EP4658470A1 - Wind turbine and method for recovering material from wind turbine - Google Patents

Wind turbine and method for recovering material from wind turbine

Info

Publication number
EP4658470A1
EP4658470A1 EP24704688.1A EP24704688A EP4658470A1 EP 4658470 A1 EP4658470 A1 EP 4658470A1 EP 24704688 A EP24704688 A EP 24704688A EP 4658470 A1 EP4658470 A1 EP 4658470A1
Authority
EP
European Patent Office
Prior art keywords
fibre reinforced
reinforced epoxy
epoxy polymer
acid treatment
wind turbine
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24704688.1A
Other languages
German (de)
French (fr)
Inventor
Benjamin Green
Stephen Sandercock
David Williams
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vestas Wind Systems AS
Original Assignee
Vestas Wind Systems AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vestas Wind Systems AS filed Critical Vestas Wind Systems AS
Publication of EP4658470A1 publication Critical patent/EP4658470A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
    • C08J11/18—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by treatment with organic material
    • C08J11/22—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by treatment with organic material by treatment with organic oxygen-containing compounds
    • C08J11/26—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by treatment with organic material by treatment with organic oxygen-containing compounds containing carboxylic acid groups, their anhydrides or esters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F03D80/011—Decommissioning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0293—Dissolving the materials in gases or liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins

Definitions

  • the present invention relates generally to a wind turbine, and methods for recovering material from a wind turbine.
  • a first aspect of the present invention provides a wind turbine as disclosed in claim 1.
  • the wind turbine comprises a rotor blade comprising a first fibre reinforced epoxy polymer; and a further component comprising a second fibre reinforced epoxy polymer, wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment.
  • first and second fibre reinforced epoxy polymers each comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment.
  • first and second fibre reinforced epoxy polymers are configured to be chemically disassemblable by the acid treatment, for instance by cleaving or depolymerising.
  • first and second fibre reinforced epoxy polymers each comprise an amine cured epoxy resin, such as Olin Airstone 760, Hexion RIMR 035C infusion epoxy, or Aditya Birla Recyclamine®.
  • an amine cured epoxy resin such as Olin Airstone 760, Hexion RIMR 035C infusion epoxy, or Aditya Birla Recyclamine®.
  • first and second fibre reinforced epoxy polymers each comprise the reaction product of a set of reactants comprising: a) at least one epoxy resin, b) at least one hardener, and c) at least one additive represented by formula wherein
  • R 1 , R 2 , and R 3 are independently selected from the group consisting of H, and an optionally substituted C1 -05 alkyl group,
  • R 4 is selected from the group consisting of -H, -OH, -SH, -ON, -OCN, and -COOR, wherein
  • R is selected from the group consisting of H and an optionally substituted C1-C5 alkyl group, and n is an integer from 1-10.
  • the first and second fibre reinforced epoxy polymers are based on the same polymeric system.
  • first and second fibre reinforced epoxy polymers have substantially the same chemical composition.
  • the acid treatment comprises exposure to a treatment liquid comprising acetic acid or formic acid.
  • the acid treatment comprises exposure to acid at a concentration of between 20% to 100% in aqueous solution.
  • first and second fibre reinforced epoxy polymers are configured to generate the same product by the acid treatment.
  • the same product comprises a monomer, co-monomer, epoxy oligomer or epoxy polymer fraction.
  • the same product comprises particles of epoxy polymer.
  • the same product comprises bisphenol A.
  • first and second fibre reinforced epoxy polymers are configured to release the same type of fibre material by the acid treatment, and to generate the same bi-product by the acid treatment.
  • the wind turbine comprises a tower, a nacelle and a hub, and the further component is a part of the tower, nacelle or hub.
  • the further component is a part of the tower of the wind turbine, such as: a tower coating, a tower platform, a composite tower wall, a tower door or a tower hatch.
  • the further component is a part of the nacelle of the wind turbine, such as: a nacelle cover, a nacelle platform, a helihoist platform, a helihoist fence, a nacelle hatch, a nacelle door, or a cooler component such as a cooler frame.
  • the further component is a part of the hub of the wind turbine, such as a hub nose cone, a hub spinner, or a hub hatch.
  • the wind turbine comprises a floating foundation, and the further component is a part of the floating foundation.
  • the first fibre reinforced epoxy polymer comprises carbon fibres and/or glass fibres; and the second fibre reinforced epoxy polymer comprises carbon and/or glass fibres.
  • each of the first fibre reinforced epoxy polymer and the second fibre reinforced epoxy polymer comprises glass fibres.
  • a further aspect of the invention provides a method of recovering material from a wind turbine, the wind turbine comprising a rotor blade comprising a first fibre reinforced epoxy polymer; and a further component comprising a second fibre reinforced epoxy polymer, the method comprising: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material from the disintegrated second fibre reinforced epoxy polymer.
  • first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component are disintegrated by the same acid treatment.
  • first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component are disintegrated at the same time by the same acid treatment.
  • the same acid treatment comprises exposure to treatment liquid with substantially the same chemical composition.
  • the (or each) acid treatment comprises exposure to treatment liquid.
  • the treatment liquid comprises acetic acid or formic acid.
  • the acid treatment of the first fibre reinforced epoxy polymer and the acid treatment of the second fibre reinforced epoxy polymer are performed by the same acid treatment apparatus and/or at the same acid treatment station and/or by exposure to the same treatment liquid.
  • the acid treatment apparatus comprises an acid bath or acid spraying apparatus.
  • the method further comprises: separating the rotor blade and the further component from the wind turbine; then transporting the rotor blade and the further component to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material from the disintegrated second fibre reinforced epoxy polymer.
  • the method further comprises disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer.
  • the method further comprises recycling the first material together with the second material.
  • the first material comprises first fibre material and the second material comprises second fibre material.
  • the first material comprises first epoxy polymer material and the second material comprises second epoxy polymer material.
  • the rotor blade and the further component are transported to the acid treatment station by rail, road or sea.
  • the rotor blade and the further component are transported to the acid treatment station by the same vehicle or vessel.
  • the acid treatment of the first fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles; and the acid treatment of the second fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles.
  • the acid treatment of the first fibre reinforced epoxy polymer causes it to chemically decompose; and the acid treatment of the second fibre reinforced epoxy polymer causes it to chemically decompose.
  • the method further comprises: separating the first fibre reinforced epoxy polymer and the second fibre reinforced epoxy polymer from the wind turbine; then transporting the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer; recovering the first material and the second material from the disintegrated first fibre reinforced epoxy polymer and the disintegrated second fibre reinforced epoxy polymer.
