Zero Emission Composite Materials Recycling by Pyrolysis

AI Quick Summary

The first composite materials are reaching the end of their useful life, and are being landfilled or burnt. Composite Recycling is a Swiss company that has developed a process to fully recover composite materials. The byproducts obtained are fibers that can be used in new composites, and pyrolysis oil that can replace carbohydrates to make new plastics. The purpose of the project is to uprgade Composite Recycling’s process, characterizing and purifying pyrolysis oil to match industry's requirements. Thematic focus What's the thematic focus of your project idea?The focus of the project idea is recycling of plastics, in particular, Glass Fiber Reinforced Plastics (GFRP).How does this fit to the thematic focus of the project call?Composite Recycling is developing a process to recycle these GFRP, without emitting any CO2, and making the glass fibers reuseable to make new GFRP.Degree of innovation What is the novelty in the technological and/or economic approach of the idea?Composite Recycling has developed a solution to separate the fibers from the plastic in composite materials. The method is derived from pyrolysis, consisting in heating up the material in absence of oxygen. When heating in absence of oxygen, the carbon chains of carbohydrates within the plastic part are shortened, allowing the solid plastic to be turned into a liquid referred to as pyrolysis oil. The fibers can then be subsequently treated and recovered. Composite Recycling is currently operating a prototype machine treating 5kg of composites per day, while developing a full-scale production pyrolysis machine, capable of treating 2 tons of composites per day, yielding 1.2 tons of pyrolysis oil daily. These machines will be transportable in containers that will be installed on-site, where boats or wind turbine blades for example, are being dismantled.The pyrolysis oil is of particular interest for several applications. The carbon-carbon chemical bonds being highly energetic, the oil can be used as fuel. This is, however, not the route Composite Recycling has decided to favor. A better use would be to make new plastics out of it. The pyrolysis oil would then replace carbohydrates extracted from the soil. Composite Recycling has been solicited by major companies active in plastic manufacturing, such as BASF. The price for this oil stands around 0.30ct per liter, representing a significant part of Composite Recycling’s revenues. After a first set of analysis, though, the pyrolysis oil extracted from samples of old boats presents high levels of mercury, around 2400ppb, high oxygen content, around 10%, chlorine levels higher than 300ppm and bromine higher than 150ppm. In particular, the mercury levels are too high to use the oil as feedstock in the chemical industry.How much did the idea profit from the support of the Innovation Booster so far, i.e. during the Co-Creation Workshop?The Co-Creation Workshop has allowed us discussing with people about our respective ideas, challenging our points of view, and perfecting our concept. The best partner found is indeed the Plastic Innovation Competence Center. Effect What is the potential to create sustainable economic added value for the implementation partner(s)?Composite Recycling has designed its recycling concept to make it economically viable, that is, to be profitable. Recycling one ton of composite generates 960CHF of revenues via sales of glass fiber mat, pyrolysis oil, and collection fees. Scaling up the operation simply implies to increase the number of machines and technical staff, it is anticipated to generate 100MCHF revenues by 2030, with a 50% net margin.How much potential to reduce CO2 emissions does the idea have? (Use a preliminary estimate if you don't have this data yet.) For example, burning 1 ton of composite releases around 2.5 tons of CO2 in the atmosphere. Moreover, recovering fibers allows avoiding forming new ones, which are fabricated at 1300°C. The study “Carbon Footprint and Sustainability of Different Natural Fibres for Biocomposites and Insulation Material – Study providing data for the automotive and insulation industry” is stating that the glass fiber manufacturing process induces between 1.7 to 2.5 tons of CO2-eq per ton of fibers. The energy required to form the fibers is estimated to be 300kWh per ton of fiber. As in 2021 2.4 million tons of glass fiber composites waste was produced, the potential saving on CO2-eq is about 5 million tons, and 300GWh of energy yearly, in constant growth. Methodological quality How is it ensured that the funds for the development