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Prof. Dr.-Ing., Dipl.-Phys. Joachim Schmidt
eMobility Workshop
Nelson Mandela Metropolitan University NMMU, Port Elizabeth
South Africa 25. November 2015
Recycling of Electric Cars
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 1
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 2
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
3
Preparation of
raw material
Recycling Loops
Resources Production Use End of life product
Post Production
RecyclingPost Industrial
RecyclingRe use
Post Consumer Recycling
Landfill Mining
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Recycling of Electric Cars, eMobility Workshop 25. November 2015
4
Why recycling?
Preservation of material resources
Preservation of energy resources
Reduction of waste
Reduction of pollutions
Reduction of emissions
Ensuring the availability of special materials
(Rare Earth metals, Conflict minerals,..)
Ore, Oil, Minerals,…
Oil, Natural Gas, Uranium…
Dysprosium, Terbium, Gold, Coltan
(Tantalium), Gallium, Indium,…
Carbon dioxide, Nitrogen oxides,
Methane,…
Dangerous Waste, Sludges, Acids,…
Lead, Cadmium, Mercury, Dioxins,
Furans,…
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 5
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
6
Present post consumer recycling for ELV’s
ELV‘s
Dismantling workshop Shredder plant Post shredder technologies
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
End of Life Vehicles directive (ELV Legislation):
Recyclability rate: 85 %
Recoverability rate: 95 %
Maximum 60 g Pb before Shredder operation
In Diskussion: Dismantling of 17 kg electronics before Shredder operation
Recycling of Electric Cars, eMobility Workshop 25. November 2015
2
Status Quo of Automobile Recycling
ELV‘s
Dismantling workshop Shredder plant Post shredder technologies
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Battery, Airbag-dismantling/ -controlled demolition
Tyres, Drainage, Spare parts
Treatment operations for depollution
Dismantling of parts to promote recycling (Plastics, glass, katalyst)
Recycling of Electric Cars, eMobility Workshop 25. November 2015
3
Status Quo of Automobile Recycling
ELV‘s
Dismantling workshop Shredder plant Post shredder technologies
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Magnet separator => Ferrous metals
Sorting by hand
Eddy current separator => Nonferrous metals
Swim sink plant
Recycling of Electric Cars, eMobility Workshop 25. November 2015
4
Status Quo of Automobile Recycling
ELV‘s
Dismantling workshop Shredder plant Post shredder technologies
Product for feedstock recycling or energy recovery
Ferrous and Non-ferrous metals
Fluff (for the drying of sludge)
Mineral product for remelters (Shredder sand)
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 7
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Unusual features at electric vehicles
Battery
Trend: Lithium ion battery
DC/AC Voltage transducer
Battery charger
Electromotor
Trend: Three-phase current
synchronous motor with
permanent magnets from NdFeB
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Car body lightweight construction materials
8
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Electric Vehicles and Car body materials
E-up!
BMW i3
Tesla
Twizy
Source: Wikipedia
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Fe Steel
Mg Magnesium
CFK texture
GFK
Al Aluminium
Plastic
9
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Operation and construction of an electromotor - Synchronous motor
(inside runner)
Stator with magnets excited
electrically
Rotor with permanent magnets
from neodymium iron boron alloy
Nd2Fe14B (Sinter material)60 – 70 % Fe
28 – 35 % Rare Earth Metals REM
1- 2 % Boron
0 - 4 % Cobalt
Magnetically hard material (high
residual magnetism and high
magnetic field strength)
Temperature stability by
Dysprosium or Terbium
Corrosion resistance by cobalt
1
2 1
2
4
3
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Nd Neodymium Dy Dysprosium Te Terbium
Co CobaltFe Steel
10
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Power unit from Electric Vehicles
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Au Gold Ag Silver Cu Copper
Ga Gallium In Indium Ge Germanium Ta Tantalum
11
DC/DC voltage transducer
DC/AC voltage transducer Three-phase motor
Auxiliary
units
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Operation and construction of a Li-Ion-battery
Ve-
Porous graphite structure
on Copper collector
-+
Li-Metal oxide in Layer strukture
(LiNiO2, LiCoO2, LiMn2O4, Li4Ti5O12,…)
Electrolyte made of lithium salts with solvent
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Cu Copper Ni Nickel Co Cobalt Mn Mangan Li Lithium C Graphite
12
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Present recycling quotas for different metals
