Browse Topic: Recycling
This document provides recommendations involving BEV battery data retention and battery design that enhance the potential for BEV battery reuse and serviceability and that can improve recyclability. These recommendations have been developed by a group of professionals skilled in the secondary-use of batteries and in the research, development, and manufacture of BEV batteries and battery systems.
Enterprises that develop complex products or systems often struggle to reuse technology efficiently across their portfolios. This challenge is especially prevalent in aerospace, transportation, energy, and defense industries, where preserving freedom of action is critical. In this context, freedom of action is defined as the ability to avoid vendor lock imposed by integrators or third parties, while enabling competition within clearly defined functional boundaries that establish effective market segments for system components. This paper presents eight best practices for Enterprise Reference Architecture (ERA) development to address this challenge and applies them to aviation functionality spanning both vertical lift and fixed wing platforms. Because complex systems can be modularized in many ways, a consistent set of guiding rules is required to produce an organized set of modules that are reusable across an enterprise portfolio. The best practices presented in this paper are intended to fulfill that role.
Clean, safe water is vital for human health and well-being. It also plays a critical role in our food security, supports high-tech industries, and enables sustainable urbanization. However, detecting contamination quickly and accurately remains a major challenge in many parts of the world. A groundbreaking new device developed by researchers at the National University of Singapore (NUS) has the potential to significantly advance water quality monitoring and management.
This research paper offers a comprehensive evaluation of lithium-ion battery recycling methods, tracing the entire journey from global demand to the practical challenges and solutions for sustainable battery recycling. It starts with the analysis of worldwide LIB demand growth alongside the exponential growth in volumes of spent batteries and recycling rates. The study focuses on the imbalance in production and recovery of critical battery components and its environmental and economic effects. The paper then systematically examines six major recycling methodologies: mechanical, pyrometallurgical, hydrometallurgical, biotechnological, direct, and ion-exchange recycling. It goes into detail about their advantages, limitations, and roles in maximizing the recovery of valuable metals such as lithium, cobalt, and nickel. Traditional techniques like hydrometallurgical and pyrometallurgical methods, and emerging approaches including bioleaching and ion-exchange, are evaluated for their technical effectiveness and sustainability. Utilizing a multi-criteria decision analysis framework, the study compares these recycling methods across technical, environmental, and economic factors. The role of cutting-edge technologies, including automation and artificial intelligence, is also explored and discussed for their potential to optimize recycling processes, reduce chemical waste, and scale operations to meet escalating global demand. Pushing the transition toward circular economy models and closed-loop systems, this paper underscores the importance of emerging recycling solutions to preserve finite resources and build a resilient and sustainable LIB supply chain. The strategic recommendations are provided with the aim to guide industries and policymakers toward efficient, scalable, and environmentally responsible battery recycling technologies, which are critical for supporting the clean energy transition and future technological growth.
The rising importance of sustainability in the automotive sector has led to increased interest in circular and environmentally responsible materials, particularly for plastic trims parts, both interior and exterior. This study focuses on developing textile solutions using recycled polyethylene terephthalate (r-PET) sourced from post-consumer plastic waste, along with bio-based fibres such as bamboo. These materials made into woven and knitted fabrics are studied to suit different vehicle interior applications. r-PET textiles show promising strength, aesthetic appeal, and durability performance. Bamboo fabrics are known for their natural antimicrobial properties and enhanced breathability. Extensive testing is performed to validate explored sustainable materials performance against key automotive requirements. With this study, we gain an understanding of the performance of variedly sourced sustainable raw materials for automotive specific textile applications by different manufacturing methods.
