Comparative LCA Analysis of Selected Recycling Methods for Carbon Fibers and Socio-Economic Analysis
Abstract
:1. Introduction
2. Materials and Methods
2.1. Goal and Scope Definition
- To evaluate the potential environmental impact and identify key drivers for the developed recycling processes (Scenario 1 and 2);
- To compare the recycling of the secondary carbon fiber with the primary production.
2.2. Life Cycle Inventory (LCI)
2.3. Life Cycle Impact Assessment (LCIA)
3. Results
4. Socio-Economic Analysis
Carbon Fiber Market
5. Discussion
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Recycling Method | Description | Key Limitations | Source |
---|---|---|---|
Mechanical Recycling | Grinding/shredding CFRP into small particles for fillers or low-grade reuse | Fibers are short and damaged; Loss of mechanical properties; Low-value recycled product | [15] |
Thermal Recycling | Pyrolysis or fluidized bed to burn off resin and recover fibers | High energy demand; Potential fiber surface degradation; Emission of VOCs without control | [16] |
Chemical Recycling (Solvolysis) | Use of solvents under heat/pressure to dissolve matrix and recover clean fibers | Complex solvent handling; High process cost and time; Challenges in scaling up and purifying recovered oligomers | [17] |
Name of Input/Output | Amount | Unit |
---|---|---|
Inputs | ||
Wasted carbon fiber component (B&T Composites) | 1.44 | kg |
Transport of wasted carbon fiber component, lorry 16–32, Euro 5 (100 km) | 1.44 × 102 | kgkm |
Solvent (closed looped circulation) | 5.74 | kg |
Ethylene glycol | 8.97 × 10−1 | kg |
Potassium Hydroxide | 8.97 × 10−2 | kg |
Electricity (low voltage, at grid, Poland) | 2.16 | kWh |
Outputs | ||
Reclaimed carbon fiber | 1.00 | kg |
Solvent (closed looped circulation) | 5.74 | kg |
Liquid waste | 9.87 × 10−1 | kg |
Name of Input/Output | Amount | Unit |
---|---|---|
Inputs | ||
Wasted carbon fiber component (B&T Composites) | 1.67 | kg |
Transport of wasted carbon fiber component, lorry 16–32, Euro 5 (100 km) | 1.67 × 102 | kgkm |
Nitric Acid 65%/H2O2 30% (closed looped circulation) | 2.77 × 101 | kg |
Nitrogen gas | 1.63 × 101 | kg |
Acetone | 4.00 | kg |
Electricity (low voltage, at grid, Poland) | 7.17 × 101 | kWh |
Outputs | ||
Reclaimed carbon fiber | 1.00 | kg |
NOX gasses that enter the wet scrubber | 6.83 | kg |
NOX gasses that escape the wet scrubber | 5.00 | kg |
Wet scrubbing solution (HNO3) | 1.83 | kg |
Nitric Acid/Nitrous Acid/Resin solution/H2O2 (closed looped circulation) | 2.08 × 101 | kg |
Nitrogen gas | 1.63 × 101 | kg |
Acetone/resin residuals | 4.00 | kg |
Impact Category | Scenario 1 | Scenario 2 | Scenario 3 (Virgin) | |||
---|---|---|---|---|---|---|
mPt | % | mPt | % | mPt | % | |
Single Score | 3.31 × 10−1 | 100% | 2.14× 101 | 100% | 5.85 | 100% |
Climate change | 1.43 × 10−1 | 43% | 2.38 | 11% | 2.27 | 39% |
Resource use, fossils | 8.77 × 10−2 | 27% | 1.36 | 6% | 1.25 | 21% |
Particulate matter | 2.09 × 10−2 | 6% | 1.38 | 6% | 9.24 × 10−1 | 16% |
Ecotoxicity, freshwater | 1.79 × 10−2 | 5% | 8.24 × 10−2 | 0.4% | 6.21 × 10−2 | 1.1% |
Acidification | 1.58 × 10−2 | 5% | 3.41 | 16% | 5.02 × 10−1 | 9% |
Photochemical ozone formation | 1.58 × 10−2 | 5% | 6.85 | 32% | 2.71 × 10−1 | 5% |
Water use | 1.07 × 10−2 | 3% | 1.60 × 10−1 | 0.7% | 1.04 × 10−1 | 2% |
Eutrophication, terrestrial | 6.50 × 10−3 | 2% | 2.38 | 11% | 1.55 × 10−1 | 3% |
Eutrophication, marine | 4.20 × 10−3 | 1.3% | 3.04 | 14% | 1.03 × 10−1 | 2% |
Human toxicity, non-cancer | 2.70 × 10−3 | 0.8% | 1.45 × 10−1 | 0.7% | 7.58 × 10−2 | 1.3% |
Eutrophication, freshwater | 2.20 × 10−3 | 0.7% | 1.67 × 10−1 | 0.8% | 5.53 × 10−2 | 0.9% |
Ionizing radiation | 1.30 × 10−3 | 0.4% | 1.96 × 10−2 | 0.1% | 2.86 × 10−2 | 0.5% |
Land use | 9.00 × 10−4 | 0.3% | 1.45 × 10−2 | 0.1% | 2.13 × 10−2 | 0.4% |
Human toxicity, cancer | 8.00 × 10−4 | 0.2% | 3.63 × 10−2 | 0.2% | 1.89 × 10−2 | 0.3% |
Resource use, minerals and metals | 4.00 × 10−4 | 0.1% | 3.60 × 10−3 | 0.02% | 5.60 × 10−3 | 0.1% |
Ozone depletion | 1.00 × 10−4 | 0.03% | 7.00 × 10−4 | 0.00% | 5.00 × 10−4 | 0.0% |
Impact Category | Unit | Scenario 1 | Scenario 2 | Scenario 3 (Virgin) |
---|---|---|---|---|
Acidification | mol H+ eq | 1.42 × 10−2 | 3.06 | 4.50 × 10−1 |
Climate change | kg CO2 eq | 5.12 | 8.54 × 101 | 8.16 × 101 |
Ecotoxicity, freshwater | CTUe | 5.30 × 101 | 2.43 × 102 | 1.83 × 102 |
