Libro blanco de sostenibilidad en los materiales compuestos

La prioridad durante los últimos 40 años en el área de materiales compuestos ha sido:

El desarrollo de nuevos materiales estructurales
Aplicaciones estructurales en diversas industrias
Desarrollo de tecnologías de fabricación
Nuevos métodos de cálculo y diseño
Métodos de inspección y control de calidad

Nunca se ha considerado la gestión de desechos de fabricación, final del tiempo de vida de la estructura o circularidad de los materiales ... show more

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CAPITULO 24: LEGISLACIÓN ACTUAL EN ESPAÑA Y UE: PRESENTE Y FUTURO
T. López

libro-blanco-materiales-compuestos (2024). 59

Abstract
Los residuos procedentes de los materiales compuestos están regulados por la normativa básica de residuos (Directiva Marco y normativas asociadas a la misma y sus trasposiciones), no existiendo actualmente una legislación específica para ellos como existe para determinados tipos de residuos. En lo que respecta a su composición, es la normativa relativa al registro, la evaluación, la autorización y la restricción de las sustancias y preparados químicos la que los regula. La clasificación de los residuos, según la Lista Europea de Residuos (códigos LER), es fundamental para asegurar una correcta gestión así como interpretación de las regulaciones aplicables. Una correcta identificación como no residuo después de una operación de valorización o conseguir las consideraciones de “subproducto” y/o “fin de condición de residuo” si resulta necesario para dejar de tratarlos como tales, es fundamental para lograr un ecosistema adecuado que propicie el reciclado, por lo que hay que abordar este camino en los próximos años por parte de fabricantes y recicladores y contar con el apoyo de la administración para agilizar dichos trámites. El contexto actual y futuro contribuye a potenciar el reciclaje de estos materiales, ejemplo de ello son las políticas y estrategias ambientales en curso y futuras; como la estrategía europea del plástico, los planes de economía circular de las distintas administraciones, los compromisos de sectores industriales como el eólico, así como las ayudas públicas dirigidas a mejorar la circularidad de los materiales como las recogidas a nivel estatal en el Plan de Recuperación y Resiliencia. Asimismo, las restricciones previstas para el vertido de determinados tipos de residuos susceptibles de reciclaje, las normativas sobre la responsabilidad ampliada del productor para determinados productos como medios de transporte como los vehículos donde se establecen objetivos de reciclaje y de utilización de materiales reciclados y la evolución de nuevas normativas como el reglamento de ecodiseño, pueden favorecer e impulsar de forma definitiva el reciclaje y reuso de los materiales compuestos.
Abstract
Los residuos procedentes de los materiales compuestos están regulados por la normativa básica de residuos (Directiva Marco y normativas asociadas a la misma [...]
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Organismos y empresas colaboradoras
libro-blanco-materiales-compuestos (2024). 58
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CAPÍTULO 1: MOTIVACIÓN
J. Sanchez, A. Güemes

libro-blanco-materiales-compuestos (2024). 57
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CAPÍTULO 2: ÁMBITO DE ESTUDIO Y APLICACIÓN
J. Sanchez

libro-blanco-materiales-compuestos (2024). 56
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CAPÍTULO 6: GESTIÓN DE LOS MATERIALES COMPUESTOS EN FIN DE USO: SITUACIÓN ACTUAL
A. Chiminelli, M. Lizaranzu, C. Crespo

