Periodic Reporting for period 2 - VIBES (IMPROVING RECYCLABILITY OF THERMOSET COMPOSITE MATERIALS THROUGH A GREENER RECYCLING TECHNOLOGY BASED ON REVERSIBLE BIOBASED BONDING MATERIALS)
Période du rapport: 2023-06-01 au 2025-05-31
VIBES project tackled a current and future environmental issue. While thermoset materials are being used in long term applications, nowadays a lot of material is being sorted and there is no circular way to manage this "waste". Therefore, VIBES project has developed solutions that will enable to bring future generations of thermoset composites towards a circular economy concept while adapting the current chemical structrues used in thermosets to those obtained from sustainable sources. It is by these two paths how VIBES is contributing to a greener and more circular society in the field of thermoset materials.
VIBES established specific objectives:
- Design and development of three 100% biobased bonding materials (BBM) for thermoset composites (one per resin type) with tailored debonding functionalities
- Design, develop and validate VIBES composite materials with intrinsic recycling properties for 3 high demanding industrial sectors: aeronautical, construction and naval
- Design and implementation of VIBES green recycling technology to separate and valorise the composite components.
Significant scientific and technological advancements were achieved. Develoment of three biobased bonding materials (one successfully scaled up). Biobased carbon fibres were produced using lignin/CAB precursors and designed recyclable thermoset composites tailored for the construction, aeronautical, and naval sectors. A solvolysis recycling process was developed, marking a key milestone in the project’s technical progress. Validation and testing revealed that flax composites are suitable for non-structural applications in construction and aeronautics, while in the naval sector, they could potentially replace traditional glass fibre woven roving composites. From a sustainability and economic perspective, LCA and s-LCA indicated improved environmental performance of biobased resins and fibres. It demonstrated potential to reduce CO2 emissions and promote a circular economy. A fully functional pilot recycling plant was designed and built, demonstrating the feasibility of separating fibres from resins using solvolysis, successfully recovering high-quality fibres.
VIBES established specific objectives:
- Design and development of three 100% biobased bonding materials (BBM) for thermoset composites (one per resin type) with tailored debonding functionalities
- Design, develop and validate VIBES composite materials with intrinsic recycling properties for 3 high demanding industrial sectors: aeronautical, construction and naval
- Design and implementation of VIBES green recycling technology to separate and valorise the composite components.
Significant scientific and technological advancements were achieved. Develoment of three biobased bonding materials (one successfully scaled up). Biobased carbon fibres were produced using lignin/CAB precursors and designed recyclable thermoset composites tailored for the construction, aeronautical, and naval sectors. A solvolysis recycling process was developed, marking a key milestone in the project’s technical progress. Validation and testing revealed that flax composites are suitable for non-structural applications in construction and aeronautics, while in the naval sector, they could potentially replace traditional glass fibre woven roving composites. From a sustainability and economic perspective, LCA and s-LCA indicated improved environmental performance of biobased resins and fibres. It demonstrated potential to reduce CO2 emissions and promote a circular economy. A fully functional pilot recycling plant was designed and built, demonstrating the feasibility of separating fibres from resins using solvolysis, successfully recovering high-quality fibres.
VIBES developed new bio-based bonding materials and successfully produced them on a larger scale. These materials were tested with different fibres and resins.
During RP1, VIBES made strong progress in developing sustainable composite materials. In WP1, researchers created innovative bonding materials (BBMs) using different chemical strategies, aiming to combine their strengths into one recyclable and durable solution. After thorough testing, the vitrimer-based approach was chosen for further development due to its excellent performance. WP1 was completed and shared results through scientific publications and events. Meanwhile, WP2 advanced in the creation of bio-based epoxy resins and carbon fibres made from lignin. These materials were combined to form fully bio-based composites compatible with the BBMs from WP1. , Early results were promising, and materials were shared with other teams for further testing.
RP2 confirmed the successful synthesis and upscaling of BBMs using supramolecular, vitrimer, and Diels-Alder approaches. These BBMs were tested for compatibility with various resins and fibres, and one BBM was scaled up to kilogram level, enabling its use in composite manufacturing.WP2 concentrated on the development of sustainable components for thermoset multilayer fibrous composites. A significant achievement was the scale-up of lignin/CAB precursor into carbon fibre weavings and unidirectional layers. The final carbonized patches were flexible and showed no signs of sintering, indicating successful processing and potential for industrial application.
In WP3, the consortium designed and developed inherently recyclable thermoset composites tailored for the construction, aeronautical, and naval sectors. Industrial partners validated the processability of VIBES-developed resins. The three different demonstrators were manufactured using flax and biobased carbon fibres, as well as baseline fibres. While VIBES resins met the technical requirements for civil infrastructure, flax composites showed lower mechanical performance, making them suitable for nonstructural applications. In the case of the aeronautic sector, mechanical testing revealed that tensile, flexural, Tg and many other properties are not only reached with VIBES systems but in some cases even overgrown. Naval sector composites using VIBES resins performed comparably to commercial alternatives. Proving to be a perfect solution for the industry.
Overall, the project demonstrated the feasibility of sustainable composite materials.The recycling aspect was addressed through the development of a solvolysis process using acetic acid and hydrogen peroxide. This method effectively separated the matrix from the fibres, with carbon and glass fibres remaining intact. A pilot recycling plant was designed and constructed, incorporating all phases from waste reception to fibre drying. The plant successfully scaled up the solvolysis process, demonstrating effective recycling of composite materials and high-quality fibre recovery. Life Cycle Assessment (LCA) and Social Life Cycle Assessment (s-LCA) showed that bio-based resins and fibres had improved environmental performance, especially when scaled up. Life Cycle Costing (LCC) revealed that bio-based carbon fibres were more cost-effective than benchmarks at pilot scale, while bio-based resins remained more expensive due to raw material costs.