and verification of the idea are used promisingly?Composite Recycling has already received financing that has allowed preparing the prototype infrastructure, and is now entering a phase consisting in refining the process parameters, and in particular, studying their influence on the quality of pyrolysis oil in view of using it to form new plastics. In this endevour, Composite Recycling will benefit from the knowledge of the Plastic Innovation Competence Center of HEIA Fribourg, partner in this project.Gender and Diversity • How is it ensured that both genders are adequately represented in the project team?Both genders are adequately represented in the project team :Plastic Innovation Competence CenterThe Plastic Innovation Center is the competence center of HEIA Fribourg.Maria Stewart, Sustainable Business Developper (F)Prof. Véronique Bréguet Mercier, Professor of Industrial Process Chemistry (F)Prof. Roger Marti, Professor of Organic and Process Chemistry (M) Composite RecyclingDr. Pascal Gallo, Chief Scientific Officer (M)Dr. Mitchell Anderson, Chief Technology Officer (M) Scope and Tasks What is the scope of the project that you plan to cover in this project phase?The scope of the project is the study and improvement of the quality of our pyrolysis oil, as a function of the input material, studying the molar fraction of the various carbohydrates composing the oil, as well as potential contaminants present in the oil.Which work packages need to be completed to reach the goals of this project phase?WP1 : Analysis of pyrolysis oil from several customer's samplesThe first step consists in analyzing the contaminants present in oil obtained with pyrolysis of composite material from several customers. It is expected that the most contaminated oil will be obtained from samples of old boats, the anti-fouling containing traces of mercury for instance.WP2 : Filtering oil to eliminate the most problematic contaminantsThe second step will consist in implementing the technical solution envisaged by the ChemTech Institute, HEIG-SO. Two main technologies will be envisaged, thiol or thiouronium- functionalized chelating resins, and active charcoal for filtering.WP3 : Study scalability and implementation costs of solutions used in second stepThe third step will be a precursor of industrialization, understanding the cost, environmental impact, and scalability of the solutions envisaged. How are the work packages split between the project partners?The project partners will both collaborate on the first work package, as Composite Recycling needs to provide pyrolysis oil samples to the ChemTech Institute.The second work package will mainly be carried out by the ChemTech Institute.The third work package will mainly be carried out by Composite Recycling.Budget How much budget does your project idea need in total (including internal costs of all project partners)?The budget required 38’000CHF.How will this budget be distributed among the project partners and the different work packages?Work Package 1Composite Recycling : 3’000CHFChemTech Institute : 15’000CHFWork Package 2ChemTech Institute : 7’500CHFWork Package 3Composite Recycling : 5'000CHFChemTech Institute : 5’000CHF How much seed money do you expect from the NTN Innovation Booster Plastics for Zero Emission? (Has to be in the range of CHF 10'000 to CHF 25'000).The partners kindly ask 25’000 CHF from the NTN Innovation Booster Plastics for Zero Emission. Composite Recycling will pay 2'500CHF to the NTN Innobooster. Do you plan to do the mandatory assessment of the CO2 reduction potential within your team or do you choose to get support by our recommended external experts for a lump sum of CHF 1000?We would like to get support by your recommended external experts for a lump sum of 1'000 CHF.Co-Funding Which project partner(s) or third parties will act as implementation partner(s) in this project and pay the required financial contribution of at least 20% of the seed money (10% to be paid to the NTN Innovation Booster Plastics for Zero Emission for assistance during the phase II and at least 10% which must be paid into the project)?Composite Recycling will pay 20% of the seed money.Lead Organisation The name and details of the organisation which will act as the contact between the NTN Innnovation Booster and your project team. This should also be the organisation which handles the funds for the project team and is responsible for the financial reporting. Therefore, this shouldn’t be an implementation partner who will contribute with co-funding.Composite Recycling SàRLChemin des Champs Courbes 51024 Ecublenspascal.gallo@composite-recycling.ch

