Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...

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Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
Serge Da Silva – R&D Director
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis                                                           s.dasilva@alpharecyclage.com

                   This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No
                   831858. This publication reflects only the author’s views and the European Union is not liable for any use that may be made of the information contained therein.”
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
1. Company presentation

                          2
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
A SME in an industrial environment

                          Luikov Institute

                            Tech               Engineering
                          Transfer

                    R&D

                                               Shareholders

                                                              JLS group

            Funds
                                Construction
                                   plant          Markets

                            Modum Techno

                                                                          3
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
A joint lab with R&D centres

                               4
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
Retrait du
                                      composite
A 2 tons per day reactor available….
                               Fibre           Composite
                                                              Mise en
                  Refroidissement
                             extraction         feeding
                                                           température du
                     du réacteur
                Temperature
                                                              réacteur
                                                              Temperature
                         (45mn)
                  decrease                                    (45  mn)
                                                               increase

                                                                             Steam
  Seam Water
                                                                              Water
thermolysis (~2h)
                                                                            injection

Vapothermolyse
  Steam                                                                     Injection de
                                                                       Seam Water
      (2h)
   water                                                               vapeur      (15
                                                                     thermolysis (~2h)
                                                                                      mn)
    injection

                Temperature
                                         Mise en              Temperature                Implantation site of Steam Water Thermolysis unit for
                  increase                                      decrease
                                     température du                                              Composite in Castelsarrasin (France)
                                      composite (15                               Introduction
                               Composite       Fibre
                                          mn)extraction                                du
                                feeding
                                                                                   composite
                                                                                                                                                 5
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
… now and in operation at the end of 2019

                       Confidential pictures

                                               6
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
2. Technology presentation

                             7
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
The steam water thermolysis principle

                         Steam Water

                                                    Carbone fibers

      Composites    Steam water thermolysis

                                              Gas       Liquid

                           Treatment and
                           burning and/or
                             valorisation
                                                                     8
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
Steam water thermolysis advantages
             PA6 reinforced by carbon fibres*
                                                                          Activation energy of PA6* degradation (kJ/mole)
                          Same parameters

                                                                                            Steam water          Pyrolysis
                                                                                            thermolysis
                                                                      Kissinger                175 ± 5,0         232 ±11,0

                                                                      IKP                      178 ± 1,5         186 ± 4,0
                                                                     * A.O. Nunes – PhD thesis – November 2015
Steam water thermolysis                          Pyrolysis

                                      Steam water thrmolysis vs. pyrolysis

                                            •   Safer process

                                            •   Higher thermal transfer

                                            •   Catalysis by water
                                                                                                                             9
Workshop 08/10/2019| Recycling of carbon fibres by steam water thermolysis - Leitat ...
3. Some technical cases

                          10
Waste qualification - Methodology

                              Optimal
      ATG  – DSC
       TGA-DSC                                   • Fibre surface state =MEB
 (thermogravimétrie,
                       parameters      in Lab-
                        Pilote Instrumenté  de    •   Etat de surface des fibres = microscopie
                                                 • Resin degradation ration = Chemical attack & mass balance
                        Recherche   – PriTherm    •   Taux de résine en surface = attaque chimique
     calorimétrie)      scale conditions         • Gas and liquid characterisation = GC & GC-MS
                                                 •    Nature des gaz = chromatographie

                        Traitement par
  Caractérisation
     Thermal              Steam Water                  Caractérisation
                                                           Product
                             vapo-
    thermique
  characterisation        Thermolysis                   des produits
                                                       characterisation
                          thermolyse                                                                           Industrialisation

                          Lab scale characterisation

                                                                                                                                   11
Example of wastes

                    12
Up to 92,3 % (w/w) of resin elimination
Example of material
                 • From an aeronautic
                 • M21 prepreg
                 • 2 mm thick

                                    Fibres

 Steam Water Thermolysis :                   Gases
                                                            In progress
       400 – 600 °C

                               Liquids
                                              In progress
                                                                                                   13

                                                                                              13
Example of material
                                                                                                      • From an aeronautic company
                                                                                                      • M21 prepreg
                                                                                                      • 2 mm thick

                        Nitrogen                                                                  Oxygen                                                                                                                                                 Nitrogen atmosphere
         TG /%        atmosphere                                                                atmosphere                                                  Temp. /°C
                                                                                                                                                   DTG /(%/min)                                              TG /%                                                                                                                                                          DTG /(%/min)

                                       Valeur: 272.7 °C                                                                                                  [1]                                                                                                                                                             Valeur: 457.0 °C
     100                                                                                                                                                 [1]                    1000                     100                                                                                                                                                                               0.2
                                                                                                                                                               0.0
                                                          Var. masse: -22.71 %
                                                                                                                                                                                                            98                                                                                                                                                                             0.0
                                                                                                                                                               -0.5
        80                                                                                                                                                                      800
                                                                                                    Var. masse: -10.32 %                                                                                    96
                                                     Valeur: 543.5 °C                                                                                          -1.0                                                                                                                                                                                                                        -0.2
                                                                            Valeur: 403.3 °C
        60                                                                                                                                                     -1.5             600                         94                                                                                                                                                                             -0.4

