Horizontal Reactor for Composite Recycling
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Solution Overview
Problem
Current recycling methods for composite materials with carbon fiber and/or glass fiber reinforcement, such as mechanical recycling and incineration, either destroy the material's properties or result in low-quality products due to incomplete separation and high process costs, while existing technologies like pyrolysis furnaces intermingle product zones, reducing effectiveness.
Innovation Solution
A horizontal reactor system divided into three leak-tight zones, where the composite material undergoes pyrolysis, gasification, and cooling in sequential phases, allowing for controlled decomposition and separation of reinforcement fibers from the matrix, preventing combustion and maintaining fiber integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical recycling is used to recycle composite materials, then the recycling process is simple, but the material properties are destroyed and only short fibers are obtained
Solution Approach 1:
The invention changes the thermal parameters by implementing a controlled heating process that raises the temperature to the matrix decomposition point (typically 300-500°C) while maintaining an oxygen-free atmosphere. This parameter change enables the matrix to decompose and separate from the fibers without mechanical force, preserving fiber length and quality while achieving effective recycling
Solution Approach 2:
The invention creates an inert atmosphere by completely excluding oxygen from the decomposition chamber. This inert environment prevents combustion of the polymer matrix and ensures controlled thermal decomposition, allowing the matrix to break down into volatile compounds while leaving the reinforcement fibers intact and reusable
2Reliability
If pyrolysis furnace is used to recover carbon fibers, then fiber recovery is achieved, but the product zones intermingle and process effectiveness is reduced
Solution Approach 1:
The invention segments the processing system into distinct functional zones: a decomposition chamber where the matrix breaks down, a separation zone where volatiles escape through permeable walls, and a fiber collection area. This spatial segmentation prevents product intermingling and maintains process effectiveness by allowing each stage to occur independently
3Manufacturing precision
If ultra-high energy impact system is used for size reduction, then particle size is reduced to fine particles, but later separation of milled materials is not possible and cooling costs are high
Solution Approach 1:
The invention replaces the mechanical impact system with a thermal-chemical process. Instead of using high-speed impactors to reduce particle size, the matrix is heated to its decomposition temperature where it spontaneously breaks down into volatile compounds and leaves the reinforcement fibers. This substitution eliminates the need for subsequent separation processes and avoids high cooling costs while achieving effective size reduction
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves high-quality separation and reuse of carbon or glass fibers, improving final product quality and process efficiency by maintaining controlled atmosphere conditions and sequential phase processing, resulting in a simple and effective recycling method.
Implementation Method 1
a first phase of pyrolysis, wherein the composite material enters into the first zone and is heated to a temperature comprised between 500 and 700° C. in a controlled atmosphere with an absence of oxygen
Implementation Method 2
with continuous rotational movement
Implementation Method 3
a second phase of gassing, wherein when the process performed in the first zone ends, the resulting material enters into the second zone and air is introduced into the second zone at the same time the resulting material is heated to a temperature comprised between 500 and 700° C.
Implementation Method 4
a third zone which is leak-tight and independent of the horizontal reactor and a third phase of cooling, wherein when the process performed in the second zone ends, the reinforcement material enters into the third zone and cooling of the reinforcement material is performed
Data Source
AI summary
The invention relates to a installation (4) for recycling composite materials comprising a horizontal reactor (5) with a first zone (1), second zone (2) and third zone (3), which are leak-tight and independent, aligned with and separated from one another by means of gates that allow the passage of the composite material to be recycled only when the process has ended in a previous zone. The first zone (1) comprises a rotation mechanism (9) for rotating the material and gas outlet means (8). The second zone (2) comprises air injectors (10) and gas outlet means (11). The third zone (3) comprises cooling means.The invention also relates to a method for recycling composite materials comprising a first pyrolysis phase, a second gassing phase for gassing the material resulting from the first phase, and a third cooling phase for cooling the reinforcement material.