Part 4

Recycling of composite materials MSK 20110211 ETEAM

Definitions Recycling = Reuse + Recovery Reuse = Reuse of products in similar or different applications Recovery = material recovery + energy recovery MSK 20110211 ETEAM

RECYCLING CLASSIFICATIONS PRIMARY REUSE AS A NEW PRODUCT WITH SIMILAR PROPERTIES SECONDARY REUSE AS A NEW PRODUCT WITH LESS DEMANDING PROPERTIES TERTIARY CONVERTING WASTE INTO BASIC CHEMICALS BY PYROLYSIS, GASIFICATION OR HYDROLYSIS QUATERNARY WASTE INCINERATION TO RECOVER ENERGY CONTENT AS HEAT Source: Rusch. K., Recycling of Automotive SMC - the Current Picture, 48th Annual Conference, SPI 1993 MSK 20110211 ETEAM

DRIVING FORCES FOR THE RECYCLING OF COMPOSITE WASTE Landfill disposal will no longer be allowed because of legislation Regulatory and economic constrains are directing the waste management Customer and public demands MSK 20110211 ETEAM

COMPOSITE WASTE TYPES 1. PRODUCTION WASTE AND REJECTED PRODUCTS SHORT LIFE-TIME EASY TO COLLECT AND SORT NO CONTAMINATION 2. END-OF-LIFE DISCHARGED PRODUCTS CONTAINING COMPOSITE COMPONENTS MEDIUM LIFE-TIME COLLECTING, DISMANTLING, SORTING AND CLEANING CONTAMINATION POSSIBLE TRANSPORTED WITH OTHER WASTE COMPONENTS 3. END-OF-LIFE DISCHARGED SINGLE COMPOSITE PRODUCTS LONG LIFE-TIME STRUCTURE DOWNSIZING NEEDED FOR TRANSPORTATION MSK 20110211 ETEAM

Typical production waste 7 MSK 20110211 ETEAM

METHODS FOR RECYCLING OF COMPOSITE WASTE Material recovery: Mechanical particle size reduction of the cured composite with direct reuse of the resulting ground fractions Energy recovery: Incineration of the composite waste together with other fuels Material recovery with energy recovery: Energy recovery of matrix by incineration, reuse of inorganic ash in suitable products Chemical recycling: Decomposition of the matrix resin through hydrolysis or pyrolysis to basic raw materials MSK 20110211 ETEAM

MATERIAL RECOVERY OF COMPOSITE WASTE Mechanically ground fractions of recycled composites are used in new products Recycled composite is mixed with virgin material as filler or reinforcement Up to 5 - 15 % by weight of recycled fractions can be used in the virgin material MSK 20110211 ETEAM

REQUIREMENTS FOR MATERIAL RECYCLING Logistic system for collecting, sorting and dismantling Quality system for producing ground fractions free from contamination Feasible process technology and applications for recycled materials 10 MSK 20110211 ETEAM

Dismantling of waste products – one example 11 MSK 20110211 ETEAM

Recycling of automotive composite components Mechanical recycling of SMC parts from the automotive industry was done commercially by ERCOM in Germany during 1990-1995, but this has now ended Over 2 million parts have been recycled Potential for increase of SMC recycling rate (currently < 1 % of SMC production in Europe) Cost of recycled SMC higher than virgin SMC at present volumes MSK 20110211 ETEAM

ERCOM - a concept for material recycling MSK 20110211 ETEAM

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CASE II: CONCEPT-BOAT CONTAINING 20 % RECYLED MATERIALS BASED ON TOTAL WEIGHT DEMONSTRATOR FROM 1990 Layer of recycled laminate between layers of virgin laminate Ground, recycled fractions are mixed with virgin material Application by special spray-up equipment Cost and performance similar as for conventional boats MSK 20110211 ETEAM

CASE III. CONCEPTS FOR MATERIAL RECYCLING IN JAPAN Mobile incinerator for GRP waste 17 MSK 20110211 ETEAM

Collection of used leisure boats in Finland Finnboat rf and Kuusakoski Oy 4 collection points in southwest Finland Collection June – August 2005 Fragmentation at waste collection site 18 MSK 20110211 ETEAM

MSK 2007-11-30 19 MSK 20110211 ETEAM Foto: Aulis Nikkola

20 MSK 20110211 ETEAM Foto: Aulis Nikkola

MSK 2007-11-30 21 MSK 20110211 ETEAM Foto: Aulis Nikkola

Conclusions and experiences 170 boats were collected A very large part wood or partially wood containing boats The fragmentation gives relatively large parts which must be fragmented additionally 22 MSK 20110211 ETEAM

