vehicle recycle
TRANSCRIPT
Vehicle Recycling
Published by : Environmental Affairs Div., Toyota Motor CorporationPublished : April 2014Contact : Environmental Affairs Div. TEL : +81-565-28-2121
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T a b l e o f C o n t e n t s
・・ Table of Contents
・ Introduction
・ Resource saving and recycling, looking at the entire life cycle of vehicle
・ Specific content of efforts
Development and design with the environment in mind Easy to dismantle vehicle structure Examples of efforts other than recycling ・Development and wider use of plastics derived from plants
Promotion of effective use of resources ・Reduction of discarded materials from the plants
・Reduction of water usage
・Reduction of packaging and wrapping materials
Recycling at the Sale Stage ・Reuse of used parts
General overview of the recycling Recycling of automobile shredder residue from end-of-life vehicles Research and development of recycling technologies Resource recycling of rare metal and rare earth
・ Compliance with the domestic act for promotion of use of recycled resources
・ Compliance with overseas recycling laws
・ Result of Toyota Group’s Efforts
DevelopmentandDesign
Productionand
Logistics
Sales
End-of-life
Development
and Design
Production
and Logistics
Sales
End-of-life
N a m e : KurukuruGender : UnknownInterest : Driving (The most recommended place to go is Toyota Automobile Museum.) Search by "Toyota Automobile Museum"! Horoscope : Virgo
〈Vehicle recycling〉 Character profiles
2 3
Development and Design
Working together with Society
Recycling
Development and Design
Production
Working together with Society
Toyota Environmental Action Plan system
T O D A Y F O R T O M O R R O W
Enhancing environmental education at TOYOTA Shirakawa-Go Eco-Institute
Promoting initiatives on biodiversity(Photo: Toyota’s approach to biodiversity brochure)
Establishing technologyaimed at recycling advancement
(photo: Exterior view of a recycling plant)
Enhancing development of recycling technology for effective reutilization of resources(Fig. Resource flow)
Promoting integrated actions on CO2 reduction (photo: Smar t House collaboratively controls home electric appliances, cars and solar power to use home energy more effectively)
Promoting use of Ecological Plastic for plastic parts(Photo: Parts of the SAI where Ecological plastic is used)
Eco-driving enlightenment activities (Photo: Monitor of ESPO installed in SAI and Prius α)
Development of next-generation vehicles using electricity, and promoting combination of different power sources in ways that maximise the strengths of each
Supporting activities in Japan and overseas through the Toyota Environmental Activities Grant Program
Resourceinput Products
Recycling for profitsWaste at costIncineration of wasteLandfill waste
Internal recycling
Materials discarded
Internal reutilizationIntra-process reutilization
The right vehicle for the right place atthe right time
Ultimate Eco-Car
Hybrid Technology
VVT- i
Leanburn
D-4
EV
DPNR
Common-railDICNG
FCHV
DieselHV
Alternativefuel HV Plug-in
HV
Syntheticfuel
Biofuel
Dieselengines
Alternativefuel engines
Electricalenergy
Gasolineengines
Further performance improvement through theuse of hybrid technology
THS Ⅱ
Mid / long-term movement and direction
Universal guiding principles
and policies
The FifthToyota Environmental
Action Plan2011 - 2015
Make effective use of
the earth’s limited resources,
so the children of
the future can always
live affluent lives.
Toyota is constantly
working towards that goal
through the most advanced
efforts in the field of
resource recycling.
We also contribute
to sustainable
progress for society
and the earth.
Establishing alow-carbon society
Significantly reduce GHG emissions
Establishing arecycling-based societyEnhancing recycling of resources through 3R
Environmental protection and establishing a society inharmony with nature Receiving and continuing the
blessings of nature
Toyota Earth Charter (Environmental Basic Policies) Toyota Global Vision
Guiding Principles at Toyota
Life cycle of vehicle
It is necessary to consider recycling through the entire life cycle of a car, from its production to the end of its usefulness.
Resource saving and recycling, looking at the entire life cycle of vehicle
Toyota applies the following activitieswithin these stages,
which from the life cycle of vehicle
●Suppress the generation of waste.●Repeatedly use reusable items.●Recycle waste.
To make more effective use of limited resources, we feed the results back into the development and design stages, working on creating cars with recycling in mind.
Development/Design
Sales
Production/Logistics
End-of-life
ASR＊
HV Batteries HV Motors
Engineundercover
Seat back boardLuggage trimLuggage door trim
Pallets fortransport,etc.
Used bumpersreplaced duringrepair at dealers
Increasing use of returnable shipping containers
Recycling from end-of-life vehicles
Recycling of repair/replacement parts
Reduction of materials discarded
Resourceinput
Internal recycling
Recycling improvement design/development of Ecological Plastic
Developmentand Design
Sales
Productionand Logistics
End-of-life
s.
It keeps goinground and round!
Introduction
Environmental management
＊ ASR ： Abbreviation of Automobile Shredder Residue. It is the residue left from shredding end-of-life vehicles.
