JEC conference Thermoplastics - Multimaterial solutions. THERMOSAÏC, a patented technology for thermoplastic composite material recycling
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1 JEC conference Thermoplastics - Multimaterial solutions THERMOSAÏC, a patented technology for thermoplastic Paris, March 14-16, 2017
2 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
3 1. Composite market : impact on recycling World s production : 8.7 million tons/year Geographic distribution France France Europe Wider world Europe Monde Breakdown by activities Automotive/transport Auto/transport Building Construction/génie civil Equipements Elec. equipment électriques/électroniques Sports loisirs/nautisme Sport/leisure Aéronautique Aeronautic Autre Other Source of information : JEC 2013
4 1. Composite market : impact on recycling Which matrix? Thermoplastic TP composite (Axyal) Thermoset Thermoset (polyester, epoxy ) Thermoplastic (PP, PA, PPS, PEEK ) Thermoset composite (IDI Composites)
5 >10 /kg THERMOSAÏC, a patented technology for thermoplastic 1. Composite market : impact on recycling Which reinforcement? /kg 2-4 /kg Glass fiber Carbon fiber Kevlar, flax, hemp
6 Tons THERMOSAÏC, a patented technology for thermoplastic 1. Composite market : impact on recycling Composite waste in Europe : 0.3 million tons/year Déchets Post-consumer en fin de vie Déchets Production de production waste Source of information : Techniques de l ingénieur
7 Photograph : Consoglobe.com THERMOSAÏC, a patented technology for thermoplastic 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.
8 2. Production loss, end-of-life products : which technical solutions? Mechanical process (grinding, milling ) filler recovery 1-2 wt %? <1wt %? Biological process (biodegradation) waste-to-biomass or Glass powder or fiber/thermoset resin Thermal process (pyrolysis, ) waste-to-energy carbon fiber recovery Waste-to-energy+material 1-2 wt %? Chemical process (solvolysis) carbon fiber recovery or or 3-4 wt %? Energy Carbon fiber Cement factory Carbon fiber Sources of information : Techniques de l ingénieur, AgroComposites, ELG Carbon Fiber
9 2. Production loss, end-of-life products : which technical solutions? Almost no economical/technical solution for current composite waste 90 wt % Photograph : Consoglobe.com, Perspective Consuting Lansink scale Composite wastes
10 2. Production loss, end-of-life products : which technical solutions? Material recovery : current composite waste transformed into filler (mechanical properties mainly lost) Sources of information : ABVal Composite, Reprocover, MCR, Polyplast/Rescoll/Cermatex
11 3. Thermoset vs thermoplastic matrix : which trends? Thermoplastic composites : partial replacement of thermoset composites and metals Industrial output THERMOSAÏC, a patented technology for thermoplastic Thermoplastic composites Thermoset composites
12 3. Thermoset vs thermoplastic matrix : which trends? Thermoset matrix Advantages : Cost effectiveness Long-life material Disadvantages : VOC released while processing Complex mechanical assembly Long cycle time Low recyclability 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
13 Trademarks notified by way of example THERMOSAÏC, a patented technology for thermoplastic 3. Thermoset vs thermoplastic matrix : which trends? IXIS 157 Thermoplastic composites : a growing industrial offer Carbostamp Celstran CFRTP GMT GMTex SymaLITE
14 3. Thermoset vs thermoplastic matrix : which trends? + Cutting of semi-finished products, easily formable Source of information : Fokker Welding Stamping
15 3. Thermoset vs thermoplastic matrix : which trends? Trailer (EPL) Bumper crash beam (CQFD) for a growing applications Boat s hull (2Win) Side intrusion beam (DuPont) Aircraft wing element (Fokker) Tailgate (Saint-Gobain)
16 Photographs : Cetim ; Consoglobe.com THERMOSAÏC, a patented technology for thermoplastic 3. Thermoset vs thermoplastic matrix : which trends? and a growing production waste and post-consumer waste
17 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 )
18 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 Continuous fibre reinforced plastic Continuous fibre reinforced plastic Thermosaic Thermosaic Short fibre reinforced plastic Short fibre reinforced plastic Sources : Global trends, from Kelly&Tison and Cox models (PP/GF)
19 4. Thermosaïc technology : a new recycling approach for thermoplastic composite waste Thermo-mechanical process 100% recycled composite panel production Pilot line THERMOSAIC composite panel
20 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 PP/GF plates joined by welding (Thermosaïc ) PP/GF thermoformed part (Thermosaïc )
21 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 Industrial equipment Transport Building and infrastructure Energy Customer markets
22 THERMOSAIC TECHNOLOGY VIDEO
23 An innovation offered by In partnership with Institutional partners / funders
24 Join us at HALL 5A E64 Contact : Frédéric Ruch info@cetim-cermat.fr
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