requiring complex intermediate handling and reassembly operations.
Solution Approach 2:
Instead of sectioning blades primarily for transportation purposes, the system inverts the approach by bringing the sectioning equipment to the site and performing all size reduction operations in-situ. This eliminates the need for complex transportation logistics of pre-sectioned blade parts.
3Loss of substance
If mechanical comminution is used to recycle blades, then fiber materials are liberated, but fibers become short and randomly oriented requiring further processing
Solution Approach 1:
The system employs chemical recycling processes (solvolysis, pyrolysis) that change the chemical parameters of the resin matrix, allowing for more effective fiber liberation and potential restoration of fiber properties. These chemical treatments can help maintain fiber length and orientation better than mechanical comminution alone.
Solution Approach 2:
The recycling system processes the composite material by separating and treating different components (fibers, resin, fillers) using appropriate methods for each material type. This composite approach allows recovered fibers to be processed into products with specific orientation requirements while recovering other materials for different applications.
4Productivity
If large recycling plants are operated continuously, then economies of scale are achieved, but dependency on steady waste delivery increases operational rigidity
Solution Approach 1:
The mobile recycling system transforms the static, continuous-operation model into a dynamic, on-demand deployment model. Units can be transported to and from different wind farm sites as needed, allowing the system to adapt its location and operational timing to match actual decommissioning schedules rather than requiring constant material flow.
Solution Approach 2:
The mobile processing units are designed with universal applicability to handle different types of composite materials and can be deployed at various locations. This multi-functionality allows the same equipment to serve multiple wind farms and potentially other composite recycling applications, reducing operational rigidity.
Data Source
AI summary
A recycling ship configured to sail to an offshore site for recycling a composite material rich structure at the site. The composite material rich structure can include a wind turbine blade, a boat or a ship comprising fiber reinforced composite material. The recycling ship comprises a first processing unit having a cutter configured to receive the composite material rich structure and to section it into composite parts, and a second processing unit having a crusher and/or grinder configured to reduce the size of the composite parts into composite material granulates.