4 5
Vehicle Recycl ing
＊1 ISO14001 : The international standard for environmental management systems Toyota was the first in the auto industry to introduce it in 1998.＊2 Life Cycle Assessment (LCA) : The product’s impact on the environment is assessed in each process, from development to disposal, as a way of selecting production methods, alternative raw materials, and other options with lower environmental burdens.＊3 Eco-VAS : Eco-Vehicle Assessment System＊4 CE : Chief Engineer
Specific content of efforts
In 1998, Toyota was the first in the auto industry to introduce ISO14001＊1 in its design and development division. Since then, it has been assessing recyclability in advance, at the vehicle development stage. From 2005, we introduced the “Eco-VAS”＊3 comprehensive environmental assessment system, which is based on the approach of LCA＊2 (Life Cycle Assessment), through the entire vehicle development process.
Development and design with the environment in mind
Environmental performance
・Fuel economy improvement・Reduction of exhaust gas, noise, and environmental load substances・Recycle・LCA
Vehicle planning
Setting targets that reconcile environmental performance with customer needs
Design and prototyping
Target attainment
Assessment using the “Eco-VAS” environmental assessment system
・Customer needs・Cost・CE＊4 concept
Before the production start
Final confirmation of environmental performance
Information disclosure to customers
Development and Design Development and Design
The wiring harness can be stripped out without interfering with other components.
Easy to dismantle vehicle structure
■Wire harness Using pull tab-type ground terminals
■Wire harness layout innovation
Assembled condition When dismantled
The positioning of the V grooves makes it easy to remove the instrument panel by pulling it strongly.
■ Instrument panel removal
Points at which the load required for peeling door trim off can be reduced by 30% were identified, and marked with easy to dismantle mark.
■ Door trim peeling
“Disassembly facilitation marks” are added to show key points for disassembly tasks.
■ Use of "Easy to dismantle mark"
Component removal times for the Prius are further reduced. New easy to dismantle mark is added, so that heavy components can be hoisted with good balance.
■ Removal of heavy parts of batteries from hybrid cars
Pull-off direction
Separates at thinner areas
Development
and Design
Production
and Logistics
Sales
End-of-life
Vehicle Recycl ing
6 7
Increasingleanspecificationsfor wrapping,etc.
Increasingreturnablecontainers
Total
Serviceparts
Changing packaging specifications, reuse, etc.
Increasing lean specifications for wrapping
Production parts
Serviceparts
Productionparts
Improvement of storage capacity, simplification of packing specifications, etc.
Expanding the use of returnable containers(Expansion to more product types)
Expanding applications of returnable containers(Expansion to more product types)
Topics DetailsProducts
1.6
0.3
0.1
0.3
0.3
2.6
Reduction(Thousandtons/year)
■ Results of activities to reduce packaging and wrapping materials (FY2012)
＊1 Ecological plastic : The general name for plastics developed by Toyota for use in vehicles, which include plants as raw material and achieve better heat resistance, impact resistance, and other properties than general plant-derived plastics＊2 Bio-PET : PET that is manufactured by replacing the monoethylene glycol that is one of the raw materials of polyethylene terephthalate with biological raw material derived from sugar cane＊3 New Ecological plastic : Plastic that provides far better heat resistance, durability, expansion and contraction resistance, and other properties, than other general plastics derived from plant materials ＊1 Waste at cost : Materials discarded that are recycled for a fee
Development
and Design
Production
and Logistics
Sales
End-of-life
Reduction of discarded materials from the plants
Production
Promotion of effective use of resourcesProduction and Logistics
■ Resource Flow ■ Environment Center
ProductsResourceinput
We promote resource loss reduction activities to cut waste from the plants. In particular, we are tackling yield improvement measures and waste reduction to steadily cut down the amounts of waste output by the company.
The Toyota Environment Center is an energy recovery plant that is adjacent to the Motomachi plant. The Center generates electricity and steam by burning combustlble waste and functions as the energy source for the Motomachi plant.
・The Center had been completely shut down due to decrepit facili-ties and resumed its operation in April 2009 after the renewal. Managing combustion drastically reduced the emissions of substances of concern in the exhaust gas.・Incinerated ash shall be recycled outside of Toyota as materials for cement or pavement , etc.
Usage is reduced by simplification of wrapping specifications, including slimmer bumper wrapping, and wider use of returnable shipping containers.
Reduction of packaging and wrapping materials
Logistics
Reduction of water usageWe are constantly working on ways to use water effectively in the plants, with particularly thorough attention to management in car assembly plants, which use large volumes, to reduce overall water usage
Development and wider use of plastics derived from plants
CT200h
Toyota is suppressing CO2 emissions by other methods besides recycling, to prevent global warming.
・Suppress CO2 emissions to prevent global warming・Helping to reduce the usage of oil resources
Use of Ecological plastic in the “Raum” in May 2003 Use of Ecological plastic＊1 in cars
Use of new Ecological plastic in the “CT200h” in Jan. 2011 Bio-PET＊2 derived from sugar cane is usedin new Ecological plastic＊3.
Use of new Ecological plastic for interior surfaces in the “SAI” in Nov. 2011Usage has reached 80% of the surface area of all interior decor components.
Use in components that are difficult with previous Ecological plasticReach the same level as petroleum-based plastics, including component costs.
