Automotive Recycling - amtc.mandela.ac.za

Automotive Recycling

Engineering Workshop at the

Nelson Mandela Metropolitan University NMMU

Port Elizabeth

South Africa 2011

Prof. Dr.-Ing. Joachim Schmidt

3 Process chain of automobile recycling

Engineering Workshop Automobile Recycling

2 Prof. Dr.-Ing. Joachim Schmidt, Faculty of Vehicle Engineering

3 Process chain of automobile recycling

ELV‘s

Dismantling workshop Shredder plant Post shredder technologies

Depositing on landfill

All dismantling enterprises and shredder enterprises must be certified

according to environment standards in Europe. In Germany:

~ 1300 certificated dismantling plants

~ 40 certificated shredder plants

Post shredder technologies in development.



Dismantling workshop – Process chain

ELV‘s

Storage

Expertise

Battery

Airbag-

dismantling/

-controlled

demolition

Work steps

Visual inspection of the vehicle

Dismantling plan for spare parts.



Dismantling workshop – Removal/neutralization of explosive

components

Inflatet Airbag

Dismantling Airbag

Air bags and seat belt tensioners

can be fired or disassembled.

When airbags are ignited, safety

rules, a special training of staff

and special ignitors are required.

In case of dismantling also a

special training is necessary to

provide specific requirements for

storage and transportation of the

components.




ELV‘s

Storage

Expertise

Battery

Airbag-

dismantling/

-controlled

demolition

Drainage

Tyres

Remove of 20-30 litres of

liquids.

The dismantling of tyres is specified.

The drain off works better (better

access to the liquides). Is a further

reason, the rubber harms the steel

grade. Steel gets brittle.



Dismantling workshop - Drainage, Fuel

Tool: Drill with a

hole in the centre

The drill is screwed into the polyethylene

tank and the fuel can flow.

All activities must be carried out in

an explosion-proof atmosphere.

In most cases the petrol tank is

bored into with a drill. This drill has a

hole in his centre, where the petrol

can flow off.



Dismantling workshop – Drainage, oil

Oil drain through drain plug

Engine oil

Oils are drained through holes in a

free fall. The drain plugs are opened

and the liquids are collected by a oil-

tube.



Dismantling workshop – Drainage, oil

Engine oil

Often, no complete removal of the oil is

guaranteed.

Reasons for this:

The drain plug is not at the lowest point

of the container. A residual amount is left

in the container.

The viscosity of the oil rises at low

temperature. Through this it flows off

worse and the draining process takes an

extremely long time.



Dismantling workshop- Drainage, shock absorber oil

The removal of the shock absorber oil

requires a relatively high effort.

The oil is located in a double-walled

container, which must be pierced.

After drilling, the oil you can siphon

through the hole.




ELV‘s

Storage

Expertise

Battery

Airbag-

dismantling/

-controlled

demolition

Drainage

Tyres

Spare parts

There are regulations

for the storage of the

spare parts.

For oil contained parts

the floor must be

impermeable.




ELV‘s

Storage

Expertise

Battery

Airbag-

dismantling/

-controlled

demolition

Drainage

Tyres

Spare parts

Dismantling of

parts to promote

recycling

(Plastics, glass)

Treatment operations

for depollution

A dismantling of the spare parts is also

carried out besides the dismantling of

the pollutants parts. The sequence is

depending on vehicle.



Dismantling workshop –dismantling of catalytic converter

Ceramic with platinum

and rhodium

The catalytic converter of a car must be

dismantled before the shredder process.

If not, the precious metals platinum and

rhodium can not be extracted.

In practice, industrial hydraulic cutters

have proven best for the catalyst

separation from the exhaust.



Dismantling workshop – Plastic components

Removal of large plastic components (bumpers,

dashboard, fluid containers, etc).

The dismantling is necessary for the material

recycling of the plastics. One receives high-

quality and pure material only in such a way.



Dismantling workshop – Dismantling of glass

Cutting blade, System Fein

In modern vehicles, the screens are glued and the adhesive bond must be dissolved. There are basically the following options:

Cutting the adhesive with a hydraulic or electric knife or a cutting wire.

Resistive heating or inductive heating. The inductive coil is placed right on the edge of the windscreen and the body metal will be heated by induction. The glue dissolves, and thus the windscreen can be removed.

Infrared radiation. Similar experiments with various infrared emitters have been carried out.

In practice, the hydraulic or electric knife is used. The figure shows the electric cutting knife of the company "Fein".




ELV‘s

Storage

Expertise

Battery

Airbag-

dismantling/

-controlled

demolition

Drainage

Tyres

Spare parts

Dismantling of

parts to promote

recycling

(Plastics, glass)

Press/ car body

store

Treatment operations

for depollution

Before the transport to the

shredder the car-body is

pressed. One gets a lower

transportation volume through

this.



Dismantling workshop - Press

After the dismantling and the press-

operation one describes the bodywork as

shredder raw material. The next step is then

the transportation to the shredder.