Source: Project OPTUM
> 50 %
> 25 – 50 %
> 10 -25 %
1 -10 %
< 1 % %
Cu Copper Au Gold Ag Silver Pt PlatinumPd Palladium
Ru Rutherium
Ga Gallium In Indium Ge Germanium Tb Terbium
Pr Praseodymium Nd Neodymium Dy DysprosiumOnly Post
Production
Recycling
(China)
Sn TinPb Lead Al Aluminium
Zn Zinc
Well established
recycling loops
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 13
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 14
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
15
Improvement of the current Automobile Recycling for Electric Vehicles
Electric ELV‘s
Dismantling workshop Shredder plant Post shredder technologies
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Necessary dismantling operations before the shredder process
Dismantling of Electromotor
Dismantling of Power Unit
Dismantling of Battery
Special training for the handling of high
voltage components
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 16
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Recycling strategies for electromotors and materials from electromotors
Reuse after Repair
Reuse after cleaning and
testing
Material recycling by dismantling and crushing
=> Magnet powder for metal sintering or polymer binding
Reuse after an industrial
exchange components
manufacture
Feedstock recycling: recovery of the base elements by pyro-metallurgical methods,
recovery the rare earth metals from slag by hydro-metallurgical methods
Spare parts
Exchange parts
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 17
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Production of magnets bei powder metallurgy (sintering)
Homogenizing the alloying
in a high frequency furnace
Powder production
Powder press
=> green part
Sinter process
Mixing the alloying metals
Magnetization
Finishing
Quality control
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 7
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Production of magnets by metal injection moulding (polymer binding)
Metal powder
Polymer binder
Mixing
Solvent debindingInjection molding
Thermal
debinding
Feed stockGranulation
Green part
Brown part
Sintering
Finished part
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 18
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Hydro-metallurgical treatment of magnets from electromotors
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Leaching of
magnet scrap
metal with
hydrochloric
acid (Solvent)
Precipitation agent
PrecipitationPrecipitate
Oxalate REM2 (C2O4)3
Oxalic acid
19
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Hydro-metallurgical treatment of magnets from electromotors (strongly
simplified)
Magnet scrap metal
LeachingLaugung
FeOOHFe-PrecipitationFällung
C2H2O2 REM2(C2O4)3
Na2S
HCl Dissolving into hydrochloric acid
NaOH, H2O2
Co-Precipitation
Oxalate-Precipitation
CoS
Heat treatment
REM2O3
Reduction-
processes
Rare Earth
Metals
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 20
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Only production waste is utilized till now (in China)
Industrial recycling for magnets from electromotors is in the development
Economically recycling of electromotors requires an automatic dismantling
Material amount is too low for economically recycling within the next years
Material recycling of the magnet materials leads to remanence loss
Recovery of the materials about hydro-metallurgical methods is favored at the moment
Recycling of electromotors – state of the art
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 21
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 22
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Recycling strategies for circuit boards from power unit
Base operations for recycling metals from circuit boards
Metallurgical treatment of circuit boards in the copper plant (Converter method)
Hydro-metallurgical methods
Mechanical processing of circuit boards for the extraction of mixed metal granules for the further smelting
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 23
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Metallurgical treatment of circuit boards in the copper plant (Converter)
Copper Converter
Anode furnaceFire refining
Copper scrap metal,
electronic scrap metal
Anode casting machine
Cable scrap metal
Copper electrolysisElectrorefining
Anode mud with noble metals
Pure Copper
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 24
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Mechanical processing of circuit boards
Dismantling
Pre-shreddering
Power Unit
Magnetic sorting
Steel, Al, Plastics
Classifying
SortingPolymer mixed granules
Copper-rich mixed metal granules
to copper plant
Granulation
Steel
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 25