Petroleum-based plastics
Plastics derived from plants
■ Record of use in cars
〈Use of Ecological plastic in interior parts of partially redesigned SAI〉
■ The Ecological plastic CO2 circulation concept
Sugar cane
Before improvement : Corrugated cardboard
After improvement : Air bubble sheet (polyethylene)
SAI
：Areas where new eEcological plastic is used：Areas where Ecological plastic is used (approximately 80% of interior decor surface area)
g p
Parts which require high wear resistance... Seat covers, floor carpets, etc.
mponents.Used in
mass-produced cars!!
Toyota researched how to use plasticsmade from plants in cars!
CO2
CO2
CO2CO2
Photonicsynthesis
Plant-basedmaterials
Raw materials
Heat recovery
Automobileparts
Worldfirst
Worldfirst
Examples of efforts other than recyclingDevelopment and Design
Internal recycling
Materials discarded (Wastenot processed within Toyota)
Internal reutilizationIntra-process reutilization
Recycling for profitWaste at cost＊1Incineration of wasteLandfill waste
Vehicle Recycl ing
8 9
＊1 Rebuilt parts : Parts that have been disassembled and cleaned, have had internal parts replaced etc., and are at the same standard as new parts
Dealer
Customer
DeliveryPart
request
Vehicle repair
Repair consultationand request
Inventoryinformationdatabase
e-commercesite
Partsdistributor
Used partsdealer B
Used partsdealer C
Wants to useused bumpers
Access
Product(Delivery via parcel service)
Searchandorder
Shipping instruction
■ How e-commerce works
Used parts andrebuilt parts
Part name New parts(reference)
Number supplied
Automatick transmission 3,775
Remanufacturing parts
Power steering 9,908
3,758
Used parts
Torque converter
46,135
99
4,721
5,766
ー
■ Supply of rebuilt parts＊1 and new parts (FY2012)
Deflector for engine compartment
Used partsdealer A
Development
and Design
Production
and Logistics
Sales
End-of-life
Recycling in Changing Times, and Toyota’s Response
Established Toyota Metal Co., Ltd.
＊1 EU ELV Directive : Reduce waste output from end-of-life vehicles, recover materials for environmental protection, promote reuse and recycling. It is legally binding.＊2 3R (Reduce, Reuse, Recycle) : Reduce the amount of waste generated, reuse it, and then recycle it.＊3 Thermal recycling : Rather than simply incinerating waste, use the heat and gases etc. that are generated by incineration.＊4 Material recycling : Process the waste produced by used products, and use it as materials or raw materials for new products.
Changing times
Toyota’s Responses
1970～ 1990～ 2001 2002 2003 2004 2005 2006 2007 2008～
・Advance of the car society・Factory pollution problems →Rising environ mental awareness
・The 2000 EU ELV Directive＊1 ・Recycling rate 95% in 2015 ・Mandatory disclosure of disassembly information・Enactment of the 2000 Basic Law for Establishing the Recycling-based Society and the 3R Law＊2 ・Demand for the promotion of recycling design
・2005 Act for promotion of Use of Recycled Resources(Japan) ・Recycling rate 95% in 2015 ・Mandatory removal of three items (airbags, flon, ASR)
・Rising resource prices, rare metal shock Expanded action towards securing resources・Growing momentum for promoting 3R Advancing recycling technologies (thermal＊3 → material＊4)
Towards the creation of a recycling-based society
Efforts for recycling design(design for easy removal of components)
More advanced recycling of resources (rare earths, rare metals, etc.)
Compliance with the Automobile Recycling Law
★1970～
Started ASR operations
★1998～
Established Recycle Technical Center
★2001
Implementation of the Automobile Recycling Law
★2005
P12 P14 P17
Prepared scenarios for recycling technologies in 2020
★2007
Established the Resource Recirculation Committee
Recycling design efforts based on recycling technology scenarios
★2008
Various recycling design points are extended to all new vehicles from the Raum
Toyota Metal Co., Ltd. (Handa City, Aichi Prefecture) Recycle Technical Center
(Toyota Metal Co., Ltd.)
Raum Prius
ASR recycle plant (Toyota Metal Co., Ltd.)
Discarded bumpers are made which allows easy recycling when they are discarded, so we actively collect them through Toyota dealers nationwide.
Handling of used parts began and extends nationwide in 2001, using e-commerce (electronic commercial transactions) to make ef fect ive use of components, through wider use of used parts, supply of remanufacturing parts, etc.
Collecting discarded bumpers from dealers and recycling of plastics
Reuse of used parts
We have advanced the technology built up by recycling bumpers, developing a recycled mater ia l with end-of - l i fe vehicle bumpers as the raw material.
Sales
●Thorough removal of foreign material, such as grit adhering to bumpers●Quality acquisition through detailed adjustment of constituents●Start of use in deflectors
Parts distributor : Company for the distribution and sale of car repair parts and accessories, established with joint investment from Toyota Motor Corporation and local dealers. 34 companies nationwide
We also established technologies that allow eco-plastics and recycled plastics to be used for 20% of all plastic compo-nents in 2013.
New technology development towards use of recycled plastic materials from discarded bumpers
●Decision of the target components and track of progress●Removal of coating fragments etc., which reduce impact resistance
World'shighestlevel
ng of plastics
Bumpers replacedfor repairs at car dealers
are recycled.
