Nelson Mandela Metropolitan University NMMU, Port Elizabeth South Africa 25. November Recycling of Electric Cars

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1 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

2 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 1

3 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 2

4 Recycling Loops Preparation of Resources raw material Production Use End of life product Post Production Recycling Post Industrial Recycling Re use Post Consumer Recycling Landfill Mining Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 3

5 Why recycling? Preservation of material resources Ore, Oil, Minerals, Preservation of energy resources Oil, Natural Gas, Uranium Ensuring the availability of special materials (Rare Earth metals, Conflict minerals,..) Reduction of emissions Dysprosium, Terbium, Gold, Coltan (Tantalium), Gallium, Indium, Carbon dioxide, Nitrogen oxides, Methane, Reduction of waste Dangerous Waste, Sludges, Acids, Reduction of pollutions Lead, Cadmium, Mercury, Dioxins, Furans, Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 4

6 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 5

7 Present post consumer recycling for ELV s ELV s Dismantling workshop Shredder plant Post shredder technologies 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 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 6

8 Status Quo of Automobile Recycling ELV s Dismantling workshop Shredder plant Post shredder technologies Battery, Airbag-dismantling/ -controlled demolition Tyres, Drainage, Spare parts Treatment operations for depollution Dismantling of parts to promote recycling (Plastics, glass, katalyst) Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 2

9 Status Quo of Automobile Recycling ELV s Dismantling workshop Shredder plant Post shredder technologies Magnet separator => Ferrous metals Sorting by hand Eddy current separator => Nonferrous metals Swim sink plant Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 3

10 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 4

11 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 7

12 Unusual features at electric vehicles Car body lightweight construction materials DC/AC Voltage transducer Battery charger Battery Trend: Lithium ion battery 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 8

13 Electric Vehicles and Car body materials E-up! Tesla Fe Steel Al Aluminium Twizy BMW i3 Mg Magnesium Plastic CFK texture GFK Source: Wikipedia Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 9

14 Operation and construction of an electromotor - Synchronous motor (inside runner) 1 Rotor 2 with permanent magnets 1 from neodymium iron boron alloy Nd 2 Fe 14 B (Sinter material) % Fe % Rare Earth Metals REM 1-2 % Boron 0-4 % Cobalt 2 Magnetically hard material (high residual magnetism and high magnetic field strength) Temperature stability by Dysprosium or Terbium Corrosion resistance by cobalt Fe Steel Co Cobalt Stator 4 with magnets excited electrically 3 Nd Neodymium Dy Dysprosium Te Terbium Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 10

15 Power unit from Electric Vehicles DC/AC voltage transducer Three-phase motor Auxiliary units DC/DC voltage transducer Au Gold Ag Silver Cu Copper Ga Gallium In Indium Ge Germanium Ta Tantalum Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 11

16 Operation and construction of a Li-Ion-battery e - + V - Li-Metal oxide in Layer strukture (LiNiO 2, LiCoO 2, LiMn 2 O 4, Li 4 Ti 5 O 12, ) Porous graphite structure on Copper collector Electrolyte made of lithium salts with solvent Cu Copper Ni Nickel Co Cobalt Mn Mangan Li Lithium C Graphite Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 12

17 Present recycling quotas for different metals > 50 % Cu Copper Au Gold Ag Silver Pd Palladium Pt Platinum Pb Lead Sn Tin Al Aluminium Well established recycling loops > % Zn Zinc > % Ru Rutherium 1-10 % < 1 % % Source: Project OPTUM Pr Praseodymium Nd Neodymium Dy Dysprosium Ga Gallium In Indium Ge Germanium Tb Terbium Only Post Production Recycling (China) Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 13

18 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 14

19 Improvement of the current Automobile Recycling for Electric Vehicles Electric ELV s Dismantling workshop Shredder plant Post shredder technologies Necessary dismantling operations before the shredder process Dismantling of Electromotor Dismantling of Power Unit Special training for the handling of high voltage components Dismantling of Battery Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 15

20 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 16

21 Recycling strategies for electromotors and materials from electromotors Reuse after Repair Reuse after cleaning and testing Spare parts Reuse after an industrial exchange components manufacture Exchange parts Material recycling by dismantling and crushing => Magnet powder for metal sintering or polymer binding Feedstock recycling: recovery of the base elements by pyro-metallurgical methods, recovery the rare earth metals from slag by hydro-metallurgical methods Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 17

