Rare earth element recovery potentials from end-of-life hybrid electric vehicle components in 2010–2030

Increasing attention is currently given to the management of end-of-life (EoL) hybrid electric vehicles (HEVs), because approximately two decades have passed since they were first introduced to the market. A HEV would be one of the largest consumers of rare earth elements (REEs), and hence represents the greatest potential for REE recovery in the future. The purpose of this study is to clarify the present and future recovery potential of REEs that are disposed of as EoL HEVs. This study first estimated the numbers of EoL HEVs during fiscal years (FYs) 2010–2030, and then clarified the potential for recovery of REEs from two HEV-specific components—the hybrid transmission and NiMH battery unit. The results suggest that 0.51–0.65 million HEVs will reach the EoL stage in FY2030, compared with only 11,000 HEVs in FY2010. As of FY2030, REE recovery potentials will increase to 220 tons and 2900 tons for EoL hybrid transmission and NiMH battery units, respectively. A total of 49,000 tons of REEs will be contained within HEV-specific components of HEVs still in use. Moreover, the potential for recovery of REEs from EoL hybrid transmissions and NiMH battery units is estimated to equal 35.4 and 92.1 % of respective demand.     

Recovery of Nd and Dy from rare earth magnetic waste sludge by hydrometallurgical process

This paper describes a hydrometallurgical process for recovering neodymium (Nd) and dysprosium (Dy) from a magnetic waste sludge generated from the Nd–Fe–B(–Dy) manufacturing process. Phase analysis by XRD study revealed Nd(OH)₃ and Fe₂O₃ as main mineral phases, and chemical analysis by ICP showed the contents of 35.1 wt% Nd, 29.5 wt% Fe, 1.1 wt% Dy and 0.5 wt% B. A solution of 1 M HNO₃ + 0.3 M H₂O₂ was used to dissolve up to 98 % Nd and 81 % Dy, while keeping Fe dissolution below 15 % within 10 min. Fe dissolved in solution was completely removed as Fe(OH)₃ at pH 3 followed by precipitation of Nd and Dy with oxalic acid (H₂C₂O₄) and recovered 91.5 % of Nd and 81.8 % of Dy from solution. The precipitate containing Nd and Dy was calcined at 800 °C to obtain Nd₂O₃ as final product with 68 % purity, and final recovery of 69.7 % Nd and 51 % of Dy was reported in this process.     

Hydrometallurgical processing of Nd–Fe–B magnets for Nd purification

An evaluation of various metal purification processes subsequent to the leaching processing of the neodymium (Nd) product from neodymium–iron–boron (Nd–Fe–B) magnets has been conducted. These post-leaching purification processes included precipitation; replacement and electrolysis were studied in order to check the purity of the recovered neodymium. A hydrometallurgical investigation was adopted to digest the metal content of the scrap Nd–Fe–B magnets for the recovery of valuable Nd metal and other metals such as Fe, B, Co and Ni. The effect of leaching conditions such as solid-to-liquid ratio and temperature were optimized and 100 % Nd, 100 % Fe, 100 % B and 85.87 % Co leaching efficiencies were achieved under these conditions. The coating material of the magnet, Ni, achieved 50 % impregnation after increasing the reaction temperature to 70 °C. The metals present in the optimal leaching solution were recovered 99 % by pH adjustment. However, the replacement had the highest separation efficiency for the recovery of Nd metal. Further, the optimal leaching Nd–Fe–B solution was subjected to the electrolysis processes in order to verify the recovery efficiency for all metals.     

Dynamic flow analysis of current and future end-of-life vehicles generation and lead content in automobile shredder residue

Since end-of-life vehicles (ELVs) contain toxic substances, they have to be treated properly. The purpose of this study was to obtain useful information for ELV management from the viewpoint of toxicity. We focused on lead as a representative toxic substance contained in vehicles and investigated the dynamic substance flow of lead contained in ELVs and its content in automobile shredder residue (ASR). A population balance model was used to estimate the number of ELVs generated between FYs (fiscal year) 1990–2020, employing a Weibull distribution for the lifespan distribution. Sixteen lead-containing components of the vehicle were considered. It was estimated that the annual number of ELVs generated would be 2.9 million as of FY2020. The results implied that it is hard to remove Pb completely. This is because 5,000–11,000 t-Pb will still remain in vehicles in use in FY2020 even though most components in new model vehicles could be replaced by lead-free alternatives. As of FY2010, the substance flow showed that Pb contained in ELVs amounted to 4,600–5,700 t-Pb. Of this, 13.2–14.0 % was contained in ASR. The Pb content in ASR could be dramatically decreased by FY2020, but it will continue to contain 240–420 mg-Pb/kg if the treatment system is not improved.     