  • the method further comprises recycling the first material together with the second material.
  • An overall concept of the present invention is that both the rotor blade and the further component are designed with disintegration of rotor blade and further component as well as recycling of materials to be recovered in mind.
  • the present invention therefore facilitates and improves efficiency of future recycling through deliberate choices of combine materials selection in the individual wind turbine through increasing the volume of readily recyclable waste streams while reducing the total number of waste streams leading. This may increase the overall content recycled.
  • Figure 1 shows a wind turbine
  • Figure 2 is a schematic view of various parts of the wind turbine
  • Figure 3 shows a method of dismantling and transporting various part of the wind turbine
  • Figure 4 shows a method of performing acid treatment at an acid treatment station, followed by recovering and recycling material.
  • FIG. 1 shows a wind turbine 1 comprising a plurality of wind turbine blades 10.
  • the wind turbine 1 is a representation of a typical horizontal axis wind turbine (HAWT) that includes a tower 2, a nacelle 3 mounted at the apex of the tower 2, and a rotor hub 4 supported on the nacelle 3.
  • HAWT horizontal axis wind turbine
  • Three wind turbine blades 10 are supported by the rotor hub 4.
  • each blade 10 comprises one or more polymer-based materials in the form of a matrix material, a coating, an adhesive, or a foam.
  • the polymer- based materials may be thermoset or thermoplastic materials, but for wind turbine blades the polymer-based materials are typically thermosetting materials.
  • At least one of the polymer-based materials used to manufacture the blades 10 comprise a first fibre reinforced epoxy polymer configured to be disintegrated by exposure to an acid such as acetic acid or formic acid.
  • the first fibre reinforced epoxy polymer may comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment.
  • acid breakable epoxy polymer is herein meant an epoxy polymer capable of swelling upon exposure to acid to mechanically break some of the chemical bonds thus forming particles of swelled epoxy polymer.
  • Acid breakable epoxy polymers may for example be epoxy polymers based on amine cured epoxy resins such as for example Olin Airstone 760 or Hexion RIMR 035C infusion epoxy. In this way, the first fibre reinforced epoxy polymer may be disintegrated, thereby allowing the fibrous reinforcing material to be released from the various components making up the blade 10 and recovered for recycling.
  • the first fibre reinforced epoxy polymer may be configured to be chemically disassembled by the acid treatment, for instance by cleaving or depolymerising.
  • Chemically disassemblable polymers may for example be polymers with cleavable cross-linker such as exemplified in WO2018/050189A1.
  • Such polymers comprise the reaction product of a set of reactants comprising: a) at least one epoxy resin, b) at least one hardener, and c) at least one additive represented by formula wherein
  • R 1 , R 2 , and R 3 are independently selected from the group consisting of H, and an optionally substituted C1-C5 alkyl group,
  • R 4 is selected from the group consisting of -H, -OH, -SH, -CN, -OCN, and -COOR, wherein
  • R is selected from the group consisting of H and an optionally substituted C1-C5 alkyl group, and n is an integer from 1-10.
  • Examples of chemically disassemblable polymers are polymers bases on the resin system marketed by Aditya Birla Group under the trademark Recyclamine® and the Elium® polymeric system from Arkema. Recyclamine® is digested/decomposed due to having a scissionable link in the hardener.
  • the first fibre reinforced epoxy polymer may be configured to chemically disassemble into monomers and/or epoxy oligomers and/or cleave the polymer backbone upon exposure to acetic acid at a concentration of between 20% to 50% in water.
  • the polymer-based material or materials may be chemically disassembled, thereby allowing the fibrous reinforcing material to be released from the various components making up the blade 10 and recovered for recycling.
  • the polymeric system(s) which form the various polymer-based materials of the blade 10 are preferably selected to minimise the number of different disassembly steps required. This may be achieved by forming the various polymer-based components of the blade 10 from different polymeric systems which disintegrate under the same or similar process conditions. However, preferably all of the polymer-based materials forming the blade 10 are based on the same polymeric system (that is, the first fibre reinforced epoxy polymer) so that one set of process conditions may be used to disassemble the polymer-based materials of the blade 10 to allow recovery and recycling of the fibre reinforcing materials and also the polymer material itself (depending on the polymeric system).
  • the various polymer-based components forming the blade 10 may be based on two or more different polymeric systems which each require a specific set of process conditions in order to disintegrate.
  • polymer-based adhesives used to form the blade 10 may be based on a polymeric system requiring a first set of disintegration process conditions, while some or all of the other polymer-based components of the blade 10 are based on the first fibre reinforced epoxy polymer requiring a second set of disintegration process conditions.
  • the first set of process conditions may cause disintegration of the polymer-based adhesives at a faster rate than the second set of process conditions cause chemical disintegration of the first fibre reinforced epoxy polymer.
  • the two sets of process conditions may cause disintegration of the polymer-based materials at the same rate.
  • the bonded components of the blade may first be separated by subjecting the blade to the first set of process conditions, and, once separated, the remaining blade components may be treated under the second set of process conditions.
  • the first fibre reinforced epoxy polymer may be largely unaffected by the first set of process conditions, or disintegration of the first fibre reinforced epoxy polymer may begin during exposure to the first set of process conditions.
  • the first fibre reinforced epoxy polymer may soften during exposure to the first set of process conditions. This may be beneficial, for example, to allow the blade components which are made from the first fibre reinforced epoxy polymer to be split up into smaller pieces for faster processing during exposure to the second set of process conditions. It will be understood that the above discussion provides examples only and that any number of polymeric systems, with any number of sets of disintegration process condition requirements, may be used to make the various components of the blade 10.
  • the temperature of the acid solution may be elevated to accelerate the rate of chemical disintegration.
  • the acid solution may be at a temperature of between 60°C and 90°C.
  • each rotor blade 10 of the wind turbine 1 comprises a first fibre reinforced epoxy polymer configured to be disintegrated by an acid treatment.
  • the wind turbine also comprises a further component comprising a second fibre reinforced epoxy polymer, wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment.
  • the further component may be a part of the tower 2, for instance a part of the structure of the tower, a part housed inside the tower, or a part carried by the tower.
  • the part of the tower 2 may comprise: a tower coating 21 , a tower platform 22, a composite tower wall 23, a tower hatch 24 or a tower door 25 (shown in Figure 1).
  • the further component may be a part of the nacelle 3, for instance a part of the structure of the nacelle, a part housed inside the nacelle, or a part carried by the nacelle.
  • the part of the nacelle 3 may comprise: a nacelle cover 31 , a nacelle platform 32, a helihoist platform 33, a helihoist fence 34, a nacelle hatch or door 35, or a cooler component such as a cooler frame 36.
