Mineral wool : From landfill to a sustaianble polymer composite

Abstract: The focus of the project is recycling of the insulation material mineral wool. The aim is to investigate the potential of using post-consumer wool from landfill as fiber reinforcement in a polymer matrix. Information gathering is conducted by a literature study on previous research, with focus on sustainability, circular economy and waste management. Potential is evaluated by producing test specimens, test mechanical properties with tensile and flexural tests, and conducting a life cycle assessment and economic analysis of the material. Mechanical properties of interest in this study are maximum stress and stiffness. The conclusion is that the manufacturing methods selected in the project do not achieve sufficient quality in the material to determine whether the fibers have the desired effect. Rock wool fibers do blend well with both polypropylene (PP) and high-density polyethylene (HDPE), but polymer composites with short fibers require control of fiber length, dispersion and direction, and the material needs to be free of pores which has not been achieved at this stage. As a result, unreinforced HDPE performs best in tensile tests (19,4 MPa in stress and 1,22 GPa Young’s modulus), in bending reinforced PP of virgin plastic achieves the highest stress and unreinforced PP the highest flexural modulus (74,1 MPa and 0,74 GPa respectively). The life cycle assessment shows that recycled rock wool fibers have potential to produce 60% less CO2 emissions than the equivalent glass fiber composite. In addition, stone wool fibers show the potential to save 30 000 SEK/ton compared to glass fiber, which corresponds to a 75% lower price.