1. Part 4

2. Recycling of composite materials
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3. Definitions Recycling = Reuse + Recovery
Reuse = Reuse of products in similar or different applications
Recovery = material recovery + energy recovery
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4. 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
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5. 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
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6. 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
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7. Typical production waste7
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8. 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
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9. 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 % by weight of recycled fractions can be used in the virgin material
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10. 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
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11. Dismantling of waste products – one example11
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12. Recycling of automotive composite components
Mechanical recycling of SMC parts from the automotive industry was done commercially by ERCOM in Germany during , 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
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13. ERCOM - a concept for material recycling
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14. MSK ETEAM

15. MSK ETEAM

16. 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
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17. CASE III. CONCEPTS FOR MATERIAL RECYCLING IN JAPAN
Mobile incinerator for GRP waste 17
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18. 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
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19. MSK 19
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Foto: Aulis Nikkola

20. 20
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Foto: Aulis Nikkola

21. MSK 21
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Foto: Aulis Nikkola

22. 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
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23. 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
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24. Energy content depends on the filler and reinforcement content in the composite
Ash content and heat content for different composites
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25. Fragmentation before incineration25
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26. Residue from incineration26
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27. Recycling of wind turbine blades by a combination of energy recocery and material recovery ReFiber Danmark
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28. From wind turbine blade to insulating material
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29. RECOVERY OF GLASS FIBRES FROM THE INCINERATION PROCESS
Source: University of Nottingham, UK, 1998 29
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30. 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
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31. Controlled incineration leaving reinforcement intact31
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32. 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
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33. MSK 33
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34. 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
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35. 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
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36. 36
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37. 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 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
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38. 38
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39. Recycling insurance $ RECYCLER PRODUCER CONSUMER BILL INSURANCE
COMPANY 39
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40. 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:

41. Life cycle analysis
A tool for evaluating the total environmental impact of a product or a service from cradle to grave
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42. 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
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43. 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
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44. Life cycle analysis EPS
Environmental load =
Environmental load index X amount
ELU (Environmental Load Unit)
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45. Example: Liquid gas bottles
Material options:
Weight
Composite 6.6 kg
Aluminium 7.1 kg
Steel kg
Use environment:
Non corrosive - corrosive
Stationary use - mobile use
Mål för publikationer
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46. LIQUID GAS BOTTLES Stationary use, normal environment
+0.1
-12
-35
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47. MSK ETEAM

48. Front for passenger car
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