DESIGN FOR FULL RECYCLING OF THERMOPLASTIC COMPOSITES

AI Quick Summary

KWB manufactures high-performance uni/multi-directional continuous fibre reinforcement combined with polymer components, which are joined using injection moulding technology. Due to the challenges of maintaining fibre quality as well as mechanically recycle the thermoplastic in the commercially available recycling methods for fibre reinforced plastics, this feasibility study will focus on finding design concepts to achieve full recycling of continuously reinforced thermoplastic composites. Thematic focusKunststoffwerk Buchs AG manufactures high-performance uni/multi-directional continuous fibre reinforcement combined with high-performance polymer components, which are joined using injection moulding technology. Due to the challenges of maintaining fibre quality as well as mechanically recycle the thermoplastic in the commercially available recycling methods for carbon fibre reinforced plastics, this feasibility study will focus on finding design concepts to achieve full recycling of continuously reinforced thermoplastic composites. Degree of innovationIn order to reduce CO2 emissions, KWB must find a way to recycle the manufacturing waste and the products after their end-of-life. The CO2 emission per component is a crucial topic for KWBs customers and it is therefore necessary for KWB to find effective solutions to reduce the CO2 emission to preserve and expand its market shares. The only way to find sustainable and efficient solutions is to examine the entire life cycle of the product, starting with the selection of material, design and manufacturing method.The challenge is that the bond between the continuous fibre tape and the polymer must be reliable during the products lifetime, and then be able to be dismantled before the recycling process. Solutions such as adding a foreseen design (as in packaging industry) or adding a separation ply that can be activated (chemical, electrical or mechanically) to separate the fibre tape from the polymer component will be investigated.This idea benefits from bilateral discussion between IWK and KWB in the innovation booster phase I.EffectThe potential to create sustainable economic added value for KWB is in the short term to reduce material costs, in the aspect that they can reduce their purchases of virgin material. But more importantly in the long run, they can offer their customer a method of fully recyclable reinforced plastic products. This will enable KWB to meet their costumers’ request to minimize the CO2 emission and maintain their position as an attractive producer in the market for high-performance fibre reinforced plastic products.If a successful design for recycling is found, this would not only apply to KWB’s products but also provide the composite market with an energy efficient mechanical recycling method. This idea would reduce the CO2 emissions of KWB's products by around 50%, this is based on eco-balance calculations made in previous Innosuisse-supported projects where the change from 100% virgin material to 100% recycled material has halved the CO2 footprint. According to the European Recycling Industries' Confederation, recycling one tonne of plastic can avoid the emissions of 2.5 tonnes of CO2 when produced from virgin materials. In KWB's case with an annual production of 150 tonnes of plastic, this would mean that 375 tonnes of CO2 emissions could be avoided per year.Methodological qualityThe methodology in this project is according to the work packages (see the attached project plan). WP 1 is focusing on concept development and systematical down-selection of the most promising approaches, and the proof of concept will take place in WP 2. The proof of concepts will require tests which all can be performed in IWKs well-equipped laboratories. This procedure has been proven to be very efficient in other development projects of the IWK. Gender and DiversityBoth KWB and IWK have a strong gender equality commitment and both genders are represented in the project team.Scope and TasksThe detailed project plan is attached to this application. Here is a summary of the tasks in this feasibility study:WP1: Concept development Review of the specifications (requirements for the production, components, and recycling process)literature study: chemical, electrical and mechanical solutions for design for recycling e.g. packaging industry, wind power industry etc.Concept developmentEvaluation and selection of conceptsWP2: Proof of conceptDesign of Experimentsimplementation of the test programsystematic evaluation of the testsEvaluation and conclusionsBudgetThe detailed budget including the distributions of the budget between the WPs as well as project partners is attached to this application.Here is a summary of the budget:Total project budget: CHF 31'556Seed money from the Innovation Booster Plastics for Zero Emission: CHF 25'000The mandatory assessment of CO2 reduction potential will be done within the project team.

