Recyclage et valorisation des composites thermodurs

Recyclage et valorisation des
composites thermodurs résiduels
Pr Mathieu Robert, Ph.D.
Carrefour d’innovations en technologies écologiques (CITÉ)
Université de Sherbrooke
Recycling of Thermoset Polymer
Composites: A Working Example
LOOKING FOR A SOLUTION
René Composite Inc. (RMC) is a manufacturer of unsaturated
polyester resins-based composites for automotive and
transportation industries.
A new research program has been created at the Department of civil
engineering of the University of Sherbrooke to reuse waste
thermoset composites in a simple and economic way.
PARTNERSHIP
October 13-16, 2014
Orange County Convention Center | Orlando, FL
THE OBJECTIVE
Reuse Glass fiber/Polyester composite waste in new composites
Replace Calcium carbonate as filler
Maintain or improve properties
Open new markets
Be cost-effective
October 13-16, 2014
Orange County Convention Center | Orlando, FL
THE WAY
Prepare a fine powder from Composites pieces
Characterize the Composite powder
Prepare and characterize Composite powder/Polyester mixtures
Prepare and characterize Recycled composite materials
October 13-16, 2014
Orange County Convention Center | Orlando, FL
THE COMPOSITE POWDER
Raw material: Deflashing truck parts* after
molding. Constituted of 37 wt% glass fiber, 33 %
polyester resin and 30 % calcium carbonate
* Heated at 200C for 2 hours to remove styrene residue
Grinding: Ball mill with 10 to 15 mm silex balls
during 75 minutes; mixture of fine powder
(80%) and small solid pieces obtained.
POWDER CHARACTERIZATION
Composition by TGA:
48 % resin
43 % calcium carbonate
9 % glass fiber
Grain size distribution by laser granulometry:
80 % by weight less than 80 microns.
RECYCLED POWDER/PE MIXTURES
Resin: Commercial orthophtalic unsaturated polyester (Reichold)
Filler : 22.6 wt%
Three different filler compositions
Sample
CaCO3
Recycled
powder
A
B
C
100
75
0
0
25
100
Curing: At high temperature using 1.5 % MEKP and 0.05 % cobalt
naphthenate.
VISCOSITY
Viscosimeter: Brookfield DV-II+ equipped with spindle #2
Parameters: 2, 4 and 20 rpm at 25 °C
Thixotropic index : ratio of mixture’s viscosity at 2 and 20 rpm
Gel time determined at 140 °C
SAMPLE
VISCOSITY (CP)
THIXOTROPIC INDEX
@ 2 RPM
@ 4 RPM
@ 20 RPM
A
3240
2020
940
3.5
B
3500
2140
944
3.7
C
2700
1820
960
2.8
Results: Viscosity of systems considered as similar
Can be used in RTM process
RECYCLED COMPOSITE PROCESSING
Composition: The three resin/filler mixtures as above (13.5 wt%)
Randomly oriented short glass fiber mat (40.0 wt%)
Unsaturated PE (46.5 wt %)
Process: RTM
Note: The quality of the surface finish and hardness measurements were
in accordance with the manufacturer’ requirements.
TENSILE AND FLEXURAL PROPERTIES
Tensile Test (ASTM D 3039) : MTS 810 Materials
Test System + MTS 647 hydraulic wedge grip + 50 kN
cell + MTS 634.12F-24 extensometer. Displacement
control with 1 mm/min crosshead speed.
Flexural Test (ASTM D 790): [8]. MTS 810 + 50 kN
load cell + MTS FlexTest SE data acquisition system.
Span: 80 mm. Loading rate allow a deflection rate of 2.5
mm/min. Load increased until failure.
Mechanical test
Tensile
Flexural
ߪ௠௔௫ (MPa)
E (GPa)
ߪ௠௔௫ (MPa)
Sample
Average
SD
Average
SD
Average
Ecart-type
A
80
10
7,8
1.0
115
9
B
103
2
8,7
0.2
158
11
C
115
7
8,2
0.5
151
9
Strength increased with recycled material content.
Modulus basically unchanged.
No visible change on the mode of failure
THERMOMECHANICAL ANALYSIS (TMA)
Coefficient of thermal expansion (CET) determined using a TMA Q500
(TA Instruments); Heating rate : 3°C/min; Temperature range: 20°to 40°C.
Sample
CTE (°C-1 x 106)
Standard Deviation (°C-1 x
106)
A
46.4
3.5
B
62.4
7.6
C
89.6
5.7
CTE highly increased with recycled powder content.
CONCLUSIONS
Fine recycled powder obtained by grinding deflashing truck parts.
Replace partly (25 %) or totally calcium carbonate as filler in new parts.
Viscosity, thixotropic index and gel time comparable
High increase of UTS and flexural strength (upto 44 %)
Tensile modulus of elasticity unchanged
High increase of storage modulus (upto 50 %)
Increase of CET (upto 95 %)
GENERAL CONCLUSIONS
The use of recycled powder from composite industry as filler in
polymeric/composite materials is feasible at high scale.
Parts containing recycled material may offer better mechanical properties.
Parts with better mechanical properties could be redesigned for
production cost savings.
Manufacturing composites containing recycling materials would develop
market for “green materials”.
Fibres de renfort pour bétons techniques
Le projet CITÉ
Créer une infrastructure misant sur la
synergie Entreprises-Chercheurs
• Constituer un Carrefour de développement technologique et
écologique qui propose d’allier l’Université de Sherbrooke et les
entreprises privées dans un même lieu, et de partager équipements
et main-d’œuvre spécialisée.
• Attirer d’autres entreprises soucieuses de développer de nouvelles
technologies en lien avec le CITÉ.
Avantages que procure le CITÉ
Pour l’UdeS
• Accès partagé permettant les rapprochements et facilitant les
initiatives de recherche et de développement collaboratives entre
les chercheurs de UdeS et des entreprises. Mise à l’échelle des
technologies développées.
• Plusieurs projets déjà en cours:
–
–
–
–
–
Développement de matériaux isolants bio-sourcés (thermique, acoustique)
Élaboration de composites bio-sourcés pour des applications semi-structurales.
Bétonature: développement de FN pour les composites cimentaires.
Valorisation de la bio-masse canadienne dans les éco-matériaux
Développement de technique de valorisation des matériaux résiduels ou postconsummation.
Avantages que procure le CITÉ
Avantages pour les entreprises
• Création d'une masse critique d'expertise en matériaux et
technologies écologiques;
• Accès facile à un haut niveau d'expertise pour les entreprises
établies et émergentes des créneaux touchant les matériaux
valorisant et du développement durable;
• Accroissement des possibilités de financements de projets.
Livraison de l’infrastructure en
2016