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At least 19 records

Recyclable CFRPs with extremely high T g : hydrothermal recyclability in pure water and upcycling of the recyclates for new composite preparation

In recent years researchers have introduced different malleable and/or degradable thermosetting polymers to address the recyclability of traditional thermoset materials. Nonetheless, the mechanical properties and glass transition temperature (T g ) of these polymers are often compromised to achieve the desired depolymerization rate. In this work, a hydrothermally recyclable epoxy/anhydride thermosetting system with superior mechanical performance and high T g (>200 °C) was developed for carbon fiber reinforced plastic (CFRP) applications, using triethanolamine as the co-curing agent and tetraglycidyl methylenedianiline (TGDDM) as the epoxy matrix. The hydrothermal recycling of such cured systems is achieved at relatively low temperature (200 °C) without the addition of a catalyst. This mild recycling process decomposes the recyclable polymer matrix into an oligomer and imparts little damage to the valuable carbon fiber. The recycled carbon fiber and the decomposed polymer resin are reused to prepare a new CFRP. Here, this study has introduced a simple and practical approach for the preparation of recyclable CFRPs with high T g and a pathway for highly efficient closed-loop recycling, which sets up a framework for the future design of sustainable polymer composites.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Mild chemical recycling of carbon fiber-reinforced epoxy composites in aqueous buffers and development of hydrothermally recyclable vitrimer composites from recyclates

Carbon fiber-reinforced polymer (CFRP) composites have gained widespread adoption across diverse industries. However, their inherent stability, stemming from the crosslinked structure of the matrix resin, poses a significant challenge in managing the growing volume of CFRP waste. Consequently, there is a pressing need for an eco-friendly upcycling method that effectively recovers and reuses both the valuable carbon fibers and the polymer matrix from CFRP waste. This study presents a novel approach for upcycling CFRP waste under environmentally friendly conditions. Firstly, CFRP waste with an amine-cured epoxy matrix was completely decomposed in aqueous buffer solutions under mild conditions (≤ 220 °C, pH = 4.8). Further, decomposed matrix polymer (DMP) was employed to transform conventional epoxy resins into recyclable vitrimers. Lastly, new composites that can be hydrothermally recycled were fabricated using both DMP and recovered carbon fibers. As a result, this work proposes a novel strategy for achieving a circular economy within the CFRP industry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Life Cycle Assessment of Recycling High-Density Polyethylene Plastic Waste

Increasing production and use of various novel plastics products, a low recycling rate, and lack of effective recycling/disposal methods have resulted in an exponential growth in plastic waste accumulation in landfills and in the environment. To better understand the effects of plastic waste, Life Cycle Analysis (LCA) was done to compare the effects of various production and disposal methods. LCA shows the specific effects of the cradle-to-grave or cradle-to-cradle scenarios for landfill, incineration, and mechanical recycling. The analysis clearly indicates that increasing recycling of plastics can significantly save energy and eliminate harmful emissions of various carcinogens and GHGs into the environment. As recycling increases, the need for virgin-plastic production can be greatly reduced. Furthermore, the results of this study may help improve current mechanical recycling processes as well as potential future recycling methods, such as chemical recycling. Concerns about the current recycling/disposal methods for plastics have brought increasing attention to the waste accumulation problem. However, with the current COVID-19 pandemic, plastic accumulation is expected to increase significantly in the near future. A better understanding of the quantitative effects of the various disposal methods can help guide policies and future research toward effective solutions of the plastic waste problem.

