Life Cycle Assessment of a Thermal Recycling Process as an Alternative to Existing CFRP and GFRP Composite Wastes Management Options

Abstract

There are forecasts for the exponential increase in the generation of carbon fibre-reinforced polymer (CFRP) and glass fibre-reinforced polymer (GFRP) composite wastes containing valuable carbon and glass fibres. The recent adoption of these composites in wind turbines and aeroplanes has increased the amount of end-of-life waste from these applications. By adequately closing the life cycle loop, these enormous volumes of waste can partly satisfy the global demand for their virgin counterparts. Therefore, there is a need to properly dispose these composite wastes, with material recovery being the final target, thanks to the strict EU regulations for promoting recycling and reusing as the highest priorities in waste disposal options. In addition, the hefty taxation has almost brought about an end to landfills. These government regulations towards properly recycling these composite wastes have changed the industries’ attitudes toward sustainable disposal approaches, and life cycle assessment (LCA) plays a vital role in this transition phase. This LCA study uses climate change results and fossil fuel consumptions to study the environmental impacts of a thermal recycling route to recycle and remanufacture CFRP and GFRP wastes into recycled rCFRP and rGFRP composites. Additionally, a comprehensive analysis was performed comparing with the traditional waste management options such as landfill, incineration with energy recovery and feedstock for cement kiln. Overall, the LCA results were favourable for CFRP wastes to be recycled using the thermal recycling route with lower environmental impacts. However, this contradicts GFRP wastes in which using them as feedstock in cement kiln production displayed more reduced environmental impacts than those thermally recycled to substitute virgin composite production.

Life cycle assessment of wind turbine blade recycling approaches in the United States

“…Previous efforts have performed LCA on select recycling approaches specifically for wind turbine blades [3][4][5]. Other efforts have performed LCA in the more general context of recycling fiber reinforced polymers [6][7][8]. However, there is still a research gap where additional detailed LCA is needed across multiple recycling approaches.…”

Carbon Fiber/PLA Recycled Composite

“…CFRP waste recycling entails not only recycling carbon fiber but also using recovered carbon fibers (rCFs) in the manufacturing of new material. Therefore, the quality alongside the quantity of the recovered or recycled carbon fiber is required as an important parameter not only for the process of recycling but also for the further application of the recycled product [ 40 ].…”

A Review on the Recycling Technologies of Fibre-Reinforced Plastic (FRP) Materials Used in Industrial Fields

“…In addition, recycled materials do not require the same amount of fossil fuel consumption used to produce virgin ones. All these aspects make recycled materials more competitive, allowing the use of these materials in a closed loop in accordance with the circular economy philosophy [45][46][47][48].…”

“…the use of these materials in a closed loop in accordance with the circular economy philosophy [45][46][47][48]. To date, even if the circular economy philosophy promotes the principles of material prevention, reuse and repurposing, the main strategies to manage waste are recycling, incineration and, at least, landfill disposal; despite the last one being not considered an eco-friendly approach because it does not allow for energy recovery and leads to severe environmental impacts, it is the most common and cheapest method used to manage waste materials [49,50].…”