Coffee Break
Recycling at the Sale Stage
Vehicle Recycl ing
10 11
General overview of the recycling
Airbag collectionand recycling
Airbag
Hood (Steel)→Vehicle parts, general steel products
Wiring harness (Copper)→Copper products, engines (cast aluminum reinforcement)
Engine oil (Oil)→Alternative fuel for boilers and incinerators
Radiator (Copper, aluminum)→Gunmetal ingots, aluminum products
Coolant (Alcohol)→Alternative fuel for boilers and incinerators
Bumper (Resin)→Interior parts, tool boxes, etc.
Battery (Lead)→Batteries
Transmission (Steel, aluminum)→General steel products, aluminum products Tire (Rubber)→Raw materials, alternative fuel for cement, etc.
Engine (Steel, aluminum)→Engines, aluminum products
Window (Glass)→Tiles, etc.
Suspension (Steel, aluminum)→General steel products, aluminum products
Gear oil (Oil)→Alternative fuel for boilers and incinerator
Catalytic converter (Rare metal)→Catalytic converters
Door (Steel)→Vehicle parts, general steel products
Tire (Rubber)→Raw materials, alternative fuel for cement, etc.
Bumper (Resin)→Interior parts
Trunk (Steel)→Vehicle parts, general products
Seat (Urethane foam, fiber)→ Soundproofing materials for vehicles Body (Steel)→Vehicle parts, general steel products
Dismantlingcompanies
Collectingcompanies
Engines, transmissions, catalysts, tires,batteries, oils, fuels, flons, airbags, etc.
17～19％
40～60％
Approx. 3.6 million units/year
Shreddingcompanies
ASR recyclingcompanies
20～45％
Ferrous,nonferrous metal
Soundproofing products,copper, slag, electricity, etc.
ASR
Sorting
Recycling
Removal
Press
End-of-life vehicles
Exports ofused cars
End user
Dealers
Used cardealersServicecenters
Wheel (Steel, aluminum)→Vehicle parts, general steel products, aluminum products
ASR material composition (Wt%)
Resin33
1615
Urethane foamFabric
Combustible
Non-combustible
7Rubber
Iron 8
GlassWire harness Nonferrous metal
754
Paper2
Wood3
■Recycling/recovery route for end-of-life vehicles(Japan)■Examples of parts being recycled from end-of-life vehicles
ASR landfill,etc.
Vehiclerecycling/
recovery rate :over 99%＊2
＊1 ASR : Abbreviation of Automobile Shredder Residue.＊2 Recycling efficacy rate : Weight sent for recycling / total weight of end-of-life vehicles
End-of-life vehicles Removal of parts in good condition
Reuse as used parts, and as ferrous and non-ferrous metals
Press
Dismantling company Shredder company
Shredder
Recycling company
Reuse as materials
Sort into three
Ferrous Nonferrous metals Shredder residue（ASR＊1）
Bumper
CFC collection
Flon
Battery
Catalyst Power steering, etc.
Engine, transmission
Reuse as ferrous and non-ferrous metals
Reuse as energy
(Copper)
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life
Vehicle Recycl ing
12 13
Glass
High-strength, precise tiles
Landscape pavingResin within ASR
Development and use of ASR sorting technology
In 1993, Toyota started working jointly with Toyota Metal Co., Ltd. to develop ASR recycling technology. We built a unique recycling plant and started operating it in August 1998, recycling on a mass production basis (approximately 15,000 cars per month).
To use automobile shredder residue, leaving no residues, it is necessary to return it to the basic materials of products.That requires separation of constituents to raise their purity, so we developed special separation technologies for ASR recycling plants, using wind and magnetism, to make shredder residue reusable.
Toyota Metal Co., Ltd.
World’s firstmass production
process of shreddingand ASR recycling
ELV Shredder Plant（End of Life Vehicle）
ASR Recycling Plant（Automobile Shredder Residue）
Primary shredderMain shredder
Pneumatic sorting
Pneumaticsorting
Pneumaticsorting
Crushing
Trommel
ASR(Shredder dust)
Glass
Aluminum
Copper
Resin/rubber
Melt-solidification
Rotating sieve
Ferrous metal
Non-ferrous sorting
Magnetic sorter
Shredded ferrousmetal
Nonferrousmetal
Iron scrap (Toyota plants)
Press
Electric furnace heat source
＊ ASR ： Abbreviation of Automobile Shredder Residue.
●Toyota has established a technology to mix and heat ASR, reducing it to 1/5 of the volume.
●The amount of lead elution is reduced to 1/5 of the previous level, reducing the environmental load on landfill sites.
Recycle of glass
Technical development about landfill
We have developed technologies to recycle vehicle glass, making the most of its high-purity property.
Use as substitute fuelThe resin that is the largest ingredient of ASR, by weight, is used as alternative fuel.
Electric steel furnaces use heat sources and carbon additives when then melt ferrous scrap to turn it into steel.
By adding an appropriate amount of the resin sorted out from ASR, it has become possible to achieve a heating efficiency usable as a heat source and also to use the resin as an alternative to the recar-burizer.
The Automobile Recycling Law calls for the ASR recycling rate to be raised to 70% by 2015, but Toyota already reached that target in 2007.