libro-blanco-materiales-compuestos (2024). 52

Abstract
This chapter presents a review of the current situation in Spain, in relation to Europe and the world, regarding the treatment of composite materials and their constituents at the end of their life cycle. Such treatment may include landfill disposal, energy recovery (incineration), recycling or recovery of materials as raw materials for the same or other uses, or the reuse or repurposing at the component or subcomponent level. These pathways or processes, along with associated developments and research, are described in greater depth in subsequent sections, while this section provides a general, combined, and particularized review, as much as possible, of the Spanish case. The chapter covers three main areas: a general framework, a section on initiatives and services offered by private companies, and a section on the activities of groups, centers, and entities within the R&D sector. Issues related to legislation, including waste classification, are presented in a specific chapter dedicated to this topic.
Abstract
This chapter presents a review of the current situation in Spain, in relation to Europe and the world, regarding the treatment of composite materials and their constituents [...]
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CAPÍTULO 9: SOLVÓLISIS Y RECICLADO BIOLOGICO DE COMPOSITES. OBTENCIÓN DE MATERIAS PRIMAS
P. Aguar, N. Miazza

libro-blanco-materiales-compuestos (2024). 49

Abstract
This chapter analyses the chemical recycling technique by solvolysis and by biological recycling, explaining that it involves breaking the polymer chain by using reactive solvents, temperature, catalysts, and pressure in the first case, and enzymes and microorganisms in the second. The situation of both technologies is shown, i.e. the operating parameters found in the literature for each type of polymer. In the case of solvolysis, the companies that are currently commercializing this technology are listed; there are still no companies for the case of biological recycling as its technology readiness level (TRL) is lower than for solvolysis. The chapter ends with recommendations for future developments for both types of solvolysis.
Abstract
This chapter analyses the chemical recycling technique by solvolysis and by biological recycling, explaining that it involves breaking the polymer chain by using reactive [...]
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CAPÍTULO 10: RECICLADO MECÁNICO DE MATERIALES COMPUESTOS
S. Prolongo, A. Suárez

libro-blanco-materiales-compuestos (2024). 48

Abstract
The mechanical recycling of long-fiber composite materials is presented as an alternative of greater technological simplicity as well as low energy consumption, emission of pollutants and use of solvents, which places it in an advantageous position from the point of view of environmental sustainability. However, the products obtained are short-fibered, which reduces their mechanical reinforcement capacity, and have been used mainly as fillers for cementitious, asphalt and thermoplastic matrices. The technologies used to reduce the size of the initial pieces substantially influence the characteristics of the final product obtained, especially if they are to be used for functional purposes in terms of electrical or thermal properties. In addition, the fibers obtained have a proportion of resin from the initial composite material, so the subsequent treatment processes of these fibers, both physical and chemical, can affect the amount of final resin present in the product, its agglomeration or its surface characteristics. The current challenges for these products is to find processes that allow a better quality and greater uniformity of the final properties of the short fiber, so that the products obtained present a greater added value, which allows them to compete with other current discontinuous reinforcements.
Abstract
The mechanical recycling of long-fiber composite materials is presented as an alternative of greater technological simplicity as well as low energy consumption, emission of [...]
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CAPÍTULO 12: REDUCCIÓN DE RESIDUOS EN PRODUCCIÓN Y REUTILIZACIÓN DE MATERIALES
L. Coronado, I. Raboso

libro-blanco-materiales-compuestos (2024). 46

Abstract
The efforts to reduce, reuse and recycle scrap derived from manufacturing processes with composite materials are significantly increasing in all those sectors making use of such materials in their production systems. The rising commitment with the environmental cause and the everyday stricter regulation in terms of waste management has led to launching new initiatives to minimize the environmental impact of composite materials and derived components manufacturing. Therefore, the aim of this chapter is to provide several examples of optimization initiatives in the use of composite materials and, consequently, the reduction and reuse of waste in production environments in the aeronautical sector, having Airbus as a reference where, according to the available pre-pandemic data, 61% of the scrap corresponds to uncured material whereas 39% refers to cured waste.
Abstract
The efforts to reduce, reuse and recycle scrap derived from manufacturing processes with composite materials are significantly increasing in all those sectors making use of [...]
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CAPÍTULO 13: GESTIÓN DE RESIDUO Y TECNOLOGÍAS DE REUSOS DE MATERIALES COMPUESTOS NO POLIMERIZADOS
N. Martín, Á. Casanova