Aluminium flows in vehicles: enhancing the recovery at end-of-life

The transportation sector constitutes the major end-use market for aluminium-containing products and expectations for the future do indicate that aluminium will increase at 140 kg per vehicle. Moreover, up to 75 % aluminium recycled in Europe is used in transportation: thus, metal scrap recovered from ELVs is a key lever to act for closing material cycles. However, although the management chain of ELVs has an established procedure and aluminium scrap is usually recovered in shredding plants, a considerable fraction of the metal particles ends up in the light fraction called car fluff and is then landfilled. In this study we investigated potential of enhancing the recovery of aluminium scrap from the light fluff treatment. With this goal, the quantity of aluminium embedded in the Italian transport sector in the last 62 years was estimated, and a campaign of characterization in size and shape distribution of aluminium particles in the light fluff output has been carried out. The results estimated up to about 560,000 tons of metal are potentially recoverable from the treatment of light fluff at current operating conditions, but relevant improvements may be achieve when size and shape distribution criteria are adopt to implement eddy currents separation for a quantitative metal recovery.     

The behaviour of selected rare-earth elements during the conversion of phosphogypsum to calcium sulphide and residue

Phosphogypsum (PG) is a large hazardous waste from fertiliser and phosphoric acid industries from which useful products including rare-earth elements (REEs) can be recovered depending on the treatment process. Its conversion to calcium sulphide (CaS) which was achieved at 95% followed by the formation of S, CaCO₃ and residue is one of the plausible treatment processes leading to economic and environmental benefits. This study aimed at monitoring selected REEs behaviour during the conversion of (PG) to (CaS). The concentrations of REEs in the raw PG, the produced CaS and the obtained residue were determined after digestion (microwave and traditional acid leaching) using ICP-OES. The effect of CO₂ and H₂S used in the process of forming CaCO₃ and S from PG on the concentrations of REEs was also investigated. Microwave digestion proved to be more effective than traditional acid leaching in the recovery of REEs. Microwave digestion using 3 mL HNO₃ + 1 mL HCl was more effective than 1 mL HNO₃ + 3 mL in REEs recovery. CaS contained the highest amount of Ce, Pr, Nd, Sm, Eu, Gd, Dy, Ho, Er, La and Y with values of 2646, 476, 2255, 320, 60.5, 376, 79.8, 1.24, 476, 1185 and 318 µg/g respectively. Based on these findings, the residue could be further processed to recover REEs despite less than 40% decrease in concentration for the majority of REEs observed due to the use of H₂S and CO₂. CO₂ was found to be more suitable as fewer REEs were leached as compared to H₂S. All things considered, the obtained residue could be a good secondary source of REEs as it is easier to leach, retained good amount of REEs and lesser impurities.

     

Evaluation method of automobile recycling systems for Asia considering international material cycles: application to Japan and Thailand

To examine an appropriate recycling system for end-of-life vehicles (ELVs) from Japan in the context of Asia, an Asian international automobile recycling input-output (AI-ARIO) analysis is presented. The AI-ARIO analysis spatially expands the existing ARIO analysis within the framework of the waste input-output (WIO) analysis developed by Nakamura et al., which considers the interdependence between the flow of goods and wastes in a country. This analysis focuses on the local and global cycles for ELVs in Asia and can evaluate the environmental and economic effects of alternative recycling systems. We estimated the AI-ARIO table for Japan and Thailand and applied it to scenario analyses covering the restriction of ELV trade between the two countries, the introduction of new recycling techniques in Thailand, and centralized treatment in Japan. We verified the applicability and effectiveness of the AI-ARIO analysis through the scenario analyses.     

