Periodic Reporting for period 2 - ESTELLA (DESign of bio-based Thermoset polymer with rEcycLing capabiLity by dynAmic bonds for bio-composite manufacturing)
Période du rapport: 2023-12-01 au 2025-05-31
The ESTELLA project aims to develop sustainable thermoset epoxy composites by introducing covalent adaptable networks (CAN) in both fossil- and bio-based matrices and fibers, following the Safe-and-Sustainable-by-Design (SSbD) approach. This will enable the repolymerization of thermosets into new products and the recovery of fibers. Renewable fibers will also be used as reinforcements, redefining manufacturing and recycling processes.
The main objective is to improve the sustainability of thermosetting epoxy composites by researching the materials' value chain and incorporating CAN bonds. This will allow recycling and redefine manufacturing and recycling processes, ensuring component recovery and reducing environmental and economic impacts.
Key objectives include:
• Developing recyclable thermosetting polymers
• Creating natural fiber reinforcements (short and long)
• Evaluating biorecyclability and degradability of resins
• Designing and manufacturing composites with bio-resin and natural fibers
• Adapting current recycling processes and evaluating recyclability
• Conducting safety, environmental, economic, and social assessments (LCA, SLCA, LCC)
• Disseminating results
The main objective is to improve the sustainability of thermosetting epoxy composites by researching the materials' value chain and incorporating CAN bonds. This will allow recycling and redefine manufacturing and recycling processes, ensuring component recovery and reducing environmental and economic impacts.
Key objectives include:
• Developing recyclable thermosetting polymers
• Creating natural fiber reinforcements (short and long)
• Evaluating biorecyclability and degradability of resins
• Designing and manufacturing composites with bio-resin and natural fibers
• Adapting current recycling processes and evaluating recyclability
• Conducting safety, environmental, economic, and social assessments (LCA, SLCA, LCC)
• Disseminating results
The following is a brief description of the work performed in each technical work package (WP) during this period:
WP1 (Set-up of conditions and tools to enhance material recyclability): The objective of this WP was to pave the way for sustainable recycling of epoxy resin by identifying alternative additives, defining material requirements and discovering degradative microorganisms and enzymes. A comprehensive literature review on plastic additives was completed (Task 1.1) material properties for composite manufacture were defined (T1.2) and composite requirements for future applications were assessed (T1.3). A recyclability framework was established (T1.4) and key enzymes for the recycling process are being identified (T1.5). A protocol for isolating environmental microorganisms was also developed (T1.6). Finally, genome sequencing and identification of the enzymatic pathway is ongoing to advance this research (T1.7).
WP2(Design of thermoset polymer with CAN and obtaining natural fiber): In this WP we have worked on obtaining and functionalizing different molecular weight fractions of lignin for bio-based epoxy resins with associative CAN. In addition, fossil-based epoxy resins with associative CAN and renewable-based epoxy resins with dissociative CAN were prepared. Several continuous and discontinuous natural fibers have been obtained, functionalized and characterized. In this second period, the dispersion processes of the discontinuous fibers in the developed resins have been adapted and optimized. Finally, reprocessing methods have been studied and optimized, selecting the most promising resin (fossil-based).
WP3: This WP (Composite preparation and properties evaluation) involves the design and production of two technology demonstrators: one for sports/mobility item (platform of scooter) and a construction (window frame). The design of two final components has been carried out based on the characteristics of the matrix and reinforcement materials. Simulation work was carried out after the design activities have been completed.
WP4(Composite recycling): This WP is related to the recycling of composites, where the different partners will work on studying mechanical, biological and chemical processes in order to select and scale up which of these gives a better result. SINT has run several enzymatic degradation screenings targeting either the epoxy part of composites or the fiber part. Based on material composition data provided by other partners, SINT has selected and produced enzymes with a potential to attack key chemical bonds in the material, both in the epoxy part and the fiber. Enzymatic degradation studies targeting breakdown of each of the components have been performed. IDE has performed several preliminary tests with the selected ESTELLA materials and selected enzymes from Task 1.5 to determine the most optimal method to degrade fibres and recover resins, to carry out the scale-up.
WP5 (Safety and health assessment): This WP is related to the risk assessment of the developed materials. Such risk assessment encompasses the tasks of biodegradability determination, toxicity prediction and exposure evaluation, which will feed the evaluation of risks for human health and environment. Chemical analyses of extractables and leachables from composite materials have been analysed by SINT. Untargeted scan analysis of volatile, semi-volatile and polar compounds is still ongoing. During this period, most tasks have been carried out for every risk assessment dimension, and they currently are in the last stages before the end and the subsequent submission of the deliverables.
WP6 (Social, economic and environmental assessment): The purpose of this WP is the evaluation of economic feasibility of processes designed in ESTELLA and making sure that both the processes and products are economically and environmentally sustainable. Further goal is a broad socio-economic impact analysis focusing on the assessment of ESTELLA products on the broader society and economy. The activities within the work package (WP) are already well advanced and are being carried out in close collaboration and continuous exchange with the project partners. We are currently working intensively on the techno-economic analysis (TEA) and social impact analysis (SIA). The preliminary results were presented to the consortium at the last GA meeting. The final results will be incorporated into the deliverables that are due at the end of the project.