libro-blanco-materiales-compuestos (2024). 45

Abstract
This chapter addresses two relevant challenges to enforce in a manufacturing plant where carbon fiber prepreg is used as raw material for the manufacture of aeronautical parts. The first challenge is the segregation of fresh production waste, where the resin is fresh and has a big potential for being used as material for other applications. This chapter described a proposal for the collection of this highly valuable material in a pilot plant where aircraft stabilizers are manufactured. This second challenge addresses solutions for the reprocessing of waste material discarded during the manufacturing of carbon parts. Hereafter is described the preparation of new materials or by-products, which can be reincorporated into the production system of other composite material parts.
Abstract
This chapter addresses two relevant challenges to enforce in a manufacturing plant where carbon fiber prepreg is used as raw material for the manufacture of aeronautical parts. [...]
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CAPÍTULO 14: REUTILIZACIÓN DE MATERIALES COMPUESTOS POLIMERIZADOS
J. Fernández de la Puente Calvo, J. Jhala, R. Planche

libro-blanco-materiales-compuestos (2024). 44

Abstract
Spain, holding a prominent position in Europe's composites industry and notably in aviation composites, faces significant waste management challenges within its 500-strong composite company sector. As it shifts towards the Circular Economy to enhance competitiveness and resource efficiency, Spain adheres to the EU's waste hierarchy, emphasizing the critical need for waste minimization and the reuse of materials. This transition is particularly vital given the environmental impact of disposing of polymer-matrix composites, especially cured composites, with Europe generating roughly 400,000 tonnes of thermoset composite waste annually, a substantial portion of which is from Spain. This study delves into the reuse and repurposing of polymer composites, promoting their integration within the Circular Economy to preserve material integrity and value. It showcases innovative repurposing projects in Spain and across Europe, such as transforming wind turbine blades into materials for construction, which demonstrates the feasibility of extending these materials' lifecycles. These efforts align with sustainability goals aimed at waste reduction and resource conservation. However, challenges persist, including matching waste volume and condition with market demands and scaling these practices effectively. The concept of structural re-use, turning cured composite waste into high-value, reusable products, highlights the potential of merging reuse and recycling strategies. Innovative approaches to reuse not only mitigate sustainability challenges but also foster economically viable solutions, marking a significant stride towards sustainable and efficient resource utilization in the composites sector.
Abstract
Spain, holding a prominent position in Europe's composites industry and notably in aviation composites, faces significant waste management challenges within its 500-strong [...]
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CAPÍTULO 15: REUTILIZACIÓN DE FIBRAS Y RESINAS EN ELEMENTOS ESTRUCTURALES. PROPUESTAS DE USO EN DISTINTAS INDUSTRIAS: PROPUESTAS PRELIMINARES DE USO
R. Vera

libro-blanco-materiales-compuestos (2024). 43

Abstract
One of the main problems of composite recyclability, is to find applications with a positive business case and technically viable. In order to determine possibilities, it is necessary, first, to analyze mechanical properties of materials as well as today available manufacturing processes with this type of products.
Abstract
One of the main problems of composite recyclability, is to find applications with a positive business case and technically viable. In order to determine possibilities, it [...]
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CAPÍTULO 16: BIO-MONÓMEROS Y BIO-RESINAS TERMOESTABLES
S. Prolongo, A. Suárez

