Emphasizing

EMPHASIZING: Enhancing material properties of recycled glass fibres through sizing

Composite materials are found in most industrial sectors, mainly due to their outstanding material properties and lightweight benefits. Today, some 2.5 million tonnes of composite material are used globally in the renewable energy sector.  Glass fibre reinforced plastic (GRP) represents the majority of the £54.5 billion global market for composites, and it is estimated that there are 12-15 tonnes of GRP per megawatt of power.  Over one million tonnes of GRP are produced annually in Europe, and the growing use of glass fibres across industry has resulted in increased concern about how the associated waste is disposed of.  One example is in the wind energy sector, which is expected to decommission 40,000 to 60,000 tonnes of composite materials in the next two years (Sustainable Decommissioning: Wind Turbine Blade Recycling report).  Therefore, it is vital that composite waste is recycled using a cost-effective methodology with minimal environmental impact.

The EMPHASIZING project seeks to assess, process and analyse materials from wind turbine blades, as well as automotive and marine parts, to create roadmaps for recycling.  To achieve this, the consortium will demonstrate the concept of a circular economy for fabricating automotive end products from upcycled glass fibre materials.

The objectives of the project are to:

• Create upcycled, sized glass fibres
• Demonstrate EMPHASIZING's reclamation of high-yield, high-quality fibres via the fabrication of relevant automotive parts
• Develop, test and optimise the EMPHASIZING system for wind and maritime end of life materials
• Establish a viable value chain for the exploitation of the reclaimed, upcycled GRPs
• Evaluate the optimal End-of-Life (EoL) route for the automotive components
• Conduct impact and life cycle assessment (LCA) to validate investment in EMPHASIZING
• Work closely with BSI on standards for the recycling/upcycling of GRPs

The methodology behind EMPHASIZING introduces ‘pressolysis’, a novel recovery method and technical step change from state-of-the-art processes such as pyrolysis and solvolysis.  This will enable commercial innovation through high-yield reclamation of top-quality, clean, free from residue, reusable fibres, with retained length and properties almost akin to virgin materials.  Through innovative re-sizing, the aim is for these fibres to take on properties similar to carbon and a cost closer to glass.  The reclaimed material from the EMPHASIZING process will be used to make a Ford chassis part.

On completion, EMPHASIZING will have realised a novel reactor that can effectively recycle EoL wind and marine parts at a low cost, with low impact and carbon footprint, and in an environmentally friendly way that does not negatively impact social equality, diversity and inclusion.  It will also remove the need for harmful chemicals during composites recycling and reduce the requirement for incineration, in turn diverting composites from landfill. The clean glass fibres that result from the recycling are then ready to be deployed in the manufacture of brand new components.

Partners: B. & M. Longworth (Edgeworth) Limited; also Lead Partner, EMS-CHEMIE (UK) LTD, Ford Technologies Limited, Gen2plank Limited, Gestamp and BCC.

EMPHASIZING has received funding from Innovate UK under grant agreement No. 10035094.