Use of resin as a heat source for electric steel furnaces
Resin within ASR
Iron scrap
Steel and components for vehicles
Substitutionfor heat sourcesand carbonadditives
Dissolution
Joint technical developmentwith Aichi Steel Corporation
in Jan. 2005
Joint research with Sanei Corporationand in use since April 1999
This technology enables effec-tive use of l ight materials of low calori f ic value, such as mixed resin, which were previ-ously difficult to recycle.
Electric steel furnace
Recycling of automobile shredder residue (ASR＊1)from end-of-life vehicles
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life
Urethane foam/fibers
Vehicle Recycl ing
14 15
Automobile Recycle Technical Center
Removing a wire harness＊3 with heavy scrapping equipment
＊1 Urban mines : The valuable rare metals contained in vehicles, electrical appliances, etc. that are discarded as garbage in urban areas are seen mine resources.＊2 Neodymium and dysprosium : Rare earths used in the production of powerful permanent magnets＊3 Wire harness : The bundled electric wires that supply electricity within the vehicle.
Before scrapping
Heavy scrapping equipment
Motor removal Motor disassembly
After scrapping
Before scrapping After scrapping
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life vehicle recycling researchToyota has to date conducted extensive research to enhance the dismantlability of end-of-life vehicles and the recyclability of parts. To further advance dismantling and recycling technologies and commercialize and incorporate them in vehicle designs based on the technologies and expertise gained from this research, Toyota established the Automobile Recycle Technical Center within Toyota Metal Co., Ltd. in 2001.
Toyota Motor Corporation Dismantling and shredding industries, etc.
Component and material manufacturers, etc. Tool and instrument manufacturers, etc.
Positioning of the Automobile Recycle Technical Center
Automobile RecycleTechnical Center
・・Research into vehicle structures that are easy to recycle・Research into efficient scrapping technologies・Development of appropriate and efficient recycling technologies
Proposing easy torecycle vehicle designs
Proposing efficientdismantling technologies
Technical developmentfor recycling rare metal andrare earth resources
Disclosure ofinformation on dismantling
technologies, etc.
Disclosure ofinformation on dismantling
technologies, etc.
Technical developmentfor recycling rare metal andrare earth resources
Research into technologies for disassembling parts that use noble metals
R&D on resource recycling
We are researching technologies for the efficient dis-assembly of electronic circuit boards and sensors etc., which are viewed as urban mine resources＊1, and technologies for the removal of components containing noble metals.
Research into technologies for disassembling parts that use rare earthsWe are researching efficient dismantling technologies for the magnets used in devices such as hybrid vehicle drive motors which use neodymium and dysprosium＊2.
Research into efficient removal and recovery technologiesWe are researching dismantling technologies that are efficient when used with widely used heavy dismantling equipment, and easy to dismantle vehicle structures.
Development of appropriate and efficient recycling technologiesWe are researching and developing technologies for the recycling and appropriate treatment of parts disassembled from end-of-life vehicles, including methods for their appropriate and efficient disassem-bly and reuse.
■O2sensor
■Engine ECUWorld'shighestlevel
End-of-life
Research and development of recycling technologies
Vehicle Recycl ing
16 17
Workshop for disassembly and removal of hybrid vehicle batteries
Vehicle resin parts
Rare earth
China97%
India 2%Brazil 1%
Other0%
Chile34%
Peru 8%U.S.A 8%
Other50%
Chile41%
Australia24%
China13%
Other 22%
Russia19%
Indonesia13%Canada 13%
Other55%
Copper
Lithium
Nickel
Source: Annual report on the environment in Japan 2010
Toyota is working on rare metals to provide its customers with stable supply of good vehicles
Resin recycling researchWe are considering the possibility of reusing resin vehicle parts recovered from end-of-life vehicles, as a way of promoting the wider recycling of resin. E.g.) Bumper material from end-of-life vehicles→Reused in resin body componentsWe are also working on R&D towards future realiza-tion of bumper to bumper recycling.
Research into technology for the removal and recovery of batteries from hybrid vehiclesEnd-of-life hybrid vehicle battery units basically remain at high voltage and, if they are damaged during the removal process, they can cause sparks, fire, and fluid leakage accidents, so safe removal is required. Therefore, we are collaborating with the Japan ELV＊1 Recycler’s Association to run training sessions nation-wide on the safe and appropriate removal of hybrid vehicle batteries.
Manuals for the disassembly and removal of hybrid vehicle batteries are also available on the Toyota Motor Corporation official site (http://www.toyota.co.jp/).
In recent years, vehicles have come to use numerous motors and circuit boards. Compared to previous vehicles, hybrid vehicles, in particular, have increasing numbers of components, such as batteries and motors that use rare metals＊1 and rare earths＊2.
