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Repowering of wind turbines

Our repowering services

Our repowering process begins with a comprehensive inventory and site evaluation. Together with you, we analyse the existing potential and develop customised solutions that ensure maximum efficiency and sustainability. We place particular emphasis on the involvement of all relevant stakeholders – from authorities to the affected communities. Throughout the entire repowering project, our experienced experts are at your side to ensure the project's ongoing success.

Replacing your old wind turbines with the latest technology is carried out in an efficient and structured process. We take care of dismantling the existing turbines and install the new wind turbines quickly and reliably. In doing so, we ensure that operations are disrupted as little as possible and that the environmental impact remains minimal.

We prioritise the environmentally friendly recycling of materials. We focus on ensuring that materials are disposed of responsibly and in an environmentally friendly manner, to guarantee that they are recycled sustainably.

We are also your reliable partner after installation. We take over the technical and commercial management of your new systems and ensure that they work optimally over their entire service life. With our monitoring system, we keep an eye on all the important parameters and intervene immediately if adjustments are necessary.

FAQ on repowering

After about 20 years of operation, old wind turbines undergo a complex process of dismantling and recycling. The dismantling process includes disconnecting the turbine from the power grid, removing oils and greases, dismantling the rotor blades, dismantling the tower and nacelle, and removing the foundations. Up to 90% of the components can already be recycled, especially metals and concrete. The greatest challenge is posed by the rotor blades, which are made of composite materials that are difficult to separate. There are various recycling approaches for the rotor blades:

  • shredding and use as a substitute. Old wind turbines that have been in operation for about 20 years undergo a complex process of dismantling and recycling. Dismantling includes disconnecting the turbine from the power grid, removing oils and greases, dismantling the rotor blades, dismantling the tower and nacelle, and removing the foundations. Up to 90% of the components can already be recycled, especially metals and concrete. The greatest challenge is posed by the rotor blades, which are made of composite materials that are difficult to separate. There are various approaches to recycling the rotor blades:
  • shredding and use as a primary fuel in the cement industry
  • pyrolysis to separate fibres and resin
  • development of new recycling technologies

The industry is working on improvements such as the development of a DIN standard for sustainable dismantling, the demand for more recyclable materials and the goal of a 100% recycling rate. The handling of old wind turbines is an important challenge for the sustainability of wind energy.

During recycling, tower elements, gearboxes and housings are melted down in steelworks, the foundations are reused in building construction or road building and the rotor blades are repurposed. One example of repurposing: in early 2024, a car park was developed in the city of Lund in Sweden with cladding made from recycled rotor blades. Another large-scale project involves noise barriers along motorways and railway lines, which could also be made from recycled rotor blades.

Forecasts show that in 2070, 20 years after the energy transition is completed, the volume of rotor blades accumulated would be equivalent to about one-third of the annual household waste generated by the city of Munich. Recycling this volume is easily manageable.

The repowering process for wind turbines typically takes several years:

  • The planning and approval phase usually takes 2-5 years and takes up the majority of the time.
  • The actual construction phase for dismantling and rebuilding is comparatively short at a few months.
  • The entire process from initial planning to commissioning can take 3-7 years.

Factors that influence the duration are:

  • Project scope
  • approval procedures and possible objections
  • environmental impact assessments
  • availability of components and labour

The duration can vary greatly, as each project is individual. Efforts are being made to speed up the process by improving procedures and easing legal restrictions. Careful planning and the early involvement of all parties concerned can help to optimise the process.

The following permits are essentially required for a repowering project for wind turbines:

  1. Approval under the Federal Immission Control Act
  2. Permission under building law in accordance with § 35 of the Federal Building Code (BauGB)
  3. Environmental permits with expert opinions on nature conservation, noise protection and immission control
  4. Demolition permit for the old plants
  5. Grid connection permit
  6. Participation in the Federal Network Agency's tendering procedure for remuneration

Despite some simplifications for repowering projects, such as the delta approach to environmental impacts and new regulations in the BauGB, the approval process remains complex. In many aspects, it resembles that of a new project and requires a completely new approval procedure.

The repowering of wind turbines offers significant economic advantages for both plant operators and municipalities.

For plant operators:

  • Higher energy efficiency and yields through modern, more powerful plants
  • Extended site utilisation and optimised land use
  • Lower maintenance costs and long-term investment security

For municipalities:

  • Increasing trade tax revenues through more efficient plants
  • Financial participation in the yield according to the Renewable Energy Sources Act (EEG)
  • Regional value creation through contracts awarded to local companies
  • Infrastructure improvements
  • Enhanced attractiveness for further investments

All in all, repowering creates a win-win situation in which both sides benefit from modernisation and efficiency enhancements. It leads to sustainable energy production while simultaneously promoting the economic development of the region.