Call for Proposal n 11

Transcription

1 Call for Proposal n 11 Brussels, January 19 th 2012 JTI-CS ECO Disintegration of fibre-reinforced composites by electrodynamic fragmentation technique

2 End of life of an aircraft Per year up to 300 aircrafts are going to be put out of service Lifetime of an aircraft: years Actual solutions: Disposed in desert graveyard Rough dismantling - Engine (up to 80% of the total price) - Landing gears - Few materials sorting Aircraft recycling: Aircraft desert graveyard USA ASI (Air Salvage International UK -1995) Bartin Recycling Group (F 2005) PAMELA Project (F ) The Aircraft Fleet Recycling Association was founded in 2005 to enhance aircraft recycling.

3 End of life of an aircraft More and more aircraft parts will be made of CFRPs instead of alloy CFRP recycling is a growing challenge to be met until aircraft such as the A380, B787, A350 will be put out of service in 40 years CFRPs are already widely used in other industry sectors which already produce CFRP waste

4 Use of carbon fibres in industry (2011): Energy and Industrial sectors (67%) Windmill industry 28% (CF: 300 kg / blade) Molding compounds 13%, cars 6.1%, tooling 4.5% Sports and Leisure industries (17%) Sporting goods 12% (Golf clubs, tennis rackets, hockey sticks) Sailing boats 1.2%... Aircraft/Aerospace industry (16%) Commercial aircrafts 9.7% - A310 (1980) and Boeing 767 (1983): 5-6wt% of GFRP - A380 (2009): 25wt% of CFRP - A350XWB (2014) and Boeing 787 (2011): 50wt% of CFRP

5 Forecast of carbon fibre demand

6 CFRP wastes are Manufacturing cut-off (25% in 2009) Out of date prepreg Production tools Testing material End-of-life components FHNW-IKT, CH, 2009

7 What s done with CFRP waste? CFRP waste Recycling Landfill Incineration Desert graveyard (Aircrafts) Mechanical recycling (milling, crushing, shredding) to be used as loweconomical product Fillers in polymers/cements Carbon powders Fibre reclamation Use of aggressive chemical or thermal process to breakdown the matrix. Thermal pyrolysis

8 Why CFRP recycling? Environmental impact New Legislations New European legislation: waste disposal is the responsibility of the manufacturer Landfill (available space) and incineration (CO 2 burden) is limited Cars: 85% recyclable after 2015 (End-of-Life of Vehicles Directive ) Production cost (energy, material) End-of-life disposing cost Growing carbon fibre demand in industry (15%/year)

9 Problems with mechanical recycling high energy demand for crushing and grinding abrasion by crushing and grinding tools wear and loss of grinding tools contamination of grist only crushing, no separation generation of dust

10 Potential CFRP recycling techniques Catalytic conversion reactions Fluidised bed processing Micro-wave treatment Supercritical fluids Chemical treatment Saline treatment and solvolysis Thermal shock treatment Crushing & Grinding (Vacuum) - Pyrolysis Electrodynamic Fragmentation Problems: Current CFRP recycling processes are usually too energy or too material demanding to become economically viable. A major problem is the formation of hairballs consisting of fibres and polymers, which are difficult to separate from each other. Major Goal: Recovery of undamaged carbon fibres which ideally possess the same mechanical properties as the original ones. So far grinding and pyrolysis are the only recycling processes at industrial scale

11 Electrodynamic fragmentation Origin the process was developed in the late 40ies at the University of Tomsk in Russia further developments in the USSR for use in mining industry: Disintegration of rocks and recovering of precious minerals and crystals without damaging them Destruction of concrete plates Drilling of wells Lab-scale fragmentation around 1985 further developments at the research centre Karlsruhe (Forschungszentrum Karlsruhe FZK, today KIT) KIT is holding some patents and licenses of process set-up

12 Electrodynamic fragmentation Use of electrodynamic fragmentation technique today Industrial applications: Processing of quartz for highly pure optical conductors in glass fibre cables Processing of lithium ores at a through put of 200 tons / h Special applications: Contamination free crushing of Al 2 O 3 for medical purposes Separation of precious stones or fossils from rock matrix Separation of electronic waste into metals and plastics

13 Electrodynamic Fragmentation In line process unit for separation of steel reinforcement from concrete

14 Electrodynamic fragmentation Basic principle Electro-physical Effect: Pulse time (nsec) Dielectric strength The electrical breakdown resistance / dielectric strength of solids against a high voltage discharge depends on the pulse time! If the pulse time is below 500 nsec, the discharge will preferably run through the solid and not through the water!