  • the further component may be a part of the hub 4, for instance a part of the structure of the hub, a part housed inside the hub, or a part carried by the hub.
  • the part of the hub 4 may comprise: a hub nose cone 41 , a hub spinner 43 or a hub hatch 42.
  • the further component may be a part of a floating foundation of a floating wind turbine, such as a buoyancy part or a structural part connecting buoyancy parts.
  • the first and second fibre reinforced epoxy polymers may be based on the same polymeric system, and/or have substantially the same chemical composition.
  • the polymeric system may be one of the polymer systems named above, i.e. Olin Airstone 760, Hexion RIMR 035C infusion epoxy, Recyclamine®, Elium®, or a polymeric system as exemplified in WO2018/050189A1.
  • the first and second fibre reinforced epoxy polymers may be configured to generate the same product by the same acid treatment.
  • first and second fibre reinforced epoxy polymers are each configured to be chemically disassembled by the acid treatment
  • the same product may comprise a monomer, a co-monomer such as bisphenol A, an epoxy oligomer, or an epoxy polymer fraction.
  • first and second fibre reinforced epoxy polymers each comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment
  • the same product may be particles of epoxy polymer.
  • the first and the second fibre reinforced epoxy polymers each comprise glass fibre reinforcement in the form mats or individual glass fibres, then the same product may be chopped glass fibres.
  • the first and the second fibre reinforced epoxy polymers each comprise glass fibre reinforcement in the form of mats, then the same product may be glass fibre reinforcement mats.
  • Figure 3 illustrates initial stages of a method of recovering material from the wind turbine 1.
  • Each further component comprises a second fibre reinforced epoxy polymer as described above (i.e. configured to be disintegrated by the same acid treatment as the first fibre reinforced epoxy polymer in the rotor blades 10).
  • the blade 10 may be mechanically divided into smaller blade portions 50 by sawing or crushing, for example.
  • the further components 22, 41 may also be mechanically divided into smaller portions, if required.
  • the blade portions 50 and the further components 22, 41 may be loaded together into the same transport container 60, as shown in Figure 3.
  • the transport container 60 may comprise a shipping container.
  • the transport container 60 is then transported to an acid treatment station by a vehicle or vessel, by rail, road or sea.
  • blade portions 50 and the further components 22, 41 may be transported to the acid treatment station at the same time by the same vehicle or vessel, without necessarily being loaded together into the same transport container 60.
  • first and second fibre reinforced epoxy polymers configured to be disintegrated by the same acid treatment results in a synergistic effect during the transportation phase: the fact that blade portions 50 and the further components 22, 41 can share the same transport container 60, or share the same vehicle or vessel.
  • This synergistic effect can result in a reduction in transport time and/or transport cost.
  • One way to further enhance the synergistic effect is to separate the first fibre reinforced epoxy polymer from the rotor blade and the second fibre reinforced polymer from the further component before transportation and then transport the first fibre reinforced polymer together with the second fibre reinforced epoxy polymer to the acid treatment station.
  • the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) are disintegrated by acid treatment as shown in Figure 4.
  • the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) may be disintegrated by different acid treatments.
  • the first fibre reinforced epoxy polymer of the rotor blade may be treated by acetic acid and the second fibre reinforced epoxy polymer of the further component(s) may be treated by formic acid.
  • first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) are disintegrated by the same acid treatment - for instance by exposure to acid with substantially the same chemical composition, and/or by acid treatment performed by the same acid treatment apparatus (such as the same acid bath or the same acid spraying apparatus).
  • Figure 4 gives an example of disintegration by the same acid treatment.
  • the blade portions 50 and the further components 22, 41 are submerged at the same time in a treatment liquid 54 contained in an acid bath 52.
  • this requires that both the rotor blade and the further component are designed with disintegration of rotor blade and further component as well as recycling of materials to be recovered in mind.
  • the present invention therefore facilitates and improves efficiency of future recycling through deliberate choices of combine materials selection in the individual wind turbine through increasing the volume of readily recyclable waste streams while reducing the total number of waste streams leading. As a result, this may increase the overall content recycled.
  • the treatment liquid 42 may comprise a water-based solution with a concentration of for example 80% formic acid in water.
  • the treatment liquid 42 is heated to a temperature of 85°C before the blade portions 50 and the further components 22, 31 are submerged in the treatment liquid 42 and the temperature of 85°C is maintained for the duration of the treatment process.
  • Other temperatures are also feasible, and it is a compromise between evaporation, heating and process time.
  • Exposure of the blade portions 50 and the further components 22, 41 to the treatment liquid 54 causes disintegration of the first and second fibre reinforced epoxy polymers, by one or more of the mechanisms described above.
  • the disintegration may be by chemical disassembly of the polymer-based material(s) thereby converting the chemically disassemblable polymers into monomers and/or epoxy oligomers and/or epoxy polymer fractions while leaving the fibrous reinforcing materials and other not chemically disassemblable components intact, thereby releasing the fibrous reinforcing materials and other non-disassemblable elements.
  • the treatment liquid 54 may cause swelling of the first and second fibre reinforced epoxy polymers, thereby converting them into particles of swelled epoxy polymers while leaving the fibrous reinforcing materials (and any other components which are not disintegrated by the acid treatment) intact. This releases the fibrous reinforcing materials and other non-swellable elements.
  • the acid bath 52 may contain a mixture of treatment liquid 54; fibre material from the blade portions 50; fibre material from the further components 22, 41 ; bi-products of the acid treatment (for instance a monomer, a co-monomer such as bisphenol A, an epoxy oligomer, an epoxy polymer fraction or particles of swelled epoxy polymer); residual parts of the blade portions 50; and residual parts of the further components 22, 41 , for example.
  • Various material from this mixture may then be recovered as described below, for instance by filtering the mixture.
  • the recovered fibre material may comprise first recovered fibre material 55a from the disintegrated first fibre reinforced epoxy polymer (that is, fibre material from the blade portions 50) and second recovered fibre material 55b from the disintegrated first second reinforced epoxy polymer (that is, fibre material from the further components 22, 41).
  • the first recovered fibre material 55a and the second recovered fibre material 55b may be mixed together. Alternatively, if the first and second fibre reinforced epoxy polymers disintegrate at different rates, then the first recovered fibre material 55a may be recovered before the second recovered fibre material 55b (or vice versa) in a stepwise disintegration and filtering process.
  • the first recovered fibre material 55a can then be recycled together with the second recovered material 55b, for instance by cleaning and optionally shredding, and the fibres reused as a recycled dry fibre material 55c.
