WO2023191689A1 - Method and system for recycling objects made of carbon-fiber reinforced plastics and glass-fiber reinforced plastics - Google Patents

Method and system for recycling objects made of carbon-fiber reinforced plastics and glass-fiber reinforced plastics Download PDF

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Publication number
WO2023191689A1
WO2023191689A1 PCT/SE2023/050268 SE2023050268W WO2023191689A1 WO 2023191689 A1 WO2023191689 A1 WO 2023191689A1 SE 2023050268 W SE2023050268 W SE 2023050268W WO 2023191689 A1 WO2023191689 A1 WO 2023191689A1
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WO
WIPO (PCT)
Prior art keywords
module
gas
glass
reinforced plastics
fiber reinforced
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Application number
PCT/SE2023/050268
Other languages
French (fr)
Inventor
Torsten Granberg
Stefan KÄLLANDER
Original Assignee
Plagazi Ab
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Publication date
Application filed by Plagazi Ab filed Critical Plagazi Ab
Publication of WO2023191689A1 publication Critical patent/WO2023191689A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/50—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
    • C01B3/56—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/08—Bushings, e.g. construction, bushing reinforcement means; Spinnerettes; Nozzles; Nozzle plates
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/06—Continuous processes
    • C10J3/08—Continuous processes with ash-removal in liquid state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00002—Chemical plants
    • B01J2219/00018—Construction aspects
    • B01J2219/0002—Plants assembled from modules joined together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B2017/0094—Mobile recycling devices, e.g. devices installed in truck trailers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B2017/0424—Specific disintegrating techniques; devices therefor
    • B29B2017/0496—Pyrolysing the materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/0283—Processes for making hydrogen or synthesis gas containing a CO-shift step, i.e. a water gas shift step
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0405—Purification by membrane separation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0415—Purification by absorption in liquids
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/06—Integration with other chemical processes
    • C01B2203/066—Integration with other chemical processes with fuel cells
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
    • C08J11/12—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by dry-heat treatment only
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/31—Mobile gasifiers, e.g. for use in cars, ships or containers
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C10J2300/0906—Physical processes, e.g. shredding, comminuting, chopping, sorting
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0946—Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/12—Heating the gasifier
    • C10J2300/123—Heating the gasifier by electromagnetic waves, e.g. microwaves
    • C10J2300/1238—Heating the gasifier by electromagnetic waves, e.g. microwaves by plasma
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1625—Integration of gasification processes with another plant or parts within the plant with solids treatment
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
    • C10J2300/1643—Conversion of synthesis gas to energy
    • C10J2300/1646—Conversion of synthesis gas to energy integrated with a fuel cell
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1861—Heat exchange between at least two process streams
    • C10J2300/1884—Heat exchange between at least two process streams with one stream being synthesis gas
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/04—Purifying combustible gases containing carbon monoxide by cooling to condense non-gaseous materials
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
    • C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
    • C10K3/04—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment reducing the carbon monoxide content, e.g. water-gas shift [WGS]

Definitions

  • the present disclosure is related to a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, and to a system for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP.
  • CFRP Carbon fiber reinforced plastics
  • GFRP glass fiber reinforced plastics
  • An object of the present disclosure is to provide a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP wherein some of the above-identified problems are mitigated or at least alleviated.
  • the present disclosure proposes a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, being based on a modular system for the pre-treating the objects to a feedstock for the reproduction of glass fiber and production of hydrogen, carbon dioxide and heat, which are extracted from the feedstock material.
  • the method comprises the steps of:
  • the combustible tailgas is used for heating a centrifuge in the glass fiber spinning module.
  • the produced excess heat energy from the process is used for external heating purposes via the heat exchanger.
  • the gasification module comprises at least one pyrolytic gas generator and at least one plasma generator.
  • step (iii) the feedstock is partly gasified in the at least one pyrolytic gas generator and completely decomposed into atomic level, so-called plasma, in the gasification module comprising the at least one plasma generator producing gas out of the remaining from the pyrolytic gas generator.
  • the gasification module comprises at least one pyrolytic gas generator and at least one plasma generator.
  • the system further comprises a glass fiber spinning module.
  • the present invention is a unique method for recycling and decomposing objects and materials made of CFRP, carbon-fiber reinforced plastics, and GFRP, glass-fiber reinforced plastics, in an environmentally friendly and cost-effective way.
  • the method extracts the energy bound in the materials and converts it into hydrogen and recovered heating and is reproducing glass fiber.
  • the remaining residues contain only liquid carbon dioxide CO2. There will be no need for landfill of any residues.
  • CFRP and GFRP material e.g. wind blades are gasified and the glass fiber is reproduced.
  • the chemically energy bound to the material is converted into hydrogen and recovered heat.
  • the carbon dioxide formed in the process is taken care of before it reaches the atmosphere. Taking the use of this method to decompose CFRP and GFRP-scrap into account it gives a possible way to expand the availability to hydrogen as a replacement for fossil fuels.
  • the system for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP has all the above-mentioned advantages of the method.
  • Figure 1 is a flow diagram that shows different steps of the process according to one embodiment of the invention.
  • Figure 2 is a schematic drawing showing an example of the system for decomposing and recycling of objects containing CFRP and GFRP in a gasification plant according to the present invention.
  • the present invention is a unique method, that relates to the use of a flexible modular system for decomposing CFRP, carbon-fiber reinforced plastics, and GFRP, glass-fiber reinforced plastics, and reproduction of glass fiber, and recovery of the energy bound to the material in the form of hydrogen and heat, including: shredding module, loading device, pyrolytic gas generator and plasma gasification module, fiber spinning module, gas cleaning unit and units for concentration of hydrogen and for separation of hydrogen gas, carbon dioxide and combustible tailgas.