Evaluation of metals in the residue of paper sludge after recovery of pulp components using an ionic liquid

The quantity of sludge produced by the paper industry in Japan in 2011 was estimated to be 27.91 million tons wet weight. This amount is the third largest among all industrial wastes. To explore ways of reusing recovered paper pulp and safely disposing of the residue, we investigated the distribution of metals in the process of recovery of pulp from two types of paper sludge using an ionic liquid. 32 and 46 % of pulp from paper sludge A and B was recovered using ionic liquid, respectively; the resultant weight reduction of the solid mass was comparable to that of incineration. There were virtually no heavy metals but aluminum in the recovered pulp, which makes its reuse viable at present. The characteristics of the metals in the residues differed according to the treatment used and properties of the paper sludge. Copper accounted for ~10 % in the ionic liquid used for recovery of pulp from the paper sludges. This suggests that [bmIm]Cl has the potential to dissolve a specific amount of copper compared to other metals.     

我国报废汽车回收拆解企业发展的关键问题研究

报废汽车回收拆解具有巨大的经济、环境和社会效益。我国报废汽车回收拆解企业正面临极佳的发展环境,但目前存在着诸多问题,需要进行转型升级。提出报废汽车回收拆解企业转型升级过程中存在的若干关键问题,即回收阶段中的报废汽车量预测、回收模式选择、报废汽车回收网络构建;拆解阶段中的拆解工艺选择、拆解设备选择;产品销售阶段中的产品分类及市场分析、销售模式确定及销售网络构建、产品定价等问题,并对这些问题进行分析,提供解决方法和措施。     

End-of-Life Vehicles management: Italian material and energy recovery efficiency

Each European Member State must comply with Directive 2000/53/EC recycling and recovery targets by 2015, set to 85% and 95%, respectively. This paper reports a shredder campaign trial developed and performed in Italy at the beginning of 2008. It turns out to be the first assessment about the critical aspects belonging to the Italian End-of-Life Vehicles (ELVs) reverse supply chain involving 18 dismantling plants, a shredder plant and 630 ELV representatives of different categories of vehicles treated in Italy during 2006. This trial aims at improving the experimental knowledge related to ELVs added waste, pre-treatment, part reuse, recycling and final metal separation and car fluff disposal. Finally, the study also focuses on the calculation of the effective Italian ELV recycling rate, which results equal to 80.8%, and auto shredder residue (ASR) characterization. According to the results obtained in this work, ASR still contains up to 8% of metals and 40% of polymers that could be recovered. Moreover, physical-chemical analysis showed a Lower Heat Value of almost 20,000 kJ/kg and revealed the presence of pollutants such as heavy metals, mineral oils, PCBs and hydrocarbons.     

Waste rechargeable electric lamps: characterisation and recovery of lead from their lead-acid batteries

Electrical electronics constitute a significant quantity of municipal solid wastes which are discarded after use in open dumpsites especially in the developing countries. The aim of this study was to characterise the material and chemical components, evaluate current management practices and investigate recovery of lead from battery electrodes (BEs) of waste rechargeable electric lamps (RLs). Twenty-six waste RLs of different models were sampled in Nigeria and characterised. Their BEs were analysed for Pb, Cr, Mn, Cu, Zn, Ni and Fe after acid digestion. Questionnaires were distributed to unselected respondents to assess usage and disposal of the lamps. Reaction of citric acid solutions with Pb in the presence of H₂O₂ was used for the recovery of Pb. 69 % of the respondents disposed their waste RLs in open dumpsites. The mean ± SD concentrations of Pb, Cr, Mn, Cu, Zn, Ni and Fe in the BEs were 600 ± 0.2 g/kg, 65.4 ± 40 mg/kg, 5.05 ± 4.0 mg/kg, 6.81 ± 5.0 mg/kg, 5.98 ± 3.0 mg/kg, 50.0 ± 30 mg/kg and 40.2 ± 35 mg/kg, respectively. The results show that the batteries are lead-acid batteries which require management. At the optimal conditions of S/L = 0.14, temperature = 20 °C and leaching time = 5 h, about 95 % Pb was recovered in form of lead citrate from the battery. High recovery of Pb is possible with simple and environment-friendly reactions.     

