Environmental Comparisons of Steel and Plastic Automotive Fuel Tanks
Environmental Comparisons of Steel and Plastic Automotive Fuel Tanks Peter R. Mould Program Manager Strategic Alliance for Steel Fuel Tanks (SASFT)
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Environmental Comparisons of Steel and Plastic Automotive Fuel Tanks Peter R. Mould Program Manager Strategic Alliance for Steel Fuel Tanks (SASFT)
Presentation to Great Designs in Steel Seminar (GDISS) Livonia, MI March 9, 2005
www.autosteel.org
SAS GDISS 3_9_05 Final(2)
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INTRODUCTION Automobile Fuel Tanks
● ● ● Competitive
issues between steel and plastic
y Engineering performance — structural, fatigue, etc.
y y y y
Weight Design flexibility Cost Full service supply
AND Environmental issues
Today’s focus www.autosteel.org
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INTRODUCTION Environmental benefits of steel fuel tanks
y Proven recyclability y Low evaporative system emissions
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RECYCLING OVERVIEW Recycling of a Typical Automobile
● ● ● 1999
study by Steel Recycling Institute
— Model year 1980 - 1990 — Average vehicle weight: 3,252 pounds — Based on survey of auto dismantlers and shredders and American Metal Market automobile materials data Plastic** (212#)
Steel* (2324#) 120
120
100%
99.9% 100
100
80
80
60
60
40
40 20
20
0%
0.1%
0
0
RECYCLED
LANDFILLED
*includes steel tanks
RECYCLED
**almost no plastic tanks
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LANDFILLED
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RECYCLING — STEEL TANKS
Recycling
TODAY steel fuel tanks are fully recycled
●●●
Dismantled Re-use option
Hulk
Infrastructure in place
Scrap option
Crushing Shredding of hulk
Specific parts inc. tanks “Fluff” No value
About 40% plastic Landfilled
Other Metals 25 to 75% recycled
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Tanks Crushing, Bailing, Shredding
Steel Recycled 99.9% returned as scrap to steel mills
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RECYCLING — PLASTIC TANKS
Recycling
TODAY plastic tanks are NOT re-used or recycled
●●●
Dismantled plastic tank
Absorbed gasoline in wall of tank
Complicated recycling High cost Hazard in shredding
Hazard in re-use Landfill
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CONSEQUENCES Consequence of more plastic tanks ● ● ● f
Increased disposal of plastic tanks at end of life of automobiles — landfill — incineration
As plastic tanks increase — impact on disposal will increase
60 50
40 40 30
25
20 10 0 90
92
94
96
98
Model Year
00
02
04
06
08
No. of EOL plastic tanks in NA, millions
average vehicle life of 14 yrs.
20
16.6
15.5 16
11.5 12
8
6.9 4.1
4
0 4
6
8
10
12
14
Year
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18
20
8
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IMPACT The full impact of plastic fuel tanks In North America ● ● ● ― 254 million vehicles on the road ― If 80% of vehicles have plastic tanks when vehicles are retired ● ● ●
Plastic tanks placed end-to-end would stretch: ―125,000 miles ―5 times around the world ●●●
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IMPACT If landfilled
●●●
a mountain of plastic tanks.
1300 ft.
1300 ft. ●●●
or Incinerate?
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PILOT PROCESS FOR PLASTIC TANKS Pilot processes for plastic tanks are being developed Example: RECAFUTA . . . . . . . . . . . . . . Partnership: Solvay, Inergy, Watco, Renault, Ciba, and University of Lisbon Co-financed: European Commission
Source: Solvay website
Technically feasible: BUT . . . high cost . . . no commercial infrastructure
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COMPARISION OF RECYCLING Plastic Fuel Tanks
Steel Fuel Tanks
Tank Manufacturing
Steel processing Tank Manufacturing
Compounding Assembly on Vehicle
HDPE EOL
Feedstocks
Steel refining
Assembly on Vehicle
Iron and Steel Scrap
Dismantling
Dismantling
BROKEN LOOP
EOL
CLOSED LOOP
Deserving of….. DISPOSAL …..recycling emblem
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PROBLEM AND SOLUTION Implication
●●●
PLASTIC FROM SHREDDED HULKS
+
PLASTIC FUEL TANKS
Current burden on recycling industry
Increasing burden on recycling industry in the future
● Disposal problem ● Jeopardizes current auto recycling process
Solution
●●●
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Steel tanks 13
EVAPORATIVE EMISSIONS Vehicle Emissions California Air Resources Board (CARB)
● ● ● Lower evaporative emissions required to reduce air
pollution.
