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WingNet September 2007 Recycling solutions for cured and un- cured carbon fibre composites. http://www.afraassociation.org/

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WingNet September 2007

Recycling solutions for cured and un-cured carbon fibre composites.

http://www.afraassociation.org/

WingNet September 2007

Milled Carbon Ltd is privately owned and funded, founded in 2003 with the objective of developing a continuous, commercially viable, processes to recover carbon fibre.

We currently recycle;•carbon fibre composite manufacturing waste•composite component parts •end of life components

Based in the UK, with operations in Birmingham

We have collective experience of 200 years in the carbon fibre manufacturing and polymers industry

WingNet September 2007

• We are founder members of AFRA (Aircraft Fleet Recycling Association).

• We are a partner in ReBrake a DTI funded Technology Innovation Programme to research a recycled carbon fibre/ceramic matrix disc brake

• We are also lead partner in FibreCycle a DTI funded Technology Innovation Programme to research the conversion of recycled carbon fibre into spun yarn

• We are also members of a recent Framework 7 Project entitled Advanced Recycling and Sorting Technologies for Future Vehicles (ARTicle) This project explores the possibilities beyond the requirements specified in the ELV and Battery Directives and develops shredding and post-shredding technologies as well as material refining technologies.

WingNet September 2007

Market SegmentThousands

of MT % Mkt Thousands of MT % Mkt Thousands

of MT % Mkt

Industrial 8.2 49 11.4 52 19.1 54United States 1.9 23 3.1 27 5.3 28Europe 1.1 13 2.7 24 5.8 30Japan 1.7 21 2.2 19 3.1 16Other 3.5 42 3.4 30 4.9 26Aircraft Aerospace 4.1 24 5.6 26 10.7 30United States 2.8 70 3.4 60 6.4 60Europe 1.0 24 1.8 33 3.3 31Japan 0.2 4 0.2 4 0.6 5Other 0.1 2 0.2 4 0.4 4Sporting Goods 4.1 27 4.9 22 5.8 16United States 2.2 49 1.9 40 2.2 39Europe 0.5 12 0.7 14 0.9 16Japan 0.7 16 0.5 10 0.4 7Other 1.1 23 1.8 36 2.3 39

1999 2004 2009

Estimated Global CF Consumption by Major Market Segment

Current estimated world production: 25,000 to 30,000 mtpa

Global Carbon Fibre Consumption

WingNet September 2007

By kind permission:www.eurofighter.com /medialibrary

WingNet September 2007

Boeing 787 & Airbus A380: Carbon Fibre Composite Content

CFRP

GFRP

GLARE®

Hybrid (G+ C)

Radome

Nose landinggear doors

CentralTorsion Box

Main and centrelanding gear doors

Pylon fairingsand nacellescowlings

Main landinggear leg fairing door

Spoilers

Trailing edgeupper and lower panelsand shroud box

Overwingpanel

Apron

Pressurebulkhead

Verticalstabilizer

Tailcone

Horizontalstabilizerouter boxes

Outer flap

Upper-deck floor beams

Flap trackfairings

Ailerons

Belly fairing skins

Leading edge / J-nose

The Airbus A380 Contains 25 – 30 tonnesof composites, 85% of which are CFRP

The Boeing 787 contains50% of total weight incomposites, the remainder being 20% aluminium and 30% titanium

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F22 Raptor

F18 Hornet

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FLUIDISED RECYCLATE:

LONG FIBRES 30 –75mm

MANUFACTURING WASTE

CURED COMPONENT WASTE

END OF LIFE

CONTINUOUS PYROLYSIS PROCESS

FLUIDISED BED PROCESS

PYROLISED RECYCLATE

PRECIOUS METALS

The Process

WingNet September 2007

Pyrolised Recyclate

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Manufacturing Scrap as Received EDS Spectra

Courtesy North Carolina State University

Manufacturing Scrap

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WingNet September 2007

Single Fiber Tensile Test Results

Control AS4

Recycled AS4

* Values in the parentheses represent coefficient of variation %

Recycled AS4After 1st round of Optimization

Preliminary Results

CF4 Trend ConfirmedCF4-1 Improved after Process Optimization

Myles Connor, Brian AllenDr. Jerome J. Cuomo

CF A5

Gauge length [mm]

5

10

10

20

20

20

510

CF 4

CF 4-1

Fracture Stress [MPa]

Young’s modulus [GPa]

Fracture strain [%]

Fiber Type

2953 (13.2)2732 (13.6)2464 (12.7)

4001 (18.4)*3619 (16.1)3401 (14.8)

4148 (9.2)3691 (15.6)3143 (18.8)

165 (19.7)211 (9.0)228 (9.9)

230 (7.4)201 (14.4)

257 (8.1)

