What is the Extracthive Project?
Extracthive is a French company dedicated to the circular economy, specializing in the production of recycled carbon fibre from industrial waste. This initiative focuses on keeping primary raw materials in the loop for as long as possible by reclaiming high-quality, green, and affordable carbon fibre that would otherwise be lost. The project, built on over nine years of expertise recycling raw materials ranging from metals and mining residues to wastewater and composites, has formulated an innovative approach. Since 2016, the Extracthive team has been refining its proprietary PHYre® technology—a solvent-based solvolysis process that separates the polymer from the fibre—ensuring that the recycled carbon fibre retains its excellent mechanical properties while drastically reducing environmental impacts.
Main Benefits of the Technology
The benefits of this technology can be summarized with some striking key figures and facts:
- 100% recycled carbon fibre sourced from composite waste
- Rescues high-quality carbon fibre using an innovative solvolysis process
- Process yields clean, undamaged fibres that retain their essential properties
- Achieves up to a 90% reduction in greenhouse gas emissions compared with virgin carbon fibre
- Provides a cost-effective, sustainable alternative for industries demanding lightweight high-performance materials
Innovative Recycling Technology
PHYre® is at the heart of the Extracthive project. The technology stands as an innovative chemical process that works by separating the polymer from the carbon fibre. Designed to produce recycled carbon fibre while consuming minimal energy and reducing solvent use, PHYre® has been patented by Extracthive. This breakthrough approach is particularly significant given the ubiquity of carbon fibre in lightweight constructions for wind energy, gas storage, and even advanced design applications. Often described as “the stuff dreams are made on,” carbon fibres are lighter than aluminium and tougher than steel. They are celebrated for their potential to combine lightness and strength, although their conventional production is both energy-intensive and environmentally costly.
Sustainability in Focus
The Extracthive project is driven by sustainability. By tapping into a circular economy approach, it ensures that primary raw materials, once extracted and entering the anthroposphere, do not end up as waste. This process is key to supporting the energy transition. The recycled carbon fibre produced through Extracthive’s PHYre® technology is ideal for pre and post-consumer composite waste. This means that the material not only supports advanced technological applications but also contributes to minimizing the life cycle environmental impacts of carbon fibres. In a casually impressive development, the reduction of greenhouse gases by up to 90% compared to the production of virgin carbon fibre makes this technology a game changer in sustainability.
Environmental and Economic Impact
Carbon fibre, while offering unparalleled mechanical and aesthetic properties, has always come with an environmental price tag—90% of today’s carbon fibres are petroleum-based and manufactured through energy-intensive processes. Extracthive addresses this challenge by using recycled carbon fibre that not only reduces the environmental footprint but also makes the material more affordable. The recycling process transforms industrial composite waste into a valuable secondary raw material, effectively closing the loop. This technology not only benefits industries looking for lightweight, high-performance materials, but it also paves the way for a more environmentally friendly manufacturing process, supporting both economic growth and responsible production practices.
Applications and Product Range
The versatility of recycled carbon fibre is evident in its extensive product range. In applications demanding both long lengths and precise, robust performance, Extracthive provides an array of products suited to various needs. The main products include recycled carbon fibre, long carbon fibre, chopped carbon fibre, and micro carbon fibre. This range offers flexibility for designers and manufacturers across different sectors, from aerospace and automotive to construction and energy. Carbon fibre’s combination of lightness, durability, and the ability to be processed with textile techniques gives designers limitless creative potential. Although the technology is innovative, the fundamental core of Extracthive’s mission is to minimize waste and drive the transition to a more sustainable and resourceful industrial future.
Project Impact on SDGs
- SDG 9: Industry, Innovation, and Infrastructure – by introducing groundbreaking recycling technology
- SDG 12: Responsible Consumption and Production – through the circular economy approach and waste valorisation
- SDG 13: Climate Action – thanks to a significant reduction in greenhouse gas emissions
- SDG 7: Affordable and Clean Energy – by supporting energy transition with sustainable materials
Future Vision and Industrialisation
Looking forward, the Extracthive project aims to industrialize its proprietary PHYre® technology by 2027, paving the way for a broader adoption of recycled carbon fibre. With an eye on a future where sustainability meets high performance, the technology is set to revolutionize not just material recycling but also the complete process cycle in various industries. This vision is underscored by a clear commitment to reducing environmental impacts while opening up economic opportunities in the sustainable materials market. As industries grapple with the dual challenges of increasing demand for high-performance materials and the urgent need to address climate change, projects like Extracthive are poised to offer innovative solutions that inspire change. Simply put, the project is a dynamic force set to redefine industrial standards for environmental stewardship and technological advancement.
