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Production of Phenol Formaldehyde Resins from Recycled Composite Materials

                                            DOE Grant No. DE-FG03-00ER8611

                                                          Amount:  $500,000

The recycling of thermoset composite materials produces valuable fibers and a liquid hydrocarbon byproduct.  The liquid hydrocarbons constitute a potential hazardous wastestream that could prevent the recycling process from being adopted on a large scale by government and industrial users.  This project addresses the conversion of these liquid hydrocarbons into useful products.  Phase I showed that the phenol-rich liquid hydrocarbons could effectively be used to prepare phenol formaldehyde resins with properties equivalent to commercial resins used in the wood products industry.  Reclaimed carbon fibers were characterized and shown to have near virgin properties.  An initial economic analysis demonstrated a 34% internal rate of return, which should be attractive to potential investors.  Phase II will scale up the processes for recycling and phenolic resin production, determine variabilities in the products from those processes, and identify market requirements for their reuse.  Equipment and plant layout for a commercial recycling operation with phenolic resin production will be specified and the economics of the operation determined. 

Commercial Applications and Other Benefits as described by the awardee: Introduction of scrap composite materials into landfills is a waste of valuable resources and an insult  to the environment. As more composites are introduced in such high-volume applications as automotive components, aerospace, and sporting goods, a recycling process will be greatly needed. The process being investigated will economically produce valuable materials from composite waste and keep them from the Nation’s landfills.