UK firm leads charge in carbon recycling
UK company, Gen 2 Carbon, is revolutionising the field of carbon fibre recycling, potentially unlocking access to a fresh supply of this 'wonder material', crucial in advancing towards an energy-efficient future. Carbon fibre's high cost and supply constraints have traditionally limited its application, despite its light weight and strength making it ideal for energy-saving products.
Britannia racing boats supported by chemicals maker Ineos use recycled carbon fibre from a pioneering company in the West Midlands
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The novel recycling process developed by Gen 2 Carbon could supplement supply chains by reclaiming material from products usually designated as waste. Currently operating from Coseley in the West Midlands, the company has plans to establish two additional factories in Australia and the US in the next two years.
Gen 2 Carbon's chairman, Frazer Barnes, recognises the "massive" opportunities that this sustainable approach offers. He asserts that as carbon fibre usage grows - particularly for light-weighting vehicles and non-fossil fuel energy systems - increasing the usage of recycled fibre makes financial and environmental sense.
Frazer Barnes, Gen 2 Carbon’s chairman
Introduced commercially in the 1950s, carbon fibre has traditionally been used to reinforce plastics, offering weight savings of up to 40% in aircraft construction, translating into significant fuel cost reductions over their lifetime. Current global carbon fibre usage is about 130,000 tonnes per year, roughly double that of a decade ago. However, recovery rates remain low, with most reclaimed material deriving from manufacturing waste.
UK's Gen 2 Carbon innovates a recycling process for carbon fibre.
Recycled carbon fibre could be 30% cheaper than the virgin material.
Global carbon fibre usage in 2023 is double that of a decade ago.
By 2027, Gen 2 aims for global output of 5,000 tonnes, earning £150m annually.
By spearheading such technological advancements, Gen 2 Carbon and similar companies are demonstrating how small-scale manufacturers can significantly impact the wider economy and offer career opportunities. Currently employing 16 people, Barnes expects to double the workforce by the end of 2023.
Despite its strength, carbon fibre remains considerably more expensive than steel and aluminium. But recycled carbon fibre could sell for 30% less than virgin material, providing a significant incentive for uptake among manufacturers. As an environmental group, Green Alliance recognises the potential benefits, asserting that a successful recycling supply chain could help break into new markets where carbon fibre has previously been prohibitively costly.
Significant carbon fibre waste is projected to amass by 2050 without suitable recycling methods. This pressing issue underscores the need for successful recycling strategies. Big players in carbon fibre-intensive industries are keenly observing the advancements in recycling to assess potential applications.
Gen 2 Carbon plans to relocate its UK operations and expand globally by 2027, aspiring to output 5,000 tonnes of recycled carbon fibre annually, yielding potential revenues of up to £150m. Their journey underscores the potential of innovative, environmentally conscious technologies to catalyse economic growth and job creation, whilst assisting industries to transition towards sustainable practices.
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