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Dr Oana Ghita

Recycling and Reprocessing Techniques for Plastics and Composites CALMARE, University of Exeter Paul McCutchion Commercial Manager. Dr Oana Ghita. Title can go here. CALMARE Overview. Centre for Additive Layer Manufacturing.

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Dr Oana Ghita

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  1. Recycling and Reprocessing Techniques for Plastics and Composites CALMARE, University of Exeter Paul McCutchion Commercial Manager Dr Oana Ghita

  2. Title can go here CALMARE Overview Centre for Additive Layer Manufacturing Centre for Alternative Materials and Remanufacturing Technologies Exeter Advanced Technologies

  3. World Plastics Production

  4. Are Plastics aSustainable Choice? Durability / Life Span • BMW i3 • First BMW with an outer skin made entirely of thermoplastic. The roof is the only exception made of recycled CFRP • Uses CF not just for body panels but also its frame • Additional benefits • Reduced weight – cancels out the weight of the battery – fuel economy • Improved process – elimination of traditional paint process – 50% less energy, 70% less water BMW i3; www.bmw.com

  5. But are they recycled? • Recycling of Plastics • The UK uses over 5 million tonnes of plastic each year of which an estimated 24% is currently being recovered or recycled. • Source: British Plastics Federation • Why aren’t more plastics recycled? • Lack of facilities • Not commercially viable (resale value not sufficient) • Logistics • Lack of access to sufficient in-feed volume • Lack of demand • Reluctance in manufacturers to accept change • Negative quality perceptions • Safety rules e.g. food

  6. Drivers to increase Recycling of plastics • Legislation • End of Life Vehicle Directive • WEEE and RoHS • EU Waste Framework Directive • EU Directive on Packaging and Packaging Waste • Producer Responsibility Schemes • Landfill Tax / Landfill Bans

  7. Drivers to increaseRecycling of plastics • Commercial Opportunities • Cost Savings • Corporate Social Responsibility • Marketing • Risk reduction – materials supply

  8. EU Plastics Recycling

  9. EU Plastics Recycling

  10. Recycling Thermoplastics Thermoplastic • Relatively easy • Ground, Re-melted and Separated • Issues • Mixed waste • Contamination • Sorting and separation

  11. Recycling Thermoplastics • Drinks bottles (PET) • Milk jugs (HDPE) • Pipes, shrink wrap (PVC) • Plastic bags (LDPE) • Bottle caps (PP) • Packaging (PS) • Other www.reuseit.com

  12. CONTINUUM • A joint venture between ECO Plastics and Coca-Cola Enterprises • It can reprocess around 150,000 tonnes of plastic each year and can turn plastic from used drinks bottles into new bottles for Coca-Cola within as little as 6 weeks. • Reprocess around half of all the plastic bottles collected for recycling in GB.

  13. Mixed Plastics - Recycling Mixed plastic recycling e.g. Ecoboard - consists of approximately 80% comingled plastic waste and can replace plywood in temporary and, potentially, in permanent construction work.. http://www.ertplc.com/

  14. Recycling Thermosets Thermosets • Generally more difficult • Use largely limited to be ground up and used as a filler • Potential to recover valuable materials • Issues • Can’t be remoulded • Mixed waste • Contamination • Sorting and separation

  15. Thermoset Composites • Airbus A350 • 53% Composite www.airbus.com • Wind-turbines • Glass & carbon fibre reinforcements • Blades up to 75m long http://gurit.fangle.co.uk/breakdown-of-a-turbine-blade.aspx

  16. Recycling of Thermosets Thermal Processes (no fibre recovery) Thermal Processes (with fibre recovery) Mechanical Process Mechanical Grinding Thermal Fluid Fluidised Bed Pyrolysis Cement Kiln Energy recovery and material utilisation Fibres & chemical products Fibres & energy/ chemical products Fibrous products (potential reinforcement) Powdered fillers Fibres & energy recovery

  17. Thermosets Mechanical Recycling Separation – cyclones, sieves, zig-zag separator Hammer mill – reduces size down to as low as 50 microns Powder Fine Fibre Course Fibre Source: Wikipedia Very Course

  18. Commercial Pyrolysis Thermosets Pyrolysis – Commercial Operations Feed Stock In Finished Stock out

  19. Recycled Carbon Fibre Applications • Milled Fibre • Average fibre length 100 µ • Chopped Fibre • Random fibre lengths, 6 to 60mm • Chopped Fibre Pellets and Milled Fibre Pellets  • For the thermoplastic market Source: www.elgcf.com/

  20. Energy Recovery Cement Kiln • Compo Cycle • ZajonsZerkleinerungs GmbH grind up the fibreglass and mix with other materials. • Recycled mix sent to Holcim (Deutschland) AG’s cement kilns in Northern Germany • Polymer contributes to kiln energy demand • Fibres and fillers contribute to minerals to make cement • Accepted as a material / energy recycling route within the EU Source: www.k-zeitung.de (courtesy of Zarjons) Energy recovery + Material Utilisation GFRP / CFRP

  21. Options for GFRP in the UK • Mechanical grinding is the main opportunity • Filon Products, Brett Martin and HamblesideDanelaw (roof light manufacturers) – grind in-house waste • HamblesideDanelaw also offers a take-back scheme • Material ground up and formed into a mat • Market applications needed • Supply chains required

  22. Issues for Recyclers • Technical issues facing recyclers • Identification of materials • Imbedded materials • Mixed Waste • Sandwich / hybrid materials • Toughened epoxies / thick laminates • Commercial issues facing recyclers • Routes to market / market acceptance • Scaling up from lab scale Source: ELG

  23. The Future • Government Involvement • Legislation • Industry funding support • Grants • Industry bodies – Composite Leadership Forum • Commercial Developments • Life cycle analysis needed to identify best environmental options • Improved recycling methods and techniques • Scalable solutions and reduced costs • Higher grade aligned recyclates for more valuable markets • Supply chain collaboration – centres close to waste supply • New markets and products from recycled materials • Design for recycling

  24. Summary • Thermoplastics • Varying degrees of recycling available depending on capabilities of recycling centres – depends on proximity to large quantities of type of waste / routes to market • Thermosets • Mechanical Grinding / Pyrolysis / Cement Kiln etc. • New routes to market / lower costs needed • Carbon Fibre • Commercial options available (e.g. ELG) • Glass Fibre • 1/10 the value of Carbon – needs supply chain collaboration and commercialisation • Cement Kiln option available

  25. Summary • University of Exeter – Example Projects • Glass Fibre Recovery • Composite Development • Recycled Fibres • Natural / Bio-derived materials • Techniques / Processes to assist recycling of plastics that were not previously recyclable • Centre for Alternative Materials and Remanufacturing Technologies • Opens up the expertise to SMEs • Free Business Support (through State Aid funding) • Longer term aim to develop collaborative relationships focussed on addressing recycling and remanufacture of in-house and end of life manufacturing waste

  26. Thank You CALMARE Website: www.exeter.ac.uk/calmare Email: calmare@exeter.ac.uk p.mccutchion@exeter.ac.uk Tel: +44 (0)1392 725821 Twitter: CALMARE­_EXETER

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