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8/6/2019 Recycle VKS

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Presentation Plan

End-of-life aircraft structures Airbus & Boeing Initiatives

Composites Facts

Manufacture

Recycling of Composites Specifications

Order

EU Research

Processes: Conventional, Reclaimed Fibers,Pyrolysis


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End-of-life aircraft structures

More than 4,000 airliners will reach their end-of-life between 2005 and 2025 at a

rate of around 200 aircraft per year - but how will they be disposed of?

Up to now, most have gone to scrap yards [Boneyards], some have been used

for ground training, while the rest have been left to rot next to runways.

Cost of dismantling is higher than the scrap value!


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Cheaper to invest on low cost lands (of no value) to create

Boneyards of retired and crashed aircraft structures.

End-of-life aircraft structures


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Airbus Initiatives

Process for Advanced Management of

End-of-Life of Aircraft (PAMELA), the

EUR2.4 million project aims to set best

practice in this field while demonstrating

that 85 percent to 95 percent of aircraft

components can be recycled, reused orrecovered.

Airbus facility in southwest France at

Tarbes Airport, where procedures for the

decommissioning and recycling of aircraft

in environmentally controlled conditions

will be tested.

PAMELA members are:

SITA: Waste management firm;

EADS Sogerma Services: Maintenance co.,

EADS Corporate Research Centre in

France

Hautes-Pyrenees regional government.

The PAMELA project at Tarbes in France

[A300B2-200]


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Boeing Initiatives

Aircraft Fleet Recycling Association(AFRA)s - objectives are to develop acode of conduct for retired aircraftmanagement, establish next-generationstandards and practices within a year of

the codeslaunch, and then expandthose standards.

AFRA members are:

Milled Carbon & Adherent Technologies

Air Sa lvage International: UK-basedaircraft disassembly and parts recoveryfirm;

WINGNet: UK aerospace consortium

focused on the sustainable use ofmaterials;

Huron Va lley Fritz West: Tucson- basedrecycling company.

Europe Aviation & Bartin

The AFRA coalition has two locations:

Chateauroux Air Centre in south ofParis.

Evergreen Air Center in Marana,northwest of Tucson, Arizona.

AFRA operations at Chateauroux airport

in France


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Composites: Facts

The production of glass fiber composite in

the EU-15 is estimated at 280,000

300,000 tons per year; France, for example,

has an estimated annual discharge of end-

of-life glass fiber products between 45,000

and 50,000 tons.

The wor ld production of carbon fiber yarns

(from polyacrylonitrile) is only a fraction of

that of glass fiber: it was 32,000 tons in

2007 (Europe:8,500 tons).

Recycling and disposal of composites

concerns the end-of-life aircraft structuresthat contain carbon fiber composites.


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Recycling: Specification codes

PET: poly ethylene terephthalate

H/LDPE: high/low density polyethylene

PVC: poly vinyl chloride; PP: poly propylene; PS: polystyrene

Polycarbonate, nylon, acrylic or composite; PA6 GF30/M20 FR: polyamide-6 (caprolactam- based nylon)

30% g lass fibre

20% minera l filler

flame retardant


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Recycling: Order

Reuse

consider re-use at the design state

Recycle

potential for comminuted waste as filler

Pyrolysis/Hydrolysis etc for materials recovery, e.g. Milled Carbon Ltd.

Catalytic Conversion

resin dominant composites

Incineration

with energy recovery

Landfill

only if all else fails.


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Recycling: Conventional Methods

Composite recycling by grinding, shearing, chipping, or flaking the composite into

suitable size to be used as filler material in new moulded composite parts.


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Recycling: Reclaimed Fibers

Short length carbon fibers used for Electromagnetic interference shielding and radio

frequency shielding of electronic equipment.

Shredded carbon fibers, 100 -300 microns length, embedded in a thermoplastic

matrix serves as an effective Faradays cage on the electronic side, and

simultaneously as a reinforcing structure for the plastic housing;

Shredded carbon fibers, 10 - 50 microns length, added to liquids as an inert

emulsifier: giving paints, sealants,adhesives, bonders and cosmetics the required

viscosity (or consistency).

Demand for chopped and milled carbon fiber

is projected to steadily grow.


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Wind Turbine Blade part before & after pyrolysis

Recycling: Pyrolysis

Pyrolysis, thermal decomposition of the polymer at high temperature baths ofmolten salt (that keeps the oxygen out). At temperatures between 400 and 500Centigrade, the thermo-set matrices (in the case of carbon composites:epoxyresins) will depolymerize and eventually decompose.

This method is suitable for certain types of composite recycling, whosecomposite parts typically contain large quantities of filler.


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Recycling: Catalytic Conversion

Catalytic conversion is a tertiary recycling

method that produces chemicals or fuels from

scrap or waste products.

The first steps in recycling the complex mixtures

in scrap aircraft composite materials are

mechanical size reduction and the extraction of

carbon fibers.

Batch reactor process [ATI] mixes the scrap

composite, after, with a heat transfer f luid and

catalyst.

The mix is then processed under increased

temperature and pressure. By-products such as phenolic compound are

used to produce phenolic-based adhesives for

the wood industry.


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Recycling : Incineration & Others

Glass fiber composites can be recycled by combustion in a regular cement

oven: the glass silicate will turn into cement and the matrix resin will burn without

cinders and yield its caloric value to the process.

For the cement oven, metal parts must be removed before incineration, and the

matrix may not contain more than 0.5% chlorine (for instance: pvc, or chlorine-

containing coatings).

Complex composites and Aramid fibers can be recycled by exposing them to

electromagnetic waves in the form of microwaves inducing energy into the

composite material, leading to a separation of fibers and matrix. The separation

operation can be assisted by a suitable solvent.

Other processes such as acid digestion could be used to reclaim the fibers.

However, this process appears to be impractical from an environmental point of

view. Acid digestion uses hazardous chemicals and creates a mixture that will

require further processing.

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