Regenerated Composite Value Reinforcement (ReCoVeR)
Lead Research Organisation:
University of Strathclyde
Department Name: Mechanical and Aerospace Engineering
Abstract
The disposal of end-of-life composite products in an environmentally friendly manner is one of the most important challenges facing the industry and community. It is projected that the total global production of composite materials will significantly exceed 10 million tons by 2015, which will occupy a volume of over 5 million cubic meters. Glass fibre reinforced composites account for approximately 90% of all the fibre reinforced composites currently produced. About 60% of this volume employs thermosetting matrix materials producing composites (GRP) which are difficult and expensive to recycle in an efficient manner. The UK perspective on this issue has been recently highlighted due to the anticipated growth in the use of such composite materials in automotive and wind energy sectors. Many GRP market sectors such as wind turbine applications have growth rates well into double figures with a predicted 6 million tons of GRP wind turbine blades to be produced globally over the coming decade. Currently most of this material is destined for landfill at the end of its 10-25 year application lifetime; the UK is already estimated to produce 160,000 Tons of GRP waste each year of which 98% goes to landfill.
A number of processes are available for recycling such composites. Of these possible routes, thermal recycling is probably the most technologically advanced and has been piloted in the UK and Denmark. However, nearly all options deliver recycled fibres (which make up approximately 60% by weight of the composites) which suffer from a lack of cost competitiveness with pristine first-pass materials. A key factor in this equation is that there is a huge drop in the mechanical performance of recycled glass fibre (80-90%) in comparison to its original state. Consequently, recycled fibres have a very poor performance to cost ratio, and in most cases are considered unsuitable for reprocessing and reuse as a valuable reinforcement of composites. For these reasons, landfill is currently the most common way of composite disposal. However, expanding the use of the landfill option is increasing being perceived as environmentally and economically unacceptable.
The ultimate goal of this project is to enable cost-effective regeneration of the mechanical properties of glass fibres which have been produced from thermal recycling of glass reinforced structural composites (such as wind turbine blades). This project has the potential to totally transform the economics of recycling GRP composites which would otherwise most likely be disposed of to landfill. A breakthrough in this field will enable such recycled fibres to compete with pristine materials in many large volume composite applications. The development of an economically viable process for regenerating the properties of thermally recycled glass fibres would have major technological, societal, economical, environmental impacts. Conservative estimates indicate that there is a potential to generate a global industry with an annual production of 1 million Tons of reusable regenerated glass fibres with a market value order of magnitude of £1,000M. The reuse of these materials could result in a huge reduction in the environmental impact of the glass-fibre industry where the replacement of pristine glass fibre products would equate to a global reduction in CO2 production of 400,000 Tons/annum from reduced melting energy requirements alone. Furthermore, such a technological development would also reduce the need for an annual landfill disposal of 2 million Tons of composite materials. These developments would clearly be in line with the growing societal and environmental pressure to reduce the use of landfill disposal, increase the reuse of valuable raw materials resources, and reduce the release of CO2 to the atmosphere.
A number of processes are available for recycling such composites. Of these possible routes, thermal recycling is probably the most technologically advanced and has been piloted in the UK and Denmark. However, nearly all options deliver recycled fibres (which make up approximately 60% by weight of the composites) which suffer from a lack of cost competitiveness with pristine first-pass materials. A key factor in this equation is that there is a huge drop in the mechanical performance of recycled glass fibre (80-90%) in comparison to its original state. Consequently, recycled fibres have a very poor performance to cost ratio, and in most cases are considered unsuitable for reprocessing and reuse as a valuable reinforcement of composites. For these reasons, landfill is currently the most common way of composite disposal. However, expanding the use of the landfill option is increasing being perceived as environmentally and economically unacceptable.
The ultimate goal of this project is to enable cost-effective regeneration of the mechanical properties of glass fibres which have been produced from thermal recycling of glass reinforced structural composites (such as wind turbine blades). This project has the potential to totally transform the economics of recycling GRP composites which would otherwise most likely be disposed of to landfill. A breakthrough in this field will enable such recycled fibres to compete with pristine materials in many large volume composite applications. The development of an economically viable process for regenerating the properties of thermally recycled glass fibres would have major technological, societal, economical, environmental impacts. Conservative estimates indicate that there is a potential to generate a global industry with an annual production of 1 million Tons of reusable regenerated glass fibres with a market value order of magnitude of £1,000M. The reuse of these materials could result in a huge reduction in the environmental impact of the glass-fibre industry where the replacement of pristine glass fibre products would equate to a global reduction in CO2 production of 400,000 Tons/annum from reduced melting energy requirements alone. Furthermore, such a technological development would also reduce the need for an annual landfill disposal of 2 million Tons of composite materials. These developments would clearly be in line with the growing societal and environmental pressure to reduce the use of landfill disposal, increase the reuse of valuable raw materials resources, and reduce the release of CO2 to the atmosphere.