  • the shredding module should be understood as the shredder unit or the module for pretreatment in step (i).
  • the loading device should be understood as the loading system.
  • Plasma gasification module should be understood as the gasification module.
  • the gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator.
  • the fiber spinning module should be understood as the glass fiber spinning module.
  • the gas cleaning unit should be understood as the gas cleaning module.
  • the units for concentration of hydrogen and for separation of hydrogen gas, carbon dioxide and combustible tailgas should be understood as the water-gas-shift module and the separation module, respectively.
  • the method is based on a system comprising at least one shredder device or mill module, at least one loading device or loading module, at least one gasification module at least comprising one pyrolytic gas generator and one plasma generator, a glass fiber spinning module, a gas cooling module comprising cooling device with a heat recovery system, at least one gas cleaning module comprising at least one cleaning device, at least one water-gas-shift module with a heat recovery system for re-use in e.g. district heating networks and a separation unit for separation of combustible tailgas, hydrogen and carbon dioxide, which in turn is cooled into liquid status and stored for CCS treatment.
  • the method is designed to handle preferably CFRP and GFRP as feedstock.
  • the above paragraph should be understood as discussing the system being arranged for recycling of objects made of carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP) according to the disclosed method.
  • the at least one shredder device or mill module should be understood as the at least one of the shredder unit or the module for pretreatment of step (i).
  • CCS is meant carbon capture and storage.
  • the feedstock is partly gasified and in the plasma gasification module, that holds a very high temperature, >3000 °C, the feedstock (CFRP and GFRP) is completely decomposed into atomic level (plasma) and the module gives off a mix of carbon monoxide, hydrogen (Syngas) and molten glass.
  • the objective with the invention is therefore threefold: 1) decomposing of CFRP/GFRP materials and reproduction of glass fiber, 2) recovery of the energy bound in waste in the form of hydrogen and heat without emission to the air of any carbon dioxide, and 3) reduction of landfill.
  • the invention is based on a modular flexible system of container modules, hereinafter also called for modules, where every module has a specific task.
  • the modular construction based on standard containers of the system facilitates the transportation and assembly of the system and the process can be tailored to each customer's individual needs.
  • the modular concept also facilitates the redesign of the facility when demands are changing.
  • the invention is easy set up where the need is greatest, e.g. close to a wind turbine park.
  • the present disclosure relates to a, flexible modular system for the reproduction of glass fiber and production of district heating and hydrogen from organic material, which system comprises: a shredder unit 2, a loading system 3, at least one gasification module 4 comprising at least one pyrolytic gas generator, a spinning module 11 , a cleaning module 7 and a separation module 18.
  • the spinning module should be understood as the glass spinning module.
  • the cleaning module should be understood as the gas cleaning module.
  • the modules are connected to each other by means of an interface.
  • the interface in adjacent modules has same specifications and is connectable to the interface of the adjacent module.
  • the interface may comprise coupling means, connections for water, electric power, gases (compressed air, syngas or hydrogen) and communication. These are all standard couplings to facilitate the set up and upgrades of the system. Due to the fact that the modules can be easily connected to each other the system and method become flexible. The system can be placed and connected to a wind turbine park and thereby reduce the transport of scrapped wind blades to the recycling plant.
  • the method 100 and the process of the present invention is depicted in the flow chart in figure 1.
  • Scrap material containing CFRP and GFRP but also other kind of organic material could be treated, is transported to a facility or industrial plant and loaded to the system. If the material consists of large pieces, it should be crushed using a shredder unit to increase the homogeneity of the material to be treated. With higher homogeneity in the organic material, the entering of the atmospheric gases into the system can be controlled more easily.
  • the shredder module may be arranged for crumbling the CFRP/GFRP feedstock into pieces not bigger than 5 cm 3
  • the shredder module should be understood as the at least one of the shredder unit or the module for pretreatment of step (i).
  • the treated organic material is lead to a, well-known in the art, and therefor only briefly described here, pyrolytic and plasma gasification unit, that holds a very high temperature, >3000 °C, where the feedstock (CFRP and GFRP) is completely decomposed into atomic level, i.e. plasma.
  • the output from the module contains hydrogen and carbon monoxide (Syngas) and some traces of carbon dioxide and other chemical substances.
  • Syngas hydrogen and carbon monoxide
  • Non-gasified inorganic material from glass fibers is collected as molten glass.
  • the treated organic material should be understood as objects made of carbon-fiber reinforced plastics CFRP and glass-fiber reinforced plastics, GFRP, being pre-treated in at least one of a shredder unit or a module for pretreatment into a feedstock.
  • the pyrolytic and plasma gasification unit should be understood as the gasification module.
  • the gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator.
  • the feedstock may be partly gasified in the at least one pyrolytic gas generator and completely decomposed into atomic level, so-called plasma in the gasification module comprising the at least one plasma generator.
  • One embodiment of the invention is: the molten glass runs, from the unit for collection of molten glass, down into a spinning module reproducing glass fiber in a heated centrifuge with small holes from which the glass is forced out in thin fibers, due to the centrifugal force.
  • the fibers shaped are rapidly cooled and collected in bundles for further reuse.
  • Other embodiments for spinning fibers out of the molten glass is possible.
  • step (iv) i.e. collecting molten gas from the at least one gasification module in a heated zone.
  • Spinning module should be understood as the glass fiber spinning module.
  • Heated zone should be understood as the plasma generator 9.
