Presentations

Abstract

This paper presents a real-world case study of dismantling and recycling an onshore wind farm comprising 27 wind turbines and a substation, achieving a 99.8% recyclability rate verified and certified by Bureau Veritas. The project demonstrates a comprehensive approach to circularity in wind energy, including material recovery and extending component lifespan through second-life applications. Each major material stream was systematically identified, processed, and directed to appropriate recycling or recovery pathways. Metals such as copper, aluminium, and steel were recovered through mature, well-established mechanical and metallurgical processes, while rare earth elements underwent analysis to determine precise composition and optimal recycling routes. Oils and lubricants were collected and directed to specialized recycling facilities under an R&D framework. Notably, 100% of turbine blade material, traditionally a recycling challenge due to their composite structure, was successfully processed at a dedicated Spanish facility using advanced treatment methods. Furthermore, selected components were carefully extracted and repurposed as spare parts for similar turbines, promoting second-life use and maximizing value. This aspect underscores the potential for both recycling and reuse within the circular economy framework. By documenting and evaluating the processes applied to each component, the project provides valuable real-world data for future dismantling operations and supports the case for designing wind farms with circularity principles in mind. Beyond technical feasibility, the study contributes to discussions on environmental sustainability and social acceptance by demonstrating that effective end-of-life solutions exist for wind turbines, minimizing waste and environmental footprint. This work illustrates a near-total recyclability pathway, which is particularly relevant in the current European policy context that prioritizes circularity, critical raw materials, and recycling as key drivers of industrial resilience and sustainability. It also advances scalable and sustainable approaches to end-of-life management for wind farms.