Energy measurements and LCA of remanufactured automotive steel sheets
FARIOLI Daniele, FABRIZIO Matteo, KAYA Ertuğrul, MUSSI Valerio, STRANO Matteo
download PDFAbstract. New paradigms based on Circular Economy (CE) principles are needed for boosting the ecological transition and improving the energy and material efficiency. In this paper, a novel remanufacturing process chain for End-of-Life (EoL) automotive panels is first presented. The core of the recycling strategy is the reshaping of curved EoL automotive sheets through flattening by means of a hydraulic press. Flattening experiments together with press power consumption measurements have been performed on thin steel parts. While the experimental procedure demonstrated the technical feasibility of flattening “small-scale” steel parts, a more complete analysis on environmental sustainability was required. For this purpose, a Life Cycle Assessment (LCA) of the remanufacturing process chain proposed was set up. The results of the study demonstrated that flattening is a viable solution for reshaping EoL automotive panels, and that, for one kg of reshaped steel, approximately 2.2 kg CO2 and 24 MJ could be saved.
Keywords
Sheet Metal Remanufacturing, Energy Analysis, Circular Economy, LCA Sustainability
Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: FARIOLI Daniele, FABRIZIO Matteo, KAYA Ertuğrul, MUSSI Valerio, STRANO Matteo, Energy measurements and LCA of remanufactured automotive steel sheets, Materials Research Proceedings, Vol. 28, pp 1947-1956, 2023
DOI: https://doi.org/10.21741/9781644902479-210
The article was published as article 210 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] G. Ingarao, O. Zaheer, L. Fratini, Manufacturing processes as material and energy efficiency strategies enablers: The case of Single Point Incremental Forming to reshape end-of-life metal components, CIRP J. Manuf. Sci. Technol. 32 (2021) 145–153. https://doi.org/10.1016/j.cirpj.2020.12.003
[2] P.A. Renzulli, B. Notarnicola, G. Tassielli, G. Arcese, R. Di Capua, Life cycle assessment of steel produced in an Italian integrated steel mill, Sustain. 8 (2016). Https://doi.org/10.3390/su8080719
[3] J.M. Cullen, J.M. Allwood, M.D. Bambach, Mapping the global flow of steel: From steelmaking to end-use goods, Environ. Sci. Technol. 46 (2012) 13048–13055. https://doi.org/10.1021/es302433p
[4] P. Wang, W. Li, S. Kara, Cradle-to-cradle modeling of the future steel flow in China, Resour. Conserv. Recycl. 117 (2017) 45–57. https://doi.org/10.1016/j.resconrec.2015.07.009
[5] Nuove tensioni su logistica e materie prime nel primo trimestre 2022, Lamiera (May 2022), 2022, pp. 7–8.
[6] J.M.C. Julian, M. Allwood, Sustainable materials : with both eyes open. Cambridge, UIT, 2012.
[7] EuRIC AISBL, Metal Recycling Factsheet. Information on: https://www.euric-aisbl.eu/position-papers/download/591/335/32. (accesed on 06.02.2023)
[8] G. Ingarao, R. Di Lorenzo, F. Micari, Sustainability issues in sheet metal forming processes: An overview, J. Clean. Prod. 19 (2011) 337–347. https://doi.org/10.1016/j.jclepro.2010.10.005
[9] J. Cui, H.J. Roven, Recycling of automotive aluminum, Trans. Nonferrous Met. Soc. China (English Ed.) 20 (2010) 2057–2063. https://doi.org/10.1016/S1003-6326(09)60417-9
[10] R. Paul, End-of-life management of waste automotive materials and efforts to improve sustainability in North America, Society of Automotive Engineers International, USA, 120 (2009) 853–861. https://doi.org/10.2495/SDP090802
[11] ESTEP, Green steel by EAF route : a sustainable value chain in the EU Circular Economy scenario, 2019, pp. 1–6.
