Incidence of the level of deconstruction on material reuse, recycling and recovery from end-of life vehicles: an industrial-scale experimental study

Abstract

The European Union has set ambitious objectives for the recovery rates of end-of life vehicles (ELVs). The directive 2000/53/CE (DIR, 2000) states that by 1st January 2015 at least 95% of the mass of an ELV must be reused and recovered, of which a maximum of 10% should be in the form of energy.In order to identify the key factors for improving the rate of material reuse, recycling and recovery of ELVs, ACYCLEA (PRAXY group) launched the “OPTIVAL VHU (ELV)” research program in collaboration with INSA Lyon in 2009. Three experimental campaigns were conducted on the industrial site of ACYCLEA to compare different scenarios of deconstruction. The campaigns were done on samples of 90 ELVs. The average mass (MELV) and age were estimated at 989kg/ELV and 14 years, respectively. This article presents the results concerning the material balances of the successive operations. The contribution of each stage of the treatment (namely (i) depollution, (ii) deconstruction, and (iii) shredding and sorting operations) to the rate of recycling, reuse and recovery was calculated.Results showed firstly that the contribution of the operations of depollution was low (3.6±0.1% of the mass of vehicles). The contribution of the operations of deconstruction was higher and increased logically with the degree of deconstruction. It ranged from 5% of MELV for the minimal level of deconstruction (campaign 1) to almost 10% with the highest level of deconstruction (campaign 3). The specific contribution of the operations of deconstruction to the rate of metal recycling was found to be quite low however, in the range of 2.6–2.8% of MELV, Shredding and post-shredding sorting operations enabled the recovery of the largest amounts of recyclable materials but no significant differences were observed between the overall recovery rates in the three campaigns (results ranged from 67 to 70% of MELV). Differences were observed however, for specific fractions such as the automotive shredder residues whose recovery rate was 16.3±0.7%, 13.0±0.5%, and 12.8±0.2% for campaigns 1, 2 and 3, respectively. A larger production of non-ferromagnetic fraction was also observed in campaign 3, probably due to the extraction of the textiles during the dismantling operations which improved the efficiency of post-shredding sorting operations.The highest overall rate of reuse, recycling and energy recovery obtained in this study with the most rigorous approach was 81.5±0.6% of the average mass of the ELV even with the highest level of deconstruction. It therefore appears that the European regulatory target of 95% would be difficult to achieve in 2015, except with a much greater optimization of the sorting technologies and the development of recycling processes.