Life cycle assessment of biodiesel fuel production from waste cooking oil in Okayama City

A life cycle assessment (LCA) is performed to make clear of the actual environment impacts from conversation of waste cooking oil (WCO) to biodiesel fuel (BDF) in Okayama. A scenario analysis is carried out based on different participation rate of residents who separate WCO from general waste, corresponding to different BDF utilisation rate in transportation system. Sub scenarios complying with different gas emission standards regarding vehicles are designed as well. Afterwards, life cycle impact assessment is conducted to focus on global warming, acidification, and urban air pollution. Overall improvement of almost all kinds of life cycle inventories is significant when diesel is replaced with BDF, demonstrating that a shift from WCO-to-incineration to WCO-to-BDF is more beneficial. Under carbon neutral, compared to base scenario (S0), about 746.05 ton CO₂ emission will be reduced annually in the scenario with 100 % BDF utilisation in vehicles (S4). Meanwhile, total external cost in three environmental impacts (EI) sharply reduces by 51.90 %, showing much economic sustainability in S4. Moreover, the manufacturing cost for producing one litter WCO-to-BDF is 97.32 Yen. Sensitivity analysis shows that the gas emission standard regarding vehicles had much bigger effect on EI than BDF manufacturing process in this research.     

Current status of waste to power generation in Japan and resulting reduction of carbon dioxide emissions

We discuss the current status of waste to power generation (WPG) in Japan and various scenarios involving indirect reduction of carbon dioxide emissions by WPG. The number of WPG facilities domestically as of 2005 was 286. Power generation capacity attained 1,515 MW and power generation 7,050 GWh/year. This amount substitutes energy otherwise acquired from natural resources such as fossil fuels in thermal power plants. If the basic unit of carbon dioxide is 0.555 kg-CO₂/kWh, then the corresponding carbon dioxide emission reduction is calculated to be 3.9 million tons, equivalent to 26.7% of the 14.6 million tons emitted by municipal solid waste incinerators (MSWI) in 2005. Using various existing technological options, the power generation efficiency could reach more than 20% in MSWI facilities with capacity of 300 tons/day, although present efficiency is only 12.0%. If about 85% of MSW were incinerated in MSWI with power generation efficiency of 20% as a feasible assumption, the total power generation and the corresponding carbon dioxide reduction would be 16,540 GWh/year and 9.18 million tons, respectively, equivalent to 62.7% of the carbon dioxide emitted by MSWI. Also, the ratio of the additional reduction of carbon dioxide emissions by WPG to the total additional reduction (20,000 ktons/year) in Japan during the first commitment period would be 26.3%, suggesting that promotion of WPG in MSWI is an effective option for prevention of global warming.     

Aqueous leaching of cattle manure incineration ash to produce a phosphate enriched fertilizer

Ash produced from the combustion of livestock manure contains large amounts of phosphorus (P), which is an important resource as a fertilizer. Some studies have extracted and recovered P from incinerated biomass ash using inorganic acid or alkaline agents, which produce wastewater that requires treatment and is expensive due to the cost of chemicals. Livestock manure ash contains not only P, but also water soluble salts, which could be a negative influence on plant growth and shall be preferably removed from the recovered fertilizer. In this study, we removed salinity from cattle manure incineration ash by simple aqueous leaching, while retaining the P content. The optimal condition was a 20 min leaching time at a liquid/solid (L/S) ratio of 10 mL g-ash^?1. Under this condition, over 90 % of Cl and 20 % of Na in the original ash was removed, while over 99 % of the P was retained in the leached residue. The leached residue met the fertilizer standard in Japan in terms of citrate soluble fertilizer components and contained few heavy metals. X-ray analyses of the ash indicated that Cl was mainly present as KCl in the original ash, while P was mainly present as Ca compounds in the ash.     