  • the recovered fibre material 55a, 55b may be shredded and used in the production of chopped strand mats of randomly oriented chopped fibres.
  • the recovered fibre material 55a and 55b may be cleaned and used as recycled fibre mats of oriented fibres for preparation of new composite material. If the first recovered fibre material 55a and the second recovered material 55b are different fibre types (for instance, carbon and glass), then an additional fibre sorting step may be required if a stepwise disintegration and separation process has not been used.
  • the acid bath 52 contains a mixture 56 of treatment liquid and one or more bi-products of the acid treatment (for instance a monomer such as bisphenol A, a co-monomer, an epoxy oligomer, an epoxy polymer fraction or particles of swelled epoxy polymer).
  • a monomer such as bisphenol A, a co-monomer, an epoxy oligomer, an epoxy polymer fraction or particles of swelled epoxy polymer.
  • a bi-product of the acid treatment may optionally be recovered from the mixture 56.
  • the bi-product of the acid treatment comprises particles of swelled epoxy polymer, then these may be recovered by an appropriate separation technique, such as filtering, and recycled using known techniques (for example by depolymerization) thereby facilitating use for example in manufacturing of new resin.
  • the bi-product of the acid treatment may comprise first recovered bi-product 57a from the disintegrated first fibre reinforced epoxy polymer (that is, bi-product from the blade portions 50) and second recovered bi-product 57b from the disintegrated first second reinforced epoxy polymer (that is, bi-product from the further components 22, 41).
  • the first recovered bi-product 57a can then be recycled together with the second recovered bi-product 57b.
  • particles of swelled epoxy polymer may be recycled together using known techniques (for example by depolymerization) to produce a recycled product 57c (for instance a monomer).
  • the remaining treatment liquid 54 may be reused in the disintegration of further wind turbine blades and other wind turbine components.
  • Any metallic or other non-polymeric materials may also be recovered from the acid bath 52.
  • any mechanically removeable metal (or other material) parts may be removed from the blade 10 and/or the further component(s) 22, 41 before they are exposed to the treatment liquid 54.
  • Figure 4 gives one example of recovering material 55a, 55b, 57a, 57b from the wind turbine, but other examples fall within the scope of the present invention.
  • the blade 10 and the further component(s) 22, 41 may be exposed to the treatment liquid 54 by spraying the treatment liquid 54 from a spraying apparatus or exposing them to the treatment liquid 54 in some other way.
  • blades 10 and the further component(s) 22, 41 in the same body of treatment liquid 54 in the same acid bath 52 may be submerged in different acid baths containing treatment liquids with substantially the same chemical composition (for instance both treatment liquids comprising acetic acid).
  • first and second fibre reinforced epoxy polymers configured to be disintegrated by the same acid treatment can result in various synergistic effects at the acid treatment station shown in Figure 4.
  • blade portions 50 and the further components 22, 41 can share the same acid treatment apparatus or the same acid treatment station (for instance they can share the same acid bath 52 or the same acid spraying apparatus).
  • the first and second fibre reinforced epoxy polymers are configured to generate the same product by the acid treatment, because this enables the product of the acid treatment to be handled more easily.
  • first recovered fibre material 55a and the second recovered material 55b may comprise the same fibre type (for instance, carbon); and/or the first recovered bi-product 57a and the second recovered bi-product 57b may both comprise particles of swelled epoxy polymer; and/or the first recovered bi-product 57a and the second recovered bi-product 57b may comprise the same monomer, co-monomer, epoxy oligomer or epoxy polymer fraction.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Sustainable Development (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Medicinal Chemistry (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • Health & Medical Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Wind Motors (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

According to the present invention there is provided a wind turbine with a rotor blade comprising a first fibre reinforced epoxy polymer and a further component comprising a second fibre reinforced epoxy polymer. Wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment. Further is provided a method of recovering material from a wind turbine comprising a rotor blade comprising a first fibre reinforced epoxy polymer and a further component comprising a second fibre reinforced epoxy polymer. The method comprising: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material from the disintegrated second fibre reinforced epoxy polymer.

Description

WIND TURBINE AND METHOD FOR RECOVERING MATERIAL FROM WIND TURBINE
Technical Field
The present invention relates generally to a wind turbine, and methods for recovering material from a wind turbine.
Background
It is desirable to extract and recover materials for recycling from a wind turbine that has reached its end of life.
The use of different materials in the various components of the wind turbine such as composite components optimized for performance during use makes this process difficult and expensive. In some cases different materials of the wind turbine are therefore placed in landfill rather than being recycled and/or reused.
It is against this background that the invention has been devised.
Summary of the Invention
A first aspect of the present invention provides a wind turbine as disclosed in claim 1. The wind turbine comprises a rotor blade comprising a first fibre reinforced epoxy polymer; and a further component comprising a second fibre reinforced epoxy polymer, wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment.
The expression “configured to be disintegrated by the same acid treatment” is defined herein to mean that both polymers would disintegrate if subjected to acid treatment under substantially the same conditions. By “the same conditions” is meant exposure to the same acid (for example acetic acid or formic acid), at the same pH and the same temperature, and for the same amount of time. Optionally the first and second fibre reinforced epoxy polymers each comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment.
Optionally the first and second fibre reinforced epoxy polymers are configured to be chemically disassemblable by the acid treatment, for instance by cleaving or depolymerising.
Optionally the first and second fibre reinforced epoxy polymers each comprise an amine cured epoxy resin, such as Olin Airstone 760, Hexion RIMR 035C infusion epoxy, or Aditya Birla Recyclamine®.
Optionally the first and second fibre reinforced epoxy polymers each comprise the reaction product of a set of reactants comprising: a) at least one epoxy resin, b) at least one hardener, and c) at least one additive represented by formula wherein
R1 , R2 , and R3 are independently selected from the group consisting of H, and an optionally substituted C1 -05 alkyl group,
R4 is selected from the group consisting of -H, -OH, -SH, -ON, -OCN, and -COOR, wherein
R is selected from the group consisting of H and an optionally substituted C1-C5 alkyl group, and n is an integer from 1-10. Optionally the first and second fibre reinforced epoxy polymers are based on the same polymeric system.
Optionally the first and second fibre reinforced epoxy polymers have substantially the same chemical composition.
Optionally the acid treatment comprises exposure to a treatment liquid comprising acetic acid or formic acid.
Optionally the acid treatment comprises exposure to acid at a concentration of between 20% to 100% in aqueous solution.
Optionally the first and second fibre reinforced epoxy polymers are configured to generate the same product by the acid treatment.
