THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Paris, March 14-16, 2017

JEC conference Thermoplastics - Multimaterial solutions

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

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

1. Composite market : impact on recycling

World’s production : 8.7 million tons/year

Source of information : JEC 2013

4

20

76

France

Europe

Monde

France

Europe

Wider

world

Geographic distribution

26

30 14

16

3 11 Auto/transport

Construction/génie civil

Equipementsélectriques/électroniquesSports loisirs/nautisme

Aéronautique

Autre

Automotive/transport

Building

Elec. equipment

Sport/leisure

Aeronautic

Other

Breakdown by activities

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

1. Composite market : impact on recycling

Which matrix ?

Thermoset

Thermoplastic

Thermoset (polyester,

epoxy…)

Thermoplastic (PP, PA,

PPS, PEEK…)

Thermoset composite (IDI Composites)

TP composite (Axyal)

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

1. Composite market : impact on recycling

Which reinforcement ?

Glass fiber

Carbon fiber

Kevlar, flax, hemp…

2-4€/kg

25-30€/kg

>10€/kg

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

1. Composite market : impact on recycling

Composite waste in Europe : 0.3 million tons/year

0

50000

100000

150000

200000

250000

300000

350000

2000 2005 2010 2015

Déchets en fin de vie

Déchets de production

Post-consumer

Production waste

Ton

s

Source of information : Techniques de l’ingénieur

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

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.

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Photograph : Consoglobe.com

2. Production loss, end-of-life products : which technical solutions ?

Sources of information : Techniques de l’ingénieur, AgroComposites, ELG Carbon Fiber

Mechanical process (grinding, milling…) filler recovery

Glass powder or fiber/thermoset resin

or

3-4 wt % ?

Chemical process (solvolysis) carbon fiber recovery

Carbon fiber

1-2 wt % ?

Thermal process (pyrolysis,…) waste-to-energy carbon fiber recovery Waste-to-energy+material

Cement factory Carbon fiber Energy

or or

Biological process (biodegradation) waste-to-biomass

1-2 wt % ?

<1wt % ?

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

2. Production loss, end-of-life products : which technical solutions ?

Almost no economical/technical solution for current composite waste

90 wt %

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Photograph : Consoglobe.com, Perspective Consuting Lansink scale Composite wastes

2. Production loss, end-of-life products : which technical solutions ?

Material recovery : current composite waste transformed into filler (mechanical properties mainly lost)

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Sources of information : ABVal Composite, Reprocover, MCR, Polyplast/Rescoll/Cermatex

3. Thermoset vs thermoplastic matrix : which trends ?

Thermoplastic composites : partial replacement of thermoset composites and metals

1970 1960 1980 1990 2000 2010 2020

Thermoplastic composites

Industrial output

Thermoset composites

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

3. Thermoset vs thermoplastic matrix : which trends ?

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

Thermoset matrix

Advantages : Cost effectiveness Long-life material Disadvantages : VOC released while processing Complex mechanical assembly Long cycle time Low recyclability

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

3. Thermoset vs thermoplastic matrix : which trends ?

Celstran® CFRTP

Carbostamp

SymaLITE® GMTex®

GMT

IXIS® 157

Thermoplastic composites : a growing industrial offer…

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Trademarks notified by way of example

3. Thermoset vs thermoplastic matrix : which trends ?

+ Cutting

Stamping Welding Source of information : Fokker

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

…of semi-finished products, easily formable…

3. Thermoset vs thermoplastic matrix : which trends ?

…for a growing applications…

Boat’s hull (2Win)

Tailgate (Saint-Gobain)

Trailer (EPL)

Aircraft wing element (Fokker)

Side intrusion beam (DuPont) …

Bumper crash beam (CQFD)

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

3. Thermoset vs thermoplastic matrix : which trends ?

…and a growing production waste and post-consumer waste

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Photographs : Cetim ; Consoglobe.com

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…)

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

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

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Sources : Global trends, from Kelly&Tison and Cox models (PP/GF)

Short fibre reinforced plastic

Thermosaic®

Continuous fibre reinforced plastic Continuous fibre reinforced plastic

Short fibre reinforced plastic

Thermosaic®

4. Thermosaïc® technology : a new recycling approach for thermoplastic composite waste

Thermo-mechanical process 100% recycled composite panel production

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Pilot line THERMOSAIC® composite panel

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 …

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

PP/GF plates joined by welding (Thermosaïc)

PP/GF thermoformed part (Thermosaïc)

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

Customer markets

Industrial equipment Transport Building and infrastructure Energy …

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

THERMOSAIC® TECHNOLOGY VIDEO

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Institutional partners / funders

An innovation offered by

In partnership with

THERMOSAÏC, a patented technology for thermoplastic composite material recycling

Join us at HALL 5A E64

Contact : Frédéric Ruch info@cetim-cermat.fr

THERMOSAÏC, a patented technology for thermoplastic composite material recycling