i.e. thermoplastic polyurethanes, 2-components thermoset polyurethane foams and regenerated natural fibers,. â¡ starting from renewable biomass feedstock ...
Material & Design-related aspects of a Circular Economy Circular economy and sustainable processes in the automotive and transport value chain Thilo Bein (FhG) & David Storer (FCA) Co-Leaders ERTRAC WG Global Competitiveness
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Introduction Circular Economy is one of several measures to decarbonise the road transport Increased use of bio-based and secondary materials lowering improving the GWP balance significantly Efficient recycling of materials & recovery of critical raw materials ■ Improving efforts in terms of energy & costs of the End-of-Life phase ■ Sustainable source of materials
Re-use of components ■ Lowering the total cost of ownership thus increasing acceptance of battery electric vehicles ■ Less need for recycling & recovery energy saving
Circular Economy reduces the dependencies on critical raw materials Particular on rare earth materials and alloying elements for high performing materials
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Recycling in the automotive sector EU vehicle directive (2016) re-use and reutilisation (95%)
disposal (5%)
Re-use and recycling (85%)
re-use
material recycling
Pre-Treatment/Dismantling Shredder
removal of fluids dismantling of batteries dismantling of airbags removal of spare parts
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raw material recovery
energy recovery
Treatment Smeltery substitution of metals Furnace (iron production) substitution of oil/coal Sludge conditioning substitution of coal Non-iron metal smeltery Substitution of slag formers
Source: Homepage Wirtschaftsgesellschaft des Kfz‐Gewerbes mbH
Reutilisation of the car body
disposal
material recycling
energy recovery
Share of plastics continously increasing 4
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Source: Umweltbundesamt
Shredder Light Fraction (SLF) Composition of the SLF
30 % automotive SLF are still usable!
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Sources: Scherhaufer S., Depotech 2008/11, Angaben in Gew.%; & BHS Sonthofen
Challenges in view of Circular Economy (I) Novel materials meeting automotive standards Bio-based materials Secondary materials Reversible adhesive …..
Design for Circular Economy Methods & tools as well as design concepts allowing to assess, evaluate and taking into account ageing / degradation phenomena and EoL-strategies Design concepts for bio-based and secondary materials in a multi-material approach Design for reduced use of critical raw materials …..
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Challenges in view of Circular Economy (II) Understanding material behaviour and endured operational loads over life-time Understanding ageing and degradation mechanism (e.g. battery, electronics, structures) Monitoring of materials and structures over lifetime
New recycling strategies Upgrading instead of downgrading Recycling processes / strategies for multi-materials and high performing materials Increased efficiency of the recycling process …..
New business models
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Relevant projects within H2020 Search within CORDIS database limiting the search to H2020 Search terms: recycling, re-use, 2nd life, circular economy Limited to Advmat, Advmanu and Transport
about 13 relevant projects found, often small SME projects Many related to magnets
European Remanufacturing Network GA# 770019
GA# 680629
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New Recovery Processes to produce Rare Earth ‐Magnesium Alloys of High Performance and Low Cost
Example: Secondary Aluminium In comparison to primary aluminium secondary aluminium allows energy savings of up to 95% and a reduced global warming potential of 83%. Beyond that it is considerably cheaper. Accompanying elements in secondary aluminium alloys, like Fe, Cu und Zn, which are present in undefined concentrations influence the formation of intermetallic phases, precipitations and inclusions and for this reason ■ mechanical properties and ductility as well as ■ corrosion and also corrosion fatigue behaviour.
For potential applications it has to be clarified ■ which typical alloy compositions (concentration limits) are present, ■ how to fit the heat treatment for optimised material properties, ■ whether the requirements concerning corrosion resistance and corrosion fatigue according to the structural durability proof can be met.
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Example: 2nd Life of Batteries Dismantling and Second life Use of Batteries
dismantling as operational interface between EoL-, Reuse-Phase and Recycling Evaluation of testing and assembling cost towards building reuse and 2nd life battery applications Business feasibility of used automotive batteries as stationary energy storage applications
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GA# 770019
Example: Bio-based materials (BIOMOTIVE) Production of innovative and advanced bio-based materials with an increased bio-based content (60-80%), ■ i.e. thermoplastic polyurethanes, 2-components thermoset polyurethane foams and regenerated natural fibers, ■ starting from renewable biomass feedstock not in competition with food and feed, ■ leveraging innovative production techniques.
Validation through cars’ interior parts (door handles and automotive seats) demonstrating advanced properties in terms of ■ resistance to fire, ■ mechanical strength and flexibility ■ as well as improved recyclability of the end-of-life products.
demonstrating an innovative process for the production of 100% biobased NIPUs, with moisture-repellant properties.
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GA# 745766
Example: Upgrading during recycling Objectives Recycling of PET bottles and upgrading of resulting material to meet automotive requirements Replacing of short glass fibre reinforced polyamids with long glass fibre reinforced PET in automotive applications
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Germany, BMBF:
Example: Recycling of CFRP Energy recovery (burning) may lead to carcinogenic fibres according TRGS 905 Current recycling approaches (shredding, pyrolysis, chopping) leads to significantly downgraded fibres novel process technologies leads to non-woven fabrics (vlies) with similar properties as long-fibres (Source: G. Stegschuster, Werkstoffplus Auto 2018)
P. Quicker, ITAD Podiumsdiskussion, 2016 www.cfk‐recycling.com
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Conclusion
Only a few dedicated projects focussing on Circular Economy funded under H2020, however
Implementation of Circular Economy strategies by the European automotive industry becomes vital
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to meet targets regarding GWP
become less dependent on non‐European natural resources
Circular economy requires research on and implementation of
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bio‐based and secondary materials
new recycling & recovery strategies
digitalisation concepts along the lifetime
new business models for 2nd life and re‐use
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