Optionally the same product comprises a monomer, co-monomer, epoxy oligomer or epoxy polymer fraction.
Optionally the same product comprises particles of epoxy polymer.
Optionally the same product comprises bisphenol A.
Optionally the first and second fibre reinforced epoxy polymers are configured to release the same type of fibre material by the acid treatment, and to generate the same bi-product by the acid treatment.
Optionally the wind turbine comprises a tower, a nacelle and a hub, and the further component is a part of the tower, nacelle or hub.
Optionally the further component is a part of the tower of the wind turbine, such as: a tower coating, a tower platform, a composite tower wall, a tower door or a tower hatch.
Optionally the further component is a part of the nacelle of the wind turbine, such as: a nacelle cover, a nacelle platform, a helihoist platform, a helihoist fence, a nacelle hatch, a nacelle door, or a cooler component such as a cooler frame. Optionally the further component is a part of the hub of the wind turbine, such as a hub nose cone, a hub spinner, or a hub hatch.
Optionally the wind turbine comprises a floating foundation, and the further component is a part of the floating foundation.
Optionally the first fibre reinforced epoxy polymer comprises carbon fibres and/or glass fibres; and the second fibre reinforced epoxy polymer comprises carbon and/or glass fibres. Preferably each of the first fibre reinforced epoxy polymer and the second fibre reinforced epoxy polymer comprises glass fibres.
A further aspect of the invention provides a method of recovering material from a wind turbine, the wind turbine comprising a rotor blade comprising a first fibre reinforced epoxy polymer; and a further component comprising a second fibre reinforced epoxy polymer, the method comprising: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material from the disintegrated second fibre reinforced epoxy polymer.
Optionally the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component are disintegrated by the same acid treatment.
Optionally the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component are disintegrated at the same time by the same acid treatment.
Optionally the same acid treatment comprises exposure to treatment liquid with substantially the same chemical composition.
Optionally the (or each) acid treatment comprises exposure to treatment liquid.
Optionally the treatment liquid comprises acetic acid or formic acid. Optionally the acid treatment of the first fibre reinforced epoxy polymer and the acid treatment of the second fibre reinforced epoxy polymer are performed by the same acid treatment apparatus and/or at the same acid treatment station and/or by exposure to the same treatment liquid.
Optionally the acid treatment apparatus comprises an acid bath or acid spraying apparatus.
Optionally the method further comprises: separating the rotor blade and the further component from the wind turbine; then transporting the rotor blade and the further component to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material from the disintegrated second fibre reinforced epoxy polymer.
Optionally the method further comprises disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer.
Optionally the method further comprises recycling the first material together with the second material.
Optionally the first material comprises first fibre material and the second material comprises second fibre material.
Optionally the first material comprises first epoxy polymer material and the second material comprises second epoxy polymer material.
Optionally the rotor blade and the further component are transported to the acid treatment station by rail, road or sea.
Optionally the rotor blade and the further component are transported to the acid treatment station by the same vehicle or vessel.
Optionally the acid treatment of the first fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles; and the acid treatment of the second fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles. Optionally the acid treatment of the first fibre reinforced epoxy polymer causes it to chemically decompose; and the acid treatment of the second fibre reinforced epoxy polymer causes it to chemically decompose.
Optionally the method further comprises: separating the first fibre reinforced epoxy polymer and the second fibre reinforced epoxy polymer from the wind turbine; then transporting the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer; recovering the first material and the second material from the disintegrated first fibre reinforced epoxy polymer and the disintegrated second fibre reinforced epoxy polymer.
Optionally, the method further comprises recycling the first material together with the second material.
An overall concept of the present invention is that both the rotor blade and the further component are designed with disintegration of rotor blade and further component as well as recycling of materials to be recovered in mind. Traditionally and typically this is not the case as wind turbines sustain very heavy wear during use, so each component is designed to sustain the specific requirements of the component during use and not for potential advantages during recycling that possibly is 20-30 years into the future. The present invention therefore facilitates and improves efficiency of future recycling through deliberate choices of combine materials selection in the individual wind turbine through increasing the volume of readily recyclable waste streams while reducing the total number of waste streams leading. This may increase the overall content recycled.
Brief Description of the Drawings
So that it may be more fully understood, the invention will now be described, by way of example only, with reference to the following drawings, in which like features are assigned like reference numerals, and in which:
Figure 1 shows a wind turbine; Figure 2 is a schematic view of various parts of the wind turbine;
Figure 3 shows a method of dismantling and transporting various part of the wind turbine; and
Figure 4 shows a method of performing acid treatment at an acid treatment station, followed by recovering and recycling material.
Detailed Description
Figure 1 shows a wind turbine 1 comprising a plurality of wind turbine blades 10. The wind turbine 1 is a representation of a typical horizontal axis wind turbine (HAWT) that includes a tower 2, a nacelle 3 mounted at the apex of the tower 2, and a rotor hub 4 supported on the nacelle 3. Three wind turbine blades 10 are supported by the rotor hub 4.
Several of the components making up each blade 10 comprises one or more polymer-based materials in the form of a matrix material, a coating, an adhesive, or a foam. The polymer- based materials may be thermoset or thermoplastic materials, but for wind turbine blades the polymer-based materials are typically thermosetting materials.
In the example shown here, at least one of the polymer-based materials used to manufacture the blades 10 comprise a first fibre reinforced epoxy polymer configured to be disintegrated by exposure to an acid such as acetic acid or formic acid.
In some examples the first fibre reinforced epoxy polymer may comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment. By acid breakable epoxy polymer is herein meant an epoxy polymer capable of swelling upon exposure to acid to mechanically break some of the chemical bonds thus forming particles of swelled epoxy polymer. Acid breakable epoxy polymers may for example be epoxy polymers based on amine cured epoxy resins such as for example Olin Airstone 760 or Hexion RIMR 035C infusion epoxy. In this way, the first fibre reinforced epoxy polymer may be disintegrated, thereby allowing the fibrous reinforcing material to be released from the various components making up the blade 10 and recovered for recycling.
In other examples, the first fibre reinforced epoxy polymer may be configured to be chemically disassembled by the acid treatment, for instance by cleaving or depolymerising. Chemically disassemblable polymers may for example be polymers with cleavable cross-linker such as exemplified in WO2018/050189A1. Such polymers comprise the reaction product of a set of reactants comprising: a) at least one epoxy resin, b) at least one hardener, and c) at least one additive represented by formula wherein
R1 , R2 , and R3 are independently selected from the group consisting of H, and an optionally substituted C1-C5 alkyl group,
R4 is selected from the group consisting of -H, -OH, -SH, -CN, -OCN, and -COOR, wherein
R is selected from the group consisting of H and an optionally substituted C1-C5 alkyl group, and n is an integer from 1-10.
