Eco-friendly recycling of CFRP composites via hydrogen peroxide treatment: Preserving fabric architecture for second-life applications

Recycling carbon-fibre-reinforced polymer (CFRP) composites is essential for environmental sustainability, yet conventional methods often compromise fibre quality. This study presents a single-step recycling method for amine-cured epoxy CFRPs using 50 wt% aqueous hydrogen peroxide at 90 °C and atmospheric pressure. The process achieves 94.5% resin decomposition within 24 h, reclaiming high-quality woven fabrics with preserved architecture at the fabric-layer scale. Comparative analysis of standard and aerospace-grade CFRPs demonstrates the method’s applicability across matrices with different levels of chemical resistance. Single-fibre tensile tests and Weibull analysis confirm that tensile strength is largely unaffected, with minimal changes in strength variability. Second-life composites manufactured from the recovered fabrics retained 96.5% of the original flexural modulus, while flexural strength and interlaminar shear strength decreased by 24% and 49.4%, respectively, mainly due to reduced fibre–matrix adhesion. Analysis of the by-products via gas chromatography–mass spectrometry and gel permeation chromatography identified bisphenol A and oligomeric species, indicating revalorisation potential. Life cycle assessment showed up to 88% lower primary energy demand compared to virgin fibre production. Overall, this method offers a promising route for reclaiming high-quality carbon-fibre textiles for structural reuse in a circular economy, while further scale-up and surface-reconditioning studies are required to fully validate industrial implementation.