Planned Impact
The disposal of end-of-life composite products in an environmentally friendly manner is one of the most important challenges facing the industry and community. It is projected that the total global production of composite materials will significantly exceed 10 million tons by 2015, which will occupy a volume of over 5 million cubic meters. Glass fibre reinforced composites account for approximately 90% of all the fibre reinforced composites currently produced. About 60% of this volume employs thermosetting matrix materials producing composites (GRP) which are difficult and expensive to recycle in an efficient manner. The UK perspective on this issue has been recently highlighted due to the anticipated growth in the use of such composite materials in automotive and wind energy sectors. Many GRP market sectors such as wind turbine applications have growth rates well into double figures with a predicted 6 million tons of GRP wind turbine blades to be produced globally over the coming decade. Currently most of this material is destined for landfill at the end of its 10-25 year application lifetime; the UK is already estimated to produce 160,000 Tons of GRP waste each year of which 98% goes to landfill.
A number of processes are available for recycling such composites. Of these possible routes, thermal recycling is probably the most technologically advanced and has been piloted in the UK and Denmark. However, nearly all options deliver recycled fibres (which make up approximately 60% by weight of the composites) which suffer from a lack of cost competitiveness with pristine first-pass materials. A key factor in this equation is that there is a huge drop in the performance of recycled glass fibre (80-90%) in comparison to its original state. Consequently, recycled fibres have a very poor performance to cost ratio, and in most cases are considered unsuitable for reprocessing and reuse as a valuable reinforcement of composites. For these reasons, landfill is currently the most common way of composite disposal. However, expanding the use of the landfill option is increasing being perceived as environmentally and economically unacceptable.
The ultimate goal of this project is to enable cost-effective regeneration of the mechanical properties of glass fibres which have been produced from thermal recycling of glass reinforced thermoset composites (such as wind turbine blades). This project has the potential to totally transform the economics of recycling GRP composites which would otherwise most likely be disposed of to landfill. A breakthrough in this field will enable such recycled fibres to compete with pristine materials in many large volume composite applications. The development of an economically viable process for regenerating the properties of thermally recycled glass fibres would have major technological, societal, economical, environmental impacts. Conservative estimates indicate that there is a potential to generate a global industry with an annual production of 1 million Tons of reusable regenerated glass fibres with a market value order of magnitude of £1,000M. The reuse of these materials could result in a huge reduction in the environmental impact of the glass-fibre industry where the replacement of pristine glass fibre products would equate to a global reduction in CO2 production of 400,000 Tons/annum from reduced melting energy requirements alone. Furthermore, such a technological development would also reduce the need for an annual landfill disposal of 2 million Tons of composite materials. These developments would clearly be in line with the growing societal and environmental pressure to reduce the use of landfill disposal, increase the reuse of valuable raw materials resources, and reduce the release of CO2 to the atmosphere.
A number of processes are available for recycling such composites. Of these possible routes, thermal recycling is probably the most technologically advanced and has been piloted in the UK and Denmark. However, nearly all options deliver recycled fibres (which make up approximately 60% by weight of the composites) which suffer from a lack of cost competitiveness with pristine first-pass materials. A key factor in this equation is that there is a huge drop in the performance of recycled glass fibre (80-90%) in comparison to its original state. Consequently, recycled fibres have a very poor performance to cost ratio, and in most cases are considered unsuitable for reprocessing and reuse as a valuable reinforcement of composites. For these reasons, landfill is currently the most common way of composite disposal. However, expanding the use of the landfill option is increasing being perceived as environmentally and economically unacceptable.
