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Repurposing EoL WTB Components into a Large-Scale PV-Floating Demonstrator

Author

Listed:
  • Mário Moutinho

    (INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Campus da FEUP, R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal)

  • Ricardo Rocha

    (INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Campus da FEUP, R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal)

  • David Atteln

    (Faculty of Engineering, HTWK Leipzig—University of Applied Sciences, Karl-Liebknecht-Straße 132, 04277 Leipzig, Germany)

  • Philipp Johst

    (Faculty of Engineering, HTWK Leipzig—University of Applied Sciences, Karl-Liebknecht-Straße 132, 04277 Leipzig, Germany)

  • Robert Böhm

    (Faculty of Engineering, HTWK Leipzig—University of Applied Sciences, Karl-Liebknecht-Straße 132, 04277 Leipzig, Germany)

  • Konstantina-Roxani Chatzipanagiotou

    (IRES—Innovation in Research & Engineering Solutions SNC, 1000 Brussels, Belgium)

  • Evangelia Stamkopoulou

    (IRES—Innovation in Research & Engineering Solutions SNC, 1000 Brussels, Belgium)

  • Elias P. Koumoulos

    (IRES—Innovation in Research & Engineering Solutions SNC, 1000 Brussels, Belgium)

  • Andreia Araujo

    (INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Campus da FEUP, R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal
    LAETA—Associated Laboratory of Energy, Transports and Aeronautics, Campus da FEUP, R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal)

Abstract

The growing volume of decommissioned wind turbine blades (WTBs) poses substantial challenges for end-of-life (EoL) material management, particularly within the composite repurposing and recycling strategies. This study investigates the repurposing of EoL WTB segments in a full-scale demonstrator for a photovoltaic (PV) floating platform. The design process is supported by a calibrated numerical model replicating the structure’s behaviour under representative operating conditions. The prototype reached Technology Readiness Level 6 (TRL 6) through laboratory-scale wave basin testing, under irregular wave conditions with heights up to 0.22 m. Structural assessment validates deformation limits and identifies critical zones using composite failure criteria. A comparison between two configurations underscores the importance of load continuity and effective load distribution. Additionally, a life cycle assessment (LCA) evaluates environmental impact of the repurposed solution. Results indicate that the demonstrator’s footprint is comparable to those of conventional PV-floating installations reported in the literature. Furthermore, overall sustainability can be significantly enhanced by reducing transport distances associated with repurposed components. The findings support the structural feasibility and environmental value of second-life applications for composite WTB segments, offering a circular and scalable pathway for their integration into aquatic infrastructures.

Suggested Citation

  • Mário Moutinho & Ricardo Rocha & David Atteln & Philipp Johst & Robert Böhm & Konstantina-Roxani Chatzipanagiotou & Evangelia Stamkopoulou & Elias P. Koumoulos & Andreia Araujo, 2025. "Repurposing EoL WTB Components into a Large-Scale PV-Floating Demonstrator," Sustainability, MDPI, vol. 17(19), pages 1-29, September.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:19:p:8717-:d:1760383
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    References listed on IDEAS

    as
    1. Cromratie Clemons, Sáde K. & Salloum, Coleman R. & Herdegen, Kyle G. & Kamens, Richard M. & Gheewala, Shabbir H., 2021. "Life cycle assessment of a floating photovoltaic system and feasibility for application in Thailand," Renewable Energy, Elsevier, vol. 168(C), pages 448-462.
    2. Jensen, J.P. & Skelton, K., 2018. "Wind turbine blade recycling: Experiences, challenges and possibilities in a circular economy," Renewable and Sustainable Energy Reviews, Elsevier, vol. 97(C), pages 165-176.
    3. Avinash Borgaonkar & Greg McNamara, 2024. "Environmental Impact Assessment of Anti-Corrosion Coating Life Cycle Processes for Marine Applications," Sustainability, MDPI, vol. 16(13), pages 1-11, June.
    4. Kieran Ruane & Marios Soutsos & An Huynh & Zoe Zhang & Angela Nagle & Kenny McDonald & T Russell Gentry & Paul Leahy & Lawrence C. Bank, 2023. "Construction and Cost Analysis of BladeBridges Made from Decommissioned FRP Wind Turbine Blades," Sustainability, MDPI, vol. 15(4), pages 1-15, February.
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    6. Beauson, J. & Laurent, A. & Rudolph, D.P. & Pagh Jensen, J., 2022. "The complex end-of-life of wind turbine blades: A review of the European context," Renewable and Sustainable Energy Reviews, Elsevier, vol. 155(C).
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