The purpose of this research is to examine the fundamental principles of a circular economy (CE) in relation to the automotive industry in India, which plays a vital role in the country's economy. As a result, energy consumption and environmental impacts also pose significant challenges. CE provide a transformative approach through the life cycle of a vehicle, guiding the automotive industry toward a more sustainable transportation system. In order to decarbonize this industry, the global automotive commission recommends that recycled plastic content in vehicles be increased to 20-25% by 2030. This target necessitates the recovery of plastics from end-of-life vehicles, though these materials are rarely integrated into compounds today. The automotive industry's reliance on plastics has grown substantially due to their lightweight properties, which enhance fuel efficiency, reduce CO₂ emissions, and improve versatility and mechanical performance. polypropylene polymer and several other polyolefins are used for components like bumpers. The most prevalent recycling method for polypropylene bumpers is mechanical recycling, yet it presents notable challenges. It is important to note that paint, in particular, affects both the aesthetic quality and the structural integrity of recycled materials. This review work also explores the primary recycling methods documented in literature, particularly those that have minimal environmental impact. Further, the study provides a comprehensive analysis of India's transition toward sustainability in the automotive sector, including procedures for waste disposal and reuse. The report emphasizes the industry's growing pressure to adopt circular and sustainable approaches in production, vehicle design, and waste management while emphasizing the principles of reducing, reusing, and recycling plastic waste.
Lithium-ion batteries (LIBs) have consolidated their place in the technology market for the energetic transition, with global manufacturing capacity exceeding 1 TWh in recent years and costs falling in this competitive environment. At the same time, the number of end-of-life LIBs is increasing, stimulating the recycling industry to process battery streams, thus promoting the circular economy to meet the increased demand for strategic raw materials and decarbonization. Vehicle electrification is the main driver of battery production, but their end-of-life will take some time to be significant in volume in the next years. Consumer electronics such as smartphones, laptops and power tools are now available at an appropriate volume enabling the preparation of recycling industry for the moment. In this scenario, recyclers are looking for sustainable routes to absorb all these streams and the different LIBs chemistries (LFP, NCA, NMC, LCO, LMO) to recover the critical metals (Ni, Co, Cu, Mn and Li). Faced with these problems, Tupy in an Embrapii project with Tecnogreen LAREX at USP has developed a recycling route for EV batteries that extends its feed to electronic batteries in a flexible hydrometallurgical process. This work presents the results of this process, which includes the semi-pilot scale of 20kg LIBs obtained from electronics. Critical metals recovery efficiency was 71% of cell weight, leading for 83% of Co, 93% of Cu, 86% of Ni and 89% of Li. Such initial results exceed the Cu, Ni and Li efficiencies required by the European Union at the end of 2027.
Researchers have developed a wearable wound monitoring device with integrated sensors that could reduce infection risks by minimizing the need for frequent physical contact. The proof-of-concept device is designed for reuse, making it more cost-effective and practical than disposable smart bandages and other emerging wound monitoring technologies.
When it comes to plastics applications, cars are rarely the first products that come to mind. However, with modern vehicles containing 1,000 to 1,500 plastic parts — including dashboards, control elements, clips, trim parts, brackets, door panels, bumpers, and radiator grilles — the material is more important for mobility than we might assume. Some of these plastic parts are relevant for the drivers’ safety: for instance, airbag covers must open correctly in an accident and seat belt guides and retractors could cause severe injuries if they break or deform under load. Their quality is vital. At the same time however, cost pressure and new regulations — for instance regarding an increased use of recycled materials that is under way in the European Union — pose new challenges, especially in plastic injection molding. Digital solutions for measurement technology help control and stabilize the complex process and may even lead to increased product quality despite tougher conditions.
In a major step forward for sustainable energy technology, researchers at Worcester Polytechnic Institute (WPI), led by Professor Yan Wang, William B. Smith Professor of Mechanical and Materials Engineering, have developed a new, scalable method to recycle lithium-ion batteries in a way that is both efficient and environmentally friendly.
Researchers have created a technique to turn waste polyethylene terephthalate (PET), one of the most recyclable polymers, into components of batteries.
