Epoxy Decomposition Within Carbon Fibre Reinforced Polymer With Methanol: A Comprehensive and Thermodynamic Analysis

The escalating global production of carbon fibre reinforced polymer (CFRP) waste, projected to exceed 100,000 tonnes annually by 2030, necessitates sustainable recycling strategies to mitigate environmental and economic challenges. This study presents a comprehensive techno‐economic and thermodynamic analysis of methanol‐based solvolysis for CFRP recycling, focusing on a hypothetical 50,000‐ton/year facility operating at 150°C and 6 bar. The process yields recycled carbon fibres (rCFs) retaining > 95% of virgin tensile strength via selective transesterification under mild conditions (150°C, 6 bar) and enables solvent recovery rates up to 99%. Thermodynamic analysis reveals an exceptionally low energy demand of only 1.6–2.0 kWh/tonne of CFRP—significantly below pyrolysis or supercritical routes—making the process highly attractive for industrial‐scale materials recovery. The process yields a net present value (NPV) of $16.21 million, an internal rate of return (IRR) of 31%, a profitability index (PI) of 1.94 and a payback period of 3 years, demonstrating strong financial viability. Thermodynamic modelling reveals a low energy demand of ±1.6 kWh/ton of CFRP, significantly below that of pyrolysis or supercritical methods. Compared with hydrogen peroxide‐based solvolysis, methanol offers superior economic performance and scalability, though, with slightly higher environmental risks due to its volatility. Sensitivity analysis identifies rCF revenue and methanol costs as primary economic drivers. The process achieves a net global warming potential of ±14.17 kg CO 2 eq/kg CFRP, supporting a circular materials economy. These findings highlight methanol‐based solvolysis as a scalable, energy‐efficient and economically viable solution for CFRP waste management, with implications for high‐performance industries like aerospace and automotive.