libro-blanco-materiales-compuestos (2024). 42

Abstract
Thermosetting resins, especially epoxy resins, have historically been based on petroleum-derived monomers, posing problems of toxicity, high costs, and dependence on non-renewable resources. This chapter presents the use of natural plant sources to develop more sustainable resin precursors. The synthesis of bio-epoxy monomers from vegetable oils, polysaccharides, lignin, polyphenols, and natural resins is currently the subject of interest in several research projects and scientific papers, in some cases reaching the level of product commercialization. Vegetable oils, such as linseed and soybean, and the transformation of saccharides into epoxy monomers are examples of explored options. Naturally occurring epoxy monomers derived from polyphenols from various plant sources can also be found, although their epoxidation requires the use of toxic compounds such as epichlorohydrin. Several natural sources, such as natural rubber, resin acids, and lignin are examined as alternatives to synthesize epoxy resins of natural origin. Leutelin, recently identified in fruits and medicinal herbs, is highlighted as a promising compound to produce bioepoxy monomers. Although initially the research focused mostly on the development of monomers of natural origin, research also extends to hardeners of natural origin, highlighting the synthesis of amines from vanillin and curing agents based on phenalkamines. The development of hardeners with reversible bonds, such as lignin imines, is also being explored, and the catalytic effect of hemp fibers in the curing of epoxy resins is highlighted. The combination with traditional monomers or the development of recyclable resins and vitrimers with reversible bonds are current fields of interest for the development of these resins, especially in the context of their competitors of petrochemical origin.
Abstract
Thermosetting resins, especially epoxy resins, have historically been based on petroleum-derived monomers, posing problems of toxicity, high costs, and dependence on non-renewable [...]
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CAPÍTULO 17: VITRIMEROS
N. Markaide, A. Ruiz

libro-blanco-materiales-compuestos (2024). 41

Abstract
The development of recyclable plastics is a key focus of research in the current world due to its environmental issues and concerns about non-renewability. Recently, vitrimeric materials have garnered significant attention as an exciting class of renewable plastics due to their potential to exhibit strength, durability, and chemical resistance approaching that of traditional thermosetting plastics, while also demonstrating recyclability at the end of their lifespan. This is attributed to their chemical structure, as vitrimers possess dynamic covalent crosslinking, providing them with stability while being reprocessable. This review summarizes the latest advancements and prospects in the development of vitrimeric materials. Special emphasis is placed on vitrimer design strategies that pave the way for the development of next-generation circular materials. The emerging applications of vitrimers are also discussed in terms of their properties, including self-repair, malleability, processability, and multiple shape memory.
Abstract
The development of recyclable plastics is a key focus of research in the current world due to its environmental issues and concerns about non-renewability. Recently, vitrimeric [...]
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CAPÍTULO 18: RESINAS TERMOPLÁSTICAS REACTIVAS
. C.Elizetxea, . S.García-Arrieta, A. Calle, M. Manchado, R. Márquez, A. Bethencourt

libro-blanco-materiales-compuestos (2024). 39

Abstract
One of the main challenges currently faced by the composite materials sector is to ensure its sustainability, both at the level of the raw materials used, the production means necessary for its transformation, as well as its management and treatment. at the end of its useful life. Especially critical is the situation of thermostable composite materials, widely used in structural applications due to their excellent performance/weight ratio. There are different fields of research, oriented towards the search for more sustainable alternatives for these matrices so that these high mechanical performances continue to be guaranteed and that they can be transformed by conventional manufacturing processes. Reactive thermoplastic resins are a sustainable alternative for the manufacture of recyclable, weldable and processable structural composite components by conventional manufacturing technologies (Infusion, RTM. Pultrusion, Fillament Winding)
Abstract
One of the main challenges currently faced by the composite materials sector is to ensure its sustainability, both at the level of the raw materials used, the production means [...]
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CAPÍTULO 20: CALENTAMIENTO RÁPIDO Y DE BAJO CONSUMO ENERGÉTICO
. , L. AEMAC

