On the afternoon of the 30th of last month, CATACK-H Hwaseong Plant located in Yanggam-myeon, Hwaseong, Gyeonggi-do.

Upon entering the factory with the nameplate “Recycling Line 2,” five large drum washing machine-shaped machines measuring more than 2m in width and length were in operation. Inside the machine, waste CFRP (Carbon Fiber Reinforced Plastic) crumbs mixed with water and additives were running as if doing laundry.
Established in 2017, the start-up Katech H has developed an eco-friendly recycling technology that recovers more than 95% of carbon fiber from waste CFRP in an atmospheric pressure environment and a low temperature of 100℃ or less, using a chemical method that adds inexpensive additives to water. Global companies such as Japan, the United States, and Europe are using CFRP recycling technology, but using thermal incineration, which burns at a high temperature of 600 ° C or higher, has problems with environmental pollution and high cost. Since there is no related technology in Korea, CFRP scrap from the manufacturing process has been incinerated and landfilled.

CATACK-H received the transfer of eco-friendly CFRP recycling technology from KIST (Korea Institute of Science and Technology) in 2017, and has been improving the technology completeness and developing a mass production process for four years. The Hwaseong plant will begin mass production in the middle of this month.

Jeong Jin-ho, CEO of Cartech H, said, “CFRP has been used in aerospace, weapons, bicycles, etc., but has recently expanded its use to automobiles, hydrogen fuel storage tanks, and wind turbines.” We are struggling to find a recycling solution,” he said.

CFRP is an ultra-high-strength fiber that weighs only one-fourth of iron and has more than five times the strength of iron. However, it was expensive and caused serious environmental pollution when disposed of. The global CFRP market has grown at an average annual rate of 8.2%, reaching 180,000 tons or about 42 trillion won in 2020. The carbon fiber market has grown by 20% annually, reaching 130,000 to 140,000 tons and 5 trillion won in 2020. The recycled carbon fiber market is estimated at 3 to 4 trillion won, about one tenth of the CFRP market.

The CFRP recycling market is dominated by thermal incineration by foreign companies such as Toray and Carbon Convergence, but pollution, high cost, and low recovery rate and quality have been the limitations. The technology developed by CATACK-H solves the environmental pollution problem caused by CFRP disposal and has the effect of lowering supply costs through recycled carbon fiber.

“We have completed a technology that recovers more high-quality carbon fibers by using low-temperature water and additives instead of burning them at high temperatures,” said CEO Jung. As a result, there is a big difference from the thermal incineration method, which are 85% or less and 70% or less, respectively.”

Cost competitiveness is also excellent. The cost of recycling 1 kg of carbon fiber is less than 10 dollars, which is much cheaper than the 15 to 20 dollars of thermal incineration. The initial facility investment cost is 1 billion won per 500 tons, which is 1/10, and the maintenance cost is 1 billion won per 20 years, 1/4.

In 2019, CATACK-H installed a continuous process line with a capacity of 200 to 300 tons per year at its Hwaseong plant, followed by a batch process line with an annual capacity of 1,500 tons last year. Centered around Kim Jong-il, a former engineer in the semiconductor industry, and director of the technology research institute, he continues technical cooperation with KIST, while expanding factories with investments from materials companies and venture capital. KIST also took a stake as the second-largest shareholder.

CEO Chung said, “Domestic and foreign companies that are concerned about recycling CFRP are sending waste composite materials to the company and asking if it can be treated.” More sales are expected,” he said.

Hyundai Motor Company commissioned hydrogen fuel storage tanks, Korea Aerospace Industries scraps from the manufacturing process, such as Surion helicopters, and Korea Carbon commissioned recycling of carbon fiber composite materials. Cooperation with domestic companies such as Iljin, Lotte Chemical, Korean Air, Hanwha Q Cells, and Ilshin Chemical Industries, as well as overseas companies such as Solvay, Mitsubishi Chemical, and Carbon Revolution, is being discussed. CEO Chung said, “With wind turbine blade waste alone expected to reach 43 million tons by 2050, the problem of disposal is expected to grow, so overseas companies are asking for recycling plans.” We plan to establish corporations and factories in Australia and other countries.”

The company is also preparing to establish a large-scale mass production plant in Jangsu nationwide. It plans to secure an annual processing capacity of 4,500 tons from this year to 2023 after obtaining government approval. The plan is to secure a total processing capacity of 5,000 to 6,000 tons by 2024 to meet domestic and foreign demand.

“If we secure 6,000 tons of annual processing capacity, we can become the world’s largest carbon fiber recycling company,” said CEO Jeong. We will be a game changer in a growing market.”

Yoon Seok-jin, president of KIST, said, “The role of public institutions, including KIST, is very important for implementing carbon neutrality. “Through this, we will provide the technological basis for transforming the entire industry into a low-carbon structure,” he said.

Regenerated carbon fiber made by recycling waste CFRP. Provided by CATACK-H

Reporter Ahn Kyung-ae naturean@dt.co.kr

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