Recyclage et valorisation des composites ... 2012/04/04  · polyester resin and 30 %...

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  • 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.

    October 13-16, 2014 Orange County Convention Center | Orlando, FL

    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

  • THE OBJECTIVE

    October 13-16, 2014 Orange County Convention Center | Orlando, FL

    Reuse Glass fiber/Polyester composite waste in new composites

    Replace Calcium carbonate as filler

    Maintain or improve properties

    Open new markets

    Be cost-effective

  • THE WAY

    October 13-16, 2014 Orange County Convention Center | Orlando, FL

    Prepare a fine powder from Composites pieces

    Characterize the Composite powder

    Prepare and characterize Composite powder/Polyester mixtures

    Prepare and characterize Recycled composite materials

  • 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

    Curing: At high temperature using 1.5 % MEKP and 0.05 % cobalt naphthenate.

    Resin: Commercial orthophtalic unsaturated polyester (Reichold)

    Filler : 22.6 wt%

    Three different filler compositions Sample CaCO3 Recycled

    powder

    A 100 0

    B 75 25

    C 0 100

  • VISCOSITY

    Results: Viscosity of systems considered as similar

    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

    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

    ���� (MPa) E (GPa) ���� (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.

    Manufacturing composites containing recycling materials would develop market for “green materials”.

    Parts with better mechanical properties could be redesigned for production cost savings.

  • 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 post-

    consummation.

  • 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