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End-Of-Life Analysis of Advanced Materials

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End-Of-Life Analysis of Advanced Materials END-OF-LIFE ANALYSIS OF ADVANCED MATERIALS A Dissertation by Eylem Asmatulu Master of Science, Cukurova University, 2004 Bachelor of Science, Cukurova University, 2001 Submitted to the Department of Industrial and Manufacturing Engineering and the faculty of the Graduate School of Wichita State University in partial fulfillment of the requirements for the degree of Doctor of Philosophy May 2013 Copyright© 2013 by Eylem Asmatulu All Rights Reserved END-OF-LIFE ANALYSIS OF ADVANCED MATERIALS The following faculty members have examined the final copy of this dissertation for form and content, and recommend that it be accepted in partial fulfillment of the requirement for the degree of Doctor of Philosophy, with a major in Industrial Engineering. ______________________________________ Janet Twomey, Committee Chair ______________________________________ Michael Overcash, Committee Member ______________________________________ Vinod Namboodiri, Committee Member ______________________________________ John Perry, Committee Member ______________________________________ Esra Buyuktahtakin, Committee Member Accepted for the College of Engineering _________________________________________ Vishwanath Prasad, Interim Dean Accepted for the Graduate School _________________________________________ Abu Masud, Interim Dean iii DEDICATION To my family and friends for their unconditional love and support. iv ACKNOWLEDGMENTS I would like to express my sincere gratitude to my advisors Dr. Janet Twomey and Dr. Michael Overcash for the opportunity to carry out this research and their continuous support, patience and guidance, without whom, this dissertation would not be possible. I would like to thank to my committee members Drs. Vinod Namboodiri, John Perry and Esra Buyuktahtakin. I also thank Dr. Bayram Yildirim for his invaluable guidance, support and knowledge throughout this work. Thanks to my father, mother and brother for their unquestioning support and encouragement which has enabled me to achieve all that I have. Finally, a very special thank to my amazing husband Ramazan and son Derin, without their unwavering patience, support, understanding and love, none of this would have ever been possible. v TABLE OF CONTENTS Chapter Page 1. END-OF-LIFE ANALYSIS OF ADVANCED MATERIALS .................................... 1 1.1 Introduction ........................................................................................................... 1 1.2 General Background .............................................................................................. 1 1.3 Major Contributions of This Study............................................................................. 3 1.4 Main Organization of PhD Dissertation..................................................................... 5 1.5 Life Cycle and Nano-products: End-of-life Assessment .......................................... 5 1.6 Recycling of Fiber-Reinforced Composites and Direct Structural Composite Recycling Concept ................................................................................................. .7 1.7 Recycling of Aircraft: State of the Art in 2011 ........................................................ 9 1.8 Evaluation of Recycling Efforts of Aircraft Companies ......................................... 10 2. LIFE CYCLE AND NANO-PRODUCTS: END-OF-LIFE ASSESSMENT ............. 13 2.1 Abstract ................................................................................................................ 13 2.2 Introduction .......................................................................................................... 14 2.3 Methodology ........................................................................................................ 19 2.4 Result and Discussion .......................................................................................... 21 2.5 Limitation and Future Research ............................................................................ 31 2.6 Conclusion ............................................................................................................ 32 3. RECYCLING OF FIBER-REINFORCED COMPOSITES AND DIRECT STRUCTURAL COMPOSITE RECYCLING CONCEPT ........................................ 60 3.1 Abstract ................................................................................................................ 60 3.2 Introduction ......................................................................................................... 61 3.3 Composite Recycling Technology ........................................................................ 64 3.3.1 Mechanical Recycling ............................................................................... 65 3.3.2 Thermal Recycling ...................................................................... ………..77 3.3.2.1 Combustion Process ................................................................. 77 3.3.2.2 Fluidized Bed Combustion Process .......................................... 79 3.3.2.3 Pyrolysis Process ..................................................................... 84 3.3.3 Chemical Recycling................................................................................ 87 3.4 Comparisons of Composite Recycling Technologies ............................................. 94 vi TABLE OF CONTENTS (continued) Chapter Page 3.5 Direct Structural Recycling of Composites ............................................................ 99 3.6 Conclusions .............................................................................................................101 4. RECYCLING OF AIRCRAFT – STATE-OF-THE-ART...........................................106 4.1 Abstract....................................................................................................... .......... 106 4.2 Introduction........ .....................................................................................................107 4.3 Recent Progress in Aircraft Recycling ................................................................ 108 4.4 Marketability of Recycled Aircraft Material ........................................................ 118 4.5 Environmental Impacts of Aircraft Recycling ..................................................... 121 4.6 Limitation and Future Research .......................................................................... 125 4.7 Conclusions .............................................................................................................127 5. EVALUATION OF RECYCLING EFFORTS OF AIRCRAFT COMPANIES IN WICHITA........................................................................... ....................................... 131 5.1 Abstract....................................................................................................... ........... 131 5.2 Introduction ........................................................................................................ 132 5.3 Methodology ...................................................................................................... 133 5.4 Result and Discussion ........................................................................................ 137 5.4.1 Cradle-to-Gate Inventory Analysis .......................................................... 137 5.4.2 Recycling Benefits of Local Aircraft Companies ..................................... 157 5.5 Conclusion...............................................................................................................161 6. SUMMARY AND CONCLUSIONS...........................................................................168 6.1 Major Finding of the Studies...................................................................................168 6.2 Future Work........................................................................................................ 170 vii LIST OF TABLES Table Page 2.1 Major Nanoproduct Distribution Derived from the PEN CPI List, 2010 ................ 30 3.1 Tensile Testing of Virgin and Recycled Fibers. ..................................................... 66 3.2 Energy Consumption of Grinding Process for Some of the Composite Materials ... 68 3.3 Energy Intensity (MJ/kg) of Virgin and Recycled Materials .................................. 69 3.4 Effect of the CFRP Part Recycling on the Energy Saving (MJ/kg) of Automobile Parts. ..................................................................................................................... 72 3.5 The Composition of the CFRP/ABS Composite .................................................... 73 3.6 Tensile Strength of the Fiber Reinforced Thermoplastic Composites ..................... 75 3.7 Elastic Modulus and Strength of the Different Blends of Virgin and Reprocessed A66GF35 .............................................................................................................. 76 3.8 The required pre-processing details and fiber grades for various types before fluidized bed combustion systems ......................................................................... 80 3.9 Estimated Values for the Cost of Carbon Fibers .................................................... 81 3.10 Pyrolysis Products from SMC, Expressed as % (weight) of SMC .......................... 85 3.11 Mechanical Properties of Recovered CFRP ........................................................... 91 3.12 Mechanical Properties of Virgin and Three Recovered Carbon Fiber Processes .... 91 3.13 Strength of the Recycled Carbon Fibers and Its Virgin Precursor
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