Energy, economic, and environmental assessment of wind turbine blade thermal recycling coupled with organic Rankine cycle heat recovery and power generation

Wind turbine blade (WTB) end-of-life waste is projected to increase significantly, yet no sustainable recycling solution with a clear energy, economic, and environmental (3E) assessment exists. This paper presents a validated 3E model of a WTB thermal recycling pilot (1 t/day) to benchmark recycled glass fibre (rGF) against virgin glass fibre (vGF) and identifies the throughput at which rGF becomes competitive. This subsequently leads to a projection of 3E performance at 5000 t/y plant capacity, at which rGF achieves approximately 46% lower specific primary thermal energy, 92% of the CO2 emissions of vGF, and a selling price of 80% of vGF for a financial break-even. Building on this baseline, a novel combined material, heat, and power system is proposed and simulated, integrating the WTB recycling pilot with a 20 kWₑₗ/130 kWₜₕ organic Rankine cycle to serve residential buildings. Results show that coupling the pilot with 3000 m2 of apartments yields a near net-zero CO2 and energy-cost residential complex, with overall CO2 emissions falling below those of standalone residential buildings combined with vGF production when more than 25 apartments are integrated.