Heloisa V' de MEDINA

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Eco-Design for Clean Technologies and Recycling
Some lessons from automotive industry

• This paper aims at presenting how eco-design
  practices are promoting clean technologies
  development and diffusion throughout the life
  cycle of products from materials selection to end
  of life products recycling.
• Eco-design concept and practices
• Materials Selection and Ecomaterials
• 2. Eco-design in automotive industry
• Environmental Innovations on products and
  process
• Eco-design fostering cars recyclability
• 3. Some concluding remarks opportunities for
  Brazil

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After Rio-92 World Summit on Environment,
pollution prevention, waste minimization,
materials recovery and recycling has been a
growing subject of interest in Brazil. Since the
end of the last century product design has been
enlarged to cope with environmental requirements
from materials selection up to recycling
processes. The idea is to design products
avoiding rather than controlling environmental
impacts during theirs lifecycle, from cradle to
grave, or from mining extraction to end of life
products recycling to materials recovery. That
is exactly what eco-design means prevention
instead of end of pipe solutions. But recycling
does not always prevent environmental impacts. So
clean technologies and sound recycling processes
management are sometimes required to avoid extra
environmental contamination.
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Eco-design concept and practices

• Eco-design is a set new designing approach
  environmentally oriented such as DFR -Design for
  Recycling , which consists in providing an added
  value recycling condition to new products at the
  end of their life cycle.
• In Europe, since the year 2000, vehicles are
  being eco-designed to achieve 95 of
  recyclability and to contribute to close
  automotive materials life cycle loop, by
  incorporating recycled materials in new vehicles
  as well.

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Eco-design concept and practices (2)

• The translation of the eco-design concept in best
  environmental practices requires a lot of effort
  on technical and cultural changes.
• Besides for a successful eco-design practice the
  design team has to have a holistic and
  sustainable approach of the vehicle itself.
  Internal as well as external to the company.
• And the first step is materials selection that is
  a key element of eco-design.

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Materials Selection

• For this purpose the first step is materials
  selection that means to take
• Recyclable and renewable materials
• Materials free from toxic substances
• Monomaterials or compatible ones
• Low energy materials etc
• Secondly, complex products -automobile,
  computers and electric and electronic equipments-
  have to be designed to be assembled and
  disassembled to facilitate ELP recycling.

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Ecomaterials

• Ecomaterials is one of the newest concepts
  connected to eco-design practices and clean
  technologies.
• It has are many terms that can be taken as
  synonymous
• environmentally conscious materials,
• environmentally motivated materials,
• environmentally benign materials,
• environmentally friendly materials or
• environmentally preferable materials.
• They all mean materials developed to minimize
  adverse effects on the environment.

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Ecomaterials (2)

• From a technological viewpoint Halada classifies
  ecomaterials into four categories
• Harmful-substance free
• Low environmental profile (recycled and
  renewable)
• Recyclable materials and
• Materials for efficient energy flow.

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Eco-design in automotive industry

• According to European Directive 2000/53/EC on
  ELV, automakers are responsible for their
  products from cradle to grave. They are expected
  to coordinate the implementation of the vehicles
  recycling chain from the materials suppliers to
  the recyclers.
• They are expected to conceive a disassembly
  line, back to the auto-parts and materials
  producers, providing technical information to
  recyclers.
• So eco-design practices requires a lot of
  teamwork inside and outside the car companies.

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The European Directive on End of Life Vehicles
2000/53/EC set.2000

• It is aiming at prevention of waste disposal and
  encouraging ELV re-use, recycling and energetic
  valorization at a rate of 95 in 2015.
• Concerning eco-design the Directive states
• the requirements for dismantling, reuse and
  recycling of end-of-life vehicles and their
  components should be integrated in the design and
  production of new vehicles. (.)
• Producers should ensure that vehicles are
  designed and manufactured in such a way as to
  allow the quantified targets for reuse, recycling
  and recovery to be achieved.

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Eco-design for Solving Recycling Problems

• Automotive steel/copper contamination on
  automotive shredder residues ARS-affects the
  quality of recycled steel and do not to allow the
  reuse of this material on new automotive parts.
• There are many ways of dealing with the problem
• 1. diluting the recycled scrap with virgin metal
  
• 2. treating Cu-bearing steel in the furnace to
  remove the Cu
• 3. Increasing the tolerance of sheet steel for Cu
  by adding P
• 4. Upgrading Cu-bearing steel severely into new
  mill shapes
• 5. Using the scrap for other possible
  applications
• 6. Hot roll in a reducing atmosphere to avoid the
  oxide formation
• 7. Divert the steel scrap to iron casting, where
  the Cu content can be used as a graphitizer and
  so on.

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Environmental Innovations on products and process

• The expected technological developments are
• Nanomaterials nanotechnologies promoting
• dematerialization, cleaner superficial
  treatment, and new treatments for industrial
  residues and effluents as well.
• Near net shape techniques, in which the initial
  production of the item is very close to the final
  
• superplastic forming for plastics and composites
• sintering for metals and metals composites molded
  injection
• rapid prototyping to simulate by computer aided
  design (CAD) and to produce by computer aided
  manufacture (CAM) complex shapes in a melting-pot
  of materials.
• Ecomaterials for sctrucutral uses (bodyshop) -
  more recylcable and free from toxic substances

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Eco-design fostering cars recyclability The case
of Renault Modus

• Modus inaugurated a new segment of the compact
  mono-space., 95 recyclable, and was the first
  Renault model totally eco-designed by the
  software OPERA -Overseas Program for Economic
  Recycling Analyses.
• Its interior has numerous storage compartments in
  the dashboard, the front floor and doors, where
  we can find the environmental thought of
  eco-designed parts.
• Its dashboard incorporates around 50 of recycled
  PP corresponding to almost 5 kg.
• The OPERA is expected to be speeded the recycled
  PP evolution in Renault vehicles helping them to
  reach their goal of 50 Kg per vehicle in 2016.

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Closing Life Cycle Materials loop by Recycling
Primary Raw Materials
Materials Synthesis and Processing gas
emissions, greenhouse effect heavy metals
Engineered Materials chemical effluents gas
emissions
Mineral Extraction deforestation, acid drainage,
ecosystems disturb, waters contamination.

• Secondary Raw Materials

Components manufacturing industrial scraps
Environment
Components and ELP Recycling
Final Products Manufacturing industrial scraps
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