Criticality and Recyclability Assessment of Car Parts—A Thermodynamic Simulation-Based Approach

Using a thermodynamic approach, this paper identifies the most critical parts of a car, considering their composition. A total of 11 car parts that contain valuable and scarce materials have been selected using thermodynamic rarity, an indicator that helps assess elements and minerals in exergy terms according to their relative scarcity in the crust and the energy required to extract and refine them. A recyclability analysis using a product-centric approach was then undertaken using dedicated software, HSC Chemistry. To that end, the dismantling of these car parts into three main fractions was performed. Each car part was divided into non-ferrous, steel, and aluminum flows. A general metallurgical process was developed and simulated for each flow, including all the required equipment to extract most of the minor but valuable metals. Of the 11 parts, only 7 have a recyclability potential higher than 85%. By treating these selected car parts appropriately, the raw materials’ value recovered from the car can increase by 6%. The approach used in this paper can help provide guidelines to improve the eco-design of cars and can also be applied to other sectors. Ultimately, this paper uniquely introduces simulation-based thermodynamic rarity analysis for thermodynamic based product “design for recycling”

Jornadas de Colaboración de Iniciativas Estratégicas (PTIs y Conexiones)

Datos técnicos: 315 minutos, color, español. Ficha técnica: Gabinete de Presidencia CSIC y Departamento de Comunicación. Emitido en directo el 14 feb 2023El próximo martes 14 de febrero, de 9:30 a 14:15 la Vicepresidencia de Investigación Científica y Técnica, organiza una Jornada en la que se buscará potenciar las colaboraciones científicas del CSIC mediante iniciativas estratégicas: las Plataformas Temáticas Interdisciplinares (PTIs) y las Conexiones.CSIC, así como poner en valor el trabajo realizado por todos los investigadores que forman parte de estas estructuras. Contará con la participación de la Presidenta del CSIC, Eloísa del Pino, representantes de las Vicepresidencias, los coordinadores científicos de las iniciativas y otros socios y colaboradores externos. Como parte de la Jornada se celebrarán tres mesas redondas en las que empresas, administraciones públicas y fundaciones compartirán sus historias de éxito alcanzadas mediante la colaboración con PTIs y Conexiones.Peer reviewe

Exergy Assessment of Plastic Car Parts

Light-duty vehicles are increasingly incorporating plastic materials to reduce production costs and achieve lightweight designs. On average, a conventional car utilizes over 200 kg of plastic, comprising more than 23 different types, which often present challenges for recycling due to their incompatibility. Consequently, the focus on plastic recycling in end-of-life vehicles has intensified. This study aims to analyze critical car parts based on the plastics used, employing a novel thermodynamic approach that examines the embodied exergy (EE) of different plastics. Six vehicles from various segments, years, and equipment levels were assessed to understand their plastic compositions. The findings reveal that, on average, a vehicle contains 222 kg of plastic, accounting for 17.7% of its total weight. Among these plastics, 47.5% (105 kg) are utilized in car parts weighing over 1 kg, with plastics comprising over 80% of the part’s weight. The identified critical car parts include the front door trim panel, front and rear covers, fuel tank, floor covering, front lighting, dashboard, rear door trim panel, plastic front end, backrest pad, door trim panel pocket, plastic foam rear seat, rear lighting, window guide, molded headliner, bulkhead sound insulation, foam seat part, and wheel trim. Regarding their contribution to EE, the plastics with the highest shares are polypropylene—PP (24.5%), polypropylene and ethylene blends—E/P (20.3%), and polyurethane- PU (15.3%). Understanding the criticality of these car parts and their associated plastics enables targeted efforts in design, material selection, and end-of-life management to enhance recycling and promote circularity within the automotive industry

Disassemblability Assessment of Car Parts: Lessons Learned from an Ecodesign Perspective

A conventional vehicle requires more than 50 different metals in its manufacturing, most of which are critical. Given this circumstance, enhancing sustainability from a raw materials perspective requires improvements in the disassemblability of car parts. This enhancement aims to yield metal-rich fractions, enabling the application of effective recycling processes for the recovery of critical metals. This helps avoid the downcycling that occurs in conventional shredding processes. The present study was undertaken to analyze the challenges associated with disassembling components of significant value due to their metal content. The methodology comprises two distinct main stages: an identification of critical car parts and an assessment of disassemblability. The selection of car parts was determined by the criticality of each one through the thermodynamic rarity indicator. Disassemblability was studied experimentally, encompassing three different levels. This classification defines the stages from extracting parts from the vehicle and obtaining recycling fractions in their purest form: ferrous metals, aluminum, non-ferrous metals excluding aluminum, and plastics. This methodology was implemented on two vehicles manufactured by SEAT: SEAT Leon models II and III. As a result, not only was disassemblability information about these car parts collected, but several ecodesign recommendations were also identified as valuable guidance for future designs, specifically aimed at enhancing metals’ recyclability. In conclusion, it must be acknowledged that contemporary vehicle design often prioritizes cost-effective manufacturing processes. However, this approach may compromise the disassemblability and recyclability of the product. The ongoing transition to electric vehicles necessitates a re-evaluation of design principles, particularly from the perspective of the circular economy