European recycling and circularity in large composite components

Project Information

EuReComp

Grant agreement ID: 101058089

DOI

10.3030/101058089

Project closed

EC signature date 20 May 2022

Start date 1 April 2022

End date 31 March 2026

Funded under

• Digital, Industry and Space

Total cost

€ 8 904 882,00

EU contribution

€ 8 903 632,00

Coordinated by

ETHNICON METSOVION POLYTECHNION
Greece

Periodic Reporting for period 2 - EuReComp (European recycling and circularity in large composite components)

Reporting period: 2023-10-01 to 2025-03-31

Summary of the context and overall objectives of the project

EuReComp is committed to sustainable methodologies for recycling and reusing composite materials from aeronautical and wind energy sectors. Recognizing the environmental impact of composite waste, EuReComp emphasizes two circular pathways: firstly, repairing, repurposing, and redesigning large-scale EoL components; secondly, recycling and reclaiming valuable embedded materials. These efforts significantly reduce waste and transform recovered materials into high-value products. After three years of intensive research and technological development, EuReComp has achieved critical milestones, including completing initial work packages focused on reuse/recycling strategies and EoL material sorting methodologies. Ongoing activities demonstrate significant advancements toward circular solutions. A notable achievement includes constructing a demonstrator—a floating photovoltaic panel—from repurposed wind turbine blades, alongside implementing innovative repair methods for practical reuse applications. On the recycling front, advanced solvolysis processes have successfully reclaimed continuous carbon fibers and composite patches from EoL parts. Upscaling these processes ensures sufficient recycled material for manufacturing demonstrators, marking a critical step towards viable recycling operations. EuReComp also developed demonstrators using recycled materials, optimized composite filament fabrication, and additive manufacturing methods. A hybrid demonstrator combining reused and recycled components is underway, exemplifying practical circular economy applications. Critical digital tools developed include a waste-monitoring platform to track recycled materials, and decision-support tools to evaluate optimal recycling strategies. LCA and LCC analyses confirm demonstrable environmental and economic benefits. Educational initiatives, including training workshops and webinars, have successfully increased industry skills and awareness, essential for sustained adoption of circular composite practices.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

After 3 years of full action, EuReComp has achieved all Milestones and main targets that had set. The two first WPs have been completed, related to the reuse/recycling strategies and the methodologies of sorting/selecting the EoL materials to be further processed. In WP3, a floating photovoltaic panel made by EoL wind turbine blades was constructed. Repairing strategies with novel methodologies have also been investigated. In WP4, innovative solvolysis recycling processes were developed, to reclaim carbon fibres from the composite parts. The last months focused on the chemical solvolysis upscaling, in order to recycle adequate amounts of fibres to be used in the demonstrators manufacturing. In WP5, the first testing specimens have been fabricated by the recycled materials delivered from WP4. An optimisation campaign has been carried out both for the composite filament fabrication and the additive manufacturing process, for the AM demos. Additionally, the necessary alteration to the manufacturing equipment for all cases has been implemented. A floating container pontoon, is already under construction. In addition, a wastes monitoring platform has been developed to track all recycled materials flows used in the demo cases. In WP6, a holistic decision support tool for choosing the optimal recycling process among several alternatives has been created. In parallel, LCA and LCC analyses on the solvolysis processes and recycled materials have been carried out. Preliminary assessments were conducted fot the demonstrators. In WP7, material has been collected for the LLL programme and Open Training Workshops were scheduled in person. Also, regular training webinars on the most “hot topics” were organised and attracted numerous participants. Several DEC activities have been carried out, including submission of scientific publications, participation in International Exhibitions and Conferences, etc. A mapping of the possible exploitation of the KERs and a Standardisation Survey, to identify possible gaps in existing standards were carried out.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

-Upscaled chemical solvolysis processes efficiently reclaim continuous and chopped carbon fibers, significantly advancing recycling capabilities and opening new widespread applications.
-Advanced automated inspection and smart sorting technologies, combining spectroscopic techniques and artificial intelligence, ensure precise material identification and significantly improve recycling outcomes.
-High-quality composite demonstrators, produced through innovative additive manufacturing with reclaimed fibers, show practical reuse potential, notably in automotive and racing industries.
-A comprehensive digital monitoring platform tracks material flows within circular value chains, enhancing traceability and efficiency in recycling processes.
-Robust environmental and economic assessments (LCA and LCC) provide validated sustainability benchmarks, highlighting clear advantages over conventional practices.
-Expanded educational initiatives and stakeholder engagement enhance industry knowledge and skills essential for adopting circular composite practices.

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