Strategies for the enhancement of automobile shredder residues (ASRs) recycling: Results and cost assessment

With reference to the European regulation about the management of End-of-Life Vehicles (ELVs), Directive 2000/53/EC imposes the achievement of a recycling target of 85%, and 95% of total recovery by 2015. Over the last few years many efforts have been made to find solutions to properly manage the waste coming from ELVs with the aim of complying with the targets fixed by the Directive.This paper focuses on the economical evaluation of a treatment process, that includes physical (size and density), magnetic and electrical separations, performed on the light fraction of the automobile shredder residue (ASR) with the aim of reducing the amount of waste to dispose of in a landfill and enhancing the recovery of valuable fractions as stated by the EU Directive. The afore mentioned process is able to enhance the recovery of ferrous and non-ferrous metals of an amount equal to about 1% b.w. (by weight) of the ELV weight, and to separate a high energetic-content product suitable for thermal valorization for an amount close to (but not higher than) 10% b.w. of the ELV weight.The results of the economical assessment led to annual operating costs of the treatment ranging from 300,000 €/y to 350,000 €/y. Since the considered plant treats about 13,500 metric tons of ASR per year, this would correspond to an operating cost of approximately 20–25 €/t. Taking into account the amount and the selling price of the scrap iron and of the non magnetic metal recovered by the process, thus leading to a gain of about 30 €/t per ton of light ASR treated, the cost of the recovery process is balanced by the profit from the selling of the recovered metals. On the other hand, the proposed treatment is able to achieve the fulfillment of the targets stated by Directive 2000/53/EC concerning thermal valorization and reduce the amount of waste generated from ELV shredding to landfill.     

Leaching of rare earths from Abu Tartur (Egypt) phosphate rock with phosphoric acid

The leaching of rare earth elements (REEs) from Egyptian Abu Tartur phosphate rock using phosphoric acid has been examined and was subsequently optimized to better understand if such an approach could be industrially feasible. Preliminary experiments were performed to properly define the design of experiments. Afterward, 2⁴ full factorial design was implemented to optimize the leaching process. Optimum REEs leaching efficiency (96.7 ± 0.9%) was reached with the following conditions: phosphoric acid concentration of 30 wt.-% P₂O₅, liquid/solid ratio, mL/g, of 5:1, at 20 °C, and 120 min of leaching time. The apparent activation energy of the dissolution of REEs from phosphate rock using the phosphoric acid solution was -19.6 kJ/mol. D2EHPA was subsequently applied as an organic solvent for REEs separation from the acquired leach liquor. REEs stripping and precipitation were conducted, and finally, rare earth oxides with a purity of 88.4% were obtained. The leach liquor was further treated with concentrated sulfuric acid to recover the used phosphoric acid and produce gypsum with a purity of >95% at the same time. A flow diagram for this innovative cleaner production process was developed, and larger-scale experiments are proposed to further understand this promising approach to comprehensive phosphate rock processing.

     

Physical separation,mechanical enrichment and recycling-oriented characterization of spent NiMH batteries

Nickel–metal hydride (NiMH) batteries contain high amount of industrial metals, especially iron, nickel, cobalt and rare earth elements. Although the battery waste is a considerable secondary source for metal and chemical industries, a recycling process requires a suitable pretreatment method before proceeding with recovery step to reclaim all valuable elements. In this study, AA- and AAA-type spent NiMH batteries were ground and then sieved for size measurement and classification. Chemical composition of the ground battery black mass and sorted six different size fractions were determined by an analytical technique. Crystal structures of the samples were analyzed by X-ray diffraction. Results show that after mechanical treatment, almost 87 wt% of the spent NiMH batteries are suitable for further recycling steps. Size classification by sieving enriched the iron content of the samples in the coarse fraction which is bigger than 0.25 mm. On the other hand, the amounts of nickel and rare earth elements increased by decreasing sample size, and concentrated in the finer fractions. Anode and cathode active materials that are hydrogen storage alloy and nickel hydroxide were mainly collected in finer size fraction of the battery black mass.     