Examples of chemically disassemblable polymers are polymers bases on the resin system marketed by Aditya Birla Group under the trademark Recyclamine® and the Elium® polymeric system from Arkema. Recyclamine® is digested/decomposed due to having a scissionable link in the hardener.
For example, the first fibre reinforced epoxy polymer may be configured to chemically disassemble into monomers and/or epoxy oligomers and/or cleave the polymer backbone upon exposure to acetic acid at a concentration of between 20% to 50% in water. In this way, the polymer-based material or materials may be chemically disassembled, thereby allowing the fibrous reinforcing material to be released from the various components making up the blade 10 and recovered for recycling.
The polymeric system(s) which form the various polymer-based materials of the blade 10 are preferably selected to minimise the number of different disassembly steps required. This may be achieved by forming the various polymer-based components of the blade 10 from different polymeric systems which disintegrate under the same or similar process conditions. However, preferably all of the polymer-based materials forming the blade 10 are based on the same polymeric system (that is, the first fibre reinforced epoxy polymer) so that one set of process conditions may be used to disassemble the polymer-based materials of the blade 10 to allow recovery and recycling of the fibre reinforcing materials and also the polymer material itself (depending on the polymeric system).
In alternative examples, the various polymer-based components forming the blade 10 may be based on two or more different polymeric systems which each require a specific set of process conditions in order to disintegrate. For example, polymer-based adhesives used to form the blade 10 may be based on a polymeric system requiring a first set of disintegration process conditions, while some or all of the other polymer-based components of the blade 10 are based on the first fibre reinforced epoxy polymer requiring a second set of disintegration process conditions. The first set of process conditions may cause disintegration of the polymer-based adhesives at a faster rate than the second set of process conditions cause chemical disintegration of the first fibre reinforced epoxy polymer. Alternatively, the two sets of process conditions may cause disintegration of the polymer-based materials at the same rate.
In the example above, the bonded components of the blade may first be separated by subjecting the blade to the first set of process conditions, and, once separated, the remaining blade components may be treated under the second set of process conditions.
The first fibre reinforced epoxy polymer may be largely unaffected by the first set of process conditions, or disintegration of the first fibre reinforced epoxy polymer may begin during exposure to the first set of process conditions. For example, the first fibre reinforced epoxy polymer may soften during exposure to the first set of process conditions. This may be beneficial, for example, to allow the blade components which are made from the first fibre reinforced epoxy polymer to be split up into smaller pieces for faster processing during exposure to the second set of process conditions. It will be understood that the above discussion provides examples only and that any number of polymeric systems, with any number of sets of disintegration process condition requirements, may be used to make the various components of the blade 10.
In all the examples discussed above, the temperature of the acid solution may be elevated to accelerate the rate of chemical disintegration. For example, the acid solution may be at a temperature of between 60°C and 90°C.
As noted above, each rotor blade 10 of the wind turbine 1 comprises a first fibre reinforced epoxy polymer configured to be disintegrated by an acid treatment. The wind turbine also comprises a further component comprising a second fibre reinforced epoxy polymer, wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment.
With reference to Figure 2, the further component may be a part of the tower 2, for instance a part of the structure of the tower, a part housed inside the tower, or a part carried by the tower. By way of non-limiting example, the part of the tower 2 may comprise: a tower coating 21 , a tower platform 22, a composite tower wall 23, a tower hatch 24 or a tower door 25 (shown in Figure 1).
Alternatively, the further component may be a part of the nacelle 3, for instance a part of the structure of the nacelle, a part housed inside the nacelle, or a part carried by the nacelle. By way of non-limiting example, the part of the nacelle 3 may comprise: a nacelle cover 31 , a nacelle platform 32, a helihoist platform 33, a helihoist fence 34, a nacelle hatch or door 35, or a cooler component such as a cooler frame 36.
Alternatively, the further component may be a part of the hub 4, for instance a part of the structure of the hub, a part housed inside the hub, or a part carried by the hub. By way of nonlimiting example, the part of the hub 4 may comprise: a hub nose cone 41 , a hub spinner 43 or a hub hatch 42.
Alternatively, the further component may be a part of a floating foundation of a floating wind turbine, such as a buoyancy part or a structural part connecting buoyancy parts. The first and second fibre reinforced epoxy polymers may be based on the same polymeric system, and/or have substantially the same chemical composition. By way of non-limiting example the polymeric system may be one of the polymer systems named above, i.e. Olin Airstone 760, Hexion RIMR 035C infusion epoxy, Recyclamine®, Elium®, or a polymeric system as exemplified in WO2018/050189A1.
The first and second fibre reinforced epoxy polymers may be configured to generate the same product by the same acid treatment.
For example, where the first and second fibre reinforced epoxy polymers are each configured to be chemically disassembled by the acid treatment, then the same product may comprise a monomer, a co-monomer such as bisphenol A, an epoxy oligomer, or an epoxy polymer fraction. In another example, where the first and second fibre reinforced epoxy polymers each comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment, then the same product may be particles of epoxy polymer.
The first and the second fibre reinforced epoxy polymers each comprise glass fibre reinforcement in the form mats or individual glass fibres, then the same product may be chopped glass fibres. In another example., the first and the second fibre reinforced epoxy polymers each comprise glass fibre reinforcement in the form of mats, then the same product may be glass fibre reinforcement mats.
Figure 3 illustrates initial stages of a method of recovering material from the wind turbine 1.
First the wind turbine 1 is deconstructed to separate the rotors blades 10, and any other recyclable further components, from the rest of the wind turbine. Each further component comprises a second fibre reinforced epoxy polymer as described above (i.e. configured to be disintegrated by the same acid treatment as the first fibre reinforced epoxy polymer in the rotor blades 10).
In the example of Figure 3, only a single rotor blade 10 is shown, and the further components comprise a tower platform 22 and a hub nose cone 41.
In a first step, the blade 10 may be mechanically divided into smaller blade portions 50 by sawing or crushing, for example. Optionally the further components 22, 41 may also be mechanically divided into smaller portions, if required.
The blade portions 50 and the further components 22, 41 may be loaded together into the same transport container 60, as shown in Figure 3. By way of example, the transport container 60 may comprise a shipping container. The transport container 60 is then transported to an acid treatment station by a vehicle or vessel, by rail, road or sea.
Alternatively the blade portions 50 and the further components 22, 41 may be transported to the acid treatment station at the same time by the same vehicle or vessel, without necessarily being loaded together into the same transport container 60.