Coffee Break Periodic table of the elements1
1
(Period)
2
3
4
5
6
7
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18(Group)
Hydrogen
1
H
Lithium
3
Li
Sodium
11
Na
Potassium
19
K
Rubidium
37
Rb
Cesium
55
Cs
Francium
87
Fr
Helium
2
He
Neon
10
Ne
Argon
18
Ar
Krypton
36
Kr
Xenon
54
Xe
Radon
86
Rn
Beryllium
4
Be
Magnesium
12
Mg
Calcium
20
Ca
Strontium
38
Sr
Barium
56
Ba
Radium
88
Rg
Lanthanum
57
LaCerium
58
CePraseodymium
59
PrNeodymium
60
NdPromethium
61
PmSamarium
62
SmEuropium
63
EuGadolinium
64
GdTerbium
65
TbDysprosium
66
DyHolmium
67
HoErbium
68
ErThulium
69
TmYtterbium
70
YbLutetium
71
Lu
Scandium
21
Sc
Yttrium
39
Y
LanthanideSeries
57～71
ActinideSeries
89～103
Titanium
22
Ti
Zirconium
40
Zr
Hafnium
72
Hf
Vanadium
23
V
Niobium
41
Nb
Tantalum
73
Ta
Chromium
24
Cr
Molybdenum
42
Mo
Tungsten
74
W
Manganese
25
Mn
Technetium
43
Tc
Rhenium
75
Re
Iron
26
Fe
Ruthenium
44
Ru
Osmium
76
Os
Cobalt
27
Co
Rhodium
45
Rh
Iridium
77
Ir
Nickel
28
Ni
Palladium
46
Pd
Platinum
78
Pt
Copper
29
Cu
Silver
47
Ag
Gold
79
Au
Zinc
30
Zn
Cadmium
48
Cd
Mercury
80
Hg
Boron
5
B
Aluminum
13
Al
Gallium
31
Ga
Indium
49
In
Thallium
81
Tl
Carbon
6
C
Silicon
14
Si
Germanium
32
Ge
Tin
50
Sn
Lead
82
Pb
Nitrogen
7
N
Phosphorus
15
P
Arsenic
33
As
Antimony
51
Sb
Bismuth
83
Bi
Oxygen
8
O
Sulfur
16
S
Selenium
34
Se
Tellurium
52
Te
Polonium
84
Po
9
17
35
53
85
FluorineF
ChlorineCl
BromineBr
IodineI
AstatineAt
Rare metalRare earth
LanthanideSeries
Hybrid vehicle motors Hybrid vehicle batteries
Ni Nickel
Li Lithium
Cu Copper
Nd Neodymium
Dy Dysprosium
Procurement risks
●The potential extraction period is short●Production is concentrated in a few countries.●Procurement is easily affected by economic and political changes.●Prices are extremely volatile.
Countermeasures
●Reduce the quantities used of materials subject to procurement risks.●Stabilize procurement by opening up new routes.●Recycle resources from “urban mines”.
■Leading producing countries of non-ferrous metal resources(2009)
＊1 Rare metal : Metals difficult to obtain. Lithium, cobalt, nickel, etc.＊2 Rare earth : Rare-earth 17 metals of similar chemical properties, included in the rare metals
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life
Resource recycling of rare metal and rare earth
This is one of the factors that can have a major impact on the production and sale of cars in the future
＊1 ELV : End-of-life
Vehicle Recycl ing
18 19
Dismantler : Consolidation with recovered catalysts
③
Reverse logistics of supply deliveries
④
Distributor : Part supply and return service
③
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life
Resource recycling of rare metal and rare earth Recycling of nickel＊1 included in batteriesIn October 2010, Toyota started the world’s first “battery to battery” recycling operation, in partnership with other related companies. It extracts nickel from used nickel-metal hydride batteries and recycles it as raw material for batteries. Total recycling of rare metals has moved into the final validation phase＊2.
Development of advanced sorting and extraction technologies
Until now
Stainless
In future
＊1 Nickel : Rare metal＊2 Validation phase : Studying the problems of a newly-developed product or technology, etc. by using it in real situations, as preparation for practical use＊3 Cobalt : Rare metal
ToyotaChemicalEngineering
Toyota
PEVE（Primearth EV
Energy）
Sumitomo MetalMining Co., Ltd.
Rare earthrecycler
Nickel Rare earth
Reduction process, crushing and sorting
Refining andprocessing
Production of hybrid vehicle batteries
Hybrid vehicle production
Materials from battery recycling
Nickel battery raw materials Hybrid vehicle battery Hybrid vehicle
Product
Sumitomo MetalMining Co., Ltd.
Toyota MotorCorporation
Primearth EVEnergy Co., Ltd.
Toyota ChemicalEngineering Co., Ltd.
Hybrid vehicle battery recycling process
We have built a collection network, unique to Toyota, for the collection of used batteries, and the Toyota HV＊1 Call Center receives collection requests nationwide. This system is able to recover over 90% of used batteries (record for FY2010).
This system also increases consolidation on the returning deliv-ery trucks of Toyota service parts, reduce CO2 emissions. In future, we plan to build a global recycling system, covering North America, Europe, and elsewhere.
＊1 HV : Abbreviation of Hybrid Vehicle
Outline of the Whole Collection Network
Dismantling companies Dealers
Aggregate
① Collection request
② Recovery request
③Transportation (consolidated with catalysts)
Toyotsu RecycleCorporation Distributors
Part supply transportationcompany
Sumitomo Metal MiningCo., Ltd.
Toyota ChemicalEngineering Co., Ltd.
③Transportation (reverse logistics of service parts delivery)
④Transportation (reverse logistics of service parts delivery)
⑤Reduction process
Toyota HV call center(24 hours a day)
Customers Dismantlingcompanies
systemsystemsystem
Toyota HVCall Center
Removal ofhybrid vehicle batteries
Discarded battery receptionCollection and transportation
instructions
Hybrid vehicleproduction
Production ofhybrid vehicle batteries
Battery raw materialmanufacturing
Ni and Co refining
Rare earthcompounds
Materials frombattery recycling
NEW
Nickelhydroxide
Cathode material Anode material
NEW
Rare earth compounds
Recycled as scrap for raw material of stainless steel.