  • the gas (Syngas) is lead to a first cooling module, a spray tower for a controlled cooling of the gas and condensing of inorganic substances.
  • the first cooling module should be understood as the gas cooling module.
  • the heat generated from this cooling process is extracted through a heat exchanger.
  • the heat from the cooling unit is supplied to a closed loop, which typically uses water steam as working fluid.
  • the steam from the heat exchanger is led to a water-gas-shift unit, where the carbon monoxide-part of the cooled gas from the plasma generator module is converted into hydrogen and carbon dioxide.
  • cooling unit is meant the gas cooling module.
  • plasma generator module is meant the plasma generator.
  • This water-gas-shift process is exothermic and generates energy that is added to the loop.
  • the steam from this process is led to a second heat exchanger where the steam is cooled and condensed to liquid state.
  • the heat from this heat exchanger could preferably deliver energy to a district heating network.
  • the liquid water is passing a hydraulic pump unit where the pressure is increased.
  • the high-pressure water is then pre-heated in a heat exchanger, connected to the mentioned water-gas-shift unit, and then led back to the above mentioned first cooling unit. In this way, the energy from the process is reused and total efficiency of the system is increased.
  • the loop should be understood as the closed loop.
  • the first cooling should be understood as the gas cooling module.
  • the cooling may be performed in the gas cooling module.
  • the series of filters may be comprised in the gas cleaning module.
  • the cleaned gas is lead into the above-mentioned water-gas-shift unit where carbon monoxide reacts with water over a catalytic material to produce hydrogen and carbon dioxide.
  • Hydrogen is then separated through an also, well-known in the art, stage of membrane filtration and/or with the use of pressure swing adsorption (PSA) where the gas is circulated to ensure a high and efficient yield of hydrogen.
  • PSA pressure swing adsorption
  • the carbon dioxide can be captured and deposited according to the well-known in the art CCS technology.
  • the invention actively reduces the amount of atmospheric carbon dioxide. Combustible rest gas, tailgas, is captured and used for heating of the spinning centrifuge.
  • the separation of hydrogen is performed by the separation module.
  • the separation module may be based on pressure swing adsorption (PSA) technology.
  • PSA pressure swing adsorption
  • CCS carbon capture and storage.
  • the hydrogen is compressed to be stored in a buffer.
  • the end product consists of pure hydrogen, suitable for process industries, produced from organic material.
  • the total efficiency can be very high and about 90 % of the energy bound in the CFRP and GFRP is converted to usable energy in the process in the form of heat suitable for district heating and as pure hydrogen.
  • the organic material comprises carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP).
  • CFRP carbon-fiber reinforced plastics
  • GFRP glass-fiber reinforced plastics
  • the system described above comprises container modules, hereinafter also called modules, wherein each module has its own technical task,
  • the container modules can be directly placed on the ground that has been prepared for the system and the system can be assembled onsite and can be in operation within short time.
  • FIG. 2 schematically shows the system 200 with a plasma gasification system according to one embodiment of the invention.
  • the system 200 comprises a set of modules, where each module has a specific task.
  • the modules may include control systems for power distribution and communication with the user and the different modules. These modules or sub-systems are commercially available and are not closely described herein.
  • the plasma gasification system should be understood as the gasification module.
  • the gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator.
  • the CFRP and GFRP material is fed into a shredder unit 1 where it is crushed to increase the homogeneity of the material to be treated.
  • the crushed material is lead into the gasification module 4 via a feeder unit 3.
  • the feedstock reacts with oxygen blown in from an oxygen generator 8.
  • the gasification module 4 may be a pyrolytic gasification module.
  • the feeder unit should be understood as the loading system.
  • the material from the gasification module 4 is pushed through the gas generator 9 and the thereby produced gas is lead to the next step of the process.
  • Glass from the gas generator 9 is kept molten and runs down to a spinning module at the bottom of the gasification module.
  • the spinning module consists of a centrifuge 10 with small holes the glass is forced through due to the centrifugal force as thin threads that are rapidly cooled in 11 and collected in bundles for further reuse.
  • the centrifuge is heated with a gas flame from the combustible rest components, tailgas, from the gas separation module where hydrogen and carbon dioxide are separated, the PSA module.
  • the gas generator is meant the plasma generator.
  • spinning module is meant the glass fiber spinning module.
  • PSA module is meant the separation module. “11” should be understood as the glass fiber spinning module 11.
  • Additional plasma generators may be incorporated in the system if required so that the total gasification and disassociation of remaining chemicals can be ensured.
  • the gasification module may comprise at least one plasma generator.
  • the gas is lead form the gas generator 9 to a, well-known in the art, cooling module 5.
  • the heat from the cooling unit is supplied to a closed loop, which typically uses water as working fluid.
  • the steam from the cooling unit is led into a, well-known in the art, water- gas-shift unit 14 where the carbon monoxide part of the cooled gas from the plasma generator is converted into hydrogen and carbon dioxide. This process is exothermic and generates energy that is added to the steam.
  • the steam from this process is led to a heat exchanger 17 where the steam is cooled and condensed to fluid status.
  • the heat from this heat exchanger could preferably deliver energy to a district heating network.
  • the hereby fluid water is passing a hydraulic pump 15 unit where the pressure is increased.
  • the high- pressure water is then pre-heated in a heat exchanger, connected to the mentioned water- gas-shift unit 17 and then led back to the above-mentioned first cooling unit 5. In this way, the total efficiency of the system is increased.
  • the cooling module should be understood as the gas cooling module.
  • the cooling unit should be understood as the gas cooling module.
  • district heating network is meant external heating purposes.
  • first cooling unit is meant the gas cooling unit.
