Simulation-Based Design for Recycling of Car Electronic Modules as a Function of Disassembly Strategies

Modules (or parts) of a car are a complex functional material combination used to deliver a specified task for a car. Recovering all materials, energy, etc., into high-grade materials at their end of life (EoL) is impossible. This is dictated by the second law of thermodynamics (2LT) and thence economics. Thus, recyclability cannot be conducted with simplistic mass-based approaches void of thermodynamic considerations. We apply, in this paper, a process simulation model to estimate the true recyclability of various SEAT (Volkswagen Group) car parts within the EU H2020 TREASURE project. This simulation model is developed with 190 reactors and over 310 feed components with over 1000 reaction species in the 880 streams of the flowsheet. The uniqueness of the work in this paper is to apply the full material declaration (FMD) and bill of materials (BOM) of all 310 materials in the parts as a feed to the process simulation model to show the parts’ true recyclability. We classified all parts into categories, i.e., copper-rich, steel-rich and plastic-rich, to maximally recover metals at the desired material quality, as well as energy. Recyclability is understood to create high-grade products that can be applied with the same functional quality in these parts. In addition, disassembly strategies and related possible redesign show how much recyclability can be improved. Process simulation permits the creation of alloys, phases, materials, etc., at a desired quality. The strength of the simulation permits any feed from any End-of-Life part to be analyzed, as long as the FMD and BOM are available. This is analogous to any mineral and metallurgical engineering process simulation for which the full mineralogy must be available to analyze and/or design flowsheets. This paper delivers a wealth of data for various parts as well as the ultimate recovery of materials, elements, and energy. The results show clearly that there is no one single recycling rate for elements, materials, and alloys. It is in fact a function of the complexity and material combinations within the parts. The fact that we use a thermochemical-based process simulator with full compositional detail for the considered parts means full energy balances as well as exergy dissipation can be evaluated. This means that we can also evaluate which parts, due complex mixtures of plastics, are best processed for energy recovery or are best for material and metal recovery, with thermochemistry, reactor technology and integrated flowsheets being the basis.