EMR and partners have delivered the UK’s first end‑of‑life offshore wind turbine REPM recovery project, proving safe, scalable disassembly processes that create circular pathways for critical materials and establish Scotland as a leader in next‑generation renewable recycling.
The transition to renewable energy depends on complex technologies – from offshore wind turbines to electric vehicles – and these rely on rare earth permanent magnets (REPMs). Supply of these crucial components are geopolitically complex and subject to disruption. Through the CLIMATES programme, Innovate UK has supported EMR and its project partners to deliver the UK’s first project to disassemble an offshore wind turbine for recovery of REPMs for reuse and recycling – a critical breakthrough for the UK’s circular economy and energy security.
The UK Critical Minerals Strategy defines rare earth elements as essential to net-zero, clean energy technologies and national resilience.
EMR is a global leader in sustainable materials. EMR recycle, reuse and repurpose vital materials to ensure that today’s products become tomorrow’s new ones. In the recycling process, most end-of-life components in vehicles and in wind turbines have established recycling routes. However, electric motors and wind turbine generators must be disassembled to remove the magnets in a hazardous, labour-intensive and currently sub-economical process.
EMR’s ‘Wind Turbine Processing Centre’ enables the whole wind turbine, including major and minor components, and materials like steel and copper, to follow circular pathways, such as reuse and recycling, while also trialling innovative approaches to repurpose more challenging materials such as composite blades.
EMR’s current market focus is on onshore wind turbines. Looking ahead, the company is targeting offshore wind turbines as a medium-term to long-term opportunity. These turbines contain rare earth permanent magnets, and as offshore installations reach the end of their operational life, they present a significant opportunity for urban mining.
This initiative forms part of Re-Rewind, a collaborative project between EMR, HyProMag, Magnomatics, Offshore Renewable Energy Catapult, and the University of Birmingham.
From idea to innovation
Innovate UK funding was instrumental in moving the project from concept to reality. As Jack Lemm, Innovation Project Manager at EMR explains: “Recovering materials that contain rare earths is incredibly labour intensive. On paper, the business case doesn’t always stack up. Innovate UK gave us the push to try something and get the understanding and foundations to move forward”.
The scale and duration of the CLIMATES funding also gave EMR the confidence to invest in people and recruit specialist staff.
Handling large REPMs presents unique safety and technical challenges. Mike Hogan, Business Developer at EMR outlined the importance of hands-on learning: “Nothing beats getting your hands on the material. The scale of the challenge in recycling large wind turbine components required us to find new ways of working, making mistakes and learning along the way. CLIMATES funding enabled EMR to innovate, developing practical, repeatable processes while managing risks associated with removing magnets”.
Beyond financial support, Innovate UK enabled EMR to build key partnerships with innovative companies in the sector. Re-Rewind brought together partners who might not otherwise have worked together. For EMR, which has traditionally focused on metal recycling, this cross-sector collaboration has been crucial. “We were able to work again with HyproMag and build new relationships with Magnomatics, collaborating to develop a new supply chain,” adds Mike Hogan, Business Developer, EMR.
Learning for future impact
The project has demonstrated the feasibility of safely and efficiently extracting REPMs from end-of-life turbines – and EMR can now offer a commercial solution for magnet recovery. Technical learnings from Re-Rewind are also informing other projects, which is helping to expand EMR’s expertise in recycling challenging materials.
“This was not just about one project – it is about building the knowledge, confidence and skills that allow EMR to tackle increasingly complex materials and components in the future.” Eve Andrews. Head of Renewables, EMR
And this knowledge is key to future innovation: “We now have a framework we can apply to turbines more widely. Very few organisations can do this, and the supply chain is looking to people like us to help figure out the solution.” Bill Firth. General Manager Business Development, EMR.
Looking to the future
Re-Rewind has laid the foundations for further innovations. EMR continues to refine turbine disassembly processes, including also exploring blade recycling. The facility is now a fully-fledged offering, creating green jobs and playing a key role in positioning Scotland as a leader in circular renewables.
“This project has allowed us to showcase what is possible to the wider sector,” says Jack. “We have been able to bring customers and supply chain partners to see the process in action, encouraging future collaboration and innovation.”
Innovate UK’s support has been pivotal. As Mike Hogan concludes:
Without the funding and structure from Innovate UK, this project may have remained just an idea. Instead, it is a tangible, scalable solution that strengthens the UK supply chain and inspires the sector.
Find out how the CLIMATES programme can support you in your innovation journey.