Researchers at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL) have created a new resin for manufacturing wind turbine blades that can be chemically recycled, potentially eliminating the need for blades to be discarded in landfills at the end of their lifecycle. The breakthrough material, detailed in the journal Science, could transform the sustainability of wind energy by enabling the reuse of blade components.
The resin, developed using bio-derivable resources, matches the performance of current industry-standard blades made from thermoset resin and surpasses certain recyclable thermoplastic resins. To demonstrate the material’s potential, NREL researchers constructed a prototype 9-meter blade using the newly developed biomass-derived resin, known as PECAN, an acronym for PolyEster Covalently Adaptable Network.
The PECAN resin integrates with existing manufacturing processes and represents a significant advancement in wind turbine technology. Traditional wind blades, with a lifespan of about 20 years, are typically mechanically recycled—often shredded for use as concrete filler. In contrast, the PECAN resin allows blades to be chemically recycled through a mild process, enabling the components to be reused multiple times. According to Ryan Clarke, a postdoctoral researcher at NREL and the paper’s lead author, the process can completely break down a prototype blade in just six hours. Clarke emphasized that, “It is truly a limitless approach if it’s done right.”
The research, which involved collaboration across five NREL research hubs, including the National Wind Technology Center and the BOTTLE Consortium, demonstrated a comprehensive end-of-life strategy for PECAN blades. The scientists explored various feedstocks to develop a wind blade that could be recycled without compromising performance. The resulting composites maintained their shape, withstood accelerated weatherization tests, and could be manufactured within the same timeframe as current wind turbine blades.
While the prototype was relatively small, comparable in length to a football field, it provided proof of the manufacturing process. The U.S. Department of Energy, through its Advanced Materials and Manufacturing Technologies Office and Bioenergy Technologies Office, supported the research. The NREL team plans to continue their work with additional funding to develop larger blades and explore more bio-derived resin formulations.
NREL, operated by the Alliance for Sustainable Energy LLC, serves as the primary national laboratory for renewable energy and energy efficiency research under the U.S. Department of Energy.