The use of first and second fibre reinforced epoxy polymers configured to be disintegrated by the same acid treatment results in a synergistic effect during the transportation phase: the fact that blade portions 50 and the further components 22, 41 can share the same transport container 60, or share the same vehicle or vessel. This synergistic effect can result in a reduction in transport time and/or transport cost. One way to further enhance the synergistic effect is to separate the first fibre reinforced epoxy polymer from the rotor blade and the second fibre reinforced polymer from the further component before transportation and then transport the first fibre reinforced polymer together with the second fibre reinforced epoxy polymer to the acid treatment station.
When the transport container 60 arrives at the acid treatment station, the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) are disintegrated by acid treatment as shown in Figure 4.
The first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) may be disintegrated by different acid treatments. For instance the first fibre reinforced epoxy polymer of the rotor blade may be treated by acetic acid and the second fibre reinforced epoxy polymer of the further component(s) may be treated by formic acid.
However, more preferably the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component(s) are disintegrated by the same acid treatment - for instance by exposure to acid with substantially the same chemical composition, and/or by acid treatment performed by the same acid treatment apparatus (such as the same acid bath or the same acid spraying apparatus).
Figure 4 gives an example of disintegration by the same acid treatment. The blade portions 50 and the further components 22, 41 are submerged at the same time in a treatment liquid 54 contained in an acid bath 52. It is preferred to disintegrate the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer and recover the first material (55a, 57a) and the second material (55b, 57b) from the disintegrated first fibre reinforced epoxy polymer and the disintegrated second fibre reinforced epoxy polymer as this opens for process and equipment efficiency. However this requires that both the rotor blade and the further component are designed with disintegration of rotor blade and further component as well as recycling of materials to be recovered in mind. Traditionally and typically this is not the case as wind turbines sustain very heavy wear during use, so each component is designed to sustain the specific requirements of the component during use and not for potential advantages during recycling that possibly is 20-30 years into the future. The present invention therefore facilitates and improves efficiency of future recycling through deliberate choices of combine materials selection in the individual wind turbine through increasing the volume of readily recyclable waste streams while reducing the total number of waste streams leading. As a result, this may increase the overall content recycled.
The treatment liquid 42 may comprise a water-based solution with a concentration of for example 80% formic acid in water. The treatment liquid 42 is heated to a temperature of 85°C before the blade portions 50 and the further components 22, 31 are submerged in the treatment liquid 42 and the temperature of 85°C is maintained for the duration of the treatment process. Other temperatures are also feasible, and it is a compromise between evaporation, heating and process time.
Exposure of the blade portions 50 and the further components 22, 41 to the treatment liquid 54 causes disintegration of the first and second fibre reinforced epoxy polymers, by one or more of the mechanisms described above.
For instance, the disintegration may be by chemical disassembly of the polymer-based material(s) thereby converting the chemically disassemblable polymers into monomers and/or epoxy oligomers and/or epoxy polymer fractions while leaving the fibrous reinforcing materials and other not chemically disassemblable components intact, thereby releasing the fibrous reinforcing materials and other non-disassemblable elements. Alternatively, the treatment liquid 54 may cause swelling of the first and second fibre reinforced epoxy polymers, thereby converting them into particles of swelled epoxy polymers while leaving the fibrous reinforcing materials (and any other components which are not disintegrated by the acid treatment) intact. This releases the fibrous reinforcing materials and other non-swellable elements.
A typical process time to allow release of the fibrous reinforcing materials is 10 minutes to several days or even weeks depending on the process conditions and the polymeric system(s) in question. Once the polymer-based materials are sufficiently disintegrated by the acid treatment, the acid bath 52 may contain a mixture of treatment liquid 54; fibre material from the blade portions 50; fibre material from the further components 22, 41 ; bi-products of the acid treatment (for instance a monomer, a co-monomer such as bisphenol A, an epoxy oligomer, an epoxy polymer fraction or particles of swelled epoxy polymer); residual parts of the blade portions 50; and residual parts of the further components 22, 41 , for example. Various material from this mixture may then be recovered as described below, for instance by filtering the mixture.
One type of material that can be recovered from the mixture is recovered fibre material 55a, 55b. The recovered fibre material may comprise first recovered fibre material 55a from the disintegrated first fibre reinforced epoxy polymer (that is, fibre material from the blade portions 50) and second recovered fibre material 55b from the disintegrated first second reinforced epoxy polymer (that is, fibre material from the further components 22, 41).
The first recovered fibre material 55a and the second recovered fibre material 55b may be mixed together. Alternatively, if the first and second fibre reinforced epoxy polymers disintegrate at different rates, then the first recovered fibre material 55a may be recovered before the second recovered fibre material 55b (or vice versa) in a stepwise disintegration and filtering process.
The first recovered fibre material 55a can then be recycled together with the second recovered material 55b, for instance by cleaning and optionally shredding, and the fibres reused as a recycled dry fibre material 55c. In one example, the recovered fibre material 55a, 55b may be shredded and used in the production of chopped strand mats of randomly oriented chopped fibres. In one example, the recovered fibre material 55a and 55b may be cleaned and used as recycled fibre mats of oriented fibres for preparation of new composite material. If the first recovered fibre material 55a and the second recovered material 55b are different fibre types (for instance, carbon and glass), then an additional fibre sorting step may be required if a stepwise disintegration and separation process has not been used.
After the recovered fibre material 55a, 55b, and any residual parts, have been removed from the acid bath 52, the acid bath 52 contains a mixture 56 of treatment liquid and one or more bi-products of the acid treatment (for instance a monomer such as bisphenol A, a co-monomer, an epoxy oligomer, an epoxy polymer fraction or particles of swelled epoxy polymer).
A bi-product of the acid treatment may optionally be recovered from the mixture 56. For instance if the bi-product of the acid treatment comprises particles of swelled epoxy polymer, then these may be recovered by an appropriate separation technique, such as filtering, and recycled using known techniques (for example by depolymerization) thereby facilitating use for example in manufacturing of new resin.
The bi-product of the acid treatment may comprise first recovered bi-product 57a from the disintegrated first fibre reinforced epoxy polymer (that is, bi-product from the blade portions 50) and second recovered bi-product 57b from the disintegrated first second reinforced epoxy polymer (that is, bi-product from the further components 22, 41).
The first recovered bi-product 57a can then be recycled together with the second recovered bi-product 57b. For instance, particles of swelled epoxy polymer may be recycled together using known techniques (for example by depolymerization) to produce a recycled product 57c (for instance a monomer).
