Innovative Carbon Fibers recycling and recovery technologies through advanced sustainable processes

This PhD research explores the strategic role of carbon fiber recycling in addressing the climate crisis, supporting the transition toward a circular economy, and responding to broader societal and industrial challenges. It presents the first comprehensive global analysis of both Virgin Carbon Fiber (VCF) and Recycled Carbon Fiber (RCF), examining their production, consumption, and environmental impacts. Highlighting the high energy intensity, carbon footprint, and significant waste rates of VCF production, the study demonstrates how RCF offers a lower-emission, cost-effective, and increasingly viable alternative. The thesis maps, for the first time, all major global RCF manufacturers, innovative pilot plants, and key research centers. It critically compares all existing recycling technologies—mechanical, chemical, thermal, and hybrid - identifying best practices and limitations, and evaluates emerging innovations from TRL 5–6 and up. A special focus is placed on CURTI’s pyro-gasification technology, developed in partnership with HERA, which enables industrial-scale recycling with minimal fiber degradation and reduced costs, as validated by the EU’s newly launched Imola plant. In parallel, the study introduces a novel pricing model for both VCF and RCF that incorporates sustainability-related factors such as ESG performance, brand value, tax credits, and public grants. This multidimensional approach redefines the economic competitiveness of recycled materials by integrating social and environmental externalities into traditional P&L logic. By combining technical, market, and environmental analysis, the thesis offers a strategic framework for decision-makers across the new RCF value chain - from policymakers and OEMs to sustainability officers and new influencers. Ultimately, it demonstrates how carbon fiber recycling, though still in its early industrial phase, can contribute meaningfully to reducing global carbon emissions, lowering industrial waste, and shaping a more sustainable and resilient future for advanced materials industries.