A Comparative Environmental and Economic Analysis of Carbon Fiber-Reinforced Polymer Recycling Processes Using Life Cycle Assessment and Life Cycle Costing

The recycling of carbon-fiber reinforced polymers (CFRPs) presents significant challenges due to their thermosetting matrix, which complicates end-of-life management and often results in energy-intensive disposal or significant waste accumulation. Despite advancements in recycling methods, knowledge gaps remain regarding their sustainability and economic viability. This study undertakes a comprehensive Life Cycle Assessment and Environmental Life Cycle Costing analysis of four key recycling techniques: mechanical recycling, pyrolysis, solvolysis, and high-voltage fragmentation (HVF). By using the SimaPro software, this study identifies mechanical recycling and HVF as the most sustainable options, with the lowest cumulative energy demand (CED) of 5.82 MJ/kg and 4.97 MJ/kg and global warming potential (GWP) of 0.218 kg CO2eq and 0.0796 kg CO2eq, respectively. In contrast, pyrolysis imposes the highest environmental burdens, requiring 66.3 MJ/kg and emitting 2.84 kg CO2eq. Subcritical solvolysis shows more balanced environmental impacts compared to its supercritical counterpart. Cost analysis reveals that for mechanical recycling and pyrolysis, material costs are negligible or zero. In contrast, solvolysis and HVF incur material costs primarily due to the need for deionized water. Regarding energy costs, pyrolysis stands out as the most expensive method due to its high energy demands, followed closely by solvolysis with supercritical water.