[12] T. Hay, V.V. Visuri, M. Aula, T. Echterhof, A Review of Mathematical Process Models for the Electric Arc Furnace Process, Steel Res. Int. 92 (2021). Https://doi.org/10.1002/srin.202000395
[13] D.R. Cooper, J.M. Allwood, Reusing Steel and Aluminum Components at End of Product Life, Environ. Sci. Technol. 46 (2012) 10334–10340. https://doi.org/10.1021/es301093a
[14] D.R. Cooper, T.G. Gutowski, The Environmental Impacts of Reuse: A Review, J. Ind. Ecol. 21 (2017) 38–56. https://doi.org/10.1111/jiec.12388
[15] J. Kawai, Development of environmentally-conscious steel products at the Nippon Steel Corporation, Mater. Des. 22 (2001) 111–122. https://doi.org/10.1016/s0261-3069(00)00051-0
[16] D.R. Cooper, J.M. Allwood, Reusing steel and aluminum components at end of product life, Environ. Sci. Technol. 46 (2012) 10334–10340. https://doi.org/10.1021/es301093a
[17] G. Ingarao, R. Di Lorenzo, L. Fratini, An Exploratory Study for Analyzing the Energy Savings Obtainable by Reshaping Processes of Sheet Metal Based Components, Procedia Eng. 183 (2017) 309–315. https://doi.org/10.1016/j.proeng.2017.04.044
[18] N.K. Yusuf, M.A. Lajis, A. Ahmad, Hot press as a sustainable direct recycling technique of aluminium: Mechanical properties and surface integrity, Materials 10 (2017). Https://doi.org/10.3390/ma10080902
[19] A.S. Kore, K.C. Nayak, P.P. Date, Formability of aluminium sheets manufactured by solid state recycling, J. Phys. Conf. Ser. 896 (2017). Https://doi.org/10.1088/1742-6596/896/1/012007
[20] J.R. Duflou, A.E. Tekkaya, M. Haase, T. Welo, K. Vanmeensel, K. Kellens, W. Dewulf, D. Paraskevas, Environmental assessment of solid state recycling routes for aluminium alloys: Can solid state processes significantly reduce the environmental impact of aluminium recycling?, CIRP Ann. – Manuf. Technol. 64 (2015) 37–40. https://doi.org/10.1016/j.cirp.2015.04.051
[21] D. Baffari, G. Buffa, G. Ingarao, A. Masnata, L. Fratini, Aluminium sheet metal scrap recycling through friction consolidation, Procedia Manuf. 29 (2019) 560–566. https://doi.org/10.1016/j.promfg.2019.02.134
[22] R. Bendikiene, A. Ciuplys, L. Kavaliauskiene, Circular economy practice: From industrial metal waste to production of high wear resistant coatings, J. Clean. Prod. 229 (2019) 1225–1232. https://doi.org/10.1016/j.jclepro.2019.05.068
[23] A.K. Ali, Y. Wang, L. Alvarado, Facilitating industrial symbiosis to achieve circular economy using value-added by design: A case study in transforming the automobile industry sheet metal waste-flow into Voronoi façade systems, J. Clean. Prod. 234 (2019) 1033–1044. https://doi.org/10.1016/j.jclepro.2019.06.202
[24] H. Takano, K. Kitazawa, T. Goto, Incremental forming of nonuniform sheet metal: Possibility of cold recycling process of sheet metal waste, Int. J. Mach. Tool. Manuf. 48 (2008) 477–482. https://doi.org/10.1016/j.ijmachtools.2007.10.009
[25] Z.T. Abdullah, Assessment of end-of-life vehicle recycling: Remanufacturing waste sheet steel into mesh sheet, PLoS One 16 (2021) 1–17. https://doi.org/10.1371/journal.pone.0261079
[26] R. Haase, Remanufacturing of metal components : reforming of sheet metal blanks. Fraunhofer IWU, 2020. Available: https://www.careserviceproject.eu/wp-content/uploads/CarE-Service-Training-on-Metal-reforming-25th-of-May.pdf
[27] A.K. Ali, P.N. Kio, J. Alvarado, Y. Wang, Symbiotic Circularity in Buildings: An Alternative Path for Valorizing Sheet Metal Waste Stream as Metal Building Facades, Waste and Biomass Valorization 11 (2020) 7127–7145. https://doi.org/10.1007/s12649-020-01060-y
[28] Technology Roadmaps: Intelligent Mobility Technology, Materials and Manufacturing Processes, and Light Duty Vehicle Propulsion, Center for automotive research, 2017. https://doi.org/10.32964/tj16.6
[29] W. Asscociation, Life cycle inventory ( LCI ) study – Seventh global LCI study for steel products, no. Sustainability, 2021.
[30] SSAB, EPD for cold rolled steel sheets and coils.
[31] J. Suer, M. Traverso, N. Jäger, Review of Life Cycle Assessments for Steel and Environmental Analysis of Future Steel Production Scenarios, Sustainability 14 (2022) 14131. https://doi.org/10.3390/su142114131