● ● ● ● ● stringent requirements for certification of
gasoline powered autos
y Low EXHAUST emissions y Low EVAPORATIVE emissions « y DURABLE (15 years or 150,000 miles)
All required for certification as a Partial Zero Emission Vehicle (PZEV)
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EVAPORATIVE EMISSIONS Evaporative Emissions
HDPE PLASTIC TANKS
Permeable to gasoline hydrocarbons
STEEL TANKS Impermeable to gasoline hydrocarbons
Key Requirement Partial Zero Emission Vehicle (PZEV) certification by California Air Resources Board (CARB)
No PZEV certifications for plastic tank vehicles
Multiple PZEV certifications for steel tank vehicles
Steel is the material of choice for tanks on PZEV vehicles
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EVAPORATIVE EMISSIONS Steel Fuel Tanks . . . the choice for PZEV vehicles
Company Ford
Model Year
CARB PZEV certified vehicles for 2005 Model Name/Type Emission Rating
Tank Material
2005 2005
Escape – Hybrid Focus – Wagon - 2X3 - 2X4 - 2X5
ATPZEV PZEV PZEV PZEV PZEV
Steel Steel Steel Steel Steel
2004 2004
Sebring – Sedan Stratus – Sedan
PZEV PZEV
Steel Steel
2005 2005 2005
325CI – Coupe 325I – Sedan 325I - Wagon
PZEV PZEV PZEV
Steel Steel Steel
2004 2004 2004
Civic – Hybrid Accord – EX Sedan Accord – LX Sedan
ATPZEV PZEV PZEV
Steel Steel Steel
2005
Elantra – GLS & GT
PZEV
Steel
2004
Mazda 3
PZEV
Steel
2004
Galant DE & ES2.4L
PZEV
Steel
2004 2004
Altima 2.5, 2.55, 2.55L Sentra 1.8, 1.85
PZEV PZEV
Steel Steel
2004 2004 2004 2004 2004 2004
Legacy 2.5 GT Sedan Legacy 2.5 GT Wagon Legacy L Sedan Legacy L Wagon Outback Ltd Sedan Outback Ltd Wagon
PZEV PZEV PZEV PZEV PZEV PZEV
Steel Steel Steel Steel Steel Steel
2004 2004
Camry LE, SE or XLE Prius - Hybrid
PZEV ATPZEV
2004
Jetta – Sedan GL/GLS 2.0
PZEV
Steel
2004 2004
S60 2.4 Sesdan V70 2.4 Wagon
PZEV PZEV
Steel Steel
DaimlerChrysler
BMW
California Air Resources Board: ― Certified gasoline PZEV models ● 14 in 2003 ● 23 in 2004 ● 29 in 2005
Honda
Hyundai Mazda Mitsubishi Nissan
Subaru
Toyota Steel Steel / plastic bladder
Volkswagen
Volvo
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EVAPORATIVE EMISSIONS PZEV – most important for California vehicle sales
Vehicle sales per year
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EVAPORATIVE EMISSIONS Other states to follow California requirements
Steel fuel tanks for automobiles have environmental advantages — —
●
proven recycling using an existing, for profit infrastructure able to provide low evaporative emissions
Continued growth of plastic fuel tanks will — — —
●
jeopardize the existing automotive recycling process require substantial landfill or incineration incur end-of-life costs
SASFT and AISI will continue to communicate the environmental benefits of steel fuel tanks
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w w w . a u t o s t e e l . o r g
Great Designs in Steel is Sponsored by: •AK Steel Corporation •Mittal Steel Company •Severstal North America Inc. •Dofasco Inc. w w•Nucor w . aCorporation u t o s t e e l •United . o r g States Steel Corporation SAS GDISS 3_9_05 Final(2)