  • Output from the first cooling unit 5 is condensed inorganic material, which is led to a container 13 and cooled and partially cleaned gas (Syngas).
  • the gas is led via a blower unit 6 to a, well- known in the art, cleaning module 7 comprising filters and a circulated cleaning liquid.
  • the first cooling unit should be understood as the gas cooling module.
  • the cleaning module should be understood as the gas cleaning module.
  • the gas obtained from the cleaning modules has a desired grade of purity
  • the gas is, via a compressor 16 fed to the above-mentioned water-gas-shift and hydrogen separation module 17 comprising a water-gas-shift reactor.
  • the water-gas-shift is an exothermic process and the excess heat is recovered in the above described heat exchanger unit.
  • the cleaning modules should be understood as the gas cleaning module.
  • the gas cleaning module may comprise a plurality of gas cleaning modules.
  • the water-gas-shift separation and hydrogen separation module should be understood as the water-gas-shift module and the separation module, respectively.
  • the gas entering the water-gas-shift and hydrogen separation unit is a clean gas (Syngas) comprising carbon monoxide (CO), hydrogen (H2), and carbon dioxide (CO2).
  • Syngas clean gas
  • the water-gas- shift reactors based on the above defined reaction and suitable for use in the present invention are well known in the art and are not therefore closely defined herein.
  • the water-gas-shift and hydrogen separation unit should be understood as the water-gas-shift module and the separation module.
  • the system may further comprise a pressure-swing-adsorption device 18 and a membrane separation device, as schematically shown in figure 2.
  • the hydrogen is separated for example by using a membrane, a technology which is well known in the art, and the mixed gases are re-circulated to enhance the output of hydrogen.
  • a membrane a technology which is well known in the art
  • other conventional technologies known in the art can be used to separate the hydrogen.
  • the hydrogen gas can be used in different industrial and fuel-cell applications and is a replacement to fossils fuels. Combustible rest products from the separation module, tailgas, is also reused for heating the glass spinning centrifuge.
  • the pressure-swing-adsorption device should be understood as the separation module.
  • the separation module may comprise a pressure-swing-adsorption device and/or a membrane separation device.
  • glass spinning centrifuge should be understood as the centrifuge of the glass fiber spinning module.
  • carbon dioxide When gasifying, e.g. reinforced plastics or other organic waste into hydrogen, carbon dioxide will be separated in the process as a secondary product. This separation makes it possible to capture the carbon dioxide in liquid form and deposit it, either pressurized in cylinders, or, if the proper infrastructure is available, in bedrock surrounding oil wells (CCS). Hence, the invention can actively reduce the amount of carbon dioxide in the atmosphere.
  • gasifying e.g. reinforced plastics or other organic waste into hydrogen
  • carbon dioxide will be separated in the process as a secondary product. This separation makes it possible to capture the carbon dioxide in liquid form and deposit it, either pressurized in cylinders, or, if the proper infrastructure is available, in bedrock surrounding oil wells (CCS).
  • CCS bedrock surrounding oil wells
  • CCS carbon capture and storage
  • the method according to the present invention may comprise different kind of chopper or shredder units, more than one plasma generator, mo re than one gasification module and more than one spinning module.
  • the system comprises at least one shredder unit, at least one gasification module as described above and a spinning module for reproduction of glass fiber.
  • the system further comprises at least one gas cleaning module with an energy recovery unit, but depending on the desired quality of the hydrogen more than one cleaning and energy recovery unit module may be incorporated to the system.
  • the system comprises at least one water-gas-shift and hydrogen separation module with an energy recovery unit.
  • the system can comprise several modules of the same or different kind.
  • the additional modules can be selected from the group consisting of a chopping/shredder module, gasification module, cleaning module, water-gas-shift and hydrogen separation module, hydrogen buffer module, carbon dioxide capturing module and a control module, in which the data system required to control the system are provided, all depending on the individual needs of the system.
  • the method is performed by a system comprising modules.
  • the shredder unit By different kinds of chopper or shredder units is meant the shredder unit.
  • more than one plasma generators is meant the plasma generator.
  • the gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator.
  • spinning module is meant the glass fiber spinning module.
  • chopping/shredder module is meant the shredder unit.
  • cleaning module is meant the gsa cleaning module.
  • water-gas-shift and hydrogen separation module is meant the water-gas-shift module and the separation module.

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Abstract

The disclosure is related to a method (200) for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, based on a modular system for the pre-treating the objects to a feedstock for the reproduction of glass fiber and production of hydrogen, carbon dioxide and heat, which are extracted from the feedstock material. There is also disclosed a system (100) being arranged for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, according to the method.

Description

METHOD AND SYSTEM FOR RECYCLING OBJECTS MADE OF CARBON-FIBER
REINFORCED PLASTICS AND GLASS-FIBER REINFORCED PLASTICS
TECHNICAL FIELD
The present disclosure is related to a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, and to a system for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP.
BACKGROUND ART
Carbon fiber reinforced plastics (CFRP) and glass fiber reinforced plastics (GFRP) are gaining ground in the lightweight construction industry. However, the increasing consumption of these plastics, not least in wind turbines, also means a larger amount of waste. Decomposing CFRP and GFRP is complex and costly due to the difficulty of separating the mixed materials. Many waste disposal companies have no way of disposing the composites in a professional manner. Shredding followed by landfill is the common way to apparently get rid of the waste. The increasing number of CFRP waste disposed of in landfills is creating environmental concerns due to the potential release of toxic by-products and the need for recycling. Landfill is nowadays very costly and causes serious environmental problems in itself and should therefore be avoided to largest possible extent.
