Recycling of composite materials using fluidised bed processes

Lightweight engineering plastics have been increasingly used in automotive applications(3), this tends toward more fuel efficient vehicles(1). Glass reinforced plastics commonly include thermosetting polymers. These cannot be re-moulded, unlike thermoplastics, thus thermoset scrap is currently disposed of in landfill. This is increasingly targeted by legislation(14) and is becoming more expensive. This thesis describes work to maximise resource recovery from scrap thermoset composites. A review of relevant literature identified thermal processes for treating scrap thermoset composites. Combustion is particularly suitable for the mixed and contaminated materials arising from end of life vehicles. The literature showed that heating glass fibres reduced their properties, which is a concern for any thermal recycling process. The methodology of this work is to recover energy from the composite polymer and reuse the incombustible residues. Two experimental processes are reported: Fluidised Bed Co-combustion of Thermoset Composites with Coal. The common composite filler of calcium carbonate captures the sulphur emissions from the coal combustion. Results show that scrap composites can successfully be burned in a commercial scale fluidised bed. Retention of the sulphur from the coal by the composite filler was up to 75 % of the input. Although a technical success, economic analysis shows this disposal to be unviable compared with similar desulphurisation via crushed limestone. Fluidised Bed Thermal Processing Rig for Recovering Glass Fibres. The incombustible constituents of a crushed Sheet Moulding Compound were released from processing above 400 ° C in the fluidised bed test rig. The reinforcing glass fibres were elutriated as monofilaments, suitable for use in a veil product, and recovered from the flue gases. Scanning Electron Microscopy showed that the fibres were intact. The tensile strength of fibres from 450°C processing was reduced by approximately 50% and by 90% from 650°C(73). Strength was also found to reduce with increasing time at a temperature(76) . Flue gas analysis showed that carbon monoxide and hydrocarbons were present. This indicated that full combustion did not take place and the associated heat energy lost. Measured nitrogen oxides and sulphur dioxide concentrations were low. After initial testing, the test rig was refined by the incorporation of a Rotating Screen Collector to separate the fillers and fibres. The fibre contamination was reduced by 50% via this novel equipment. Fibre recovery rates of up to 57% were achieved. Resin Decomposition Model. Results indicate that the resin endothermic energy of decomposition maintained the temperature of the Sheet Moulding Compound significantly below the bed temperature