Novel and recycled textile waste-derived carbon black for epoxy reinforcement

Purpose This study aims to create a sustainable valorization pathway for textile waste through recycling of textile waste into useful carbon black (CB) fillers in high-performance epoxy composites. This technique not only successfully recycle various textile waste but also leads to additional energy rich bio-oil as well. Design/methodology/approach In this paper, researchers explore a sustainable valorization route through pyrolysis of most commonly used textile fabrics; cotton, polyester and polyester cotton (PC) fabrics to recover functional CB and high calorific bio-oil. The solid carbon residue was then applied as a filler in epoxy composites. Scanning electron microscope and Raman analyses revealed distinct CB morphologies and ID/IG ratios (0.82–0.88), confirming graphitic structure. Findings At 4% loading, cotton derived CB showed the best balance of properties with enhanced resilience (+46%), high elongation and 54% lower friction than neat resin, surpassing commercial carbon black. Polyester and PC CB provided higher breaking stress, while pyrolysis also produced energy rich bio-oils, highlighting dual benefits in composites and fuels. Originality/value This approach offers an eco-friendly novel solution for textile waste having different fiber content with additional advantage of energy recovery and advanced composite reinforcement within a circular economy framework.