ENERGY RECOVERY BY INCINERATION The most important replacement for landfill Energy recovery is generally accepted in Europe Is already implemented at several incineration plants for household waste in the Nordic countries Energy content of composite waste depends on the amount of inorganic fibres and fillers Incombustible residue from the glass reinforcement and the filler MSK 20110211 ETEAM

Energy content depends on the filler and reinforcement content in the composite Ash content and heat content for different composites MSK 20110211 ETEAM

Fragmentation before incineration 25 MSK 20110211 ETEAM

Residue from incineration 26 MSK 20110211 ETEAM

Recycling of wind turbine blades by a combination of energy recocery and material recovery ReFiber Danmark www.refiber.com MSK 20110211 ETEAM

From wind turbine blade to insulating material MSK 20110211 ETEAM

RECOVERY OF GLASS FIBRES FROM THE INCINERATION PROCESS Source: University of Nottingham, UK, 1998 29 MSK 20110211 ETEAM

Proposed plant Separated fibres from the incineration process can be used to make moulding compounds, with a recycled fibre content up to 50 wt-% Source: University of Nottingham, UK, 1998 30 MSK 20110211 ETEAM

Controlled incineration leaving reinforcement intact 31 MSK 20110211 ETEAM

Green Label A European recycling concept since 2003 Co-operation between composite companies Fee based: membership fee and recycling fee Technical development of recycling methods Recycling at recycling centres in Europe 32 MSK 20110211 ETEAM

MSK 2007-11-30 33 MSK 20110211 ETEAM

Recycling of automobiles Regulated by the End-of-Life-Vehicles directive 2000/53/EC In 2015: 85 % reuse + recycling, 10 % energy recovery, 5 % disposal (landfill) In 2006: 80 % reuse + recycling, 5 % energy recovery, 15 % disposal 34 MSK 20110211 ETEAM

Recycling of End-of-Life Vehicles (ELV’s) Metal components (ferrous and non ferrous) 75 % of car weight, totally recycles Non-metallic components 25 % of car weight; plastics, glass, rubber and textiles 35 MSK 20110211 ETEAM

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Plastics in cars Rapid increase in the use of plastics Fewer plastic types are used Plastics has a positive impact on environment during the use phase of a car, due to the low weight which saves fuel 100 kg plastics replaces 200-300 kg heavier materials (1000 l fuel savings!) Large pure plastics components easy to dismantle can be recycled mechanically Energy or raw material recovery is most efficient for non-separable plastics 37 MSK 20110211 ETEAM

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Recycling insurance $ RECYCLER PRODUCER CONSUMER BILL INSURANCE COMPANY 39 MSK 20110211 ETEAM

European Composites Industry Association (EuCIA) – Recycle composites as raw material for cement The relationship between fibre reinforced plastics (FRP) and cement. Typical FRP composition Use in cement 25-35% resin Energy for making cement 25-45% glass fibre Raw material for cement 20-50% inert filler Al(OH)3/CaCO3 Source: www.eucia.com

Life cycle analysis A tool for evaluating the total environmental impact of a product or a service from cradle to grave MSK 20110211 ETEAM

LCA ESTIMATES THE TOTAL ENVIRONMENTAL IMPACT USE OF RESOURCES RAW MATERIALS MATERIAL ENERGY ENVIRONMENTAL IMPACT PRODUCTION Te environmental impact and resource consumption is assessed, from raw material extraction through production, use and ultimate disposal as waste, including all transportation and other logistic flows USE OF PRODUCTS WASTE TREATMENT MSK 20110211 ETEAM

Use of LCA Identify phases in a products life cycle that account for the main environmental impact Compare different raw materials, production methods, energy-supply and transportation systems Use obtained data to select the material combinations with the lowest environmental impact MSK 20110211 ETEAM

Life cycle analysis EPS Environmental load = Environmental load index X amount ELU (Environmental Load Unit) MSK 20110211 ETEAM

Example: Liquid gas bottles Material options: Weight Composite 6.6 kg Aluminium 7.1 kg Steel 12.1 kg Use environment: Non corrosive - corrosive Stationary use - mobile use Mål för publikationer MSK 20110211 ETEAM

LIQUID GAS BOTTLES Stationary use, normal environment +0.1 -12 -35 MSK 20110211 ETEAM

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Front for passenger car MSK 20110211 ETEAM