libro-blanco-materiales-compuestos (2024). 37

Abstract
Muchos de los procesos de fabricación de estructuras de material compuesto se basan en grandes y costosasinstalaciones que originan procesos lentos, caros, y poco eficientes energéticamente. El preformado de tejidos de fibra seca, por ejemplo, se realiza en grandes instalaciones de hot drape forming, donde las fuentes convencionales de calentamiento basadas en lámparas infrarrojas son poco eficaces, ya que gran parte del calor suministrado se transfiere a los pesados moldes de aluminio en los que se lleva a cabo el proceso de preformado. En el contexto actual en el que es fundamental reducir la huella de carbono de cada componente, es fundamental reducir la energía necesaria en los procesos de producción y al mismo tiempo conseguir tiempos de ciclo competitivos. En este contexto, Tecnalia lleva años trabajando en la tecnología del calentamiento resistivo directo con el fin de acelerar y optimizar los procesos de fabricación de material compuesto. La aplicación directa de una corriente sobre el material de carbono a procesar supone la ventaja de evitar el calentamiento y enfriamiento de los moldes u otros utillajes adyacentes, obteniendo los resultados de forma mucho más rápida y eficaz que con los métodos utilizados hasta ahora. En el caso, por ejemplo, del proceso de preformado de tejidos de carbono, aplicar el calentamiento solo a la preforma permite reducir los tiempos de ciclo y el consumo energético más de un 60% y 80% respectivamente. Esto supone reducir el coste del proceso relacionado con un menor consumo energético y un menor tiempo de ciclo. La calidad de las preformas obtenidas mediante el preformado resistivo es similar a la obtenida mediante la tecnología convencional hot drape forming y, además, es un proceso repetitivo que se ha validado en entorno de fabricación industrial. En el artículo se indica también que esta tecnología de calentamiento resistivo directo no solo es aplicable en procesos de preformado de carbono, sino que también podría emplearse potencialmente en otros procesos de fabricación de componentes de material compuesto.
Abstract
Muchos de los procesos de fabricación de estructuras de material compuesto se basan en grandes y costosasinstalaciones que originan procesos lentos, caros, y poco eficientes [...]
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CAPÍTULO 21: MATERIALES AUXILIARES REUTILIZABLES. BOLSAS DE VACÍO ALTERNATIVAS
M. Rodríguez

libro-blanco-materiales-compuestos (2024). 36

Abstract
Auxiliary materials are essential elements for polymer composites manufacturing. Each of these elements performs a specific function and requires partícular characteristics depending on the process parameters. They are generally single-use materials (consumables) and thermoplastics nature, so they could be recovered and recycled. However, due to the manufacturing process of composite parts, this recycling becomes complex due to contamination by resin and fibers and the heterogeneity of the different auxiliary materials. Because of this, one of the alternatives to reduce the consume of these elements and minimize their environmental impact is to use of reusable auxiliary materials. Currently, there are commercial solutions based on silicones. This alternative must be evaluated for each case, considering parameters such as the number of parts to be manufactured or their size and geometry.
Abstract
Auxiliary materials are essential elements for polymer composites manufacturing. Each of these elements performs a specific function and requires partícular characteristics [...]
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CAPÍTULO 22: CONCEPTOS DE DISEÑO BASADOS EN CONSIDERACIONES Y METODOLOGÍAS DE BAJA HUELLA DE CARBONO, FACILIDAD DE SEGREGACIÓN Y RECUPERACIÓN.
B. Lekube

libro-blanco-materiales-compuestos (2024). 35

Abstract
In the current context of transitioning towards a circular economy and the digital age, the design of products based on composite materials requires a rethinking of decision-making processes. It is necessary to incorporate methodologies that include sustainability concepts, from selecting materials that can be revalorized to designing a product so that segregation at the end of its useful life is as simple as possible, always ensuring the technical, functional, and safety requirements of the products. This presents a complex scenario that will be elaborated on in the following sections:
Abstract
In the current context of transitioning towards a circular economy and the digital age, the design of products based on composite materials requires a rethinking of decision-making [...]
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CAPÍTULO 23: REVALORIZACIÓN DE FIBRAS DE REFUERZO RECICLADAS MEDIANTE TECNOLOGÍAS TEXTILES
I. Martínez, J. Bernabeu