Transition to complete recycling. Removal of nickel, cobalt＊3, and rare earths
End-of-lifehybrid vehicle
Hybrid vehicleHybrid vehiclepurchasepurchase
Hybrid vehiclepurchase
Reduction,crushing and sorting
Worldfirst!
Vehicle Recycl ing
20 21
Lithium battery
＊1 Neodymium/dysprosium : Rare earths used in the production of powerful permanent magnets.
Recycle loop of carbide product waste (tungsten)● With the cooperation of Sumitomo Electric Indus-tries, Ltd. and Toyota Motor Corporation, the world’s first and forefront system for recycling tungsten (rare metal) from carbide product waste in domestic reflow has been established.
● 100% recovery and recycling of tungsten from carbide product waste has been achieved.
● This activity is being extended in Toyota Group (16 companies).
Toyota(Scrap sorting)
Chips, etc.
Tungsten powder
Rotating tools,etc.
Carbidechips
Carbidedrills
Development
and Design
Production
and Logistics
Sales
End-of-life
End-of-life
Resource recycling of rare metal and rare earth
Development of systems for vehicle-to-vehicle recycling of magnets
Development of motors with less rare earths wherever possible.
Rare earth resource recyclingNeodymium and dysprosium＊1, which are rare earths, are essential for the magnets used in devices such as hybrid vehicle drive motors.
Copper resource recyclingHVs and electric vehicles use copper in their motor cables and battery electrodes, as well as in the wiring harnesses.
Resource recycling of copper, aluminum, rare metal, and non-ferrous metalCompared to nickel metal hydride batteries, lithium batteries use less metal resources to produce the same battery capacity. Toyota is developing technologies to recycle rare metals, non-ferrous metals and other elements of lithium batteries in the same way as from nickel metal hydride batteries.
■Toyota's Goal of Magnets Vehicle-to-Vehicle Recycling
Toyota’s Responses
Extracting magnetsNew car
manufacturing
Recycling ofResourcesMagnets
New carScrappingDismantling
S
N
S
N
S
N
S
N
Rare earth
Motor wires
Wire harnesses
●Development of sorting technologies
●Parts evaluation tests
●Development of manufacturing methods and other fields are R&D topics.
Copper
Group company of Sumitomo Electric Industries,Ltd.
(Material recycling)
Group company ofSumitomo Electric Industries,Ltd.(Carbide product manufacturing)
Vehicle Recycl ing
22 23
100
70
80
90
60
50’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 (FY)
Legal standard for FY2015 : 70%
93%
57%
94%
66%
96%
76%
97%
80%
97%
81%
97%
85%
99% 99%
93% 94%Toyota's recycling/recovery rate(vehicle conversion value)Toyota’s ASR recycling/recovery rate
FinlandFinlandFinlandSwedenSwedenSweden
UKUKUK
GermanyGermanyGermany
AustriaAustriaAustria
MaltaMaltaMalta CyprusCyprusCyprus
EstoniaEstoniaEstoniaLatviaLatviaLatvia
FranceFranceFrance
SpainSpainSpain
NetherlandsBelgiumLuxembourg
NetherlandsBelgiumLuxembourg
NetherlandsBelgiumLuxembourg
LithuaniaLithuaniaLithuania
PolandPolandPoland
Czech Rep.Czech Rep.Czech Rep. SlovakiaSlovakiaSlovakia
RomaniaRomaniaRomania
HungaryHungaryHungary
IrelandIrelandIreland
PortugalPortugalPortugal ItalyItalyItaly
GreeceGreeceGreece
SloveniaSloveniaSlovenia
CroatiaCroatiaCroatiaBulgariaBulgariaBulgaria
DenmarkDenmarkDenmark
■Transition in Toyota's vehicle recycling/recovery rate and ASR recycling/recovery rate
Compliance with overseas automobile recycling lawsAll EU member states have enacted automobile recycling laws based on EU ELV Directive of 2000, and as of January 2007 automakers started to take back end-of-life vehicles (ELVs) in most member states. In cooperation with TME and distributors in various member states, Toyota has completed construction of a network ELV collection of the 28 EU member states, and is proceeding with the necessary action in the remaining four member states in accordance with government authorization of dismantlers.In other countries around the world, Toyota is diligently pursuing similar responses, working closelywith its distributors to ascertain local regulatory trends and studying local infrastructure in each country.
■Legislation status
※ EFTA：4 member states of Switzerland, Norway, Iceland, and Liechtenstein
■EU member states
Enacted
Under study
EU, EFTA※, Japan, Taiwan, Korea, Turkey
Country/RegionStatus
Russia, India, China, Mexico, Vietnam
Legend
＊1 The EU ELV Directive : A directive adopted in the EU in 2000. It is legally binding.＊2 TME (Toyota Motor Europe) : the management company in overall control of Toyota’s European operations
Compliance with overseas recycling laws
Outsourced/payment
The Automobile Recycling Law, which came into effect in January 2005, mandates an appropriate division of roles between automakers and other involved parties, to promote the recycling and appropriate processing of end-of-life vehicles. In line with the Act for Promotion of Use of Recycled Resources, Toyota collects CFCs, airbags, and ASR from end-of-life vehicles and actively uses them for recycling and other applications.
