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Composite materials play an important role in the aerospace, automotive and renewable energy industries due to their numerous advantages, such as being lightweight and durable. However, as demand for composites increases, so does the amount of waste that they generate, with the end-of-life solutions having limited effectiveness and sustainability.
© Rene Notenbomer / Shutterstock
Industries are being urged to adopt a more sustainable operating model to reduce the impact of composite waste disposal on the environment and avoid increasing the pressure on landfill sites.
Composites play a crucial role in the aerospace industry due to their mechanical, thermal and environmental properties. The weight factor is important in aerospace applications, where composites provide an excellent strength-to-weight ratio compared with metals. In addition, they offer increased resistance against corrosion, enhanced fire resistance and a greater ability over other materials to manufacture components with complex shapes.
The growth of glass fibre and carbon fibre has enabled significant changes in the aerospace industry, as scientists have created new innovations. Composite materials are used extensively in aircraft, including the Eurofighter, for the forward fuselage, wing skins and rudder, while toughened epoxy skin constitutes around 75% of the exterior area. The Boeing 787 used up to 50% carbon fibre-reinforced plastic materials in its body structure.
Initially, composites were used in only the aircrafts’ secondary structure, but over time, their use in the primary structure, including the wings and fuselage, has significantly increased. Their diversified use has generated more waste materials.
The worldwide demand for carbon fibres increased between 2016 and 2022 from 63,500 tonnes to 117,000 tonnes, representing an annual growth of 8%. The aviation sector alone is expected to generate 500,000 tonnes of CFRP waste by 2050 if the growth continues at its current rate.
Composite waste must be segregated, collected and disposed of safely by law to protect the environment. Green campaigners are urging governments worldwide to devise more eco-friendly and cost-effective ways of disposing of the waste. It shouldn’t be incinerated, as carbon fibres carry a risk of oxidation and defibrillation, breaking down into fibres with a smaller diameter that can create carcinogenic emissions. They can also cause a short circuit in the incinerator’s electric flue gas filters. While composite waste can be sent to landfill sites.
In the West Midlands, the pioneering Gen 2 Carbon recycler plant dries out the carbon fibre and converts it into a range of Carbiso products, including non-woven mats and chopped or milled fibre.
Composites are also being used more in the wind turbine industry. According to scientists, the sector will produce at least 340,000 tonnes of carbon composite and glass fibre waste by 2050 if it continues to grow at the current rate. However, with the global capacity for recycling composite waste currently being around 100,000 tonnes annually, it won’t be able to cope with the increasing demand unless action is taken.
The wind energy industry has grown rapidly in recent years. Data from 2021 revealed the total amount of wind power generated globally by turbines totalled 837 gigawatts, with 93% generated onshore and the remainder offshore. This was distributed mainly to the United States, China, Germany, India and the UK.
When it comes to renewable energy sources, wind power has one of the most significant growths, according to the Global Wind Energy Council. The number of new installations increased by a massive 53% between 2020 and 2021 alone.
China has been the world leader in terms of wind energy production since 2010 and began investing significantly in waste disposal improvements in 2016. However, China alone is expected to generate 74,000 tonnes of composites waste between 2035 and 2044 and 36% of this will be sent to landfill unless something changes.
Scientists have predicted an “environmental crisis” in view of the shortfall in recycling facilities if this level of growth continues until 2050. A study published in Science Direct suggests a new strategy to integrate a circular economy in the production of wind turbine blades is the solution.
Disposing of the composite waste is uniquely challenging because the fibres contain resins and can take thousands of years to fully break down. Some also contain toxic substances and if disposed of unsafely, they can leak into soil and groundwater, adversely impacting nearby residents.
China has responded to concerns by launching a new technological strategy to convert waste to energy. Currently, it is the world’s leading country in terms of waste-to-energy conversion, with more than 300 plants operating nationwide.
Composites such as glass fibre and carbon fibre are largely used in the automotive industry, with data revealing the sector uses almost 4% of the world’s carbon fibre. Composite materials are ideal because they offer superior strength and durability, while being light and requiring almost zero maintenance.
The Composites Forecasts and Consulting study suggested the total weight of carbon composites being used in vehicle manufacture in 2022 exceeded 45,360 metric tonnes, up from 7,486 metric tonnes in 2013. However, as with other industries, there has been limited success when it comes to recycling composite waste from the sector.
In 2023, Canadian vehicle manufacturer Trouvé announced its plans to launch the world’s first full-scale recycling initiative for electric vehicles. All the carbon fibre structures of the Trouvé-EV are to be 100% recyclable, while the company’s research arm is currently improving fibreglass recycling methods, such as incineration and grinding.
The remnants will be used in different end products, such as adding recycled glass fibres to asphalt and concrete. The company estimates there will be potential growth in this technology in the future as the use of composites increases.
For anyone working with composites, keeping the air clean to prevent health issues is of the utmost importance, as the dust can cause serious problems such as irritation of the respiratory tract, occupational asthma and lung-related diseases.
In manual operations, including the finishing of composite parts, it is crucial to protect workers from dust inhalation using dust extraction systems to ensure their safety, reduce sickness and comply with the law, such as the COSHH 2002 regulations.
To combat the risks, AirBench provides composite dust extraction solutions in the shape of downdraught benches, dust control booths and cross-draught systems. To ensure a safe working environment for employees; hazardous dust particles are captured at source, before being drawn into integral filters without operator intervention. The waste can be safely disposed of afterwards: our AirBenches are designed to reduce energy use and improve efficiency too.
AirBench Ltd are the UK’s leading manufacturer of downdraught benches and cross draught extraction systems. We have more than 10,000 extraction systems in service in the UK and overseas. Along with our range of coolant mist filters and air cleaning systems, we are actively helping businesses across many industries solve their workplace dust and fume issues.
If you'd like to try an AirBench product for FREE simply book a demo and we'll bring one to you.
If you’d like to try an AirBench product for FREE simply book a demo and we’ll bring one to you.