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Fire and Ageing Resistant Biocomposite for Transportation industrY (LIFE FARBioTY)
Start date: Sep 1, 2016, End date: Aug 31, 2019 PROJECT  FINISHED 

Background The transportation sector is the largest industrial source of CO2 emissions in Europe (26% in 2011). One of the reasons for this high figure is the widespread use of glass fibre composite materials, whose production uses large amounts of non-renewable sand, water and energy; compounded by the poor recyclability of carbon and glass fibre reinforced epoxy. The current production of composite materials therefore goes against ecological priorities set in the Roadmap to a Resource Efficient Europe, the Circular Economy Package and the Roadmap to a Single European Transport Area. The latter sets objectives regarding all aspects of transportation, with the aim of reaching a 60% reduction in transport emissions by 2050. A key area of innovation for reaching this target is materials and design. The development of alternatives to lightweight glass fibre composite materials, especially using natural fibres that have equivalent qualities, would significantly reduce environmental impacts – e.g. by being more recyclable, biodegradable and less energy-consuming during their production. However, the potential of such materials has yet to be fully exploited, with combustibility being a particular concern. Objectives LIFE FARBioTY aims to reduce the environmental footprint of the transport industry by increasing the volumes of flax fibres used for producing composite materials. New techniques of integrating the materials into resins will be used to produce new composite materials with good (equivalent) mechanical properties. Crucially, the project will implement a new solution to make these natural fibres pass European fire standards, given that they cannot be used in transport applications otherwise. Flax fibres adoption has the potential to reduce fibre glass production and the exploitation of raw materials (sand, petroleum-derived materials and water). Flax is a natural and abundant resource, which can be sustainably managed to provide the natural fibres needed. The project therefore contributes to the Roadmap for a Resource Efficient Europe (including optimal resource use, and reduced climate change, air pollution, noise and health impacts) and the Circular Economy Package (which promotes production processes that innovatively use natural resources). The project will demonstrate the new material in the railway sector by measuring environmental impact and mechanical performance in situations where the innovative composite material is used instead of glass fibre reinforcement. The results will be compared with data available for currently used composite materials through a Life Cycle Assessment (LCA). Expected results: A demonstration for railway sector applications that shows that one tonne of flax fibre can replace 0.58 tonnes of glass fibre, so contributing to the avoidance of sand consumption, reducing water consumption by 30%, non-renewable energy consumption by 30%, and CO2 emissions by 56% per functional unit produced. Assuming that transportation manufactures and suppliers are willing to use biocomposite for 15% of their manufacturing processes, this will contribute to a reduction of sand consumption by 15%, water consumption by 4.5% and CO2 emissions by 8.4%; A complete preliminary study; The detailed technical specifications for the flax fibres and resins to meet standards of the railway sector; Technical and functional specifications of the railway beacon to be produced; A step-by-step description of the improved production process; The production of the new treated biocomposite material; One sample of the new railway beacon; Data on environmental benefits of the whole fabrication process, compared to the one employing glass fibres (including water quantity, energy savings and CO2 emissions avoided) through LCA; Technical data on the composite material and railway beacon performances during the year-long demonstration period, with a focus on meeting fire standards, and a longer term view through simulations; and Exploitation plan and recommendations for replicating the technology in other transport sectors and for meeting the standards of fire resistance and other properties of the biocomposite material of the naval and aeronautic sectors.
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