Evaluating the recyclability of electronic car parts through disassemblability, thermodynamic and metallurgical analyses

In the manufacturing of conventional cars, more than 50 different metals are utilized, many of which are categorized as critical or strategic. These metals are predominantly found in significant quantities within electronic car parts, necessitating specialized recycling methods for their recovery. However, conventional shredding processes often result in the downcycling of valuable metals into steel or aluminum alloys, or their disposal in landfills. To address this, a novel methodology is introduced, based on thermodynamic and metallurgical principles. It combines the Thermodynamic Rarity indicator with disassembly analysis and metallurgical process compatibility. By identifying valuable subparts and assessing dismantling costs, appropriate metallurgical processes can be designed to maximize the recovery of strategic metals. This methodology is demonstrated through three recycling scenarios— (1) shredding, (2) car dismantling, and (3) part disassembly— applied to the Combimeter and Infotainment system of a SEAT Leon Generation II model. Tailored metallurgical processes are proposed to recover steel, copper, and their compatible metals. The results highlight the potential of this approach for improving resource efficiency. For instance, dismantling the Combimeter achieves a Mineral Capital recovery of up to 59%, while part disassembly marginally improves recovery for the Infotainment system by only 2% compared to the dismantling scenario. Nonetheless, a limitation of the current processes is their inability to recover certain critical metals, such as tantalum. This work demonstrates how integrating thermodynamic and metallurgical insights can inform recycling strategies and enhance the recovery of critical and strategic metals in automotive electronics. • Thermodynamic and metallurgical approach to optimise metal recovery of car parts. • Study of 13 metals used to manufacture electronic car parts. • Recyclability of electronic parts based on metallurgical compatibility. • Designing of two recycling models based on copper and steel routes metal compatibilities. • Analysis of three recycling scenarios: shredding, dismantling, and disassembling.