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Recycling of electrical and electronic equipment is state of the art
The recovery of copper and noble metals from circuit boards is state of the art
At the time, examinations run to show the economic dismantling of power units
Recycling loops for Ga, In and Ge exist only for production waste
Recycling processes for Ga, In und Ge from power units are exermined at the moment
Recycling of Power units – state of the art
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 26
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Contents
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 27
1 Recycling loops and environment protection
2 Present post consumer recycling for ELV‘s
3 Electric vehicles
5 Recycling of Electromotors
4 Improvement of the current Automobile Recycling for Electric Vehicles
6 Recycling of power units
7 Recycling of Li-Ion-Batteries
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Recycling of Li-Ion-batteries
Dismantling in modules
and cells
Low temperature
shreddering, Sorting
Battery
Pyrometallurgical
processes
Fe, Al, Cu, Polymers
from Battery case
Hydrometallurgical
processesLi (Salt)
Li-containing Slag
Co, Ni
Al, Cu from modules and cells
State of the art
Umicore processAdditive for construction industry
Future concept
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 28
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Hydro-metallurgical treatment of Lithium contained slag
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Leaching of
magnet scrap
metal with
sulfuric acid
(Solvent)
Precipitation agent
PrecipitationPrecipitate
Li2 CO3
Na2CO3
19
Slag
Recycling of Electric Cars, eMobility Workshop 25. November 2015
There are worldwide various suppliers for the battery recycling:
Accurec GmbH – Deutschland, Batrec AG – Schweiz, Nickelhütte Aue – Deutschland,
Recupyl – F, ES, Pl, I, USA, Singapur, SNAM – Frankreich,Toxco – USA, Kanada, Umicore –
Belgien, Xstrata – Kanada
Present: Recovery of Cu, Co, Ni by pyrometallurgical methodes, Li goes into slag =>
Additive in construction material
Future: Dismantling of the batteries in modules and cells and recovery of the Li salts from
slag by hydro-metallurgical processes
Recycling of Li-Ion batteries – state of the art
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 29
Prof. Dr.-Ing., Dipl.-Phys. Joachim Schmidt
eMobility Workshop
Nelson Mandela Metropolitan University NMMU, Port Elizabeth
South Africa 25. November 2015
Back up charts
Recycling of Electric Cars, eMobility Workshop 25. November 2015
1
Preparation of
raw material
Recycling Loops
Resources Production Use End of life product
Post Production
RecyclingPost Industrial
RecyclingRe use
Post Consumer Recycling
Landfill Mining
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Recycling of Electric Cars, eMobility Workshop 25. November 2015
5
Comparison between Golf (combustion engine) and electric Golf
Material Golf 7 (mass %) Elektro Golf 7 difference
Steel and iron 62,9 55,2 - 7,7
Light alloys 8,2 10,3 + 2,1
Nonferrous heavy metals 2,6 8,2 + 5,6
Polymers 19,5 17,5 - 2,0
Process polymers 1,1 0,7 - 0,4
Other materials and
material compounds
3,3 4,3 + 1,0
Electrics/electronics 0,1 0,2 + 0,1
Fuels and auxillary means 2,3 3,6 + 1,3
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Recycling of Electric Cars, eMobility Workshop 25. November 2015
6
New Components and materials in Electric Vehicles
Motor
Power Unit
Lightweight materials
Battery
Nd Neodymium
CFK
Dy Dysprosium
Au Gold Ag Silver Cu Copper
Li Lithium Ni Nickel
C GraphiteMn ManganCo Cobalt
Cu Copper
Al Aluminium Mg Magnesium
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences
Ga Gallium Ge GermaniumIn Indium
GFK
Co Cobalt Te Terbium
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Magnetic materials
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 8
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Aluminium: 1.400 Euro/t
Mangan: 1.800 Euro/t
Kupfer: 6.000 Euro/t
Nickel: 12.000 Euro/t
Kobalt: 19.000 Euro/t
LiCoO2: 16.000 Euro/t
Material cost
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 9
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Quelle: Elwert, T. u. a. Projekt LiBri
Umicore process
Demontage/Zerlegung => Fe, Al, Kunststoff
Schlackeaufbereitung
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 10
Recycling of Electric Cars, eMobility Workshop 25. November 2015
Sources
Final report: Project MORE – Recycling components and strategic metals from electrical
traction drives
Final report: Project LiBRi – Lithium Battery Recycling Initiative (Pyrometallurgy)
Final report: Project LithoRec – Recycling of Li-ion-batteries (Hydrometallurgy)
Project ElmoRel – Recycling of power units (in work)
Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 30