Recycling solutions for cured and un- cured carbon fibre ...users.ox.ac.uk/~pgrant/Milled Carbon...
Transcript of Recycling solutions for cured and un- cured carbon fibre ...users.ox.ac.uk/~pgrant/Milled Carbon...
WingNet September 2007
Recycling solutions for cured and un-cured carbon fibre composites.
http://www.afraassociation.org/
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Milled Carbon Ltd is privately owned and funded, founded in 2003 with the objective of developing a continuous, commercially viable, processes to recover carbon fibre.
We currently recycle;•carbon fibre composite manufacturing waste•composite component parts •end of life components
Based in the UK, with operations in Birmingham
We have collective experience of 200 years in the carbon fibre manufacturing and polymers industry
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• We are founder members of AFRA (Aircraft Fleet Recycling Association).
• We are a partner in ReBrake a DTI funded Technology Innovation Programme to research a recycled carbon fibre/ceramic matrix disc brake
• We are also lead partner in FibreCycle a DTI funded Technology Innovation Programme to research the conversion of recycled carbon fibre into spun yarn
• We are also members of a recent Framework 7 Project entitled Advanced Recycling and Sorting Technologies for Future Vehicles (ARTicle) This project explores the possibilities beyond the requirements specified in the ELV and Battery Directives and develops shredding and post-shredding technologies as well as material refining technologies.
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Market SegmentThousands
of MT % Mkt Thousands of MT % Mkt Thousands
of MT % Mkt
Industrial 8.2 49 11.4 52 19.1 54United States 1.9 23 3.1 27 5.3 28Europe 1.1 13 2.7 24 5.8 30Japan 1.7 21 2.2 19 3.1 16Other 3.5 42 3.4 30 4.9 26Aircraft Aerospace 4.1 24 5.6 26 10.7 30United States 2.8 70 3.4 60 6.4 60Europe 1.0 24 1.8 33 3.3 31Japan 0.2 4 0.2 4 0.6 5Other 0.1 2 0.2 4 0.4 4Sporting Goods 4.1 27 4.9 22 5.8 16United States 2.2 49 1.9 40 2.2 39Europe 0.5 12 0.7 14 0.9 16Japan 0.7 16 0.5 10 0.4 7Other 1.1 23 1.8 36 2.3 39
1999 2004 2009
Estimated Global CF Consumption by Major Market Segment
Current estimated world production: 25,000 to 30,000 mtpa
Global Carbon Fibre Consumption
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By kind permission:www.eurofighter.com /medialibrary
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Boeing 787 & Airbus A380: Carbon Fibre Composite Content
CFRP
GFRP
GLARE®
Hybrid (G+ C)
Radome
Nose landinggear doors
CentralTorsion Box
Main and centrelanding gear doors
Pylon fairingsand nacellescowlings
Main landinggear leg fairing door
Spoilers
Trailing edgeupper and lower panelsand shroud box
Overwingpanel
Apron
Pressurebulkhead
Verticalstabilizer
Tailcone
Horizontalstabilizerouter boxes
Outer flap
Upper-deck floor beams
Flap trackfairings
Ailerons
Belly fairing skins
Leading edge / J-nose
The Airbus A380 Contains 25 – 30 tonnesof composites, 85% of which are CFRP
The Boeing 787 contains50% of total weight incomposites, the remainder being 20% aluminium and 30% titanium
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FLUIDISED RECYCLATE:
LONG FIBRES 30 –75mm
MANUFACTURING WASTE
CURED COMPONENT WASTE
END OF LIFE
CONTINUOUS PYROLYSIS PROCESS
FLUIDISED BED PROCESS
PYROLISED RECYCLATE
PRECIOUS METALS
The Process
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Manufacturing Scrap as Received EDS Spectra
Courtesy North Carolina State University
Manufacturing Scrap
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Single Fiber Tensile Test Results
Control AS4
Recycled AS4
* Values in the parentheses represent coefficient of variation %
Recycled AS4After 1st round of Optimization
Preliminary Results
CF4 Trend ConfirmedCF4-1 Improved after Process Optimization
Myles Connor, Brian AllenDr. Jerome J. Cuomo
CF A5
Gauge length [mm]
5
10
10
20
20
20
510
CF 4
CF 4-1
Fracture Stress [MPa]
Young’s modulus [GPa]
Fracture strain [%]
Fiber Type
2953 (13.2)2732 (13.6)2464 (12.7)
4001 (18.4)*3619 (16.1)3401 (14.8)