Project Idea Metadata

• Project Idea Name: DESIGN FOR FULL RECYCLING OF THERMOPLASTIC COMPOSITES
• Date: 9/30/2022 8:20:29 AM
• Administrators:
  • Karin Brändli Hedlund

Project Idea Description

Thematic focus

Kunststoffwerk Buchs AG manufactures high-performance uni/multi-directional continuous fibre reinforcement combined with high-performance polymer components, which are joined using injection moulding technology. Due to the challenges of maintaining fibre quality as well as mechanically recycle the thermoplastic in the commercially available recycling methods for carbon fibre reinforced plastics, this feasibility study will focus on finding design concepts to achieve full recycling of continuously reinforced thermoplastic composites.

Degree of innovation

In order to reduce CO2 emissions, KWB must find a way to recycle the manufacturing waste and the products after their end-of-life. The CO2 emission per component is a crucial topic for KWBs customers and it is therefore necessary for KWB to find effective solutions to reduce the CO2 emission to preserve and expand its market shares. The only way to find sustainable and efficient solutions is to examine the entire life cycle of the product, starting with the selection of material, design and manufacturing method.

The challenge is that the bond between the continuous fibre tape and the polymer must be reliable during the products lifetime, and then be able to be dismantled before the recycling process. Solutions such as adding a foreseen design (as in packaging industry) or adding a separation ply that can be activated (chemical, electrical or mechanically) to separate the fibre tape from the polymer component will be investigated.

This idea benefits from bilateral discussion between IWK and KWB in the innovation booster phase I.

Effect

The potential to create sustainable economic added value for KWB is in the short term to reduce material costs, in the aspect that they can reduce their purchases of virgin material. But more importantly in the long run, they can offer their customer a method of fully recyclable reinforced plastic products. This will enable KWB to meet their costumers’ request to minimize the CO2 emission and maintain their position as an attractive producer in the market for high-performance fibre reinforced plastic products.

If a successful design for recycling is found, this would not only apply to KWB’s products but also provide the composite market with an energy efficient mechanical recycling method.

This idea would reduce the CO2 emissions of KWB's products by around 50%, this is based on eco-balance calculations made in previous Innosuisse-supported projects where the change from 100% virgin material to 100% recycled material has halved the CO2 footprint. According to the European Recycling Industries' Confederation, recycling one tonne of plastic can avoid the emissions of 2.5 tonnes of CO2 when produced from virgin materials. In KWB's case with an annual production of 150 tonnes of plastic, this would mean that 375 tonnes of CO2 emissions could be avoided per year.

Methodological quality

The methodology in this project is according to the work packages (see the attached project plan). WP 1 is focusing on concept development and systematical down-selection of the most promising approaches, and the proof of concept will take place in WP 2. The proof of concepts will require tests which all can be performed in IWKs well-equipped laboratories. This procedure has been proven to be very efficient in other development projects of the IWK.

Gender and Diversity

Both KWB and IWK have a strong gender equality commitment and both genders are represented in the project team.

Scope and Tasks

The detailed project plan is attached to this application. Here is a summary of the tasks in this feasibility study:

WP1: Concept development

• Review of the specifications (requirements for the production, components, and recycling process)
• literature study: chemical, electrical and mechanical solutions for design for recycling e.g. packaging industry, wind power industry etc.
• Concept development
• Evaluation and selection of concepts

WP2: Proof of concept

• Design of Experiments
• implementation of the test program
• systematic evaluation of the tests
• Evaluation and conclusions

Budget

The detailed budget including the distributions of the budget between the WPs as well as project partners is attached to this application.

Here is a summary of the budget:

• Total project budget: CHF 31'556
• Seed money from the Innovation Booster Plastics for Zero Emission: CHF 25'000
• The mandatory assessment of CO2 reduction potential will be done within the project team.

KWB manufactures high-performance uni/multi-directional continuous fibre reinforcement combined with polymer components, which are joined using injection moulding technology. Due to the challenges of maintaining fibre quality as well as mechanically recycle the thermoplastic in the commercially available recycling methods for fibre reinforced plastics, this feasibility study will focus on finding design concepts to achieve full recycling of continuously reinforced thermoplastic composites.