22 Production of magnets bei powder metallurgy (sintering) Mixing the alloying metals Homogenizing the alloying in a high frequency furnace Powder production Powder press => green part Sinter process Magnetization Finishing Quality control Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 7

23 Production of magnets by metal injection moulding (polymer binding) Metal powder Mixing Granulation Feed stock Polymer binder Injection molding Solvent debinding Green part Thermal debinding Brown part Sintering Finished part Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 18

24 Hydro-metallurgical treatment of magnets from electromotors Precipitation agent Oxalic acid Leaching of magnet scrap metal with hydrochloric acid (Solvent) Precipitation Precipitate Oxalate REM 2 (C 2 O 4 ) 3 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 19

25 Hydro-metallurgical treatment of magnets from electromotors (strongly simplified) Magnet scrap metal HCl Leaching Laugung Dissolving into hydrochloric acid Rare Earth Metals NaOH, H 2 O 2 Fe-Precipitation Fällung FeOOH Reductionprocesses Na 2 S Co-Precipitation CoS REM 2 O 3 C 2 H 2 O 2 Oxalate-Precipitation REM 2 (C 2 O 4 ) 3 Heat treatment Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 20

26 Recycling of electromotors state of the art 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 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 21

27 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 22

28 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

29 Metallurgical treatment of circuit boards in the copper plant (Converter) Copper Converter Copper scrap metal, electronic scrap metal Anode furnace Fire refining Cable scrap metal Anode casting machine Copper electrolysis Electrorefining Pure Copper Anode mud with noble metals Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 24

30 Mechanical processing of circuit boards Power Unit Dismantling Steel, Al, Plastics Pre-shreddering Magnetic sorting Steel Granulation Classifying Sorting Copper-rich mixed metal granules to copper plant Polymer mixed granules Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 25

31 Recycling of Power units state of the art 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 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 26

32 Contents 1 Recycling loops and environment protection 2 Present post consumer recycling for ELV s 3 Electric vehicles 4 Improvement of the current Automobile Recycling for Electric Vehicles 5 Recycling of Electromotors 6 Recycling of power units 7 Recycling of Li-Ion-Batteries Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 27

33 Recycling of Li-Ion-batteries Battery Dismantling in modules and cells Fe, Al, Cu, Polymers from Battery case Low temperature shreddering, Sorting Al, Cu from modules and cells Pyrometallurgical processes Co, Ni State of the art Umicore process Li-containing Slag Additive for construction industry Future concept Hydrometallurgical processes Li (Salt) Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 28

34 Hydro-metallurgical treatment of Lithium contained slag Slag Precipitation agent Na 2 CO 3 Leaching of magnet scrap metal with sulfuric acid (Solvent) Precipitation Precipitate Li 2 CO 3 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 19

35 Recycling of Li-Ion batteries state of the art 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 Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 29

36 Prof. Dr.-Ing., Dipl.-Phys. Joachim Schmidt emobility Workshop Nelson Mandela Metropolitan University NMMU, Port Elizabeth South Africa 25. November 2015 Back up charts

37 Recycling Loops Preparation of Resources raw material Production Use End of life product Post Production Recycling Post Industrial Recycling Re use Post Consumer Recycling Landfill Mining Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 1

38 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 5

39 New Components and materials in Electric Vehicles Motor Nd Neodymium Dy Dysprosium Co Cobalt Te Terbium Power Unit Au Gold Ag Silver Cu Copper Ga Gallium In Indium Ge Germanium Battery Li Lithium Ni Nickel Cu Copper Co Cobalt Mn Mangan C Graphite Lightweight materials Al Aluminium Mg Magnesium CFK GFK Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 6

40 Magnetic materials Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 8

41 Material cost Aluminium: Euro/t Mangan: Euro/t Kupfer: Euro/t Nickel: Euro/t Kobalt: Euro/t LiCoO 2 : Euro/t Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 9

42 Umicore process Demontage/Zerlegung => Fe, Al, Kunststoff Quelle: Elwert, T. u. a. Projekt LiBri Schlackeaufbereitung Prof. Dr.-Ing. Joachim Schmidt, Faculty for Automotive Engineering, Ostfalia University of applied Sciences 10

43 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