Periodic Reporting for period 1 - MC4 (Multi-level Circular Process Chain for Carbon and Glass Fibre Composites)
Reporting period: 2022-04-01 to 2023-09-30
Each year about 110.000t of carbon fiber composite parts and 4.500.000t of glass fiber composites are used. 98% of these parts end up in landfills at the end of their life. To address this problem the MC4 project aims at establishing a multi-level circular process for carbon and glass fiber composite. Multi-level means that processes will be developed for short-term implementation with immediate impact and for the longer term with a wider impact on industry. Carbon and glass fiber have substantially different costs and the project takes this into account by developing economically feasible procedures that are based on chemical matrix/fibre separation for carbon fibre and on a new type of resin for the direct re-use of the composite for glass fibre. Quality grading of the recycled material will be a key element to ensure a proper use in the different domains and to minimize the need for "downcycling".
To create impact on the short term the project is also investigating methods for the mechanical recycling of glass fibre composites, with the goal of re-using larger (5-10cm) pieces of material to take advantage of the mechanical properties of the composites (rather than converting it into particles used as filler). Finally, the re-use of uncured carbon fibre scrap directly in the production process will be investigated to convert the scrap material to re-usable roll material or to directly re-use it in (smaller) parts. Within the supply chain investigated in the project the overall goal is to achieve a recycling rate of at least 60%.
As an additional benefit, the project will enable European material manufacturers to develop their own, patented processes for manufacturing of recycled material. Currently, 80% of the manufacturing of virgin carbon and glass fibre is taking place outside of Europe and the manufacturing technologies used inside of Europe are often licensed from foreign countries. MC4 puts particular emphasis on the design and manufacturing of best practice examples of parts made from recycled materials. For six different domains, including automotive, aerospace, sports equipment, boats, urban furniture and civil engineering, composite products will be manufactured, with the aim of demonstrating the use of recycled material and enhancing the demand side for recycled material in the different domains. The consortium includes process developers, material manufacturers and SME end users, who manufacture composite parts. It covers the whole value chain and thus enables the creation of real circular process for composites.
To create impact on the short term the project is also investigating methods for the mechanical recycling of glass fibre composites, with the goal of re-using larger (5-10cm) pieces of material to take advantage of the mechanical properties of the composites (rather than converting it into particles used as filler). Finally, the re-use of uncured carbon fibre scrap directly in the production process will be investigated to convert the scrap material to re-usable roll material or to directly re-use it in (smaller) parts. Within the supply chain investigated in the project the overall goal is to achieve a recycling rate of at least 60%.
As an additional benefit, the project will enable European material manufacturers to develop their own, patented processes for manufacturing of recycled material. Currently, 80% of the manufacturing of virgin carbon and glass fibre is taking place outside of Europe and the manufacturing technologies used inside of Europe are often licensed from foreign countries. MC4 puts particular emphasis on the design and manufacturing of best practice examples of parts made from recycled materials. For six different domains, including automotive, aerospace, sports equipment, boats, urban furniture and civil engineering, composite products will be manufactured, with the aim of demonstrating the use of recycled material and enhancing the demand side for recycled material in the different domains. The consortium includes process developers, material manufacturers and SME end users, who manufacture composite parts. It covers the whole value chain and thus enables the creation of real circular process for composites.
The first half of the project was dedicated to implementing the single process steps along the circular values chain. As a first step the processes have been developed individually and in the second half of the project the consortium will aim at closing the loop and demonstrating a flow of (recycled) material along the whole circular processes developed in the project. Within the first reporting period the following main results have been achieved:
• Characterisation of the circular processes and of recycled materials at a technical and economic level
• Design and start of the construction of a reactor for matrix/fibre separation using a solvolysis process for end-of-life carbon fibre parts
• Two different process designs for the re-use of uncured material in production of carbon fibre prepreg parts, including the first manufacturing of recycled sample materials
• Adaptation of specific resin (“3R”) which enables the re-shaping of end-of-life glass fibre parts and characterization of the resin in the application of sports equipment
• Development of a process for the re-use of larger, shredded glass fibre composite pieces in new parts and manufacturing of first sets of sample parts
• Development of textile processes to create nonwoven material and tapes from recycled carbon fibre
• Design and construction of a sensor system for the quality control of recycled carbon fibre at three different stages of the recycling process.
All of these developments were demonstrated in structured way, including the evaluation of the resulting materials, processes at prototypes at a technical and economic level. This first demonstration included all 4 recycling processes (carbon & glass, long-term & short-term) that are developed in the project and initial results about the quality grading methods. Each single process step was be demonstrated and its output assessed relative to the material and process specifications. This also included auxiliary processes such as sorting of parts and vitrimerization. The results of the assessment will be used to fine-tune research activities for the second half of the project.
