The ZEBRA (Zero wastE Blade ReseArch) consortium has successfully completed full-scale validation testing of the first recyclable blade and produced the second recyclable thermoplastic blade. This is a significant achievement that further advances the wind industry’s commitment to achieving a circular economy.
The second ZEBRA blade, measuring 77 meters in length, was made using Arkema’s thermoplastic liquid resin Elium and Owens Corning’s high-performance glass fabrics. The blade features a new Carbon-Elium resin spar cap technology and a new adhesive from Arkema.
Moreover, what sets the second ZEBRA blade apart is its use of recycled Elium resin in the shear web, a vital component of the blade structure and the first of its kind in the world. It demonstrates the potential of the resin technology to deliver sustainable blade designs and simulate the circularity of the Elium resin.
“The second ZEBRA blade builds on the learnings and valuable insights gained from the creation of the first blade and has helped us understand the structural potential to use Elium resin in carbon blades,” said John Korsgaard, Senior Director, LM Wind Power. “It complements the efforts led by our partners to demonstrate the recycling technologies for elium-based composites using glass fiber and even carbon fiber. This blade marks a key milestone for the ZEBRA project and highlights the significance of plant collaboration in new technology development, in addition to supporting sustainability objectives for our company and our customers.”
The completion of the second blade and the successful test campaign on the first blade is a significant accomplishment for the wind energy industry and the consortium. Looking forward to the milestones in 2024, which include a complete life cycle analysis based on the blades produced in the ZEBRA project, the emphasis on recycling activities, and validation testing on the second blade with the new Carbon-Elium resin spar cap.
After successfully manufacturing the first recyclable ZEBRA blade in March 2022, the consortium continued to develop technologies to create a Carbon-Elium resin spar design. Testing and validation of these blades are being carried out at LM Wind Power’s Test and Validation Centre in Denmark, with full-scale structural lifetime testing of the second blade already underway.
Launched in September 2020, the ZEBRA project is a unique partnership between various industrial companies, including Arkema, CANOE, ENGIE, LM Wind Power, Owens Corning, and SUEZ, with the aim of demonstrating the technical, economic, and environmental relevance of thermoplastic wind turbine blades on a full scale, while facilitating recycling through eco-design.