WP1 (Set-up of conditions and tools to enhance material recyclability): The objective of this WP was to pave the way for sustainable recycling of epoxy resin by identifying alternative additives, defining material requirements and discovering degradative microorganisms and enzymes. A comprehensive literature review on plastic additives was completed (Task 1.1) material properties for composite manufacture were defined (T1.2) and composite requirements for future applications were assessed (T1.3). A recyclability framework was established (T1.4) and key enzymes for the recycling process are being identified (T1.5). A protocol for isolating environmental microorganisms was also developed (T1.6). Finally, genome sequencing and identification of the enzymatic pathway is ongoing to advance this research (T1.7).
WP2(Design of thermoset polymer with CAN and obtaining natural fiber): In this WP we have worked on obtaining and functionalizing different molecular weight fractions of lignin for bio-based epoxy resins with associative CAN. In addition, fossil-based epoxy resins with associative CAN and renewable-based epoxy resins with dissociative CAN were prepared. Several continuous and discontinuous natural fibers have been obtained, functionalized and characterized. In this second period, the dispersion processes of the discontinuous fibers in the developed resins have been adapted and optimized. Finally, reprocessing methods have been studied and optimized, selecting the most promising resin (fossil-based).
WP3: This WP (Composite preparation and properties evaluation) involves the design and production of two technology demonstrators: one for sports/mobility item (platform of scooter) and a construction (window frame). The design of two final components has been carried out based on the characteristics of the matrix and reinforcement materials. Simulation work was carried out after the design activities have been completed.
WP4(Composite recycling): This WP is related to the recycling of composites, where the different partners will work on studying mechanical, biological and chemical processes in order to select and scale up which of these gives a better result. SINT has run several enzymatic degradation screenings targeting either the epoxy part of composites or the fiber part. Based on material composition data provided by other partners, SINT has selected and produced enzymes with a potential to attack key chemical bonds in the material, both in the epoxy part and the fiber. Enzymatic degradation studies targeting breakdown of each of the components have been performed. IDE has performed several preliminary tests with the selected ESTELLA materials and selected enzymes from Task 1.5 to determine the most optimal method to degrade fibres and recover resins, to carry out the scale-up.
WP5 (Safety and health assessment): This WP is related to the risk assessment of the developed materials. Such risk assessment encompasses the tasks of biodegradability determination, toxicity prediction and exposure evaluation, which will feed the evaluation of risks for human health and environment. Chemical analyses of extractables and leachables from composite materials have been analysed by SINT. Untargeted scan analysis of volatile, semi-volatile and polar compounds is still ongoing. During this period, most tasks have been carried out for every risk assessment dimension, and they currently are in the last stages before the end and the subsequent submission of the deliverables.
WP6 (Social, economic and environmental assessment): The purpose of this WP is the evaluation of economic feasibility of processes designed in ESTELLA and making sure that both the processes and products are economically and environmentally sustainable. Further goal is a broad socio-economic impact analysis focusing on the assessment of ESTELLA products on the broader society and economy. The activities within the work package (WP) are already well advanced and are being carried out in close collaboration and continuous exchange with the project partners. We are currently working intensively on the techno-economic analysis (TEA) and social impact analysis (SIA). The preliminary results were presented to the consortium at the last GA meeting. The final results will be incorporated into the deliverables that are due at the end of the project.
The defined expected impacts and result as are reviewed below:
1. Reduction of accumulated waste in landfills.- ONGOING: The design of the recyclable resins is well advanced and almost completed, with successful results.
The recyclability tests of the manufactured materials have already begun.
The analysis of the recyclability of the composite will continue in the coming periods
2. Boosting the consumption of bio-based materials.- ONGOING: Work began on the preparation and technical-economic evaluation in terms of cost estimates and economic feasibility of the main potential production routes.
3. Emissions reduction.- ONGOING: For the evaluation and identification of opportunities to improve the environmental performance of the production value chain, LCA analysis has begun to be used.
4. Cost reduction.- ONGOING: Techno economic analysis in terms of cost estimation and economic viability has been initiated.
5. Social and environmental benefits.- ONGOING: Social Impact analysis in terms of potential impact on employment and health issues has been commenced.
6. Sustainable Development Goals.- ONGOING: Techno-economic analysis in terms of cost estimation and economic viability has been initiated.
7. Extend the application of responsible research and innovation (RRI) practices.- ONGOING: The scientific and technical dissemination of the results of the project is being carried out through different activities.
1. Reduction of accumulated waste in landfills.- ONGOING: The design of the recyclable resins is well advanced and almost completed, with successful results.
The recyclability tests of the manufactured materials have already begun.
The analysis of the recyclability of the composite will continue in the coming periods
2. Boosting the consumption of bio-based materials.- ONGOING: Work began on the preparation and technical-economic evaluation in terms of cost estimates and economic feasibility of the main potential production routes.
3. Emissions reduction.- ONGOING: For the evaluation and identification of opportunities to improve the environmental performance of the production value chain, LCA analysis has begun to be used.
4. Cost reduction.- ONGOING: Techno economic analysis in terms of cost estimation and economic viability has been initiated.
5. Social and environmental benefits.- ONGOING: Social Impact analysis in terms of potential impact on employment and health issues has been commenced.
6. Sustainable Development Goals.- ONGOING: Techno-economic analysis in terms of cost estimation and economic viability has been initiated.
7. Extend the application of responsible research and innovation (RRI) practices.- ONGOING: The scientific and technical dissemination of the results of the project is being carried out through different activities.