Composite Recycling with Biocatalytic Thermoset Reforming

Area of Science:

• Materials Science
• Biotechnology
• Chemical Engineering

Background:

• Carbon fiber reinforced polymers (CFRPs) are replacing traditional materials in automotive, aerospace, and energy industries.
• Developing effective end-of-life processes for CFRPs is crucial to recover value from both carbon fibers and polymer matrices.
• Current recycling methods often result in material degradation or low-value products.

Purpose of the Study:

• To develop an upcycling strategy for polystyrene-containing CFRPs.
• To demonstrate the recovery of valuable chemicals and intact carbon fibers from end-of-life CFRPs.
• To establish a sustainable method for CFRP recycling that preserves material value.

Main Methods:

• Utilized an engineered strain of *Aspergillus nidulans* for biocatalysis of the thermoset polymer matrix.
• Developed a process to convert polystyrene-containing CFRPs into benzoic acid and valuable secondary metabolites.
• Engineered reactions to preserve carbon fibers and their sizing for subsequent composite manufacturing.

Main Results:

• Successfully upcycled CFRPs into benzoic acid and high yields of secondary metabolites, such as (2Z,4Z,6E)-octa-2,4,6-trienoic acid.
• Isolated carbon fibers retained their integrity and sizing, enabling their use in new composite materials.
• Manufactured composite coupons from recycled fibers exhibited mechanical properties comparable to virgin substrates.

Conclusions:

• This work presents the first integrated system for high-value recovery from both the fiber and matrix of CFRPs.
• The biocatalytic upcycling approach offers a sustainable alternative to traditional CFRP waste management.
• The method facilitates a circular economy for advanced composite materials.