THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Paris, March 14-16, 2017
JEC conference Thermoplastics - Multimaterial solutions
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Summary 1. Composite market : impact on recycling
2. Production waste, end-of-life products : which technical solutions ?
3. Thermoset vs thermoplastic composites : which trends ?
4. Thermosaic® technology : a new recycling approach for thermoplastic composite waste
1. Composite market : impact on recycling
World’s production : 8.7 million tons/year
Source of information : JEC 2013
4
20
76
France
Europe
Monde
France
Europe
Wider
world
Geographic distribution
26
30 14
16
3 11 Auto/transport
Construction/génie civil
Equipementsélectriques/électroniquesSports loisirs/nautisme
Aéronautique
Autre
Automotive/transport
Building
Elec. equipment
Sport/leisure
Aeronautic
Other
Breakdown by activities
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
1. Composite market : impact on recycling
Which matrix ?
Thermoset
Thermoplastic
Thermoset (polyester,
epoxy…)
Thermoplastic (PP, PA,
PPS, PEEK…)
Thermoset composite (IDI Composites)
TP composite (Axyal)
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
1. Composite market : impact on recycling
Which reinforcement ?
Glass fiber
Carbon fiber
Kevlar, flax, hemp…
2-4€/kg
25-30€/kg
>10€/kg
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
1. Composite market : impact on recycling
Composite waste in Europe : 0.3 million tons/year
0
50000
100000
150000
200000
250000
300000
350000
2000 2005 2010 2015
Déchets en fin de vie
Déchets de production
Post-consumer
Production waste
Ton
s
Source of information : Techniques de l’ingénieur
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
1. Composite market : impact on recycling
What about current composite waste ?
1. Mainly, a cheap and non-meltable matrix (polyester), combined to a cheap
reinforcement (glass fiber)
2. A growing field.
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Photograph : Consoglobe.com
2. Production loss, end-of-life products : which technical solutions ?
Sources of information : Techniques de l’ingénieur, AgroComposites, ELG Carbon Fiber
Mechanical process (grinding, milling…) filler recovery
Glass powder or fiber/thermoset resin
or
3-4 wt % ?
Chemical process (solvolysis) carbon fiber recovery
Carbon fiber
1-2 wt % ?
Thermal process (pyrolysis,…) waste-to-energy carbon fiber recovery Waste-to-energy+material
Cement factory Carbon fiber Energy
or or
Biological process (biodegradation) waste-to-biomass
1-2 wt % ?
<1wt % ?
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
2. Production loss, end-of-life products : which technical solutions ?
Almost no economical/technical solution for current composite waste
90 wt %
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Photograph : Consoglobe.com, Perspective Consuting Lansink scale Composite wastes
2. Production loss, end-of-life products : which technical solutions ?
Material recovery : current composite waste transformed into filler (mechanical properties mainly lost)
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Sources of information : ABVal Composite, Reprocover, MCR, Polyplast/Rescoll/Cermatex
3. Thermoset vs thermoplastic matrix : which trends ?
Thermoplastic composites : partial replacement of thermoset composites and metals
1970 1960 1980 1990 2000 2010 2020
Thermoplastic composites
Industrial output
Thermoset composites
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
3. Thermoset vs thermoplastic matrix : which trends ?
Thermoplastic matrix
Avantages : No VOC released while processing Easy mechanical assembly Short cycle time (QSP®, thermocompression…) Recyclability (Thermosaïc®, Cetim-Cermat/Cetim) Heat-formed material Disadvantage : Limited industrial maturity Price
Thermoset matrix
Advantages : Cost effectiveness Long-life material Disadvantages : VOC released while processing Complex mechanical assembly Long cycle time Low recyclability
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
3. Thermoset vs thermoplastic matrix : which trends ?
Celstran® CFRTP
Carbostamp
SymaLITE® GMTex®
GMT
IXIS® 157
Thermoplastic composites : a growing industrial offer…
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Trademarks notified by way of example
3. Thermoset vs thermoplastic matrix : which trends ?
+ Cutting
Stamping Welding Source of information : Fokker
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
…of semi-finished products, easily formable…
3. Thermoset vs thermoplastic matrix : which trends ?
…for a growing applications…
Boat’s hull (2Win)
Tailgate (Saint-Gobain)
Trailer (EPL)
Aircraft wing element (Fokker)
Side intrusion beam (DuPont) …
Bumper crash beam (CQFD)
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
3. Thermoset vs thermoplastic matrix : which trends ?
…and a growing production waste and post-consumer waste
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Photographs : Cetim ; Consoglobe.com
4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste
Key information about Thermosaic® technology
Cost effectiveness process
Low environnemental impact
No separation between polymer matrix and fiber reinforcement
Convenient for any thermoplastic matrixes (PP, PA, PEI…) and any reinforcement (GF, CF…)
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste
Key information about Thermosaic® technology
Isotropic mechanical properties
Mechanical properties of recycled material mostly maintained
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Sources : Global trends, from Kelly&Tison and Cox models (PP/GF)
Short fibre reinforced plastic
Thermosaic®
Continuous fibre reinforced plastic Continuous fibre reinforced plastic
Short fibre reinforced plastic
Thermosaic®
4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste
Thermo-mechanical process 100% recycled composite panel production
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Pilot line THERMOSAIC® composite panel
4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste
100% recycled composite panel adapted to traditional processing techniques
cutting folding welding machining stamping thermoforming …
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
PP/GF plates joined by welding (Thermosaïc)
PP/GF thermoformed part (Thermosaïc)
4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste
Targeted applications
Niche markets in substitution of traditional materials Small and medium volume production
Customer markets
Industrial equipment Transport Building and infrastructure Energy …
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
THERMOSAIC® TECHNOLOGY VIDEO
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Institutional partners / funders
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THERMOSAÏC, a patented technology for thermoplastic composite material recycling
Join us at HALL 5A E64
Contact : Frédéric Ruch [email protected]
THERMOSAÏC, a patented technology for thermoplastic composite material recycling
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