4148 (9.2)3691 (15.6)3143 (18.8)
165 (19.7)211 (9.0)228 (9.9)
230 (7.4)201 (14.4)
257 (8.1)
211 (9.6)231 (9.8)224 (8.7)
2.64 (17.5)1.94 (14.7)1.53 (13.3)3.28 (35.6)1.48 (20.5)1.19 (15.4)2.40 (17.4)1.74 (14.8)1.63 (16.5)
CF A5
Gauge length [mm]
5
10
10
20
20
20
510
CF 4
CF 4-1
Fracture Stress [MPa]
Young’s modulus [GPa]
Fracture strain [%]
Fiber Type
2953 (13.2)2732 (13.6)2464 (12.7)
4001 (18.4)*3619 (16.1)3401 (14.8)
4148 (9.2)3691 (15.6)3143 (18.8)
165 (19.7)211 (9.0)228 (9.9)
230 (7.4)201 (14.4)
257 (8.1)
211 (9.6)231 (9.8)224 (8.7)
2.64 (17.5)1.94 (14.7)1.53 (13.3)3.28 (35.6)1.48 (20.5)1.19 (15.4)2.40 (17.4)1.74 (14.8)1.63 (16.5)
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Contact Angle & Surface Energy
Diiodomethane Water
Fiber Average cos θ[measured]
Average cos θ[measured]
Dispersive Surface Energy
(mN/m)[calculated]
Non-Dispersive Surface Energy
(mN/m)[calculated]
CF1 0.72 ± 0.08 0.16 ± 0.02 31.2 9.7CF4 0.87 ± 0.02 0.25 ± 0.03 35.9 10.5CF-A 0.76 ± 0.02 0.30 ± 0.02 32.2 12.8CF-B 0.84 ± 0.02 0.22 ± 0.06 35.1 9.9
• At least six different specimens were tested for each sample set• CF4 (Milled Carbon) sample contained the highest dispersive surface energy characteristic and the second highest non-dispersive surface energy characteristic• Recycled CF1 contained the lowest surface energies for both dispersive and non-dispersive components
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Preliminary Data of Reclaimed Carbon Fiber BMC by QCI – ASTM D790 Flexural Test
Resin (Vinyl Ester) Filler Fiber AVE SD AVE SD
Virgin 60 0 40 23.97 4.05 2.89 0.58Virgin 37.5 37.5 25 21.92 2.28 2.69 0.19
MC (E) 29 56 15 (UK) 16.52 4.30 2.55 0.27AT (F) 29 56 15 (US) 11.21 3.12 2.14 0.12
Compound ID.
Flexural Strength (ksi.) Flexural Modulus (msi)Content (%)
0.00
5.00
10.00
15.00
20.00
25.00
30.00
B D E F
Compound ID.
Flex
ural
Str
engt
h (k
si.)
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
B D E F
Compound ID.
Flex
ural
Mod
ulus
(msi
.)
AMC 8590 SMC (55% 1” Carbon Fiber): Strength = 88 ksi., Modulus = 5.6 msi.
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We have observed the aesthetic appeal of carbon fibre increase in use. In this case we have used woven sheet recyclate to trial a number of consumer goods.
Carbon fibres have other, industrially advantageous properties which can also beexploited. These IC trays contain 30 to 40% carbon fibre. Recycled carbon fibre has theelectrical properties required for such end uses.
Applications
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Future Applications• Flocking; using recycled milled carbon fibre for conductive substrates,
filter medium, decorative interiors
• Metal replacement; working with alternative advanced/recycled fibre matrix to replace aluminium panels
• Concrete reinforcement; using short recycled fibres to enhance the strength and durability of concrete used in construction
• Glass Fibre Replacement; exploring the possibility of replacing glass fibre to reduce weight and enhance recyclability
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Future Technologies• Microwave: we are currently researching the use of microwaves to
improve the thermal efficiency of the process which also leads to considerable reduction in processing costs and is a more environmentally sustainable process
• Fluidised Bed; we are researching the use of a fluidised bed system for the processing of end of life shredded material, such as aeroplanes and motor vehicles
• Atomic Level Cleaning; we have also been working with partners on Plasma Re-engineering of waste carbon fibre composites
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USA: Seattle, Tucson, Wichita, Greenville
Europe:UK, Germany, Italy
Asia:Japan, Taiwan, China
South Africa:Johannesburg
Going Global
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John Davidson MScManaging Director
Milled Carbon LtdWootton MeadStratford RoadWootton WawenHenley in ArdenWarwickshireB95 6AP
Mobile: +44 (0)7768 566661Head Office Tel: +44 (0)121 705 9000Head Office Fax: +44 (0)156 479 3749Works Tel: +44 (0)121 522 2022Works Fax: +44 (0)121 557 1081