Transcript

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


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