Particulate matter | disease inc. | 1.39 × 10−7 | 9.17 × 10−6 | 6.14 × 10−6 |
Eutrophication, marine | kg N eq | 2.80 × 10−3 | 2.01 | 6.77 × 10−2 |
Eutrophication, freshwater | kg P eq | 1.00 × 10−4 | 9.60 × 10−3 | 3.20 × 10−3 |
Eutrophication, terrestrial | mol N eq | 3.08 × 10−2 | 1.14 × 101 | 7.40 × 10−1 |
Human toxicity, cancer | CTUh | 6.48 × 10−10 | 2.94 × 10−8 | 1.53 × 10−8 |
Human toxicity, non-cancer | CTUh | 1.89 × 10−8 | 1.01 × 10−6 | 5.30 × 10−7 |
Ionizing radiation | kBq U-235 eq | 1.13 × 10−1 | 1.65 | 2.41 |
Land use | Pt | 9.19 | 1.50 × 102 | 2.20 × 102 |
Ozone depletion | kg CFC11 eq | 8.30 × 10−8 | 5.81 × 10−7 | 4.15 × 10−7 |
Photochemical ozone formation | kg NMVOC eq | 1.35 × 10−2 | 5.86 | 2.32 × 10−1 |
Resource use, fossils | MJ | 6.86 × 101 | 1.06 × 103 | 9.76 × 102 |
Resource use, minerals and metals | kg Sb eq | 3.37 × 10−7 | 3.03 × 10−6 | 4.72 × 10−6 |
Water use | m3 depriv. | 1.44 | 2.15 × 101 | 1.40 × 101 |
Category | Impact/Description |
---|---|
Job creation | Recycling generates employment in sectors such as collection, processing, and the production of new products from secondary raw materials. |
Increase in economic competitiveness | The use of secondary raw materials reduces production costs and makes the economy less dependent on the import of primary raw materials. |
Innovations in recycling technology drive the development of new industrial sectors. | |
Costs and savings related to recycling | Costs of selective waste collection systems and processing technologies. |
Savings resulting from a reduced need for waste landfilling and lower costs of extracting natural resources. | |
Social environmental awareness | Environmental education and changing consumption habits. |
Social campaigns and local government initiatives promoting waste segregation. | |
Health benefits | Reduced environmental pollution improves air, water, and soil quality. |
Lower emissions of harmful substances decrease the incidence of pollution-related diseases. | |
Impact on quality of life | Recycling promotes a cleaner environment and reduces the number of illegal dumpsites. |
Increased availability of secondary raw materials supports the development of a circular economy. | |
Environmental awareness | Increasing environmental awareness influences the formation of more sustainable consumption habits, promotes waste segregation, and encourages responsible resource management. Environmental education and social campaigns inspire people to take everyday actions for environmental protection, such as reducing plastic use, reusing products, or choosing local and eco-friendly goods. Greater awareness makes society more likely to demand systemic change, support pro-environmental initiatives, and pressure companies and institutions to adopt more sustainable strategies. In the long run, this leads to improved quality of life, reduced pollution, and healthier ecosystems, benefiting both people and the planet. |
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Poranek, N.; Pikoń, K.; Generowicz-Caba, N.; Mańka, M.; Kulczycka, J.; Marinis, D.; Farsari, E.; Amanatides, E.; Lewandowska, A.; Sajdak, M.; et al. Comparative LCA Analysis of Selected Recycling Methods for Carbon Fibers and Socio-Economic Analysis. Materials 2025, 18, 2660. https://doi.org/10.3390/ma18112660
Poranek N, Pikoń K, Generowicz-Caba N, Mańka M, Kulczycka J, Marinis D, Farsari E, Amanatides E, Lewandowska A, Sajdak M, et al. Comparative LCA Analysis of Selected Recycling Methods for Carbon Fibers and Socio-Economic Analysis. Materials. 2025; 18(11):2660. https://doi.org/10.3390/ma18112660
Chicago/Turabian StylePoranek, Nikolina, Krzysztof Pikoń, Natalia Generowicz-Caba, Maciej Mańka, Joanna Kulczycka, Dimitrios Marinis, Ergina Farsari, Eleftherios Amanatides, Anna Lewandowska, Marcin Sajdak, and et al. 2025. "Comparative LCA Analysis of Selected Recycling Methods for Carbon Fibers and Socio-Economic Analysis" Materials 18, no. 11: 2660. https://doi.org/10.3390/ma18112660
APA StylePoranek, N., Pikoń, K., Generowicz-Caba, N., Mańka, M., Kulczycka, J., Marinis, D., Farsari, E., Amanatides, E., Lewandowska, A., Sajdak, M., Werle, S., & Sobek, S. (2025). Comparative LCA Analysis of Selected Recycling Methods for Carbon Fibers and Socio-Economic Analysis. Materials, 18(11), 2660. https://doi.org/10.3390/ma18112660