The project aligned with EU Green Deal and Sustainable Development Goals, contributing to climate neutrality and circular economy objectives. Sector-specific Extended Producer Responsibility (EPR) models were developed, and stakeholder engagement was facilitated through workshops and roundtables. Exploitation strategies were defined for nine Key Exploitable Results, and business plans were created for the most promising innovations. The consortium engaged in extensive outreach through social media, newsletters, videos, and events. Workshops, roundtables, and a final conference were organized to showcase project achievements. Training activities included summer courses and industry-focused sessions, enhancing knowledge transfer and stakeholder involvement.
During RP1, VIBES made strong progress in developing sustainable composite materials. In WP1, researchers created innovative bonding materials (BBMs) using different chemical strategies, aiming to combine their strengths into one recyclable and durable solution. After thorough testing, the vitrimer-based approach was chosen for further development due to its excellent performance. WP1 was completed and shared results through scientific publications and events. Meanwhile, WP2 advanced in the creation of bio-based epoxy resins and carbon fibres made from lignin. These materials were combined to form fully bio-based composites compatible with the BBMs from WP1. , Early results were promising, and materials were shared with other teams for further testing.
RP2 confirmed the successful synthesis and upscaling of BBMs using supramolecular, vitrimer, and Diels-Alder approaches. These BBMs were tested for compatibility with various resins and fibres, and one BBM was scaled up to kilogram level, enabling its use in composite manufacturing.WP2 concentrated on the development of sustainable components for thermoset multilayer fibrous composites. A significant achievement was the scale-up of lignin/CAB precursor into carbon fibre weavings and unidirectional layers. The final carbonized patches were flexible and showed no signs of sintering, indicating successful processing and potential for industrial application.
In WP3, the consortium designed and developed inherently recyclable thermoset composites tailored for the construction, aeronautical, and naval sectors. Industrial partners validated the processability of VIBES-developed resins. The three different demonstrators were manufactured using flax and biobased carbon fibres, as well as baseline fibres. While VIBES resins met the technical requirements for civil infrastructure, flax composites showed lower mechanical performance, making them suitable for nonstructural applications. In the case of the aeronautic sector, mechanical testing revealed that tensile, flexural, Tg and many other properties are not only reached with VIBES systems but in some cases even overgrown. Naval sector composites using VIBES resins performed comparably to commercial alternatives. Proving to be a perfect solution for the industry.
Overall, the project demonstrated the feasibility of sustainable composite materials.The recycling aspect was addressed through the development of a solvolysis process using acetic acid and hydrogen peroxide. This method effectively separated the matrix from the fibres, with carbon and glass fibres remaining intact. A pilot recycling plant was designed and constructed, incorporating all phases from waste reception to fibre drying. The plant successfully scaled up the solvolysis process, demonstrating effective recycling of composite materials and high-quality fibre recovery. Life Cycle Assessment (LCA) and Social Life Cycle Assessment (s-LCA) showed that bio-based resins and fibres had improved environmental performance, especially when scaled up. Life Cycle Costing (LCC) revealed that bio-based carbon fibres were more cost-effective than benchmarks at pilot scale, while bio-based resins remained more expensive due to raw material costs.
The project aligned with EU Green Deal and Sustainable Development Goals, contributing to climate neutrality and circular economy objectives. Sector-specific Extended Producer Responsibility (EPR) models were developed, and stakeholder engagement was facilitated through workshops and roundtables. Exploitation strategies were defined for nine Key Exploitable Results, and business plans were created for the most promising innovations. The consortium engaged in extensive outreach through social media, newsletters, videos, and events. Workshops, roundtables, and a final conference were organized to showcase project achievements. Training activities included summer courses and industry-focused sessions, enhancing knowledge transfer and stakeholder involvement.
Developed (3) and scaled up (1) Biobased Bonding Materials (BBMs)
Produced biobased carbon fibres from lignin/CAB precursors
Designed recyclable thermoset composites for construction, aeronautical, and naval sectors
Developed solvolysis recycling process to pilot scale
Pilot demonstrators successfully manufactured and tested
LCA and s-LCA showed improved environmental performance of biobased resins and fibres
Biobased carbon fibres cost-effective at lab scale
Biobased resins remain expensive due to raw material costs
Solvolysis process promising
Demonstrated feasibility of solvolysis process at pilot scale to separate fibres from resins
Recovered high quality fibres
Identified 9 Key Exploitable Results (KERs)
Business plans developed for the most promising KERs (3)
Extensive outreach via social media, newsletters, workshops, and training
14 Scientific publications
Demonstrated potential to reduce CO2 emissions and promote circular economy
Developed Extended Producer Responsibility (EPR) models for key sectors
Produced biobased carbon fibres from lignin/CAB precursors
Designed recyclable thermoset composites for construction, aeronautical, and naval sectors
Developed solvolysis recycling process to pilot scale
Pilot demonstrators successfully manufactured and tested
LCA and s-LCA showed improved environmental performance of biobased resins and fibres
Biobased carbon fibres cost-effective at lab scale
Biobased resins remain expensive due to raw material costs
Solvolysis process promising
Demonstrated feasibility of solvolysis process at pilot scale to separate fibres from resins
Recovered high quality fibres
Identified 9 Key Exploitable Results (KERs)
Business plans developed for the most promising KERs (3)
Extensive outreach via social media, newsletters, workshops, and training
14 Scientific publications
Demonstrated potential to reduce CO2 emissions and promote circular economy
Developed Extended Producer Responsibility (EPR) models for key sectors