36 MATERIALS SCIENCE↗

Hygrothermal aging and recycling effects on mechanical and thermal properties of recyclable thermoplastic glass fiber composites

Abstract Glass fiber‐reinforced polymer composites are widely used in marine applications, including renewable energy devices and submarines, due to their strength‐to‐weight ratios and corrosion resistance. As sustainability becomes more important, recyclable thermoplastic composites are gaining attention in marine energy applications. These materials face harsh conditions such as high chloride water, UV radiation, pressurization, and thermal cycling, which can affect their durability and recyclability. This study examines the impact of hygrothermal aging on the recyclability of an Elium glass fiber (GF) composite. Samples were mechanically ground for recycling, and mechanical and thermal properties were compared between aged and unaged samples. After seawater aging, the tensile strength and modulus of the unaged composite dropped by 25% and 13% respectively, due to water ingress along the fiber‐matrix interface. The recycled composite showed reduced flexural strength as the long fiber composite was converted into short fibers during the process. Differential scanning calorimetry (DSC) revealed no change in glass transition temperature after aging. Weight loss (25%) was attributed to the thermal stability of the glass fibers. Dynamic mechanical analysis (DMA) showed that the storage modulus increased with aging, and fracture analysis confirmed a mixed mode of failure for aged composites. Highlights Hygrothermal aging lowers mechanical performance of Elium® GF composites. Failure mechanism tends to be matrix cracking and interface bonding. Glass transition temperature is not reduced by hygrothermal aging. Fractured composite was successfully recycled via thermoforming. Flexural strength of the recycled composite is lower.

17 WIND ENERGY↗

Fast Determination of Lithium Content in Spent Cathodes for Direct Battery Recycling

Determination of the lithium ion content in cathode materials, which is currently performed by inductively coupled plasma mass spectrometry (ICP-MS), involves tedious procedures and error-prone preparation. This work introduces a new methodology to quickly determine the lithium content in spent cathode materials (LiNix Mny Coz O2, x + y + z = 1, NMC) using a thermalgravimetric analysis, which bypasses the use of ICP-MS and significantly reduces the cost and time required for determining the lithium content. Based on this new method, a new approach is developed to identify spent cathode materials suitable for direct relithiation recycling. Finally, these new methods have been applied to investigate the effectiveness of direct electrochemical-relithiation on recycling the spent cathodes, and provide insights for future development of direct battery materials recycling.

cathode recycling↗

Enabling Partnership between South Carolina and NREL for Advancing Opportunities in Plastics Recycling Research (EPSCOR for Plastics Recycling)

Proposal Objectives: 1. Utilize depolymerization/fractionation techniques to recover highly processable and reactive feedstocks for polymer synthesis from lignin. 2. Synthesize lignin‐derived non‐isocyanate polyurethane, epoxy, and polyamide using non‐ toxic, biobased route designed for chemical recycling. Characterize resulting materials. 3. Design a high‐yielding chemical recycling process for as‐synthesized materials yielding usable building blocks for many generations of polymer synthesis. 4. Optimize chemical recycling of PET waste for the synthesis of lignin‐based polymers. Compare properties to commercial materials. 5. Optimize reaction conditions and recycling steps to facilitate enhanced sustainability of the synthetic steps and final properties of materials. 6. Complete a lifecycle assessment of lignin utilization and chemical recycling to compare their environmental performance to that of materials produced from virgin material. Identify hot spots and benefits using the chemical recycling process.

36 MATERIALS SCIENCE↗

A direct recycling case study from a lithium-ion battery recall

Direct recycling of lithium-ion is a promising method for manufacturing sustainability. It is more efficient than classical methods because it recovers the functional cathode particle without decomposition into substituent elements or dissolution and precipitation of the whole particle. This case study of cathode-healing™ applied to a battery recall demonstrates an industrial model for recycling of lithium-ion, be it consumer electronic or electric vehicle (EV) batteries. The comprehensive process includes extraction of electrolyte with carbon dioxide, industrial shredding, electrode harvesting, froth flotation, cathode-healing™ and finally, building new cells with recycled cathode and anode. The final products demonstrated useful capability in the first full cells made from direct recycled cathodes and anodes from an industrial source. The lessons learned on recycling the prototypical chemistry are preliminarily applied to EV relevant chemistries.