15 Electrodynamic fragmentation Voltage: kv Current: ka Impulse energy: Joule / cm Power: 100 MW 1,5 GW discharge time: nsec

16 Electrodynamic fragmentation The electric discharge preferably goes along phase boundaries, the resulting plasma channel with temperatures of ~ 10 4 K generates a first pressure wave (tensile stress) with up to Pa. The pressure wave is reflected by the vessel wall and generates a second compression wave which enhances the liberation of the components.

17 Recycling of concrete reinforcement electrodynamic fragmentation calcite Old concrete before fragmentation aggregates fine fraction After fragmentation: reinforcement, aggregates, calcite from process water and a fine fraction < 2mm Diploma thesis of V. Thome: Mineralogische Veränderungen in Glimmer und Zementhydraten nach einer elektrodynamischen Fragmentierung, FZK 1998

18 Electrodynamic Fragmentation of CFRPs Process parameters: voltage: 180 kv pulse frequency: 5 Hz CFRP sample after 500 impulses after 1200 impulses Standard parameters on lab-scale batch processing machine as used for old concrete

19 Electrodynamic Fragmentation of CFRPs Weight loss of CFRP samples in dependence of voltage and electrode distance Sample weight [g] Optimal carbon fibre liberation on lab-scale batch processing machine at: Electrode distance = 20 mm & voltage = 180 kv Number of pulses

20 Electrodynamic Fragmentation of CFRPs REM pictures of CFRPs after electrodynamic fragmentation Polymer matrix with one single carbon fibre Carbon fibre with polymer residues

21 Electrodynamic Fragmentation of CFRPs Feasibility test to process CFRPs with high voltage pulses in batch mode Test specimen with carbon and glass fibres before and after electrodynamic fragmentation

22 High Voltage Fragmentation High voltage fragmentation of carbon fibre reinforced epoxy resin, trials by FHNW-IKT, CH, 2011 Plate of RTM6 with 60 vol% CF (before fragmentation) RTM6 with 60 vol% CF (Filtrate after HV Fragmentation) Time: 1 min 30 sec Carbon Fibres from RTM6 composite (400 impulses) magnification 200 x HV Fragmentation of thermoset composites Removing of the polymeric matrix to recover clean fibres Quick process No chemicals used (only water) No dust

23 High Voltage Fragmentation High voltage fragmentation of carbon fibre reinforced thermoplastic, trials by FHNW-IKT, CH, 2011 Plate of PEEK with 55 vol% CF before HV Fragmentation Material after HV Fragmentation (PEEK with 55 vol% CF) Material after HV Fragmentation (PEEK with 55 vol% CF) HV Fragmentation of thermoplastic composites Fragmentation of parts to gain grains out of the material. No tools/blades wearing compared to mechanical shredding No dust

24 Open questions Influence of material properties: chemistry of the polymer type of the plastic (Duroplasts, Thermoplasts, etc.) cross-link level (2D or 3D) etc. Analyses of the process water and products therein degree of liberation (fibre / fibre + polymer) fibre quality, fibre length, etc. analyses of elements Process optimisation without / with subsequent pyrolysis (further cleaning of fibres?) optimisation of machine parameters (electrode shape / distance) maximum liberation and separation Up-scaling

25 JTI-CS ECO Disintegration of fibre-reinforced composites by electrodynamic fragmentation technique Status Pulsed power processing techniques such as electrodynamic fragmentation have been commercially applied for geological explorations (diamonds, Li-minerals, etc.) and for silicon / waver industry Initial small lab scale batch trials with electrodynamic fragmentation of mineral composites such as waste concrete or small carbon fibre reinforced plastic (CFRP) pieces have been performed Objectives: Main expectancies Adaptation of a pulsed power processing technique for recycling of CFRPs and fibremetal laminates Design and construction of a demonstrator (up-scaling to larger parts processing, preferably a continuous process rather than a batch process) Selective disintegration and separation of carbon fibres, metals and laminates Secondary objectives to be addressed: Recovery of high quality carbon-fibres Assessment of recyclability of processed products

26 JTI-CS ECO Disintegration of fibre-reinforced composites by electrodynamic fragmentation technique WP Location WP 2 Eco-Design for Airframe WP 2.4 End of Life WP A Materials Recycling WP A Separation into subcomponents Special skills: The applicants should have : wide experience in the development and adaptation of electrodynamic fragmentation techniques technical know-how in mechanical and electrical engineering for design and construction of pulsed power processing plants in-depth knowledge in process optimisation for various composites Duration: 20 Months Topic value: not to exceed 435 k