Conventional incineration of these kind of plastics causes emission of carbon dioxide and a row of hazardous rest products from decomposition of complex epoxy resins, which should also be avoided. Experimental models for regaining especially CF (carbon fiber) from such waste are tested at the laboratory level, but they are very complex and have not reached the commercial level. The strength of the carbon fibers is also reduced when exposed to the rather high temperatures needed to decompose the epoxy resin so the benefits are limited. SUMMARY OF THE INVENTION
An object of the present disclosure is to provide a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP wherein some of the above-identified problems are mitigated or at least alleviated.
The present disclosure proposes a method for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, being based on a modular system for the pre-treating the objects to a feedstock for the reproduction of glass fiber and production of hydrogen, carbon dioxide and heat, which are extracted from the feedstock material. The method comprises the steps of:
(i) pre-treating the objects into a feedstock in at least one of shredder unit or module for pre-treatment,
(ii) feeding the feedstock by at least one loading system into at least one gasification module comprising at least one pyrolytic gas generator,
(iii) decomposing the feedstock in at least one gasification module comprising at least one plasma generator, producing gas out of the remaining from the pyrolytic gas generator,
(iv) collecting molten glass from the at least one gasification module in a heated zone,
(v) reproducing glass fiber from the molten glass by a spinning module,
(vi) heating the centrifuge of the spinning module by a gas flame,
(vii) cleaning and separating hydrogen, carbon dioxide and combustible tailgas from the gas-mix produced from the feedstock by a cleaning module and a separation module,
According to a further development, large objects like wind turbine blades and plastic boats, are pre-treated in a chopper before fed into the shredder unit.
According to a further development, the combustible tailgas is used for heating a centrifuge in the glass fiber spinning module.
According to a further development, the produced excess heat energy from the process is used for external heating purposes via the heat exchanger. According to a further development, in step (ii), the gasification module comprises at least one pyrolytic gas generator and at least one plasma generator.
According to a further development, in step (iii) the feedstock is partly gasified in the at least one pyrolytic gas generator and completely decomposed into atomic level, so-called plasma, in the gasification module comprising the at least one plasma generator producing gas out of the remaining from the pyrolytic gas generator.
According to claim 5, a system for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP according the method is proposed.
According to a further development, the gasification module comprises at least one pyrolytic gas generator and at least one plasma generator.
According to a further development, the system further comprises a glass fiber spinning module.
At least some of the embodiments have the following advantages. The present invention is a unique method for recycling and decomposing objects and materials made of CFRP, carbon-fiber reinforced plastics, and GFRP, glass-fiber reinforced plastics, in an environmentally friendly and cost-effective way. The method extracts the energy bound in the materials and converts it into hydrogen and recovered heating and is reproducing glass fiber. The remaining residues contain only liquid carbon dioxide CO2. There will be no need for landfill of any residues. The above-stated deficiencies and problems of the prior art methods are to a large extent eliminated with the present invention in which CFRP and GFRP material e.g. wind blades are gasified and the glass fiber is reproduced. The chemically energy bound to the material is converted into hydrogen and recovered heat. The carbon dioxide formed in the process is taken care of before it reaches the atmosphere. Taking the use of this method to decompose CFRP and GFRP-scrap into account it gives a possible way to expand the availability to hydrogen as a replacement for fossil fuels. The system for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP has all the above-mentioned advantages of the method.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a flow diagram that shows different steps of the process according to one embodiment of the invention. Figure 2 is a schematic drawing showing an example of the system for decomposing and recycling of objects containing CFRP and GFRP in a gasification plant according to the present invention.
DETAILED DESCRIPTION
The present invention is a unique method, that relates to the use of a flexible modular system for decomposing CFRP, carbon-fiber reinforced plastics, and GFRP, glass-fiber reinforced plastics, and reproduction of glass fiber, and recovery of the energy bound to the material in the form of hydrogen and heat, including: shredding module, loading device, pyrolytic gas generator and plasma gasification module, fiber spinning module, gas cleaning unit and units for concentration of hydrogen and for separation of hydrogen gas, carbon dioxide and combustible tailgas.
The above paragraph should be understood as discussing the system being arranged for recycling of objects made of carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP) according to the disclosed method. The shredding module should be understood as the shredder unit or the module for pretreatment in step (i). The loading device should be understood as the loading system. Plasma gasification module should be understood as the gasification module. The gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator. The fiber spinning module should be understood as the glass fiber spinning module. The gas cleaning unit should be understood as the gas cleaning module. The units for concentration of hydrogen and for separation of hydrogen gas, carbon dioxide and combustible tailgas should be understood as the water-gas-shift module and the separation module, respectively.
The method is based on a system comprising at least one shredder device or mill module, at least one loading device or loading module, at least one gasification module at least comprising one pyrolytic gas generator and one plasma generator, a glass fiber spinning module, a gas cooling module comprising cooling device with a heat recovery system, at least one gas cleaning module comprising at least one cleaning device, at least one water-gas-shift module with a heat recovery system for re-use in e.g. district heating networks and a separation unit for separation of combustible tailgas, hydrogen and carbon dioxide, which in turn is cooled into liquid status and stored for CCS treatment. The method is designed to handle preferably CFRP and GFRP as feedstock. The above paragraph should be understood as discussing the system being arranged for recycling of objects made of carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP) according to the disclosed method. The at least one shredder device or mill module should be understood as the at least one of the shredder unit or the module for pretreatment of step (i). By CCS is meant carbon capture and storage.