Composition and management of rechargeable electric torch wastes in Ibadan,Nigeria

The consumption, disposal, material and chemical compositions of rechargeable electric torch wastes (RETWs) were investigated in Ibadan, Nigeria. Twenty-five RETWs of ten models were collected and disassembled. Their battery electrodes (BEs) and printed circuit boards (PCBs) were acid digested and leached using United States Environmental Protection Agency (USEPA) method 3050B and USEPA Method 1311, respectively. The digests and extracts were analysed for total and extractable Pb, Cd, Cr and Ni using atomic absorption spectrophotometer. The US Test method (CPSC-CH-E 1002-08) was used for digestion of the plastic components. Two hundred questionnaires were distributed to users in Ibadan to determine their usage of RETs and their management when spent. The results indicated that BEs contributed the highest percentage (44 %) component, followed by plastic (38 %). Other components include metal, PCBs, glass and wire. Of the respondents, 61.9 % dispose their spent torches in dumpsites. The mean ± SD concentrations of Pb, Cd, Cr and Ni in the BEs were 500 ± 109 g/kg, 3.94 ± 6.84 mg/kg, 0.33 ± 0.88 mg/kg, 1.68 ± 0.74 mg/kg respectively; in the PCBs, they were 684 ± 42 g/kg, 13.7 ± 17.8 mg/kg, 13.5 ± 10.2 mg/kg and 193 ± 437 mg/kg; and in the plastics, they were 14.1 g/kg, 5.33 mg/kg, 17 mg/kg, and 4.67 mg/kg respectively. The extractable Pb in BE (2670 mg/L) and PCBs (235 mg/L) exceeded the Toxicity Characteristics Leaching Procedure (TCLP) limit of 5 mg/L. RETWs present potential environmental problems in the absence of effective recycling.     

Sustainable design for automotive products: Dismantling and recycling of end-of-life vehicles

The growth in automotive production has increased the number of end-of-life vehicles (ELVs) annually. The traditional approach ELV processing involves dismantling, shredding, and landfill disposal. The “3R” (i.e., reduce, reuse, and recycle) principle has been increasingly employed in processing ELVs, particularly ELV parts, to promote sustainable development. The first step in processing ELVs is dismantling. However, certain parts of the vehicle are difficult to disassemble and use in practice. The extended producer responsibility policy requires carmakers to contribute in the processing of scrap cars either for their own developmental needs or for social responsibility. The design for dismantling approach can be an effective solution to the existing difficulties in dismantling ELVs. This approach can also provide guidelines in the design of automotive products. This paper illustrates the difficulty of handling polymers in dashboards. The physical properties of polymers prevent easy separation and recycling by using mechanical methods. Thus, dealers have to rely on chemical methods such as pyrolysis. Therefore, car designers should use a single material to benefit dealers. The use of materials for effective end-of-life processing without sacrificing the original performance requirements of the vehicle should be explored.     

PCBs,PBDEs and dioxin-related compounds in floor dust from an informal end-of-life vehicle recycling site in northern Vietnam: contamination levels and implications for human exposure

Floor dusts from Vietnamese end-of-life vehicle (ELV)-processing households were investigated to elucidate the contamination levels and exposure risk of polychlorinated biphenyls (PCBs), polybrominated diphenyl ethers (PBDEs) and dioxin-related compounds (DRCs). The concentrations were in order of PBDEs (260–11,000, median 280 ng/g overall) > PCBs (19–2200, median 140 ng/g) > dioxin-like PCBs (8.8–450, median 22 ng/g) ? polybrominated dibenzo-p-dioxin/dibenzofurans (PBDD/Fs, 2000–28,000, median 8500 pg/g) > polychlorinated dibenzo-p-dioxin/dibenzofurans (PCDD/Fs, 440–4100, median 1800 pg/g) > MoBPCDD/Fs (1.9–1200, median 250 pg/g). Concentrations of PCBs and DRCs were higher than those reported for Vietnamese urban houses, indicating ELV processing as a significant source of these contaminants. Higher concentrations of PCBs relative to PBDEs suggest the abundance of old electrical capacitors/transformers in ELVs. The PBDD/F and PCDD/F profiles were indicative of DecaBDE-containing materials and combustion sources, respectively. PBDFs, PCDFs and DL-PCBs were the most important dioxin-like toxic equivalent (TEQ) contributors. The estimated PCB and TEQ intake doses from dust ingestion approached or exceeded the reference doses for children living in some ELV-processing households, indicating potential health risk. More comprehensive risk assessment of the exposure to PCBs and DRCs is required for residents of informal ELV recycling sites.