Periodic Reporting for period 1 - EuReComp (European recycling and circularity in large composite components)
Reporting period: 2022-04-01 to 2023-09-30
EuReComp aims to provide sustainable methods towards recycling and reuse of composite materials, coming from components used in aeronautics and from the wind energy sector. The main pathways to achieve circularity include: i) repairing, repurposing and redesigning parts from end-of-life large scale products and ii) recycling and reclamation of the materials used in such parts; thus, accomplishing reduction of waste and transformation to high-added value products. Currently, EuReComp targets to develop innovative solvolysis recycling processes, to reclaim continuous carbon fibres from the composite parts. These will be used in demonstrators for representative use cases and specifically for the automotive industry and for the construction industry. EuReComp suggests an R6 strategy which includes the following aspects, with priority order: Reuse, Repair, Refurbish, Remanufacture, Repurpose, Recycling. Starting from the dismantling strategies, which investigate optimised procedures for the segmentation and removal of EoL structures, a smart sorting system of materials based on Artificial Intelligence and Machine Learning methodologies is suggested. Large EoL parts are downscaled and reshaped through novel sequencing of routes to high-added value products, without downgrading. In addition, novel solvolysis alternatives are considered as the main recycling process routes. Advanced manufacturing processes, incorporating recycled materials obtained from the different solvolysis processes will lead to a range of new circular composites. The recycled materials will find a second life: an automotive shaft will be manufactured with recycled continuous CFs through filament winding; a racing car seat via compression moulding with recycled fabric patches; a racing steering wheel through additive manufacturing with continuous CF; finally, a container pontoon will be constructed through conventional composite manufacturing techniques, exploiting recycled materials and reusing large EoL parts. In addition, EuReComp will result in the development of a wastes monitoring platform, to identify all recycled materials used in the demo cases. Moreover, a holistic decision support tool for choosing the optimal recycling process among several alternatives will be implemented. Last but not least, a lifelong learning concept based on 'co-design of learning resources' will be developed, to attract and secure current and future generations of employees for the recycling of carbon fibre reinforced composites in cooperation with local and regional educational organizations. Advanced training and professional qualification are seen as essential to establish this new technology. In the training modules to be developed, the complete process chain will be taught, from potential applications of recycled CFRP composites for the establishment of closed-loop material cycles, the dismantling/sorting processes, the reuse or recycling process, the re-manufacturing technology to the management and logistic aspects and the LCA.
EuReComp is running for 18 months and 3 milestones have been achieved. The first is related to the definition of the R6 strategy and the investigation of relevant business cases that ensure the composites circularity. A strategic approach is introduced for returning decommissioned composite parts back into the material chain with a particular focus on waste reduction, consequent energy and emission savings. Regarding the treatment method of repurpose, possible 1st generation applications are recommended. Furthermore, a market analysis for the composite material, wind turbine, aviation and container pontoon boat market is performed. This enables the identification of feasible business cases (eco-settings). These eco-settings comprise closed loops, starting with sorting and dismantling of used composite structures which help to realize a cascade use of the composite products. The second milestone is related to the smart sorting system for EoL parts. Through this tool, recommendations will be provided about the optimal possible 2nd life for EoL parts or even their possible best route for recycling, based on quality previous checking (by means of NDT techniques such as active IR-based thermography, ultrasonics, composition and chemical analysis). The third achieved milestone deals with a Smart Management Tool for Safety-Environment-Performance (SEP) labelling and it is based on EU Ecolabel-basic principles. The initial SEP assessment of the composite materials used in solvolysis processes and demonstrators has been performed, based on the safe and sustainable by design (SSbD) index as formulated by the Chemicals Strategy for Sustainability (CSS).
- The first EoL parts are available for resin identification/quality assessment, through advanced spectroscopic techniques.
- The first meters of continuous CFs have already been reclaimed through plasma enhanced solvolysis, from filament winding parts.
- Ecosettings have been defined for the new use cases.
- A photovoltaic floating platform has already been built from EoL wind blade parts.
- The first EuReComp workshop has taken place, where composites manufacturing and testing have been demonstrated.
- Selection, installation and setup of the learning management system “Moodle” was accomplished.
- The first meters of continuous CFs have already been reclaimed through plasma enhanced solvolysis, from filament winding parts.
- Ecosettings have been defined for the new use cases.
- A photovoltaic floating platform has already been built from EoL wind blade parts.
- The first EuReComp workshop has taken place, where composites manufacturing and testing have been demonstrated.
- Selection, installation and setup of the learning management system “Moodle” was accomplished.