Composite Recycling

AI Quick Summary

Composite Recycling has designed a very energy efficient solution to separate the resin from the fibres, using smart pyrolysis: the composites are heated without oxygen to prevent combustion. The resin becomes gas and pyrolysis oil, and thanks to the specific design of the reactor, the fibres are recovered. Pyrolysis oil is used to make decarbonated plastics. Thematic focusThe project aims to treat epoxy-based composite materials produced by Huntsman. Specifically, the technique that will be used is referred to as pyrolysis, consisting in heating up the composite material to vaporize the resin, and depolymerize it. Once condensed, the vapor is turned into an oil that can be used to synthesize new polymers. The purpose of the project is to adjust the pyrolysis parameters in order to optimise the pyrolysis oil in view of recycling it into most valuable monomers in order to get a economical full recycling process for Epoxy based composites. The work should show us what kind of pyrolytic oil we get based on input material and how easy such oil can be converted into valuable monomers.Degree of innovationComposite Recycling is currently operating a pyrolysis machine in its premises, and has already demonstrated that fibres from composite materials could be recovered. Composites made with recovered fibres exhibited excellent mechanical properties, up to 95% of new ones. After the fibres, In collaboration with Huntsman and the Fachhochschule Nordwestschweiz, Composite Recycling is now focusing on optimizing the pyrolysis oil. The tests will be performed in a small-scale pyrolysis unit, defining parameters that will be used in a larger, industrial scale system Composite Recycling is currently designing. Up to today there is no solution or process in place which described the kind of and quality of pyrolytic oil based on Epoxy based composites and how easy this “oil” can be converted into valuable monomers. We missing the understanding of outcome of the pyrolytic oil based on input material, means which kind of Epoxy resin hardener combination is used provide what outcome and how much energy it requires.EffectAccording to the European Composites Association the Thermoset Composite waste is estimated by 400kto/a for 2018. Most of it is landfilled or or burnt. Composite Recycling has already developed a process to recover the fibres from composites, this project would allow to extend the outcome to their plastic part. It would therefore allow closing the loop for the whole composite material, and in particular the composites used by Huntsman.Methodological qualityThree types of epoxy-based composites will be provided by Huntsman, representative of the ones used in production (systems used in pressure vessel production ( anhydride cured EP), systems used in automotive (i.e. battery box or leaf springs ) and one representative system for wind mill blades. Composite recycling will perform 12 pyrolysis experiments tuning the reaction temperature, the pressure and power. The pyrolysis gas and oil obtained from these samples will be characterised by the FHNW and PSI using LC-MS and GC-MS. The optimised temperature will be deduced from the experiments. Options for the reuse of the pyrolytic oil will be evaluated by Huntsman together with the FHNW and first distillation experiments will be performed.Gender and DiversityAll parties are driving towards a sustainable material future, to which a sustainable and diverse team structure is key. The project includes the following contact points and respects both genders.· Prof. Dr. Christian Brauner, Head of competence field lightweight design and composite technologies at the FHNW Institute of Polymer Engineering· Ms. Nour Halawani and Marguerite Lavarini, Project Manager at Composite Recycling· M. Klaus Ritter, Technology Intelligence Manager at HuntsmanScope and TasksThe work packages will be:· WP1: Selection of possible polymers and characterisation ( three different epoxy formulations from different sectors)· WP2: Pyrolysis with different condition (temperature, pressure, power)· WP3: Analysis of the pyrolytic oil· WP4: Definition of potential application and next steps towards using the pyrolytic oil to synthesise monomers and LCA analysisBudget and Co-FundingExperiment at Composite Recycling: Analysis at PSI :Destillation trials of pyrolytic oil Life Cycle AnalysisTotal9280CHF for 12 Pyrolysis2’500CHF for methodology development 3’360CHF for 12 measurements of pyrolysis gas 3’360CHF for 12 measurements of pyrolysis oil 4.500 CHF2’000CHF25.000CHF

Project Idea Metadata

• Project Idea Name: Composite Recycling
• Date: 10/10/2022 2:56:39 PM
• Administrators:
  • Guillaume Perben