The ultimate goal of this project is to enable cost-effective regeneration of the mechanical properties of glass fibres which have been produced from thermal recycling of glass reinforced thermoset composites (such as wind turbine blades). This project has the potential to totally transform the economics of recycling GRP composites which would otherwise most likely be disposed of to landfill. A breakthrough in this field will enable such recycled fibres to compete with pristine materials in many large volume composite applications. The development of an economically viable process for regenerating the properties of thermally recycled glass fibres would have major technological, societal, economical, environmental impacts. Conservative estimates indicate that there is a potential to generate a global industry with an annual production of 1 million Tons of reusable regenerated glass fibres with a market value order of magnitude of £1,000M. The reuse of these materials could result in a huge reduction in the environmental impact of the glass-fibre industry where the replacement of pristine glass fibre products would equate to a global reduction in CO2 production of 400,000 Tons/annum from reduced melting energy requirements alone. Furthermore, such a technological development would also reduce the need for an annual landfill disposal of 2 million Tons of composite materials. These developments would clearly be in line with the growing societal and environmental pressure to reduce the use of landfill disposal, increase the reuse of valuable raw materials resources, and reduce the release of CO2 to the atmosphere.
Publications
Jenkins P
(2014)
Investigation of the strength loss of glass fibre after thermal conditioning
in Journal of Materials Science
Nagel U
(2016)
Effects of Thermal Recycling Temperatures on the Reinforcement Potential of Glass Fibers
in Polymer Composites
Thomason J
(2013)
The strength of glass fibre reinforcement after exposure to elevated composite processing temperatures
in Journal of Materials Science
Thomason J
(2016)
Glass Fibre Strength-A Review with Relation to Composite Recycling
in Fibers
Thomason J
(2016)
Regenerating the strength of thermally recycled glass fibres using hot sodium hydroxide
in Composites Part A: Applied Science and Manufacturing
Thomason J
(2014)
The properties of glass fibres after conditioning at composite recycling temperatures
in Composites Part A: Applied Science and Manufacturing
Thomason JL
(2012)
Mechanical study on surface treated glass fibres after thermal conditioning
Thomason, J
Glass Fibre Recovery
Yang L
(2015)
Can thermally degraded glass fibre be regenerated for closed-loop recycling of thermosetting composites?
in Composites Part A: Applied Science and Manufacturing
Yang L
(2013)
The thermal behaviour of glass fibre investigated by thermomechanical analysis
in Journal of Materials Science
Description | • The development of a cost-effective technology to regenerate the properties of thermally recycled glass fibres will have major environmental benefits • Glass fibres lose most of their strength after a short recycling heat treatment above 400°C • Mechanism of strength loss involves both glass fibre sizing degradation and changes in glass fibre structure • Thermal conditioning of glass fibres also drastically reduces end-use composite performance • We have developed cost-effective treatments to ReCoVeR the strength of thermally recycled glass fibres and 80% or more of the composite performance |
Exploitation Route | Our results have clearly proven that the concept of regenerating the performance (and value) of recycled glass fibres is valid. We have also discovered a number of very promising routes to a cost-effective process which require further research and development. At this time we are actively seeking funding to pursue the fundamental issues. However we are also looking to build a consortium of interested partners in order to move the ReCoVeR technology to higher TRLs and develop a pilot facility based on this technology. |
Sectors | Aerospace Defence and Marine Chemicals Environment Manufacturing including Industrial Biotechology Transport |
Description | Project partnership with DSM Research BV |
Organisation | DSM |
Department | DSM Research |
Country | Netherlands |
Sector | Private |
PI Contribution | DSM Research BV worked with the research team and assisted/contributed to the project outcomes |
Start Year | 2011 |
Description | Project partnership with SABIC |
Organisation | Saudi Basic Industries Corporation |
Country | Saudi Arabia |
Sector | Private |
PI Contribution | SABIC worked with the research team and assisted/contributed to the project outcomes |
Start Year | 2011 |
Description | Project partnership with Vestas |
Organisation | Vestas Wind Systems A/S |
Country | Denmark |
Sector | Private |
PI Contribution | Vestas worked with the research team and assisted/contributed to the project outcomes |
Start Year | 2011 |
Title | GLASS FIBRE RECOVERY |
Description | Recovered fibre suffers a huge drop in mechanical performance of 80-90% in comparison to fresh glass fibre. Consequently, recovered glass fibre is unsuitable for use as reinforcement in composite materials. However, disclosed herein is a method by which the majority or substantially all of the mechanical strength may be recovered, by elevating the temperature of a basic solution and treating the recovered glass fibre with the basic solution. The treated, recovered glass fibres may therefore subsequently used in the manufacture of new glass fibre-reinforced composite material. |
IP Reference | WO2015011490 |
Protection | Patent application published |
Year Protection Granted | 2015 |
Licensed | No |
Impact | None as yet |