libro-blanco-materiales-compuestos (2024). 34

Abstract
This chapter addresses the environmental and energy challenges posed by the increasing production of composite materials, particularly those reinforced with carbon and glass fibres. Current recycling technologies focused on fibre recovery, such as thermal and chemical methods, now enable the production of fibres suitable for reintegration into the value chain. The chapter details adapted textile technologies for processing these recycled fibres, covering methods from non-woven fabric production to the newest manufacturing technology of yarns and unidirectional tapes. Technologies such as carding and yarn formation are analyzed, highlighting the need for hybridization with virgin materials to enhance the mechanical properties of the final products. While current advances do not yet match the performance of virgin materials, ongoing research continues to optimize these processes, paving the way for the industrialization of more sustainable composites, with applications ranging from lightweight structures to sectors with higher mechanical requirements.
Abstract
This chapter addresses the environmental and energy challenges posed by the increasing production of composite materials, particularly those reinforced with carbon and glass [...]
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CAPÍTULO 25: CONCLUSIONES
libro-blanco-materiales-compuestos (2024). 33
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ANEXO 1: EMPRESAS ASOCIADOS A AEMAC
libro-blanco-materiales-compuestos (2024). 32
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CAPITULO 24: LEGISLACIÓN ACTUAL EN ESPAÑA Y UE: PRESENTE Y FUTURO

Organismos y empresas colaboradoras

CAPÍTULO 1: MOTIVACIÓN

CAPÍTULO 2: ÁMBITO DE ESTUDIO Y APLICACIÓN

CAPÍTULO 6: GESTIÓN DE LOS MATERIALES COMPUESTOS EN FIN DE USO: SITUACIÓN ACTUAL

CAPÍTULO 9: SOLVÓLISIS Y RECICLADO BIOLOGICO DE COMPOSITES. OBTENCIÓN DE MATERIAS PRIMAS

CAPÍTULO 10: RECICLADO MECÁNICO DE MATERIALES COMPUESTOS

CAPÍTULO 12: REDUCCIÓN DE RESIDUOS EN PRODUCCIÓN Y REUTILIZACIÓN DE MATERIALES

CAPÍTULO 13: GESTIÓN DE RESIDUO Y TECNOLOGÍAS DE REUSOS DE MATERIALES COMPUESTOS NO POLIMERIZADOS

CAPÍTULO 14: REUTILIZACIÓN DE MATERIALES COMPUESTOS POLIMERIZADOS

CAPÍTULO 15: REUTILIZACIÓN DE FIBRAS Y RESINAS EN ELEMENTOS ESTRUCTURALES. PROPUESTAS DE USO EN DISTINTAS INDUSTRIAS: PROPUESTAS PRELIMINARES DE USO

CAPÍTULO 16: BIO-MONÓMEROS Y BIO-RESINAS TERMOESTABLES

CAPÍTULO 17: VITRIMEROS

CAPÍTULO 18: RESINAS TERMOPLÁSTICAS REACTIVAS

CAPÍTULO 20: CALENTAMIENTO RÁPIDO Y DE BAJO CONSUMO ENERGÉTICO

CAPÍTULO 21: MATERIALES AUXILIARES REUTILIZABLES. BOLSAS DE VACÍO ALTERNATIVAS

CAPÍTULO 22: CONCEPTOS DE DISEÑO BASADOS EN CONSIDERACIONES Y METODOLOGÍAS DE BAJA HUELLA DE CARBONO, FACILIDAD DE SEGREGACIÓN Y RECUPERACIÓN.

CAPÍTULO 23: REVALORIZACIÓN DE FIBRAS DE REFUERZO RECICLADAS MEDIANTE TECNOLOGÍAS TEXTILES

CAPÍTULO 25: CONCLUSIONES

ANEXO 1: EMPRESAS ASOCIADOS A AEMAC

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Martinez, Xavier 1995

SANCHEZ GOMEZ, JOSE 71

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