Project Idea Metadata

• Project Idea Name: Zero Emission Composite Materials Recycling by Pyrolysis
• Date: 4/1/2022 9:04:25 AM
• Administrators:

Project Idea Description

Thematic focus

What's the thematic focus of your project idea?

The focus of the project idea is recycling of plastics, in particular, Glass Fiber Reinforced Plastics (GFRP).

How does this fit to the thematic focus of the project call?

Composite Recycling is developing a process to recycle these GFRP, without emitting any CO₂, and making the glass fibers reuseable to make new GFRP.

Degree of innovation

What is the novelty in the technological and/or economic approach of the idea?

Composite Recycling has developed a solution to separate the fibers from the plastic in composite materials. The method is derived from pyrolysis, consisting in heating up the material in absence of oxygen. When heating in absence of oxygen, the carbon chains of carbohydrates within the plastic part are shortened, allowing the solid plastic to be turned into a liquid referred to as pyrolysis oil. The fibers can then be subsequently treated and recovered. Composite Recycling is currently operating a prototype machine treating 5kg of composites per day, while developing a full-scale production pyrolysis machine, capable of treating 2 tons of composites per day, yielding 1.2 tons of pyrolysis oil daily. These machines will be transportable in containers that will be installed on-site, where boats or wind turbine blades for example, are being dismantled.

The pyrolysis oil is of particular interest for several applications. The carbon-carbon chemical bonds being highly energetic, the oil can be used as fuel. This is, however, not the route Composite Recycling has decided to favor. A better use would be to make new plastics out of it. The pyrolysis oil would then replace carbohydrates extracted from the soil.

Composite Recycling has been solicited by major companies active in plastic manufacturing, such as BASF. The price for this oil stands around 0.30ct per liter, representing a significant part of Composite Recycling’s revenues. After a first set of analysis, though, the pyrolysis oil extracted from samples of old boats presents high levels of mercury, around 2400ppb, high oxygen content, around 10%, chlorine levels higher than 300ppm and bromine higher than 150ppm. In particular, the mercury levels are too high to use the oil as feedstock in the chemical industry.

How much did the idea profit from the support of the Innovation Booster so far, i.e. during the Co-Creation Workshop?

The Co-Creation Workshop has allowed us discussing with people about our respective ideas, challenging our points of view, and perfecting our concept. The best partner found is indeed the Plastic Innovation Competence Center.

Effect

What is the potential to create sustainable economic added value for the implementation partner(s)?

Composite Recycling has designed its recycling concept to make it economically viable, that is, to be profitable. Recycling one ton of composite generates 960CHF of revenues via sales of glass fiber mat, pyrolysis oil, and collection fees. Scaling up the operation simply implies to increase the number of machines and technical staff, it is anticipated to generate 100MCHF revenues by 2030, with a 50% net margin.

How much potential to reduce CO2 emissions does the idea have? (Use a preliminary estimate if you don't have this data yet.)

For example, burning 1 ton of composite releases around 2.5 tons of CO₂ in the atmosphere. Moreover, recovering fibers allows avoiding forming new ones, which are fabricated at 1300°C. The study “Carbon Footprint and Sustainability of Different Natural Fibres for Biocomposites and Insulation Material – Study providing data for the automotive and insulation industry” is stating that the glass fiber manufacturing process induces between 1.7 to 2.5 tons of CO₂-eq per ton of fibers. The energy required to form the fibers is estimated to be 300kWh per ton of fiber. As in 2021 2.4 million tons of glass fiber composites waste was produced, the potential saving on CO₂-eq is about 5 million tons, and 300GWh of energy yearly, in constant growth.

Methodological quality

How is it ensured that the funds for the development and verification of the idea are used promisingly?

Composite Recycling has already received financing that has allowed preparing the prototype infrastructure, and is now entering a phase consisting in refining the process parameters, and in particular, studying their influence on the quality of pyrolysis oil in view of using it to form new plastics. In this endevour, Composite Recycling will benefit from the knowledge of the Plastic Innovation Competence Center of HEIA Fribourg, partner in this project.

Gender and Diversity

• How is it ensured that both genders are adequately represented in the project team?