■System for collection and recycling under the Automobile Recycling Law
Registration required Certification requiredLicense required
Flow of expensesFlow of materials
Used parts, etc.
Return of vehicleweight tax
Metals, etc.
Metal, electricity,etc.
Final owner
Landfill
Collection company(dealer, vehicle maintenance company, etc.)
Flon collecting company
Dismantling company
Shredding company
ASR recycling company, etc.
Recycling fee
Collection of flon,etc.
Fee payment
Outsourced/payment
Claim
Payment
Contract
〈ART※〉
Collection ofairbags
Payment
Outsourced/payment
Outsourced/payment
Outsourced/payment
Airbagrecyclingcompany
Fluorocarbondestructioncompany
Japan automobile recycling promotion center(JARP)〈Three designated companies〉
〈Collection management companies by team〉
※ ART：Automobile shredder Residue recycling promotion Team
Japan AutoRecyclingPartnership(JARP)
De-registration system
under the road vehicles act
Usable parts market/
Usable metal market
Used car
End-of-lifevehicle
End-of-lifevehicle
End-of-lifevehicle
Disassembledvehicle
ASRcollection
Residue
〈TH team〉 8 companies(Toyotsu Recycle Corporation)Toyota, Honda, Daihatsu, Hino, VW, Audi, Peugeot, BMW
New vehicle owner, etc.
Fund management corporation
Information management center
Designated recycling support organization
Automakers and importers (self implementation or outsourced)
Targets: 4-wheel passenger vehicles(including mini-vehicles) and 4-wheel commercial vehicles(standard, small, mini-trucks and buses)
Outline of the Law for recycling of end-of-life vehicles (Automobile Recycling Law)(in effect since January 1st, 2005)
Compliance with the domestic act for promotion of use of recycled resources
Vehicle Recycl ing
24
Milestone
Toyota Metal Co., Ltd. established to meet future demand for responsible disposal of end-of-life vehicles
・ First automaker to establish a recycling company・ Approx. 6.5 million vehicles recycled between 1972 and 2012
1970
Year
1973 ・ Established by Toyota Tsusho Corporation; 30,000 kL of waste oil processed and recycled between 2008 and 2011
Toyota Chemical Engineering Co., Ltd. established to process and recycle cutting oil from Toyota production plants
Detai l s
1985 ・ Established by Toyota Tsusho Corporation; approximately 16 million catalysts recycled between 1985 and 2012
Toyotsu Recycle Corporation established to recover and recycle precious metals from exhaust gas catalysts
2005 ・ Expanded to 13 plants worldwide; approximately 2.5 million tons recycled between 2005 and 2012
Aluminum recycling business established at Toyota production plants
2009 Recycling guidance commences in countries where hybrid vehicles are sold
・ Aiming for development of NiMH battery collection systems outside Japan
1996 ・ Approximately 10 million recycled between 1996 and 2012Bumper recycling across Japan commences
1998 ・ Established at Toyota Metal Co., Ltd.・ World's first dedicated ASR plant・ ASR recycled into soundproofing materials for 22 million vehicles between 1998 to 2012
Automobile Shredder Residue (ASR＊2) recycling plant established
・ Approximately 30,000 collected between 1998 and 2012End-of-life hybrid vehicle NiMH battery collection and recycling commences
2001 ・ Established at Toyota Metal Co. Ltd.; first automaker to establish an independent recycling research institute
Automobile Recycle Technical Center established
・ Established by Toyota Tsusho Corporation; approximately 200,000 used parts handled annually
Ecoline Corporation, a used parts sales network operator, established
・ Approx. 600,000 used parts sold between 2001 and 2012Parts e-commerce system introduced for Toyota parts distributors throughout Japan
2003 Toyota Recycling Vision formulated ・・ Sets targets for 2015
"Raum" model launched ・・ Incorporates Toyota's proprietary "Design for Recycling" (DfR) features
・ World-firstBio-plastics used in parts for the first time
2007 95% vehicle recycling rate achieved
2010 Battery-to-battery recycling of hybrid vehicle NiMH batteries commences
・ World-first
2011 99% vehicle recycling rate achieved
2012 Magnet-to-magnet hybrid vehicle motor magnet recycling system launched
・ World-first
2013 System for reusing NiMH batteries in stationary rechargeable batteries launched
・ World-first
Redesigned "Sai" dedicated hybrid sedan launched ・・ Achieved 20 percent usage of Ecological Plastic and recycled resin materials
Toyota wins JEMAI Rare Metal Recycling Award ・ First automaker to win the award
Toyota wins Prime Minister's Prize in the 3Rs Awards ・ First automaker to win the award
Tungsten recycling system launched ・ World-first; approximately 75 tons recycled between 2010 and August 2013
＊1 Toyota Motor Corporation, Toyota Tsusho Corporation, and their affiliates＊2 ASR : Abbreviation of Automobile Shredder Residue. It is the dust left from shredding end-of-life vehicles.
Result of Toyota Group’s Efforts＊1
1992 Toyota Environment Committee established ・ Chaired by TMC president