Carbon Fibre Reinforced Composite Waste: An Environmental Assessment Of Recycling, Energy Recovery And Landfilling

The environmental benefits of recycling are assessed against other end-of-life (EOL) treatments for Carbon Fibre Reinforced Plastic (CFRP) waste. Recycling via pyrolysis, incineration with energy recovery, and disposal via landfilling are compared. To account for physical changes to materials from use and recycling, equivalence between recycled and virgin materials is calculated based on the ability to produce a short fibre composite beam of equivalent stiffness. Secondary effects of using Recycled Carbon Fibre (RCF) in a hypothetical automotive application are also analysed. Results underline the ecological constraints towards recycling CFRPs and demonstrate that benefits from recycling are strongly linked to the impacts of the selected recovery process, the materials replaced by RCF in a secondary application, and also to the type of secondary application in which they are used. (C) 2013 Elsevier Ltd. All rights reserved

Assessing the life cycle costs and environmental performance of lightweight materials in automobile applications

Life cycle assessment (LCA) and manufacturing focused life cycle costing are used to evaluate the potential advantages of composites in automotive applications. The life cycle costs and environmental performance of several suitable lightweight polymer composites are quantified and compared against magnesium and steel for a representative component. The results indicate that weight reduction will not always lead to improved environmental performance. Materials offering high weight savings such as carbon fibres and magnesium have been shown to give limited or negative environmental benefits over their life cycles due to increased environmental burdens associated with their production. Lower performance materials such as sheet moulding compounds were found to perform better from a life cycle perspective despite not being recycled. Lighter weight vehicle components were found to be always more costly; however their use did lead to reduced costs for the consumer through lower fuel consumption. (C) 2011 Elsevier Ltd. All rights reserved

Economic and environmental assessment of alternative production methods for composite aircraft components

The use of carbon fibre reinforced plastics is steadily increasing in the aerospace industry as rising fuel costs and concerns over the environment push airframe manufacturers to improve aircraft efficiency. The high costs associated with manufacturing carbon fibre reinforced components in autoclaves have prompted interest in alternative out-of-autoclave processing methods. In this study a combined cost modelling and life-cycle assessment approach is applied to selected out-of-autoclave production scenarios. Out-of-autoclave specific "prepregs" and resin infused fabrics are cured in thermal and microwave ovens of comparable volume and assessed against a benchmark autoclave scenario. Results showed that materials, in particular carbon fibres, contributed most significantly to component cost and environmental impacts. Resin infusion processes were effective at reducing costs, as reinforcement fabrics and resin were less expensive. Due to the small contribution of energy to total cost, reductions in energy use did not lead to significant savings, although they did improve the environmental performance of the manufacturing process. Out-of-autoclave specific prepregs did not perform as well due to their higher costs, longer associated cycle times and the need for lengthy de-bulking operations. Microwave oven curing offered little in terms of cost reduction and environmental improvement as investment costs were comparable to those of an autoclave, and energy consumption was relatively high compared with traditional thermal oven use. Opportunities for improvement exist if investment costs can be reduced and additional work carried out to promote more efficient transfer of energy. Improvement of the carbon fibre production process would be the most effective approach for reducing impacts and costs from carbon fibre components. (C) 2012 Elsevier Ltd. All rights reserved