Later in the first half of the project activities were started to develop part designs of parts made from recycled material for six different domains: automotive, aerospace, boatbuilding, urban furniture, sports queipment and civil engineering. The specific properties of recycled material have been particularly taken into account and initial test with the materials have taken place, in most cases still at coupon level, but the manufacturing of full size part is planned for the second half of the project.
• Characterisation of the circular processes and of recycled materials at a technical and economic level
• Design and start of the construction of a reactor for matrix/fibre separation using a solvolysis process for end-of-life carbon fibre parts
• Two different process designs for the re-use of uncured material in production of carbon fibre prepreg parts, including the first manufacturing of recycled sample materials
• Adaptation of specific resin (“3R”) which enables the re-shaping of end-of-life glass fibre parts and characterization of the resin in the application of sports equipment
• Development of a process for the re-use of larger, shredded glass fibre composite pieces in new parts and manufacturing of first sets of sample parts
• Development of textile processes to create nonwoven material and tapes from recycled carbon fibre
• Design and construction of a sensor system for the quality control of recycled carbon fibre at three different stages of the recycling process.
All of these developments were demonstrated in structured way, including the evaluation of the resulting materials, processes at prototypes at a technical and economic level. This first demonstration included all 4 recycling processes (carbon & glass, long-term & short-term) that are developed in the project and initial results about the quality grading methods. Each single process step was be demonstrated and its output assessed relative to the material and process specifications. This also included auxiliary processes such as sorting of parts and vitrimerization. The results of the assessment will be used to fine-tune research activities for the second half of the project.
Later in the first half of the project activities were started to develop part designs of parts made from recycled material for six different domains: automotive, aerospace, boatbuilding, urban furniture, sports queipment and civil engineering. The specific properties of recycled material have been particularly taken into account and initial test with the materials have taken place, in most cases still at coupon level, but the manufacturing of full size part is planned for the second half of the project.
By midterm of the project the following results beyond the state of the art have been achieved:
* a chemical recycling process for the separation of matrix and fibre of carbon fibre composite parts. The process works at comparably mild conditions and is less energy intensive than other chemical recycling processes. It is has been tested at laboratoy level for composites eopxy-amine hardener and could be shown to completely dissolve composites while obtaining very clean carbon fibre with high mechanical performance.
* an adaptation of the a particular type of resin ("3R") for the use with glass fibre. The resin has properties very similar to thermoset resins, but has the advantage to be re-shapable und heat and pressure. This enables a "second life" for end-of-life glass fibre composite parts.
* two methods to transform srcap of uncured carbon pre-preg into material that can be directly used in the manufacturing of carbon fibre composite parts, with not-so-critical requirements in terms of mechanical perfomance.
* a process for the re-use of larger pieces of glass fibre composites in parts while obtaining suitable mechanical properties and good surface quality.
These main recycling processes have reached TRL4-5 at this stage of the project. Further developments are needed to increase the level to TRL 6.
In order to maximize the potential impact, the project still aims at the demonstration of the processes in six different domain. For each of these domains at least one typical sample part will be designed and manufactured from recycled composite material. These parts will serve as best practice examples and will be dissemination at a wide scale to create a demand for recycled material. This will be the key to start a circular process for carbon and glass fibre composites.
Even though the project will aim at economically feasible solution, the take-up by industry will substantially benefit from legislation that requires certain recycling rates for part manufacturers.
* a chemical recycling process for the separation of matrix and fibre of carbon fibre composite parts. The process works at comparably mild conditions and is less energy intensive than other chemical recycling processes. It is has been tested at laboratoy level for composites eopxy-amine hardener and could be shown to completely dissolve composites while obtaining very clean carbon fibre with high mechanical performance.
* an adaptation of the a particular type of resin ("3R") for the use with glass fibre. The resin has properties very similar to thermoset resins, but has the advantage to be re-shapable und heat and pressure. This enables a "second life" for end-of-life glass fibre composite parts.
* two methods to transform srcap of uncured carbon pre-preg into material that can be directly used in the manufacturing of carbon fibre composite parts, with not-so-critical requirements in terms of mechanical perfomance.
* a process for the re-use of larger pieces of glass fibre composites in parts while obtaining suitable mechanical properties and good surface quality.
These main recycling processes have reached TRL4-5 at this stage of the project. Further developments are needed to increase the level to TRL 6.
In order to maximize the potential impact, the project still aims at the demonstration of the processes in six different domain. For each of these domains at least one typical sample part will be designed and manufactured from recycled composite material. These parts will serve as best practice examples and will be dissemination at a wide scale to create a demand for recycled material. This will be the key to start a circular process for carbon and glass fibre composites.
Even though the project will aim at economically feasible solution, the take-up by industry will substantially benefit from legislation that requires certain recycling rates for part manufacturers.