Recycling of plastic composites as basis for a competitive advantage h - GenVind Consortium Justine Beauson (DTU) Qian Wang (Aalborg Universitet) Aalborg Universitet Institut for Kemi, Miljø og Bioteknologi
Summary GenVind Consortium Background and Purpose Ambitions and Objectives Aalborg University in GenVind State of the art in chemical and fibre reinforcement recovery from composite DTU in GenVind State of the art in the application of recovered fibers Dissemination Partners 2 DTU Vindenergi, Danmarks Tekniske Universitet
Background and Purpose Composite Waste Amount and Trend Light, high stiffness, high strength and extremely durable; Many application and increasingly used; Industries: Wind energy; Aeronautics; Automotive; Construction; Marine; Mass transportation; Pipes; Blade Material, Mg/a 2010: 7000 tons composite waste in Denmark; 3 DTU Vindenergi, Danmarks Tekniske Universitet
Background and Purpose Recycling wind turbine blades Why is it a difficult problem? Wind turbine blades: Mix of materials; Dimension of blades; 20 years design life time. Until now: No viable recycling techniques; No landfill restriction; 4 DTU Vindenergi, Danmarks Tekniske Universitet
Ambitions and objectives To find a permanent solution for end of life wind turbine blades - A competitive solution from an industrial point of view; - A sustainable solution lasting from an environmental point of view; Type of project Research Technology Demonstration Description Recovery of chemicals and fibre reinforcement; Optimization and application of recovered fibre reinforcement; Pilot scale study. Development of processes to recover composite materials based on thermal, chemical and mechanical processes; Development of processes to reuse fiber reinforcement and resin side products; Assessment of the environmental impact and the energy consumption of these technologies. Products made with recovered materials, fibers, resin 5 DTU Vindenergi, Danmarks Tekniske Universitet
Ambitions and objectives To find a permanent solution for end of life wind turbine blades - A competitive solution from an industrial point of view; - A sustainable solution lasting from an environmental point of view; Type of project Research Technology Demonstration Description Recovery of chemicals and fibre reinforcement; Optimization and application of recovered fibre reinforcement; Pilot scale study. Development of processes to recover composite materials based on thermal, chemical and mechanical processes; Development of processes to reuse fiber reinforcement and resin side products; Assessment of the environmental impact and the energy consumption of these technologies. Products made with recovered materials, fibers, resin 6 DTU Vindenergi, Danmarks Tekniske Universitet
Aalborg University in GenVind Chemical recycling of composites 1. Composites: fibers embedded in resin matrix 2. Resin matrix: crosslinked network Crosslinks: Epoxy resin C-O, C-N, C-C, COO Polyester COO 3. Interface bonding between fiber and matrix The crosslinks and interface bonding need to be broken down to recycle the composites 7 DTU Vindenergi, Danmarks Tekniske Universitet
Aalborg University in GenVind Chemical recycling of composites To use thermo-chemical treatment to decompose the resin matrix and recycle the fiber and resin degradation products Factors that influence the composites decomposition process Diffusion of chemicals into composites Reactivity of chemicals Removal of resin degradation products 8 DTU Vindenergi, Danmarks Tekniske Universitet
Aalborg University in GenVind Chemical recycling of composites Recyclability of epoxy composite by conc. HNO 3 90 o C, 8M HNO 3 90 o C, 12M HNO 3 Epoxy/carbon fiber composite treated by HNO 3 in a circulating flow system, Lee 2011 9 DTU Vindenergi, Danmarks Tekniske Universitet
Aalborg University in GenVind Chemical recycling of composites Process Degradation products Application Drawbacks Decalin, tetralin, alcohols acetone or water, Catalyst, 280-440 0 C, epoxy, polyester and phenolic resins, Recovery of carbon and aramid fiber, Adherent Technologies (Mexico, Allred 2000, pilot scale, 300 0 C, 30 min) High temperature, Not good for glass fiber, reuse of residues Water, alcohols, amines, glycols, Catalyst, For polyester resin SINTEF/Veolia (Norway, 2011, 220 0 C, 2h 80% decomposition, polyester/glass fiber boats) Long reaction time 10 DTU Vindenergi, Danmarks Tekniske Universitet
Aalborg University in GenVind Chemical recycling of composites Barriers for efficient fiber and chemicals recycling hazadous reagents (conc. HNO 3 ) high temperature (mostly at 350 0 C or higher) Objectives and challenges How to lower reaction temperature and shorten reaction time? To get sufficient separation of fiber, resin and fillers To reuse the resin degradation products 11 DTU Vindenergi, Danmarks Tekniske Universitet
DTU in GenVind Optimization and application of recovered fibre reinforcement 1.Description of the recovered glass fibers 2.Application of recovered glass fibers and challenges Virgin glass fibers properties Tensile Strength: 2 GPa Tensile Modulus: 75 GPa Aspect 43 μm Virgin glass fiber macro and microscopic aspect (Palmer 2009) 12 DTU Vindenergi, Danmarks Tekniske Universitet 12 September
DTU in GenVind Description of recovered fibers Mechanical recovery Thermal recovery Chemical recovery Recovered glass fibers (Palmer 2009) Glass fibers recovered with pyrolysis (Cunliffe and Williams 2003)? Microscopic aspect (Palmer 2009) 43 μm Glass fiber recovered with pyrolysis x2500 (Allred and Busselle 2000)? 13 DTU Vindenergi, Danmarks Tekniske Universitet
DTU in GenVind Application and challenges Application of recovered fibers in composites; Observation: Decreased mechanical properties; Potential solution: Adapt manufacturing procedure; Adjust compound formulation; Improve the mechanical properties of the recovered fibers; Improve the binding between recovered fibers and new resin. 14 DTU Vindenergi, Danmarks Tekniske Universitet
Dissemination of results As an essential element in GenVind, FORCE Technology, Danish Technological Institute, AAU, DTU Windenergy and Danish Plastics Federation will through existing specialist ensure that knowledge is developed and secured at a high level in Denmark. The knowledge generated in the Innovation Consortium will be marketed in developmentoriented companies, SME s as well as large companies in Denmark and abroad. A dissemination plan will be developed at the start of the project; A Dissemination and Communication Committee will be formed that will ensure the dissemination of results and communication both internally in GenVind consortium and externally; A reference group will be formed. 15 DTU Vindenergi, Danmarks Tekniske Universitet
Consortium Partners Teknologiske Institut Plastindustrien i Danmark 16 DTU Vindenergi, Danmarks Tekniske Universitet
GenVind consortium has been supported by the Danish Council for Technology and Innovation under the Ministry of Education 17 DTU Vindenergi, Danmarks Tekniske Universitet
Thank you for your attention Questions? 18 DTU Vindenergi, Danmarks Tekniske Universitet