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Project Progress
Starting with internal experiments, WH Lipex tested the feasibility of melting and spinning new fibres from decommissioned blade materials. Lab-scale trials conducted between late 2023 and early 2024 showed that recycled fibres retained tensile strength comparable to virgin fibres, paving the way for pilot-scale testing. Key steps include extracting, cleaning, and remelting the glass, followed by fibre formation, all while minimizing environmental impact.
Challenges and Innovations
Initial collaboration with one partner revealed limitations in on-site dismantling and cleaning methods. WH Lipex assumed full responsibility for fibre processing, exploring non-thermal techniques to avoid quality degradation. After evaluating potential partners, WH Lipex selected a method based on pulse and frequency to effectively clean fibres without heat exposure. Lab-scale results confirmed the viability of this approach.
Pilot Testing and Plant Design
The pilot phase involves recycling 100 kg of fibres, melting them into pellets, and forming new fibres with a 400-tip bushing. These fibres will be processed into fabrics for composite materials, and detailed analyses will compare them with virgin glass fibres. Although a physical pilot plant is not yet built, WH Lipex has designed a flexible pilot line system with potential scalability. The plant design focuses on optimizing melting efficiency, fibre forming, and overall process flow.
Future Steps and Challenges
The next phase include refining the furnace design and addressing cost factors such as energy consumption and fibre cleaning expenses. Variability in glass types from old blades poses an additional technical challenge, as does securing funding and partnerships for a full-scale plant. Success in these areas could revolutionize wind turbine blade recycling, reducing landfill waste and contributing to a circular economy.
WH Lipex's project represents a breakthrough in sustainable fibre recycling, transforming waste wind turbine blades into high-quality materials. By focusing on innovative, scalable processes, the company is setting a benchmark for reducing the environmental impact of wind energy systems.