Recycling of epoxy resin and carbon fiber from pre-impregnated thermosetting composite waste

• Grant number: 25/12938-0
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: August 01, 2025
• End date: July 31, 2028
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Nonmetallic Materials
• Principal Investigator: Clodoaldo Saron
• Grantee: Marcos Vinicius Oliveira de Jesus
• Host Institution: Escola de Engenharia de Lorena (EEL). Universidade de São Paulo (USP). Lorena , SP, Brazil
• Associated research grant: 24/17297-0 - Recycling of thermosetting composite waste through thermochemical processes for recovery of carbon fibers and epoxy resin, AP.R

Abstract

The consumption of carbon fiber reinforced epoxy matrix thermoset composites (CFRE) has been significant and shows prospects for significant growth in the coming years. Likewise, the production of post-industrial waste generated during the manufacture of CFRE composite artifacts and post-consumer waste from objects and equipment produced with this material tends to be an increasingly important solid waste management problem. Recycling is the most appropriate alternative for the treatment of this waste, since it can minimize related environmental problems and generate economic benefits. However, the most studied and applied methods for the recycling of CFRE composites use processes to decompose the epoxy matrix to recover the carbon fiber, use the material in combustion to generate thermal energy or use the ground material as filler or aggregates for the composition of other materials, which do not take full advantage of the economic potential of the waste and can generate pollutants. The main objective of this research project is to recycle FCRE composite waste from the aeronautical industry, using combined chemical and thermal processes (thermochemical) with the purpose of recycling both the carbon fiber and the epoxy matrix, which is an unprecedented proposal. The FCRE composite waste should initially be subjected to heating in an alkaline medium for subsequent controlled pyrolysis in a nitrogen flow. The molecular fragments resulting from the decomposition of the polymer matrix will be used to synthesize new thermosetting resins, while the recovered carbon fibers will be tested for the production of new polymer composites. The knowledge generated should contribute to the development of new practices for the recycling of thermosetting polymers and value actions for the consolidation of the circular economy. (AU)