from waste to valuable products
TRANSCRIPT
FROM WASTE TO VALUABLE PRODUCTS
Hülya Ucar Sokoli, Erik Gydesen SøgaardAalborg University Esbjerg, Denmark
Department of Chemistry and Bioscience
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Polymer Composites
• What is a composite?
A composite is the combination of two or more materials that when combined together creates a superior and unique material. Ex. Glass- or carbon fibers held together with a polymer matrix.
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Thermosets vs. Thermoplastics
• ThermoplastictMoldable when heated.
• Thermoset plastic Crosslinked by covalent bonds. NOT moldable when heated
Why recycle composites?
400.000 ton composite waste is deposited on landfills in Europe everyyear. This number is increase each year!
Fact: 1 MW wind turbine produce 10 ton composite waste.
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Reference: Miljøstyrelsen & DTU
www2.mst.dkReference: Miljøstyrelsen
www2.mst.dk
Compositewaste.eu
What do we do in Denmark?
Problems in the field of recycling composite waste in Denmark
1. Companies in Denmark can dispose their composite wasteon landfills or incineration plants – No regulations. Germany forbids companies to landfill their waste!
Landfilling No attempt to recycle at all, but cheapestdisposal route
Incineration Not always possible. (Where limits are imposed on the energy content of the waste). The plants are not suitable for large parts and glass fibre residue can cause process stoppages.
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Genvind – Innovation ConsortiumFunded by the Danish Agency for Science, Technology and Innovation
Sustaniablerecycling of
composite waste
Furniture
Buildingpanels
New windturbine blades Paint
Fibre reinforced concrete
Textiles
Plasticconstruc-
tions
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Contec
Dyrup
Recycling Technologies
RecyclingThermoset Polymer
Composites
Thermal
Chemical
Mechanical
Pyrolysis Fludized bed
Glycolysis HydrolysisSolvolysis
Fillerparticle
Fibrousparticle
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Recycling Technologies
RecyclingThermoset Polymer
Composites
Thermal
Chemical
Mechanical
Pyrolysis Fludized bed
Glycolysis HydrolysisSolvolysis
Fillerparticle
Fibrousparticle
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Solvolysis
Batch Reactor
200 -325 ˚C300 Bar
Methodology
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Investigation 1, The fibers
Type of recovery processReference Varying Parameters
TENSILE STRENGTH
Gpa % chg.
Fluidised bedPickering
(2000)
Standard fiber 2,80 -
450 oC 1,45 -48
550 oC 0,50 -82
650 oC 0,18 -93
Pyrolysis
Cunliffe and Williams
(2003)
Standard fiber 2,02 -
400 oC and oxidized 1,06 -48
450 oC and oxidized 0,71 -65
500 oC and oxidized 1,06 -47
650 oC and oxidized 0,99 -51
800 oC and oxidized 0,36 -82
Knudsen et al.,
(2005)
Standard fiber 3,50 -
450 oC 0,96 -72
600 oC 0,50 -86
Subcritical water Kao et al., (2012)
Standard fiber 2,14 -
350 oC – 5 minutes 0,75 -65
350 oC – 5 minutes 1,24 -42
350 oC – 5 minutes 0,69 -67
350 oC –30 minutes 0,68 -68
300 oC – 30 minutes 1,04 -51
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Initial experiments
11
Run Solvent Temperature
[°C]
Pressure
[bar]
Reaction
time
[min]
Composite
covered with
solvent inside
reactor
(%)
Quantity of
solvent
[mL]
# 1 Water 280 300 0 100 250
# 2 Water 280 300 0 100 250
# 3 Water 280 300 30 100 250
# 4 Water 280 300 60 100 250
# 5 Water 300 300 0 100 250
# 6 Water 300 300 0 100 250
# 7 Water 300 300 30 100 250
# 8 Water 300 300 60 100 250
Results
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Virgin
fiber3 4 5 6 7 8
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
Str
ength
[G
pa]
Experiment no.
Hülya Ucar Sokoli. Mail: [email protected] No.: + 45 42443116
Fiber Properties - SEM
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Investigation 2, Oil recovery
Initial thoughts
There needs to be a higher value (more gain) in the process of recovering fibers using this technology Particularly for glass fiber reinforced composite waste, since more than 95 % of all fiber reinforced waste originates from glass fibers.
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Oil Recovery
Experiments:
50/50 vol. % acetone /water
and a catalyst. Approximately 80 g
composite waste was degraded in one batch and 250 ml was applied
Process conditions:
300 °C, < 150 bar, 30 min residencetime
Results:
Up to 50 ml oil from one batch.
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Is it beneficial?
Costs related to one batchProduction of 50 ml oil costs:
Beneficial because:1. It is possible to produce oil
simultaneously with the elimination of a problematic waste product
2. The oil has properties close to petroleum fuel oil and can potentially be used as a fuel oil
3. The long range of chemicals produced through acetone aldol reactions are valuable petrochemical feedstock.
4. In fact, up to 20 g/L was found through quantification of one of the high value chemicals.
Assay: 98%Quantity: 1 gPrice (USD): $ 3,040 / 1 g (FOB, NY, USA)Lead time: 2 weeks
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0
0.5
1
1.5
2
2.5
Kr.
2,5
0,1
Acetone Catalyst Energy Consumption
0,50
Hülya Ucar Sokoli. Mail: [email protected] No.: + 45 42443116
Recovery of chemicals
Composite waste
RecoveredResin
Recoveredcarbon/glass
fibers
Recoveredsolvent
Solvent
200-325 ˚C, 40-300 bar
Monomers
Chemicals
Fuel
Newmaterials
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Hülya Ucar Sokoli. Mail: [email protected] No.: + 45 42443116
Recovery of chemicals
Composite waste
RecoveredResin
Recoveredcarbon/glass
fibers
Recoveredsolvent
Solvent
200-325 ˚C, 40-300 bar
Monomers
Chemicals
Fuel
Newmaterials
Great potential
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Succes of turning other kind of wasteinto valuable products
RIBE BIOGAS A/S startet in 1990. Biggest biogas plant in the world in the beginning.Farmers disposed their
manure waste at the biogas plant
Slaughterhouses disposedtheir waste at the biogas plant
The biogas plant receivedmoney from the farmers and slaughterhouses back then.
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More work done so far
• Up scaling from 250 mL to 1 L
• Microwave assisted degradation
• Investigations of different solvents activity in solvolysis
• Chemical analysis of chemicals from the elimination of resins from several compositetypes
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More work to be done
• Reuse of resins for the production of new composites (in collaboration with DTU)
• Reaction kinetical investigations of the elimination process in up-scaled reactor in collaboration with Force Technology
• Use of inorganic binder (Aalbinder) in the reuse of partly purified fibres
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