Enva's Sustainable Approach to Wind Energy Waste Management
Background
When Enva faced the complex challenge of processing end-of-life wind turbine blades, one of the most demanding materials in renewable energy waste, they turned to CRJ Services for an innovative solution.
Challenge
With the growing wind energy sector, Enva faced the complex challenge of processing end-of-life wind turbine blades - one of the most challenging materials in the renewable energy waste stream. Wind turbine blades, primarily composed of durable composite materials like fiberglass and carbon fiber, pose significant recycling challenges due to their resistance to breakdown. Their enormous size, often up to 95 meters, complicates transportation to recycling facilities, making the process logistically challenging and expensive. Current recycling technologies, including mechanical processes, pyrolysis, and solvolysis, are limited and not yet cost-effective or widely adopted. Environmental concerns arise from disposing of blades in landfills or through incineration, which can generate microplastics and release pollutants, harming ecosystems and air quality. Additionally, the high cost of recycling and the lack of economic incentives deter investment in recycling technologies. While efforts are ongoing to develop more sustainable methods, such as repurposing materials for cement production or new composite products, these solutions are still in early implementation stages.
Solution
After consulting with CRJ Services' hires team, Enva opted to hire the HAAS Tyron 2000XL 7/7-4, specifically configured for processing composite materials. Using a large slow-speed shredder, offers efficient size reduction, as the shredder can handle the tough composite materials of the blades, breaking them down into smaller, more manageable pieces. It also reduces the need for extensive blade preparation, streamlining the recycling process. Operating at lower speeds, the shredder minimises dust generation, maintaining a safer and cleaner working environment. The versatility of the shredded material allows it to be repurposed for various applications, such as in cement manufacturing or as composite materials for industrial use. While this method shows great potential, it is part of a broader strategy to improve the sustainability of wind turbine blade disposal. Continuous advancements in recycling technologies and methods are essential to address the growing volume of decommissioned blades.
The HAAS Tyron 2000XL was selected for its:
- Robust dual-shaft shredding system
- Independent shaft speed control
- Enhanced cutting system with 7/7-4 tooth configuration
- Heavy-duty construction capable of handling tough composite materials
- Ability to produce consistent output size
Implementation
The HAAS Tyron was hired at Enva's processing facility with the following setup:
- Custom configuration of cutting tools optimised for composite materials
- Shaft speeds adjusted to handle the fibrous nature of turbine blades
- Implementation of specific loading procedures to maximise throughput
- Regular maintenance schedule to maintain optimal cutting performance
Technical Specifications
Machine Configuration:
- Model: HAAS Tyron 2000XL 7/7-4 slow speed shredder
- Shredding Unit: Double-shaft system
- Power Unit: 2 x 235 kW diesel engines
- Shaft Configuration: 7/7-4 tooth design
- Control System: IFM display with programmable settings
Results
Since handover, the HAAS Tyron shredder has shown impressive results in processing wind turbine blade sections. Key performance metrics include consistent reduction of blade sections to manageable output sizes, sustained reliability under challenging conditions, and adherence to environmental compliance standards. The shredder’s efficiency in processing complex composite materials has reduced manual handling and maintained consistent output sizes suited for further processing, with minimal operational downtime. CRJ Services has supported this hire with comprehensive initial operator training, continuous technical support, regular maintenance checks, and remote troubleshooting.
For more information about our hire solutions for specialised waste processing applications, contact Becky and her team at [email protected] or 01565 723886 (option 2).
The successful implementation of this solution has positioned Enva to handle increased volumes of wind turbine blade waste as the renewable energy sector continues to grow. The hire arrangement provides flexibility to scale operations based on demand while maintaining access to CRJ's technical expertise and support.
Becky Curley, Hires Manager
CRJ Services