In the pyrolytic gas generator, the feedstock is partly gasified and in the plasma gasification module, that holds a very high temperature, >3000 °C, the feedstock (CFRP and GFRP) is completely decomposed into atomic level (plasma) and the module gives off a mix of carbon monoxide, hydrogen (Syngas) and molten glass.
The objective with the invention is therefore threefold: 1) decomposing of CFRP/GFRP materials and reproduction of glass fiber, 2) recovery of the energy bound in waste in the form of hydrogen and heat without emission to the air of any carbon dioxide, and 3) reduction of landfill.
The invention, the decomposing and recycling method, is based on a modular flexible system of container modules, hereinafter also called for modules, where every module has a specific task. The modular construction based on standard containers of the system facilitates the transportation and assembly of the system and the process can be tailored to each customer's individual needs.
The modular concept also facilitates the redesign of the facility when demands are changing. The invention is easy set up where the need is greatest, e.g. close to a wind turbine park.
The present disclosure relates to a, flexible modular system for the reproduction of glass fiber and production of district heating and hydrogen from organic material, which system comprises: a shredder unit 2, a loading system 3, at least one gasification module 4 comprising at least one pyrolytic gas generator, a spinning module 11 , a cleaning module 7 and a separation module 18.
The spinning module should be understood as the glass spinning module. The cleaning module should be understood as the gas cleaning module.
The modules are connected to each other by means of an interface. The interface in adjacent modules has same specifications and is connectable to the interface of the adjacent module. The interface may comprise coupling means, connections for water, electric power, gases (compressed air, syngas or hydrogen) and communication. These are all standard couplings to facilitate the set up and upgrades of the system. Due to the fact that the modules can be easily connected to each other the system and method become flexible. The system can be placed and connected to a wind turbine park and thereby reduce the transport of scrapped wind blades to the recycling plant.
The method 100 and the process of the present invention is depicted in the flow chart in figure 1. Scrap material containing CFRP and GFRP, but also other kind of organic material could be treated, is transported to a facility or industrial plant and loaded to the system. If the material consists of large pieces, it should be crushed using a shredder unit to increase the homogeneity of the material to be treated. With higher homogeneity in the organic material, the entering of the atmospheric gases into the system can be controlled more easily. The shredder module may be arranged for crumbling the CFRP/GFRP feedstock into pieces not bigger than 5 cm3
The shredder module should be understood as the at least one of the shredder unit or the module for pretreatment of step (i).
The treated organic material is lead to a, well-known in the art, and therefor only briefly described here, pyrolytic and plasma gasification unit, that holds a very high temperature, >3000 °C, where the feedstock (CFRP and GFRP) is completely decomposed into atomic level, i.e. plasma. The output from the module contains hydrogen and carbon monoxide (Syngas) and some traces of carbon dioxide and other chemical substances. Non-gasified inorganic material from glass fibers is collected as molten glass.
The treated organic material should be understood as objects made of carbon-fiber reinforced plastics CFRP and glass-fiber reinforced plastics, GFRP, being pre-treated in at least one of a shredder unit or a module for pretreatment into a feedstock. The pyrolytic and plasma gasification unit should be understood as the gasification module. The gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator. The feedstock may be partly gasified in the at least one pyrolytic gas generator and completely decomposed into atomic level, so-called plasma in the gasification module comprising the at least one plasma generator.
One embodiment of the invention is: the molten glass runs, from the unit for collection of molten glass, down into a spinning module reproducing glass fiber in a heated centrifuge with small holes from which the glass is forced out in thin fibers, due to the centrifugal force. The fibers shaped are rapidly cooled and collected in bundles for further reuse. Other embodiments for spinning fibers out of the molten glass is possible.
The above paragraph should be understood as step (iv), i.e. collecting molten gas from the at least one gasification module in a heated zone. Spinning module should be understood as the glass fiber spinning module. Heated zone should be understood as the plasma generator 9.
The gas (Syngas) is lead to a first cooling module, a spray tower for a controlled cooling of the gas and condensing of inorganic substances.
The first cooling module should be understood as the gas cooling module.
After cooling of the gas, the heat generated from this cooling process is extracted through a heat exchanger. The heat from the cooling unit is supplied to a closed loop, which typically uses water steam as working fluid. The steam from the heat exchanger is led to a water-gas-shift unit, where the carbon monoxide-part of the cooled gas from the plasma generator module is converted into hydrogen and carbon dioxide.
By cooling unit is meant the gas cooling module. By plasma generator module is meant the plasma generator.
This water-gas-shift process is exothermic and generates energy that is added to the loop. The steam from this process is led to a second heat exchanger where the steam is cooled and condensed to liquid state. The heat from this heat exchanger could preferably deliver energy to a district heating network. The liquid water is passing a hydraulic pump unit where the pressure is increased. The high-pressure water is then pre-heated in a heat exchanger, connected to the mentioned water-gas-shift unit, and then led back to the above mentioned first cooling unit. In this way, the energy from the process is reused and total efficiency of the system is increased.
The loop should be understood as the closed loop. The first cooling should be understood as the gas cooling module.
When cooling and cleaning of the gas (Syngas) is terminated and water-soluble elements are washed out, depending on the properties of the organic material and the composition of the chemicals, the gas is lead through a series of filters to even further ensure the purity of the gas.
The cooling may be performed in the gas cooling module. The series of filters may be comprised in the gas cleaning module.
The cleaned gas is lead into the above-mentioned water-gas-shift unit where carbon monoxide reacts with water over a catalytic material to produce hydrogen and carbon dioxide.
