The ReCoVeR Project. thermally recycled from end-of-life GRP. composites. Jim Thomason. L.Yang, P.Jenkins, E.Sáez, U.Nagel

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1 INDUSTRY LEADER INNOVATION GLOBAL VISION The ReCoVeR Project Regenerating the strength and value of glass fibres SOLUTIONS thermally recycled from end-of-life GRP PARTNERSHIP composites Jim Thomason L.Yang, P.Jenkins, E.Sáez, U.Nagel Advanced Composites Group Department of Mechanical & Aerospace Engineering University of Strathclyde Glasgow, Scotland

2 INDUSTRY LEADER ReCoVeR INNOVATION GLOBAL VISION SOLUTIONS PARTNERSHIP Introduction Some Results - Performance ReCoVeRed Glass Fibres - Composite Performance - (Fundamentals of Glass Fibre Strength Loss) Some Conclusions Future Developments?

3 Global Reinforcement Fibre Usage KTon/year 2013 Glass Carbon Aramid 4660

4 Global Reinforcement Fibre Usage KTon/year

5 Million Tons Global Glass Fibre Demand 5 Source OCV (E-glass excluding yarns) Production waste 10-20%

6 Composites in Automotive BMW photo as shown in Modern Plastics Magazine

7 Global GF in EoL Blades (kt/a) GF in End-of-Life Wind Turbine Blades 1,000 Assuming 20 year Blade Life Source - Composites Technology, June 2008, GWEC 2013 Year

8 Million Tons Glas Fibre Global Glass Fibre Numbers Global Demand [1] Total ReCoVeRable GF In 20y EoL GRP In GF Man. Waste (15%) In GRP Man. Wast (15%) 2 1 Assume 60% in Thermoset

9 Million Tons Glas Fibre 5 4 Global Glass Fibre Numbers Global Demand [1] Total ReCoVeRable GF If we could recycle just 10% = 280KTpa business potential today (value approx $420M)

10 GRP Recycling Techniques Mechanical grinding Thermal Processes Thermo-chemical processes Incineration Pyrolysis Fluidized bed Solvolysis Not clean fibres Mainly reuse as very low value filler Some energy recovery from composites High content of inorganic material no longer fibrous Energy recovery Not suitable for inorganic products Clean fibres and length retains Energy recovery with subsequent combustion of organic products applies Recover organic components Clean fibres and length retains

11 Glass Fibre Strength (%) GF Strength (Value) after Thermal Recycling Thomason OC 1999 (E) Pickering et al 2000 (E) ACG 2008 (A) Feih et al 2009 E) Feih et al 2009 (A) ACG 2009 (A) ACG 2012 (A) Conditioning Temperature ( C )

12 The ReCoVeR Project Regenerated Composite Value Reinforcement The ReCoVeR Mission Enable the development of cost-effective, drop-in, glass fibre and composite products based on recycled glass fibres with regenerated mechanical performance The Research Goals Research fundamentals of ( C)RGF property changes Cost effective treatments to regenerate RGF performance? Produce examples of GF or composite products using RRGF , 1M EPSRC funding, 8 Researchers in ACG team

13 Glass Fibre Strength (%) Strength after Thermo-Mechanical Treatment Thomason OC 1999 Pickering et al 2000 ACG 2008 Feih et al 2009 E Feih et al 2009 A ACG 2009 ACG Conditioning Temperature ( C )

14 Tensile Strength (MPa) Unnotched Charpy (kj/m^2) GF Heat Treatment & Composite Performance TS UC ReCoVeR Target Zone Injection Moulded 30%GF-PP (1% MaPP) GF Preconditioning Temperature ( C)

15 Single Fibre Strength (GPa) Target Strength for ReCoVeRed Fibre? Commercial chopped strand products - Average single fibre strength 1.5 GPa At 20 mm gauge length should be sufficient Chopped Fibre 1 Chopped Fibre 2 4mm chopped fibres for GF-PA Injection Moulding applications Gauge Length (mm)

16 Glass Fibre Strength ReCoVeRy Average Fibre Strength(GPa) 2.0 No ReCoVeR ReCoVeR 1 ReCoVeR 2 ReCoVeR 3 HF Treated Glass Pretreatment Temperature ( C)

17 Average Fibre Strength(GPa) Glass Fibre Strength ReCoVeRy C Heat Treated Fibres Fibres Recycled from Composite at 600 C No ReCoVeR ReCoVeR 1 ReCoVeR 2 ReCoVeR 3

18 Tensile Strength (MPa) Unnotched Charpy (kj/m^2) 80 ReCoVeR Composite Performance TS UC ReCoVeR Injection Moulded 30%GF-PP (1% MaPP) GF Preconditioning Temperature ( C)

19 Tensile strength (MPa) ReCoVeR Composite Performance Wet Laid 30%GF-PP GMT (9mm fibres, no MaPP) 70 71% ReCoVeRy 60 42% ReCoVeRy 57% ReCoVeRy PP strength GF as received GF 500 C HT GF 500 C HT +ReCoVeR 2 GF 500 C HT +ReCoVeR 1 GF 500 C HT +ReCoVeR 3

20 Initial Results on ReCoVeR Glass Fibres in PP Composites 72% ReCoVeRy of Composite Tensile Strength 87% ReCoVeRy of Unnotched Charpy Impact Non-optimized sizing on ReCoVeR fibres Higher potential ReCoVeRy performance to come Patent Application submitted

21 Strength Loss Mechanisms Investigation TMA for single fibre modulus and dimension changes during conditioning TGA of silane film degradation AFM/SEM analysis of surface morphology changes Fibre strength after heating (or composite recycling) TVA of water evolution and dehydroxylisation IR analysis of silane NH 2 group on fibre XPS surface analysis of %N on fibre XRD for crystal growth (devitrification)

22 Current State of Strength Loss Mechanisms Investigation Strength loss probably involves sizing degradation surface flaws (number/severity increase) change/relaxation in glass structure removal of water/dehydroxylization More work required for full understanding

23 Conclusions The development of a cost-effective technology to regenerate the properties of thermally recycled glass fibres will have major environmental benefits Glass fibres lose most of their strength after a short heat treatment above 400 C Mechanism of strength loss involves both sizing degradation and changes in glass fibre structure Thermal conditioning of fibres also drastically reduces end-use composite performance The ACG is developing cost-effective treatments to ReCoVeR the strength of thermally recycled glass fibres

24 Future Development? Continue fundamental research of GF strength loss and new options for regeneration Integration of ReCoVeR technology into full recycling/regeneration/reuse process requires Formation and funding of consortium of vested interests Identification of input material stream, end-of-life GRP, production waste (GRP or GF)? Identification of recycling process for fibre input to ReCoVeR Identification of target end-use application (GF-PP in Automotive?) We are seeking partners to move this technology forward