A Comparative Environmental and Economic Analysis of CFRP Recycling Processes Using Life Cycle Assessment and Life Cycle Costing

The growing adoption of Carbon Fiber Reinforced Polymers (CFRPs) in advanced structural applications has emphasized the need for sustainable recycling methods to address environmental and economic challenges associated with end-of-life (EoL) management. While CFRPs offer exceptional specific mechanical properties, their thermosetting matrix complicates recycling efforts, often resulting in energy-intensive disposal or significant waste accumulation. In recent years, considerable advancements have been made in CFRP recycling, with three primary processes emerging: mechanical, thermal, and chemical recycling. Existing comparisons of these methods have focused on the mechanical performance of recovered fibers, yet their broader sustainability implications warrant further exploration. This study undertakes a comprehensive Life Cycle Assessment (LCA) and Environmental Life Cycle Costing (eLCC) analysis of four key recycling techniques: mechanical recycling, pyrolysis, solvolysis, and high-voltage fragmentation. The analysis encompasses the metrics of cumulative energy demand, global warming potential, damage assessment by the Recipe endpoint method, and cost. In the analysis, available data from the literature, process models, and experimental and manufacturing procedures were used. The study's findings emphasize that CFRP recycling methods significantly reduce energy consumption and carbon footprints compared to the production of virgin fibers. Among the recycling techniques evaluated, mechanical recycling and high-voltage fragmentation demonstrate the lowest environmental impact, contributing positively to human health and the preservation of natural resources. The results enable the informed selection of sustainable and cost-effective CFRP recycling processes, supporting advancements in sustainable manufacturing and end-of-life product management.