Sloop, Steve↗

Compression Molding of Composite of Recycled HDPE and Recycled Tire Particles

Plastic and rubber recycling is an effective means of reducing solid waste to the environment and preserving natural resources. A project aimed at developing a new composite material from recycled high density polyethylene (HDPE) and recycled rubber is currently being conducted at Eastern Illinois University. The recycled plastic pellets with recycled rubber particles are extruded into some HDPE/rubber composite strands. The strand can be further cut into pellets that can be used to fabricate other material forms or products. This experiment was inspired by the above-mentioned research activity. In order to measure Durometer hardness of the extruded composite, a specimen with relatively large dimensions was needed. Thus, compression molding was used to form a cylindrical specimen of 1 in. diameter and 1 in. thickness. The initial poor quality of the molded specimen prompted a need to optimize the processing parameters such as temperature, holding time, and pressure. Design of experiment (DOE) was used to obtain optimum combination of the parameters.

Liu, Ping↗

A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

The use of secondary aluminum for structural components in the automotive industry is limited by the high Fe contents in recycled alloys which often result in the formation of brittle β-Al 5 FeSi phase which reduces the ductility of aluminum castings. In this study, a new secondary Al-Si-Mg alloy with high Fe content (about 0.44 wt.%) was developed for die casting applications. Based on thermodynamic modeling, manganese was added to obtain a designed Fe-to-Mn ratio of 2 which successfully suppressed the formation of β-Al 5 FeSi phase, by forming α-Al 15 (Fe,Mn) 3 Si 2 phase with rounded or hexagonal morphology. Additionally, a fine needle-like π-Al 8 FeMg 3 Si 2 phase was also formed within the eutectic regions. The new recycled alloy showed comparable mechanical properties in as-cast and heat treated (T5 and T6) conditions to three major primary die cast alloys (≤ 0.2 wt.% Fe) with similar composition. Ductility up to 7.4% from tensile elongation was achieved in as-cast recycled alloy due to the modification and refinement of α-Al 15 (Fe,Mn) 3 Si 2 by Mn and Sr additions. Tensile elongation was further improved to 9.1% after T6 treatment as a result of dissolution of π-Al 8 FeMg 3 Si 2 phase, defragmentation of α-Al 15 (Fe,Mn) 3 Si 2 and the spheroidization of Si phase. This new alloy provides a promising path for increasing usage of recycled aluminum with high Fe content in structural die castings for automotive and other applications.

36 MATERIALS SCIENCE↗

Contribution of Tibetan Plateau ecosystems to local and remote precipitation through moisture recycling

The ecosystems of the Tibetan Plateau (TP) provide multiple important ecosystem services that benefit both local populations and those beyond, such as through climate regulation services on precipitation for East Asia and China. However, the precipitation regulation service of the TP ecosystems for supplying moisture and maintaining precipitation is yet to be evaluated. In this study, we used the moisture recycling framework and a moisture tracking model to quantify the precipitation regulation services of TP ecosystems for their contribution to precipitation. We found TP ecosystems contributed substantially to local and downwind precipitation, with a declined contribution from 221 mm/year for the TP and neighboring areas, to <10 mm/year for eastern China and other surrounding countries. Among ecosystem types, grassland contributed most to precipitation, followed by barren and snow lands, forests, and shrublands. In terms of seasonality, precipitation contribution from TP ecosystems was greater in summer months than in non-summer months for western China, while the opposite was true for eastern China – though the magnitude was much smaller. Over the past two decades, the significant evapotranspiration increases in TP translated to a widespread increase in precipitation contribution for TP and downwind beneficiary regions from 2000 to 2020. Our study provides a quantitative way to understand the precipitation regulation services of TP ecosystems through moisture recycling, substantiating their key role to safeguard precipitation and the water cycle for downwind regions– effectively acting as an ecological security shelter that could be perceived by the public.

