Design and manufacture of sustainable processes for recovery and production of Carbon Fibers
Topic(s) : Special Sessions
Co-authors :
Stavros ANAGNOU (GREECE), Stefania TERMINE , Konstantinos MPALIAS , Dimitrios KRIFOS (GREECE), Vasilios VASILIOS GAKOS (GREECE), Georgios VASILEIOU , Panagiotis NTAKOS (GREECE), Nikolaos ROGKAS (GREECE), Christos KALLIGEROS (GREECE), Vasilios SPITAS , Costas CHARITIDISAbstract :
Carbon fiber reinforced plastic (CFRP) material, one of the future lightweight structures has been spreading in several high-performance sectors of industry. Market demand of (CFRP) materials is highly increased combined with rapid rise of CFRPs applications regarding aerospace, automotive, wind turbines, sports equipment etc. These conditions are emerging a waste recycling challenge and a regulation of energy necessity [1].
Environmental footprint and life cycle sustainability of CFRP’s industry are a high-priority issue that need to be seriously compromised from production until final use, targeting high material utilization and energy efficiency [2]. Recycling has been widely used as an end-of-life option for CFRP wastes management based on potential value recovery. Recycling waste materials fulfills legislative and sustainability targets compared to being disposed in landfills or incineration [3]. Conventional mechanical recycling, thermal recycling pyrolysis and fluidized bed process as well as chemical recycling consist modern recycling methods [4, 5]. Recovered Carbon fibers maintain elastic modulus and demonstrate a reduction of 18%–50% in tensile strength [5, 6].
In this study, a holistic approach is being developed considering the combination of bio-sourced fibers production and end-of-life composite materials recycling, in order to decrease the impact of energy demanding processes. The aim is mainly achieved by the R&D of the coupling bio/circular-materials and processes. The design investigates the combination of carbonization and pyrolysis processes as an innovative approach for sustainable, optimized energy reduced pyrolysis, using waste stream from carbonization of precursors, reducing environmental impact of carbon fiber production. As the production of CFs is a high energy demanding process, this energy will be imposed for pyrolysis of CFRPs and CFs will be retrieved with extant energy. Implementation of a circular economy that can eliminate waste and re-use resources warrants the use of efficient processes to recycle end-of-life CFRP components and manufacturing wastes.
The designed production line will consist of the Continuous Carbonization Furnace and the Pyrolysis Chamber. The Pyrolysis chamber will have a useful volume of 0.125 m3, in which the heated waste gases from the carbonization line will be guided under controlled temperature and flow conditions. Additionally, the chamber can be used independently with electrical heating to reach a temperature of 600°C. More specifically, the pyrolysis chamber will incorporate a system for collecting liquid by-products, and the waste gases from the pyrolysis process will be appropriately condensed and filtered.
Acknowledgments: This work has been funded by the European Union’s Horizon Europe research and innovation program "SUSPENS" under Grant Agreement No. 101091906
Environmental footprint and life cycle sustainability of CFRP’s industry are a high-priority issue that need to be seriously compromised from production until final use, targeting high material utilization and energy efficiency [2]. Recycling has been widely used as an end-of-life option for CFRP wastes management based on potential value recovery. Recycling waste materials fulfills legislative and sustainability targets compared to being disposed in landfills or incineration [3]. Conventional mechanical recycling, thermal recycling pyrolysis and fluidized bed process as well as chemical recycling consist modern recycling methods [4, 5]. Recovered Carbon fibers maintain elastic modulus and demonstrate a reduction of 18%–50% in tensile strength [5, 6].
In this study, a holistic approach is being developed considering the combination of bio-sourced fibers production and end-of-life composite materials recycling, in order to decrease the impact of energy demanding processes. The aim is mainly achieved by the R&D of the coupling bio/circular-materials and processes. The design investigates the combination of carbonization and pyrolysis processes as an innovative approach for sustainable, optimized energy reduced pyrolysis, using waste stream from carbonization of precursors, reducing environmental impact of carbon fiber production. As the production of CFs is a high energy demanding process, this energy will be imposed for pyrolysis of CFRPs and CFs will be retrieved with extant energy. Implementation of a circular economy that can eliminate waste and re-use resources warrants the use of efficient processes to recycle end-of-life CFRP components and manufacturing wastes.
The designed production line will consist of the Continuous Carbonization Furnace and the Pyrolysis Chamber. The Pyrolysis chamber will have a useful volume of 0.125 m3, in which the heated waste gases from the carbonization line will be guided under controlled temperature and flow conditions. Additionally, the chamber can be used independently with electrical heating to reach a temperature of 600°C. More specifically, the pyrolysis chamber will incorporate a system for collecting liquid by-products, and the waste gases from the pyrolysis process will be appropriately condensed and filtered.
Acknowledgments: This work has been funded by the European Union’s Horizon Europe research and innovation program "SUSPENS" under Grant Agreement No. 101091906