Project Idea Description

Thematic focus

The project aims to treat epoxy-based composite materials produced by Huntsman. Specifically, the technique that will be used is referred to as pyrolysis, consisting in heating up the composite material to vaporize the resin, and depolymerize it. Once condensed, the vapor is turned into an oil that can be used to synthesize new polymers. The purpose of the project is to adjust the pyrolysis parameters in order to optimise the pyrolysis oil in view of recycling it into most valuable monomers in order to get a economical full recycling process for Epoxy based composites. The work should show us what kind of pyrolytic oil we get based on input material and how easy such oil can be converted into valuable monomers.

Degree of innovation

Composite Recycling is currently operating a pyrolysis machine in its premises, and has already demonstrated that fibres from composite materials could be recovered. Composites made with recovered fibres exhibited excellent mechanical properties, up to 95% of new ones. After the fibres, In collaboration with Huntsman and the Fachhochschule Nordwestschweiz, Composite Recycling is now focusing on optimizing the pyrolysis oil. The tests will be performed in a small-scale pyrolysis unit, defining parameters that will be used in a larger, industrial scale system Composite Recycling is currently designing. Up to today there is no solution or process in place which described the kind of and quality of pyrolytic oil based on Epoxy based composites and how easy this “oil” can be converted into valuable monomers. We missing the understanding of outcome of the pyrolytic oil based on input material, means which kind of Epoxy resin hardener combination is used provide what outcome and how much energy it requires.

Effect

According to the European Composites Association the Thermoset Composite waste is estimated by 400kto/a for 2018. Most of it is landfilled or or burnt. Composite Recycling has already developed a process to recover the fibres from composites, this project would allow to extend the outcome to their plastic part. It would therefore allow closing the loop for the whole composite material, and in particular the composites used by Huntsman.

Methodological quality

Three types of epoxy-based composites will be provided by Huntsman, representative of the ones used in production (systems used in pressure vessel production ( anhydride cured EP), systems used in automotive (i.e. battery box or leaf springs ) and one representative system for wind mill blades. Composite recycling will perform 12 pyrolysis experiments tuning the reaction temperature, the pressure and power. The pyrolysis gas and oil obtained from these samples will be characterised by the FHNW and PSI using LC-MS and GC-MS. The optimised temperature will be deduced from the experiments. Options for the reuse of the pyrolytic oil will be evaluated by Huntsman together with the FHNW and first distillation experiments will be performed.

Gender and Diversity

All parties are driving towards a sustainable material future, to which a sustainable and diverse team structure is key. The project includes the following contact points and respects both genders.

· Prof. Dr. Christian Brauner, Head of competence field lightweight design and composite technologies at the FHNW Institute of Polymer Engineering

· Ms. Nour Halawani and Marguerite Lavarini, Project Manager at Composite Recycling

· M. Klaus Ritter, Technology Intelligence Manager at Huntsman

Scope and Tasks

The work packages will be:

· WP1: Selection of possible polymers and characterisation ( three different epoxy formulations from different sectors)

· WP2: Pyrolysis with different condition (temperature, pressure, power)

· WP3: Analysis of the pyrolytic oil

· WP4: Definition of potential application and next steps towards using the pyrolytic oil to synthesise monomers and LCA analysis

Budget and Co-Funding

Experiment at Composite Recycling: Analysis at PSI :

Destillation trials of pyrolytic oil Life Cycle Analysis

Total

9280CHF for 12 Pyrolysis

2’500CHF for methodology development 3’360CHF for 12 measurements of pyrolysis gas 3’360CHF for 12 measurements of pyrolysis oil 4.500 CHF

2’000CHF

25.000CHF

Composite Recycling has designed a very energy efficient solution to separate the resin from the fibres, using smart pyrolysis: the composites are heated without oxygen to prevent combustion. The resin becomes gas and pyrolysis oil, and thanks to the specific design of the reactor, the fibres are recovered. Pyrolysis oil is used to make decarbonated plastics.