Dismantling workshop versus dismantling plant

Dismantling

Dismantling station with

lifting ramp

Dismantling line

(semi-automatic)

Dismantling line

(automatic)

Expandable

High flexibility

Cost-effective

Disadvantage:

time consuming inner

logistics

Standard equipment for car

dismantlers

Accessibility sometimes

difficult

Not expandable

Low flexibility

Simple inner logistics

Relatively high

investment

Plants in Germany,

Netherlands and USA In most cases one works on

dismantling stations, however, also are

some larger plants which work

according to the assembly line concept



Dismantling station with lifting ramp

In small companies lifts for

handling of the vehicles and

forklifts for the transport of

vehicles are used.

The boxes for the storage of

materials will be situated in a way

to allow short distances.



Dismantling plant with lifting ramps, System Intecus, Alba, Berlin

Pre-treatment Inspection

Dismantling area

Store for spare parts

Shop

The most dismantling shops operates with an island disassembly plant. The main components of this

system are the drainage area, the dismantling area and the warehouse.

In the plant a sales shop is integrated, in which the customer directly can purchased the spare parts.



Devices for car dismantling

To be able to work ergonomically,

different devices have been

developed (engine lift, hydraulic-lift

etc.).

With the engine lift the engine can be

taken out without any effort, and

taken to further treatment.

With help of the hydraulic-lift the ELV

can be tilted by 90 degrees and one

can then work without problems on

the bottom of the car body.



Dismantling plant with disassembly line, Allgäu Recycling, Kempten

Fully automatic conveyor system for vehicles.

The core of the plant are turning machines in which the

ELV `s can be rotated in any direction in space.

Thus, the liquids can be largely removed and an

ergonomically friendly working on all parts of the vehicle is

possible.



Dismantling plant with disassembly line, Car Recycling Systems

The best known plant in Europe is the plant

from Car Recycling Systems in the

Netherlands.

The vehicles are transported on rails. The

centerpiece is also a turning machine

allowing an ergonomically work with their

assistance.



Addition: Dismantling of trucks and busses

Busses and heavy freight

vehicles are utilized

similarly as automobiles.

Because they are very long-

lasting, an extensive use of

spare parts and exchange

parts take place.

For dissassembling one

frequently uses cutting

scissors (scrapcutter).



Addition: Dismantling of locomotive engines (Fa. Bender)



Addition: Dismantling of tanks (Battle Tank Dismantling GmbH)

For the dismantling of armed forces

vehicles special companies are

commissioned. Their activity is

supervised by the armed forces and

state places so that all weapons are

destroyed.



Addition: Dismantling of aircrafts

Recycling aircrafts takes place

mainly in the USA. There are only a

couple of small plants in Europe.

The aircraft will be dismantled with

the help of cranes and excavators.

The aim, among others are the

production of aluminium from the

outer skin of Aircraft and a

recovery of copper from the

electrical system.

In addition, the tyres and other

rubber parts are dismantled.

They are used in the USA as a base

for road construction.



Addition: Dismantling of ships in India

Currently, ships are recycled in large

numbers in India.

These vessels are driven ashore and

broken down with simple tools of

migrant workers.

Problems are:

No protective clothing

No safety standards

Dismantling is carried out by hand with

simple tools

Asbestos is broken off by hand

Workers climb without scaffoldings onto

ships

The workers live in poverty. Workers are

not registered and therefore it is difficult

to identify them.



Addition: Approaches for an environmentally compatible utilization

IMO (International Maritime Organization) and

ILO (International Labor Organization) have

published recommendations and guidelines

with the focus

Identification of hazardous materials

Preparation of a green passport

Minimisation of hazardous substances

Recycling oriented design

Choice of a suitable dismantling plant,

preparation for a recycling plan.

In Turkey there are plants in which there will be

more stringent environmental standards.

Similarly, there are plans to build a major

dismantling center on the Dutch coast in.

The figure shows a model of the plant.

The company Ecodock plans to build

a recycling plant in Eemshaven at

the Dutch coast (dismantling

capacity, 13 ships per annum).



Addition: Process chain of electric/electronic recycling

WEEE

Dismantling workshop

Dismantling and taking apart

in reusable components

Metals

Circuit boards

Cable

Plug and hardware

connections

Cathode ray tubes

Polymer materials

Parts to be removed

(Annex II)

Packing materials and

materials to be disposed

Shredder

Special enterprises for

Circuit boards

Cathode ray

tubes

Lamps

...

There are three important laws for

recycling electrical and electronic

equipments in Europe. The

requirements are similar as in the

ELV.

An additional demand is the

determination of the carbon

footprint about the lifetime of the

product.

http://www.karletshofer.de/Portals/2/Elektronikschrott 3.JPG



Addition: Todays handling of electric/electronic devices in dismantling

workshops

Dismantling of

electrical and

electronic

equipment



Addition: Todays handling of electric/electronic devices in industrial

plants

MEWA Recycling plant In addition to the dismantling

workshops, there are large

industrially oriented

dismantlers who cooperate

with device manufacturers.

These holdings, besides large

mechanical treatment plants,

also have dismantling

stations, in which most metals

are recovered.

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Automotive Recycling - amtc.mandela.ac.za