CO + H2O => co2 + H2. Hydrogen is then separated through an also, well-known in the art, stage of membrane filtration and/or with the use of pressure swing adsorption (PSA) where the gas is circulated to ensure a high and efficient yield of hydrogen. Through the separation, the carbon dioxide can be captured and deposited according to the well-known in the art CCS technology. Through the deposit of carbon dioxide, the invention actively reduces the amount of atmospheric carbon dioxide. Combustible rest gas, tailgas, is captured and used for heating of the spinning centrifuge.
The separation of hydrogen is performed by the separation module. The separation module may be based on pressure swing adsorption (PSA) technology. By CCS is meant carbon capture and storage.
Finally, the hydrogen is compressed to be stored in a buffer. The end product consists of pure hydrogen, suitable for process industries, produced from organic material. The total efficiency can be very high and about 90 % of the energy bound in the CFRP and GFRP is converted to usable energy in the process in the form of heat suitable for district heating and as pure hydrogen.
The organic material comprises carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP).
The system described above comprises container modules, hereinafter also called modules, wherein each module has its own technical task,
On the industrial site and place for use of the system, the container modules can be directly placed on the ground that has been prepared for the system and the system can be assembled onsite and can be in operation within short time.
Figure 2 schematically shows the system 200 with a plasma gasification system according to one embodiment of the invention. The system 200 comprises a set of modules, where each module has a specific task. The modules may include control systems for power distribution and communication with the user and the different modules. These modules or sub-systems are commercially available and are not closely described herein.
The plasma gasification system should be understood as the gasification module. The gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator.
The CFRP and GFRP material is fed into a shredder unit 1 where it is crushed to increase the homogeneity of the material to be treated. The crushed material is lead into the gasification module 4 via a feeder unit 3. In the gasification unit the feedstock reacts with oxygen blown in from an oxygen generator 8. The gasification module 4 may be a pyrolytic gasification module.
The feeder unit should be understood as the loading system.
The material from the gasification module 4 is pushed through the gas generator 9 and the thereby produced gas is lead to the next step of the process. Glass from the gas generator 9 is kept molten and runs down to a spinning module at the bottom of the gasification module. The spinning module consists of a centrifuge 10 with small holes the glass is forced through due to the centrifugal force as thin threads that are rapidly cooled in 11 and collected in bundles for further reuse. The centrifuge is heated with a gas flame from the combustible rest components, tailgas, from the gas separation module where hydrogen and carbon dioxide are separated, the PSA module.
By the gas generator is meant the plasma generator. By spinning module is meant the glass fiber spinning module. By PSA module is meant the separation module. “11” should be understood as the glass fiber spinning module 11.
Additional plasma generators may be incorporated in the system if required so that the total gasification and disassociation of remaining chemicals can be ensured.
The above paragraph should be understood as the gasification module may comprise at least one plasma generator.
The gas is lead form the gas generator 9 to a, well-known in the art, cooling module 5. The heat from the cooling unit is supplied to a closed loop, which typically uses water as working fluid. The steam from the cooling unit is led into a, well-known in the art, water- gas-shift unit 14 where the carbon monoxide part of the cooled gas from the plasma generator is converted into hydrogen and carbon dioxide. This process is exothermic and generates energy that is added to the steam. The steam from this process is led to a heat exchanger 17 where the steam is cooled and condensed to fluid status. The heat from this heat exchanger could preferably deliver energy to a district heating network. The hereby fluid water is passing a hydraulic pump 15 unit where the pressure is increased. The high- pressure water is then pre-heated in a heat exchanger, connected to the mentioned water- gas-shift unit 17 and then led back to the above-mentioned first cooling unit 5. In this way, the total efficiency of the system is increased.
The cooling module should be understood as the gas cooling module. The cooling unit should be understood as the gas cooling module. By district heating network is meant external heating purposes. By first cooling unit is meant the gas cooling unit.
Output from the first cooling unit 5 is condensed inorganic material, which is led to a container 13 and cooled and partially cleaned gas (Syngas). The gas is led via a blower unit 6 to a, well- known in the art, cleaning module 7 comprising filters and a circulated cleaning liquid.
The first cooling unit should be understood as the gas cooling module. The cleaning module should be understood as the gas cleaning module.
When the gas obtained from the cleaning modules has a desired grade of purity the gas is, via a compressor 16 fed to the above-mentioned water-gas-shift and hydrogen separation module 17 comprising a water-gas-shift reactor. The water-gas-shift is an exothermic process and the excess heat is recovered in the above described heat exchanger unit.
The cleaning modules should be understood as the gas cleaning module. The gas cleaning module may comprise a plurality of gas cleaning modules. The water-gas-shift separation and hydrogen separation module should be understood as the water-gas-shift module and the separation module, respectively.
The gas entering the water-gas-shift and hydrogen separation unit is a clean gas (Syngas) comprising carbon monoxide (CO), hydrogen (H2), and carbon dioxide (CO2). The water-gas- shift reactors based on the above defined reaction and suitable for use in the present invention are well known in the art and are not therefore closely defined herein.
The water-gas-shift and hydrogen separation unit should be understood as the water-gas-shift module and the separation module.
The system may further comprise a pressure-swing-adsorption device 18 and a membrane separation device, as schematically shown in figure 2. After the shift reaction, the hydrogen is separated for example by using a membrane, a technology which is well known in the art, and the mixed gases are re-circulated to enhance the output of hydrogen. Also, other conventional technologies known in the art can be used to separate the hydrogen. The hydrogen gas can be used in different industrial and fuel-cell applications and is a replacement to fossils fuels. Combustible rest products from the separation module, tailgas, is also reused for heating the glass spinning centrifuge.