Li, Yan↗

Direct Cathode Recycling of End-Of-Life Li-Ion Batteries Enabled by Redox Mediation

The ongoing surge of electric vehicle (EV) adoption forecasts an unprecedented amount of lithium-ion battery wastes in the near future. Since cathode materials have the highest economic and engineering values, it is essential to recycle and reuse the end-of-life (EOL) cathode materials. Here, we show that redox mediators can deliver lithium ions and electrons from a lithium source to the cathode, efficiently relithiate the EOL cathode materials, and make them ready for new battery production after a postheat treatment. We have found that some quinone-based redox mediators, especially 3,5-di-tert-butyl-o-benzoquinone (DTBQ), can shuttle the charges very fast between Li metal and EOL cathode. Reduction of DTBQ on lithium is evidenced by chemical changes of Li metal and DTBQ, and successful relithiation of the EOL cathode by the subsequent oxidation of DTBQ is verified by electrochemical and structural evaluations.

battery recycling↗

Upcycling of CFRP Waste: Viable Eco-friendly Chemical Recycling and Manufacturing of Novel Repairable and Recyclable Composites

The rapid growth of the carbon fiber-reinforced polymer (CFRP) composite market has driven researchers to find value-added applications for outdated prepregs, manufacturing scraps, and end-of-life components. Currently, most CFRP waste is incinerated or landfilled, which squanders its residual value and burdens the environment. Various mechanical, thermal, and chemical approaches have been attempted to recover the carbon fiber, polymer matrix, or both. However, these current practices are often costly, energy-intensive, and generate secondary waste and pollution. To address these shortcomings, this project aims to develop a viable and sustainable chemical recycling technology for CFRP waste that can efficiently and cost-effectively decompose the polymer matrix and manufacture new recyclable composites from both the recovered carbon fiber (rCF) and decomposed matrix polymer (DMP).

36 MATERIALS SCIENCE↗

GaAs Substrate Recycling Using in-situ Deposited NaCl Layers via Molecular Beam Epitaxy

This work presents an alternative method to conventional III-V substrate recycling methods via growth of NaCl on nearly-lattice matched GaAs (001) substrates. Reflection high energy electron diffraction and transmission electron microscopy confirm an epitaxial relationship between the NaCl layers and the underlying GaAs. If the sample is heated too much prior to GaAs deposition, the NaCl fully desorbs from the surface. The quality of the deposition of GaAs on NaCl ranges from amorphous at low temperature to polycrystalline at intermediate temperatures. Exposure to electron beams during growth results in larger and (001) textured grains. The substrate is separated from the GaAs film in seconds via submersion in water, revealing a substrate surface comparable to the original.

electron beams↗

Virgin-like High-Density Polyethylene from Recycled Mixed Polyolefins

Reported herein is the compatibilization of mixed polyolefins containing a rheology modifier (M-PO RM ) derived from municipal solid waste (MSW) by using different types of compatibilizers. One compatibilizer was produced “in situ” during reactive extrusion (REX), and the other compatibilizers were commercial styrenic block copolymer and maleated polymer-based compatibilizers. Both “in situ” and commercial compatibilizers were first used in laboratory-controlled polyolefins containing a rheology modifier (denoted as L-PO RM ) and were investigated for their mechanical properties. The study was then extended to a rheology modifier containing recycled mixed polyolefins (M-PO RM ), where the effects of both compatibilizers were evaluated. Compared to the in situ and other commercial compatibilizers, the styrenic block copolymer offered superior performance, as it enabled the synthesis of virgin-like high-density polyethylene (HDPE) from the M-PO RM . The findings suggest that M-PO RM can be transformed into blends with virgin HDPE-like properties, thus offering an industrially relevant approach for the re- and upcycling of mixed polyolefins. Finally, the M-PO RM pellets with uniform MFI and good mechanical properties can be used as injection mold feedstocks for different applications such as in the construction and automotive sectors.

compatibilization↗