Carbon composite recycling

Keywords: Carbon, Recycling, Waste handling

Aircraft carbon fiber products have traditionally caused disposal difficulties at the end of their useful lifespan. Milled Carbon Ltd, a recycling specialist, informs us that it has the answer with a new process which turns rejected carbon parts into a valuable reusable material. The process is said to be creating considerable interest with the likes of Boeing and Airbus.

Since, late 2003, Milled Carbon has developed a system which continuously recycles cured and un-cured carbon fiber composites: a process considered almost impossible – until now. Despite retaining considerable residual value,carbon fibre composite waste has, historically, been dumped in landfill sites or incinerated at considerable expense to the environment and companies concerned. Now, Milled Carbon reports that it can continuously recycle cured parts up to 2m wide and 250mm high to a current thickness of 25mm and uncured material in the form of manufacturing off-cuts or unused rolls of pre- impregnated material are processed in a similar fashion.

Working with several major composites manufacturers which are interested in disposal and recycling of this previously problematic material, Milled Carbon has designed its method – a simple treatment of the composites by pyrolysis – to remove any resin or binder from the carbon. The result is a material which is said to be only slightly lower in properties than virgin carbon fibre and can be used to make new products.

Milled Carbon is developing a range of end uses for its valuable “recyclate.”A healthy market for the material looks sure to grow, with interest already being shown by injection moulders and for use in non-woven materials. Milled Carbon is also working with several UK universities – including Dr Steve Picketing of Nottingham University – to improve the recycling process. The company is a member of AFRA (Aircraft Fleet Recycling Association) scheme,recently brokered by Boeing, which brings together experts to address the disposal of unwanted aircraft.

“Our aim is to solve the environmentally problematic disposal of waste carbon fiber composites, while also growing our business by supplying carbon fibers to customers that don't need the stringent physical properties of virgin material,” Milled Carbon Ltd managing director John Davidson said. “We're getting a lot of enquiries from companies that want to use the recyclate for applications where its strength, weight, durability and electrical properties are of interest. We're also developing forms of the recycled fibers where,traditionally, virgin carbon fibers have always been used.” Boeing aircraft and composite recycling project manager Bill Carberry said.

“Recycling is good for the environment and good for business. Boeing supports efforts like this one that will foster environmentally sound practices. This new carbon fiber recovery technology is a great step forward.”

Milled Carbon Ltd is solely involved in the recycling of carbon fiber composites. The company's head office is based in Wootton Wawen, near Henley in Arden, Warwickshire, UK, while its factory is located at West Bromwich, West Midlands.

Details available from: Milled Carbon Ltd, Tel: +44 (0) 121 705 9000, E-mail: milled. carbon@btconnect.com web site: www.milledcarbon.com/