Recycling of composite materials from the industry
Project funded by Danish Agency for Science, Technology and Innovation

Mission

The purpose of the GenVind Innovation Consortium is to develop enabling technologies for a sustainable recycling of plastic composites, and demonstrate that the waste can be used in many different products, components and structures.

Among end-products which could be produced from waste plastic composites are
This project does not stand alone and must be seen in conjunction with a number of efforts. The overall objective is to develop a technically, environmentally and economically satisfactory handling of waste products and production waste plastic composites.

The project is based on cradle-to-cradle philosophy, which is to produce products such that all be included in the closed biological and technical cycles - and thus completely dispose of waste. In regards to the project, this means the composite wastes must be usable as new resources in the form of, inter alia, raw materials and semi-finished products. The vision of the threads is to implement a coordinated and coherent action carried out in cooperation between companies, universities and GTS institutes, and to give the Danish composite industry and a wide range of end users considerable knowledge and technology boost in relation to size reduction, analysis, design and manufacture of competitive recycled products to the world market.

The research goals of the threads are to identify and develop methods for recycling of both short and long, continuous fibers in new composite materials. In addition to challenges in regards to shredding and sorting technologies, there are research challenges in restoring properties of the fibers from the waste composites.

After pretreatment (mechanical and/or chemical) changes occur in the fibers (including surface topography), resulting in deterioration of the mechanical properties of the composites. It is therefore necessary to restore the mechanical properties of the fibers, which can be done by a post-treatment with a new surface layer (sizing). The fibers can then reinjected with new binders (resins) and, depending on the final use, a qualification of the new material, from fiber/matrix level to component level. There are also major research challenges in separating the various types of fiber glass, carbon and hybrid fibers and finding opportunities for reuse of sandwich core materials. Design-related questions and methods for the manufacture of components from recycled fibers also constitutes important research challenges.



Project structure

planGenVind


Research projects (FP)
involving Barsmark, Velux, Dovista, Averhoff, DPF, AAU, UN, DTU Risø
FP-WP1: Recovery of chemicals and Fiber Reinforcement
FP-WP2: Optimization and Application of Recovered Fiber Reinforcement
FP-WP3: Pilot Scale Studies
Technology Projects (TP) TP1: Development of mechanical technologies for reuse of composite
TP2: Development and optimization of thermal/chemical process technologies for the regeneration of resin and fiber.
TP3: Development of process technologies for the manufacture of new products from recycled fibers and/or the regenerated resin.
TP4: Assessment of environmental and energy issues from recycling of composites.
Demonstration projects (DP) DP1: Composite Waste
DP2: Construction
DP3: High Tech Products and constructions



planGenVind
More and more processing steps
A. Reuse of the whole blade DP1

B. Reuse of major part of blades for bus stop, or the production of new smaller wind turbine blades TP1, DP1, DP2, DP3

C. Cutting out of construction element, plates, beams, planks,... TP1, DP1, DP2, DP3



D. Shredding TP1, DP1, DP2, DP3






F. Recovery of polymer and short fibres FP1, FP2, TP2, TP3, DP1, DP2, DP3


E. Recovery of long fiber/fabrics and polymer FP1, FP2, TP2, TP3, DP1, DP2, DP3






© 2014 GenVind Innovation Consortium