The pressure-swing-adsorption device should be understood as the separation module. The separation module may comprise a pressure-swing-adsorption device and/or a membrane separation device. By glass spinning centrifuge should be understood as the centrifuge of the glass fiber spinning module.
When gasifying, e.g. reinforced plastics or other organic waste into hydrogen, carbon dioxide will be separated in the process as a secondary product. This separation makes it possible to capture the carbon dioxide in liquid form and deposit it, either pressurized in cylinders, or, if the proper infrastructure is available, in bedrock surrounding oil wells (CCS). Hence, the invention can actively reduce the amount of carbon dioxide in the atmosphere.
By CCS is meant carbon capture and storage.
The method according to the present invention may comprise different kind of chopper or shredder units, more than one plasma generator, mo re than one gasification module and more than one spinning module. However, the system comprises at least one shredder unit, at least one gasification module as described above and a spinning module for reproduction of glass fiber. The system further comprises at least one gas cleaning module with an energy recovery unit, but depending on the desired quality of the hydrogen more than one cleaning and energy recovery unit module may be incorporated to the system. Further, the system comprises at least one water-gas-shift and hydrogen separation module with an energy recovery unit. The system can comprise several modules of the same or different kind. The additional modules can be selected from the group consisting of a chopping/shredder module, gasification module, cleaning module, water-gas-shift and hydrogen separation module, hydrogen buffer module, carbon dioxide capturing module and a control module, in which the data system required to control the system are provided, all depending on the individual needs of the system.
The above paragraph should be understood as discussing the system being arranged for recycling of objects made of carbon-fiber reinforced plastics (CFRP) and glass-fiber reinforced plastics (GFRP) according to the disclosed method.
By the above paragraph is meant that the method is performed by a system comprising modules. The above paragraph describes an example if the system. By different kinds of chopper or shredder units is meant the shredder unit. By more than one plasma generators is meant the plasma generator. The gasification module may comprise at least one pyrolytic gas generator and at least one plasma generator. By spinning module is meant the glass fiber spinning module. By chopping/shredder module is meant the shredder unit. By cleaning module is meant the gsa cleaning module. By water-gas-shift and hydrogen separation module is meant the water-gas-shift module and the separation module.
In the above description particular embodiments of the present invention have been disclosed. Other modifications of the present invention shall be apparent to those skilled in the art from the teachings herein within the scope of the following claims.

Claims

1. Method (100) for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, is based on a modular system for the pre-treating the objects to a feedstock for the reproduction of glass fiber and production of hydrogen, carbon dioxide and heat, which are extracted from the feedstock material, the method comprises the steps of:
(i) pre-treating (110) the objects into a feedstock in at least one of a shredder unit (2) or a module for pretreatment,
(ii) feeding (120) the feedstock by at least one loading system (3) into at least one gasification module (4) comprising at least one pyrolytic gas generator,
(iii) decomposing (130) the feedstock in the at least one gasification module (4) comprising at least one plasma generator, producing gas out of the remaining from the pyrolytic gas generator (9),
(iv) collecting (140) molten glass from the at least one gasification module (4) in a heated zone,
(v) reproducing (150) glass fiber from the molten glass by a glass fiber spinning module (11 ),
(vi) heating (160) the centrifuge (10) of the spinning module (11 ) by a gas flame,
(vii) cleaning and separating (170) hydrogen, carbon dioxide and combustible tailgas from the gas-mix produced from the feedstock by a gas cleaning module (7) and a separation module (18).
2. The method (100) according to claim 1 , wherein large objects like wind turbine blades and plastic boats, are pre-treated in a chopper (1 ) before fed into the shredder unit (2).
3. The method (100) according to any of the preceding claims, wherein the combustible tailgas is used for heating a centrifuge in the glass fiber spinning module (10).
4. The method (100) according to any of the preceding claims, wherein the produced excess heat energy from the process is used for external heating purposes via the heat exchanger (17).
5. The method (100) according to any of the preceding claims, wherein in step (ii), the gasification module comprises at least one pyrolytic gas generator (4) and at least one plasma generator (9).
6. The method (100) according to any of the preceding claims, wherein in step (iii) the feedstock is partly gasified in the at least one pyrolytic gas generator (4) and completely decomposed into atomic level, so-called plasma, in the gasification module comprising the at least one plasma generator (9) producing gas out of the remaining from the pyrolytic gas generator (4).
7. System (200) comprising a shredder unit (2), a loading system (3), a gasification module (4), a heated zone for collection of molten glass (9) , a gas cleaning module (7) and a separation module (18), wherein said system is arranged for recycling objects made of carbon-fiber reinforced plastics, CFRP, and glass-fiber reinforced plastics, GFRP, according to the method of any of claims 1 to 6.
8. The system (200) according to claim 7, wherein the gasification module comprises at least one pyrolytic gas generator (4) and at least one plasma generator (9).
9. The system (200) according to any of claims 7 or 8, wherein the system further comprises a glass fiber spinning module (11).
PCT/SE2023/050268 2022-03-28 2023-03-24 Method and system for recycling objects made of carbon-fiber reinforced plastics and glass-fiber reinforced plastics WO2023191689A1 (en)

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JPH0640735A (en) * 1992-07-21 1994-02-15 Nippon Electric Glass Co Ltd Treatment of waste frp
CN108997609A (en) * 2018-08-15 2018-12-14 冀州中意复合材料股份有限公司 A kind of recovery method of the waste and scrap generated in fibre glass product manufacture production process
US20200140315A1 (en) * 2018-11-05 2020-05-07 University Of Tennessee Research Foundation Molten salt assisted pyrolysis recycling of glass fiber reinforced polymer composites
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