                                                                                               Valeur: 579.4 °C
                                                                                                                                                               -2.0                                         92                                                                                                                                                                             -0.6
        40                                                                                                                        Var. masse: -65.34 %                          400
                                                                                                                                                               -2.5                                         90                                                                                                                                                                             -0.8

        20                                                                                                                                                     -3.0                                         88                                                                                                                                                                             -1.0
                                                                                                                                                                                200
                                                                                                                                                               -3.5                                                                                                                                                                                                                        -1.2
                                                                                                                                                         [1]
                                                                                                                                                                                                            86                                                                                                                                                                      [1]
                                                                                                                                                                                                                                                                                                                                                                                    [1]
             0                                                                        Masse résiduelle: 0.44 % (208.0 min/999.7 °C)
                                                                                                                                                                                0
                                                                                                                                                               -4.0                                                                                                                                                                                                                        -1.4
                 0                                  50                             100                            150                              200                                                                                 100              200                     300          400                                500                     600
                                                                                 Temps /min                                                                                                                                                                                        Température /°C
 Principal   2019-09-25 12:26   Utilisateur: emac                                                                                                                                                    Principal   2019-09-25 12:28   Utilisateur: emac

Instrument : NETZSCH STA 409 PC/PG Fichier : C:\NETZSCH\Resultats\Antonio MONTERO\AIRBUS\echantillon2_airbus_norme2.ngb-dsv                                                                        Instrument : NETZSCH STA 409 PC/PG Fichier : C:\NETZSCH\Resultats\Antonio MONTERO\AIRBUS\fibre_700_5_air.ngb-dsv
                                                                                                                                                                                                   Projet :               marvapol            Échantillon :           fibre _700°C_5_air, 62.091 mg Porte-éch./TC :     TG HIGH RG 2 / S                         Corr. TG/Gamme m. : 820/30000 mg

TGA of prepreg before the Steam Water Thermolysis                                                                                                                                                                TGA of fibres after the Steam Water Thermolysis
Projet :               marvapol                         Matériau :              Divers                           Segments :             1-4/4
Identité :             AM                               Fich. correction :      norme_20193008.ngb-bsv           Creuset :              DTA/TG crucible Al2O3                                      Identité :             AM                  Matériau :              Divers                        Mode/Type de mes. : TG / Éch.+Correction                     Corr. DSC/Gamme m. : 820/
Date / temps d'heure : 31/08/2019 11:59:05              Cal. temp./Fich. sens : TCALZERO.TCX /                   Atmosphère :           ARGON/15 / AIR(80/20)/100 / NITROGEN/100                   Date / temps d'heure : 06/09/2019 16:46:56 Fich. correction :      blanc_700°C_5_air.ngb-bsv     Segments :          1/1
Laboratoire :          alpha                            Gamme :                 20....1000/-10.0....10.0K/min    Corr. TG/Gamme m. :    620/30000 mg                                               Laboratoire :          alpha               Cal. temp./Fich. sens : TCALZERO.TCX /                Creuset :           DTA/TG crucible Al2O3
Opérateur :            AM                               Porte-éch./TC :         TG HIGH RG 2 / S                 Corr. DSC/Gamme m. :   620/                                                       Opérateur :            AM                  Gamme :                 20/5.0(K/min)/700             Atmosphère :        ARGON/15 / AIR(80/20)/100 / NITROGEN/100
                                                                                                                                                                                                                                                                                                                                                                Créé avec le logiciel Proteus de NETZSCH
Échantillon :          fibre_airbus_norme2, 71.206 mg   Mode/Type de mes. : TG / Éch.+Correction
                                                                                                                                                        Créé avec le logiciel Proteus de NETZSCH

                                                                                                                                                                                                                                                                                                                                                                                                           14
Example of material
                                                                  96,8 % (w/w) of resin elimination

           • Rossignol (Look)
           • Epoxy resin
           • 3 mm Thick
                                 Fibres

                                                         MEB pictures x 2000 et x 500

 Steam Water Thermolysis :                  Gases
                                                          CO 2, CO, H2, C1-C4
       400 – 600 °C

                                Liquids

                                    Phenolic molecules (85%vol)                                  15
99,7 % (w/w) of resin elimination

Example of material

            • Omega Systèmes
            • Epoxy resin
            • 8 mm thick
                                    Fibres

 Steam Water Thermolysis :                      Gases
                                                        CO 2, CO, H2, C1-C4
       400 – 600 °C

                                                                 Aminotoluene

                                             Aniline
                               Liquids
                                                                                              16

                                                                                         16
4. Some applications

                       17
18
Mechanical properties of non-woven and stitched non-
woven rCF composites compared to glass fibre 4 axes

                     Epoxy resin

                                                       19
Results

To be continued ….

                       20
Thanks for your attention   Merci pour votre attention   Gracias por su atención
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