7.1 Introduction
In this chapter, a three‐stage framework for EoL management of EVs is presented. An overview of this framework and its relationship to the waste management hierarchy, pre‐concentration and automation are discussed in the initial section. The later sections of this chapter described the specific considerations in the first stage of the framework. The second and third stages of the framework are discussed in Chapter 8 and Chapter 9 respectively.
7.2 The specific requirements for a structured approach to recycling of electric vehicles
Current innovative technologies and processes of ELVs management are primarily motivated by economic benefits, based on the capabilities and availability of the technologies and facilities. Nowadays, the introduction of new vehicle types, EVs, requires novel recycling and recovery methods due to their different components and material constitution. Increasing amounts of electronic products and components are embedded in EVs which would change the composition of existing material streams in both ecological and economic aspects. The reclamation of the PMs and SIMs that are represented in small quantities may generate new economic incentives for automotive recyclers. Furthermore, hazardous materials used in PCBs may pollute the material stream that influences the economic viability of recycling and recovery activities. Thus, there is a need to evaluate the EVs components through collecting and analysing information that is required for the development of further recycling methods.
Both driven by the legislative requirements and economic incentives, there is a need to improve the material value recovery and minimise the environmental impact in the EoL management of EV components. Based on the previous review, automated disassembly has been proposed as a novel approach for future EVs recycling and recovery. The dismantling process has seen a terminal decline as components have become electronically integrated, making them difficult to remove and replace. Moreover, the profit margins of separating material streams are dependent on material purity and contamination levels. However, it is noted that the automated robotic disassembly of components has never been attempted by the majority of EoL vehicle recycling and recovery activities. This research, therefore, aims to
improve the pre‐concentration process through robotic disassembly processes to reduce disassembly time and cost, and improve recycled material purity.
The EoL management solution for EVs is developed in the context of the waste management hierarchy, aiming to reduce waste at source, improve the feasibility of reuse and conduct recovery and recycling in a more efficient way (to achieve the maximum economic benefits from products and generate the minimum amount of waste). Figure 7.1 illustrates a schematic of the waste management hierarchy developed within the research, which addresses the connection with the EoL management solution.
The minimisation of the EoL waste is influenced by the design that determines the product characteristics and material selection. The general ELV recycling flow has been discussed in Chapter 4. The de‐pollution aims to remove hazardous substances, such as fluids and airbag.
Then recyclable and valuable components are dismantled for reuse as secondary products, reconditioning or remanufacturing, such as engines, EV batteries and other mandatory parts.
Both of these two options require the consideration of the efficiency of the disassembly operations. Disassembly operations provides the potential of achieving a higher quantity and quality of material recovered prior to the downstream material recovery process, thus, the amount of associated residual waste can be reduced. Recycling and recovery activities consist of the segregation and purification processes, which aim to liberate different materials contained in the EoL products for further downstream processes. When the recovered material is resupplied for use in the original application, the process is called a close‐loop scenario. Otherwise, the recovered material is supplied for a new application, which refers to an open‐loop scenario. The last choice is the disposal of any non‐recyclable fraction. At this stage, the separation of hazardous substances from a non‐hazardous waste stream should be conducted before the shipment to the landfill from both ecological and economic perspectives.
pollution Dismantling Press Fragmentation
& Separation Incineration Shredding
Vehicle design Landfill
Figure 7.1 Relationship between waste management hierarchy and EoL management.
The above discussion highlights the need for a systematic approach for EoL management for EVs. They are included in a series of stages of a recycling process framework, which is developed in this research and are described in the following sections.
7.3 A framework of EoL management of electric vehicles
An overview of the framework developed to support EoL management of EVs, referred to hereafter as the EoL‐EV framework is illustrated in Figure 7.2. The EoL‐EV framework has been established in a four‐stage procedure with a modular structure. It should be noted that the dismantling of the EV components is not within the scope of this research. Dismantling refers to the process of removal of components from the vehicle prior to disassembly.
The initial stage is defining challenges in EoL management of EVs, involving the identification of the EoL characteristics of the product stream, the analysis of the existing recycling technologies and relevant legislations. To support this, components of interest are identified and then classified into different groups according to their physical structure and recovery value.
A three‐step disassembly approach is developed in the second stage of the framework, which consists of non‐destructive manual disassembly, initial automated disassembly and the validation and optimisation process. The EV components are undertaken through this three‐
step disassembly process.
In the third stage of the framework, three factors are combined as a multi‐criteria decision support tool for future EV recycling, taking environmental, technological and economic performance of robotic disassembly into consideration. The individual stages of the framework are described in more detail in the following sub‐sections: the remaining of Chapter 7 details Stage 1 of this EoL‐EV framework, while Stage 2 and Stage 3 will be outlined and discussed in Chapter 8 and Chapter 9, respectively.
1. DEFINING CHALLENGES IN EOL MANAGEMENT OF EV Application of manual disassembly, automated robotic
disassembly and validation and optimisation. 7.3). Characterisation of EoL EV components (i.e. design features and material composition) are considered relevant to the development and evaluation of EoL options. In addition, based on review results, the feasibility of existing EoL vehicle recycling technologies and processes is assessed for EoL management of EV components. After analysing the target components and recycling techniques, relevant legislative constraints and requirements are investigated.
Finally, in order to achieve the economic viability of the EoL EV recycling, there is a need to understand the economic performance of the EoL recycling scenarios and processes.
1. DEFINING CHALLENGES IN EOL MANAGEMENT OF EV COMPONENTS
2. DEVELOPENT OF A THREE‐STAGE AUTOMATED DISASSEMBLY APPROACH FOR EVECYCLING
3. DEVELOPMENT OF AN EOL ASSESSMENT FOR EV RECYCLING Characteristics