211 (9.6)231 (9.8)224 (8.7)

2.64 (17.5)1.94 (14.7)1.53 (13.3)3.28 (35.6)1.48 (20.5)1.19 (15.4)2.40 (17.4)1.74 (14.8)1.63 (16.5)

CF A5

Gauge length [mm]

5

10

10

20

20

20

510

CF 4

CF 4-1

Fracture Stress [MPa]

Young’s modulus [GPa]

Fracture strain [%]

Fiber Type

2953 (13.2)2732 (13.6)2464 (12.7)

4001 (18.4)*3619 (16.1)3401 (14.8)

4148 (9.2)3691 (15.6)3143 (18.8)

165 (19.7)211 (9.0)228 (9.9)

230 (7.4)201 (14.4)

257 (8.1)

211 (9.6)231 (9.8)224 (8.7)

2.64 (17.5)1.94 (14.7)1.53 (13.3)3.28 (35.6)1.48 (20.5)1.19 (15.4)2.40 (17.4)1.74 (14.8)1.63 (16.5)

WingNet September 2007

Contact Angle & Surface Energy

Diiodomethane Water

Fiber Average cos θ[measured]

Average cos θ[measured]

Dispersive Surface Energy

(mN/m)[calculated]

Non-Dispersive Surface Energy

(mN/m)[calculated]

CF1 0.72 ± 0.08 0.16 ± 0.02 31.2 9.7CF4 0.87 ± 0.02 0.25 ± 0.03 35.9 10.5CF-A 0.76 ± 0.02 0.30 ± 0.02 32.2 12.8CF-B 0.84 ± 0.02 0.22 ± 0.06 35.1 9.9

• At least six different specimens were tested for each sample set• CF4 (Milled Carbon) sample contained the highest dispersive surface energy characteristic and the second highest non-dispersive surface energy characteristic• Recycled CF1 contained the lowest surface energies for both dispersive and non-dispersive components

WingNet September 2007

Preliminary Data of Reclaimed Carbon Fiber BMC by QCI – ASTM D790 Flexural Test

Resin (Vinyl Ester) Filler Fiber AVE SD AVE SD

Virgin 60 0 40 23.97 4.05 2.89 0.58Virgin 37.5 37.5 25 21.92 2.28 2.69 0.19

MC (E) 29 56 15 (UK) 16.52 4.30 2.55 0.27AT (F) 29 56 15 (US) 11.21 3.12 2.14 0.12

Compound ID.

Flexural Strength (ksi.) Flexural Modulus (msi)Content (%)

0.00

5.00

10.00

15.00

20.00

25.00

30.00

B D E F

Compound ID.

Flex

ural

Str

engt

h (k

si.)

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

B D E F

Compound ID.

Flex

ural

Mod

ulus

(msi

.)

AMC 8590 SMC (55% 1” Carbon Fiber): Strength = 88 ksi., Modulus = 5.6 msi.

WingNet September 2007

We have observed the aesthetic appeal of carbon fibre increase in use. In this case we have used woven sheet recyclate to trial a number of consumer goods.

Carbon fibres have other, industrially advantageous properties which can also beexploited. These IC trays contain 30 to 40% carbon fibre. Recycled carbon fibre has theelectrical properties required for such end uses.

Applications

WingNet September 2007

Future Applications• Flocking; using recycled milled carbon fibre for conductive substrates,

filter medium, decorative interiors

• Metal replacement; working with alternative advanced/recycled fibre matrix to replace aluminium panels

• Concrete reinforcement; using short recycled fibres to enhance the strength and durability of concrete used in construction

• Glass Fibre Replacement; exploring the possibility of replacing glass fibre to reduce weight and enhance recyclability

WingNet September 2007

Future Technologies• Microwave: we are currently researching the use of microwaves to

improve the thermal efficiency of the process which also leads to considerable reduction in processing costs and is a more environmentally sustainable process

• Fluidised Bed; we are researching the use of a fluidised bed system for the processing of end of life shredded material, such as aeroplanes and motor vehicles

• Atomic Level Cleaning; we have also been working with partners on Plasma Re-engineering of waste carbon fibre composites

WingNet September 2007

USA: Seattle, Tucson, Wichita, Greenville

Europe:UK, Germany, Italy

Asia:Japan, Taiwan, China

South Africa:Johannesburg

Going Global

WingNet September 2007

John Davidson MScManaging Director

Milled Carbon LtdWootton MeadStratford RoadWootton WawenHenley in ArdenWarwickshireB95 6AP

Mobile: +44 (0)7768 566661Head Office Tel: +44 (0)121 705 9000Head Office Fax: +44 (0)156 479 3749Works Tel: +44 (0)121 522 2022Works Fax: +44 (0)121 557 1081

[email protected]