Both genders are adequately represented in the project team :

Plastic Innovation Competence Center

The Plastic Innovation Center is the competence center of HEIA Fribourg.

• Maria Stewart, Sustainable Business Developper (F)
• Prof. Véronique Bréguet Mercier, Professor of Industrial Process Chemistry (F)
• Prof. Roger Marti, Professor of Organic and Process Chemistry (M)

Composite Recycling

• Dr. Pascal Gallo, Chief Scientific Officer (M)
• Dr. Mitchell Anderson, Chief Technology Officer (M)

Scope and Tasks

What is the scope of the project that you plan to cover in this project phase?

The scope of the project is the study and improvement of the quality of our pyrolysis oil, as a function of the input material, studying the molar fraction of the various carbohydrates composing the oil, as well as potential contaminants present in the oil.

Which work packages need to be completed to reach the goals of this project phase?

WP1 : Analysis of pyrolysis oil from several customer's samples

The first step consists in analyzing the contaminants present in oil obtained with pyrolysis of composite material from several customers. It is expected that the most contaminated oil will be obtained from samples of old boats, the anti-fouling containing traces of mercury for instance.

WP2 : Filtering oil to eliminate the most problematic contaminants

The second step will consist in implementing the technical solution envisaged by the ChemTech Institute, HEIG-SO. Two main technologies will be envisaged, thiol or thiouronium- functionalized chelating resins, and active charcoal for filtering.

WP3 : Study scalability and implementation costs of solutions used in second step

The third step will be a precursor of industrialization, understanding the cost, environmental impact, and scalability of the solutions envisaged.

How are the work packages split between the project partners?

The project partners will both collaborate on the first work package, as Composite Recycling needs to provide pyrolysis oil samples to the ChemTech Institute.

The second work package will mainly be carried out by the ChemTech Institute.

The third work package will mainly be carried out by Composite Recycling.

Budget

How much budget does your project idea need in total (including internal costs of all project partners)?

The budget required 38’000CHF.

How will this budget be distributed among the project partners and the different work packages?

Work Package 1

Composite Recycling : 3’000CHF

ChemTech Institute : 15’000CHF

Work Package 2

ChemTech Institute : 7’500CHF

Work Package 3

Composite Recycling : 5'000CHF

ChemTech Institute : 5’000CHF

How much seed money do you expect from the NTN Innovation Booster Plastics for Zero Emission? (Has to be in the range of CHF 10'000 to CHF 25'000).

The partners kindly ask 25’000 CHF from the NTN Innovation Booster Plastics for Zero Emission. Composite Recycling will pay 2'500CHF to the NTN Innobooster.

Do you plan to do the mandatory assessment of the CO2 reduction potential within your team or do you choose to get support by our recommended external experts for a lump sum of CHF 1000?

We would like to get support by your recommended external experts for a lump sum of 1'000 CHF.

Co-Funding

Which project partner(s) or third parties will act as implementation partner(s) in this project and pay the required financial contribution of at least 20% of the seed money (10% to be paid to the NTN Innovation Booster Plastics for Zero Emission for assistance during the phase II and at least 10% which must be paid into the project)?

Composite Recycling will pay 20% of the seed money.

Lead Organisation

The name and details of the organisation which will act as the contact between the NTN Innnovation Booster and your project team. This should also be the organisation which handles the funds for the project team and is responsible for the financial reporting. Therefore, this shouldn’t be an implementation partner who will contribute with co-funding.

Composite Recycling SàRL

Chemin des Champs Courbes 5

1024 Ecublens

pascal.gallo@composite-recycling.ch

The first composite materials are reaching the end of their useful life, and are being landfilled or burnt. Composite Recycling is a Swiss company that has developed a process to fully recover composite materials. The byproducts obtained are fibers that can be used in new composites, and pyrolysis oil that can replace carbohydrates to make new plastics. The purpose of the project is to uprgade Composite Recycling’s process, characterizing and purifying pyrolysis oil to match industry's requirements.