While new sustainability efforts aim to curb the carbon footprint of the commercial vehicle industry, old methods continue to be among the most effective. Sustainability has been among the hottest topics for the commercial vehicle industry over the past decade. OEMs, suppliers and various governmental agencies across the globe are touting new advances in clean powertrain tech that reduces the industry's dependence on fossil fuel while also considering the complete carbon footprint of the vehicle from cradle to grave. Though these initiatives have their merits, there are old-school methods of reducing the environmental impact of keeping the world moving. Remanufacturing is decidedly not the sexiest of methods for promoting the concept of sustainability. But recycling existing materials and components is a proven tactic for reducing waste and energy consumption.
With the recent rise in electric vehicles and mobile devices, managing spent batteries has become a critical global challenge. By 2040, the number of decommissioned electric vehicles is expected to exceed 40 million, leading to a sharp increase in waste batteries. Developing advanced recycling technologies has thus become an urgent priority, as the metals in batteries pose a significant risk of soil and water contamination.
From your car’s navigation display to the screen you are reading this on, luminescent polymers — a class of flexible materials that contain light-emitting molecules — are used in a variety of today’s electronics. Luminescent polymers stand out for their light-emitting capability, coupled with their remarkable flexibility and stretchability, showcasing vast potential across diverse fields of application.
A lighter, colorable and fully recyclable thermoplastic body seal from Cooper Standard won the annual Innovations in Lightweighting Award given by the Society for Automotive Analysts. At the society's December meeting, Jay Murdock, senior product development engineer for Cooper Standard, accepted the award and said its FlexiCore product was designed with an eye on strong trends in what OEMs want from suppliers: sustainability, carbon neutrality, lightweighting and recyclability.
In today's world, the electric vehicle (EV) industry is experiencing a remarkable boom with increasing global demand. With it, comes the surging and unprecedented need for EV batteries. Recycling these batteries has become of crucial importance, as it not only plays a vital role in ensuring the security of the battery supply chain but also serves as a key measure for reducing greenhouse gas emissions. However, there are still several issues that remain unresolved in this domain. Unsettled Issues Regarding Electric Vehicle Battery Recycling delves deep into these issues, thoroughly exploring the current state of the industry and potential solutions to drive sustainable EV battery recycling. By addressing these challenges, we can strive towards a more sustainable future in the EV sector. Click here to access the full SAE EDGETM Research Report portfolio.
Imagine the Moon as a hub of manufacturing, construction, and even human life. It’s no longer a far-fetched idea baked in science fiction lore — increased interest and investment in space exploration are pushing efforts to develop the technologies needed to make the moon a viable home for humans.
At Cox Automotive’s EV Battery Solutions center in Oklahoma City, the conglomerate most famous for its KBB, Autotrader, and Manheim auction brands, has become a go-to for EV battery research, repair, remanufacturing, and recycling.
Researchers have used inkjet printing to create a compact multispectral version of a light field camera. The camera, which fits in the palm of the hand, could be useful for many applications including autonomous driving, classification of recycled materials and remote sensing.
NASA Kennedy Space Center has developed a water remediation treatment system that utilizes an affordable media that is highly selective for ammonia, allowing large concentrations of ammonia in wastewater to be reduced to levels less than 1 ppm. Following treatment, the media is regenerated for reuse in the system and ammonia is captured as a by-product.
Unlike glass, which is infinitely recyclable, plastic recycling is challenging and expensive because of the material’s complex molecular structure designed for specific needs. New research from the lab of Giannis Mpourmpakis, Associate Professor of Chemical and Petroleum Engineering at the University of Pittsburgh, focuses on optimizing a promising technology called pyrolysis, which can chemically recycle waste plastics into more valuable chemicals.
Used lithium-ion batteries from cell phones, laptops, and a growing number of electric vehicles are piling up, but options for recycling them remain limited mostly to burning or chemically dissolving shredded batteries. The current state of the art methods can pose environmental challenges and be difficult to make economical at the industrial scale.
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