The remaining treatment liquid 54 may be reused in the disintegration of further wind turbine blades and other wind turbine components.
Any metallic or other non-polymeric materials (such as wood) may also be recovered from the acid bath 52. In an alternative example, any mechanically removeable metal (or other material) parts may be removed from the blade 10 and/or the further component(s) 22, 41 before they are exposed to the treatment liquid 54.
Figure 4 gives one example of recovering material 55a, 55b, 57a, 57b from the wind turbine, but other examples fall within the scope of the present invention. In one alternative example, rather than using an acid bath 52, the blade 10 and the further component(s) 22, 41 may be exposed to the treatment liquid 54 by spraying the treatment liquid 54 from a spraying apparatus or exposing them to the treatment liquid 54 in some other way.
In another alternative example, rather than submerging the blades 10 and the further component(s) 22, 41 in the body of treatment liquid 54 at the same time, they may be submerged in the same body of treatment liquid 54 one after the other.
In another alternative example, rather than submerging the blades 10 and the further component(s) 22, 41 in the same body of treatment liquid 54 in the same acid bath 52, they may be submerged in different acid baths containing treatment liquids with substantially the same chemical composition (for instance both treatment liquids comprising acetic acid).
The use of first and second fibre reinforced epoxy polymers configured to be disintegrated by the same acid treatment can result in various synergistic effects at the acid treatment station shown in Figure 4.
One synergy is the fact that blade portions 50 and the further components 22, 41 can share the same acid treatment apparatus or the same acid treatment station (for instance they can share the same acid bath 52 or the same acid spraying apparatus).
Another synergy is the fact that the blade portions 50 and the further components 22, 41 can be submerged in the same body of treatment liquid 54.
Another synergy is the fact that the material recovered from the blade portions 50 and the further components 22, 41 can be handled together, for instance recycled together.
Ideally the first and second fibre reinforced epoxy polymers are configured to generate the same product by the acid treatment, because this enables the product of the acid treatment to be handled more easily.
For instance the first recovered fibre material 55a and the second recovered material 55b may comprise the same fibre type (for instance, carbon); and/or the first recovered bi-product 57a and the second recovered bi-product 57b may both comprise particles of swelled epoxy polymer; and/or the first recovered bi-product 57a and the second recovered bi-product 57b may comprise the same monomer, co-monomer, epoxy oligomer or epoxy polymer fraction.
The skilled person will appreciate that modifications may be made to the specific embodiments described above without departing from the inventive concept as defined by the claims.

Claims

1. A wind turbine (1) comprising a rotor blade (10) comprising a first fibre reinforced epoxy polymer; and a further component (21-23; 31-35; 41 , 42) comprising a second fibre reinforced epoxy polymer, wherein the first and second fibre reinforced epoxy polymers are configured to be disintegrated by the same acid treatment.
2. The wind turbine according to claim 1 , wherein the first and second fibre reinforced epoxy polymers each comprise an amine cured epoxy resin.
3. The wind turbine according to claim 1 or 2, wherein the first and second fibre reinforced epoxy polymers each comprise an acid breakable polymer configured to swell and mechanically break into epoxy particles by the acid treatment.
4. The wind turbine according to claim 1 or 2, wherein the first and second fibre reinforced epoxy polymers are configured to be chemically disassemblable by the acid treatment, for instance by cleaving or depolymerising.
5. The wind turbine according to any preceding claim, wherein the acid treatment comprises exposure to a treatment liquid (54) comprising acetic acid and/or formic acid.
6. The wind turbine according to any preceding claim, wherein the first and second fibre reinforced epoxy polymers are configured to generate the same product by the acid treatment.
7. The wind turbine according to any preceding claim, wherein the further component is a part of the tower of the wind turbine, such as: a tower coating (21), a tower platform (22), a composite tower wall (23), a tower door (25) or a tower hatch (24).
8. The wind turbine according to any preceding claim, wherein the further component is a part of a nacelle of the wind turbine, such as: a nacelle cover (31), a nacelle platform (32), a helihoist platform (33), a helihoist fence (34), a nacelle hatch (35), a nacelle door, or a cooler component such as a cooler frame (36).
9. The wind turbine according to any preceding claim, wherein the further component is a part of a hub of the wind turbine, such as a hub nose cone (41), a hub spinner, or a hub hatch (42).
10. A method of recovering material from a wind turbine, the wind turbine comprising a rotor blade (10) comprising a first fibre reinforced epoxy polymer; and a further component (21-23; 31-35; 41 , 42) comprising a second fibre reinforced epoxy polymer, the method comprising: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material (55a, 57a) from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material (55b, 57b) from the disintegrated second fibre reinforced epoxy polymer.
11. The method of claim 10, wherein the first fibre reinforced epoxy polymer of the rotor blade and the second fibre reinforced epoxy polymer of the further component are disintegrated by the same acid treatment.
12. The method of claim 10 or 11 , further comprising: separating the rotor blade (10) and the further component (21-23; 31-35; 41, 42) from the wind turbine; then transporting the rotor blade and the further component to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer of the rotor blade by acid treatment; recovering first material (55a, 57a) from the disintegrated first fibre reinforced epoxy polymer; disintegrating the second fibre reinforced epoxy polymer of the further component by acid treatment; and recovering second material (55b, 57b) from the disintegrated second fibre reinforced epoxy polymer.
13. The method of claim 10, 11 or 12, further comprising disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer.
14. The method of any of claims 10 to 13, further comprising recycling the first material together with the second material.
15. The method of any of claims 10 to 14, wherein the acid treatment of the first fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles; and the acid treatment of the second fibre reinforced epoxy polymer causes it to swell and mechanically break into epoxy particles.
16. The method of any of claims 10 to 15, wherein the acid treatment of the first fibre reinforced epoxy polymer causes it to chemically decompose; and the acid treatment of the second fibre reinforced epoxy polymer causes it to chemically decompose.
17. The method of claim 10 or 11 , further comprising: separating the first fibre reinforced epoxy polymer and the second fibre reinforced epoxy polymer from the wind turbine; then transporting the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer to an acid treatment station; and at the acid treatment station: disintegrating the first fibre reinforced epoxy polymer together with the second fibre reinforced epoxy polymer; recovering the first material (55a, 57a) and the second material (55b, 57b) from the disintegrated first fibre reinforced epoxy polymer and the disintegrated second fibre reinforced epoxy polymer.
18. The method of any of claim 17, further comprising recycling the first material together with the second material.
EP24704688.1A 2023-01-31 2024-01-31 Wind turbine and method for recovering material from wind turbine Pending EP4658470A1 (en)

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