The Materials Which Make Up an The Materials Which Make Up an AutomobileAutomobileUnderstanding the Upstream Processes and Burdens Understanding the Upstream Processes and Burdens Associated with Materials and Parts Production Associated with Materials and Parts Production TPP 123TPP 123The task for each group will be:The task for each group will be:Propose a vehicle design which suits the goals of your Propose a vehicle design which suits the goals of your interest groupinterest groupNote: Design changes will be limited to changing the material Note: Design changes will be limited to changing the material from which the body-in-white is madefrom which the body-in-white is madePropose a policy which will promote the development and Propose a policy which will promote the development and adoption of your proposed vehicleadoption of your proposed vehicleTools for detailed analysisTools for detailed analysisCost modelsCost modelsEnvironmental inventoryEnvironmental inventoryInventory evaluation toolsInventory evaluation toolsGroup AssignmentGroup AssignmentWhy Do We Care About Material?Why Do We Care About Material?Choice of material impacts theChoice of material impacts theManufacturing processManufacturing processProduct performanceProduct performanceCostCostEnvironmental impact?Environmental impact?Three materials are the prime candidates for use Three materials are the prime candidates for use in automotive in automotive bodiesbodiesActually three groups of materialsActually three groups of materialsSteelSteelThe current dominant materialThe current dominant materialAluminumAluminumPolymer compositesPolymer compositesEster Resin with Glass Fiber ReinforcementEster Resin with Glass Fiber ReinforcementMaterialEnergy for Primary Prod (MJ/kg)Energy for Secondary Prod (MJ/kg)Aluminum 189 27Cu 100 45Steel 40 18Mg 285 27Lead 41 8Polyester 96 50PP 74 42Materials Matter -- Materials Matter -- Energy Use Primary / SecondayEnergy Use Primary / SecondayThe choice of material and its source can have a big impact on The choice of material and its source can have a big impact on the environmental impact of the productthe environmental impact of the productPlastics 8%Aluminum 7%Other Nonferrous 3%Steel 59%Iron 13%Glass 3%Rubber 4%Other 3%What is in an automobile?What is in an automobile?AluminumCopperTotal IronLeadPlastic (10 t)Platinum (oz)RubberStainless SteelTot Steel (10 t)Zinc024681012Consumption (M tons)Automotive Total U.S.Autos are significant Autos are significant consumers of resourcesconsumers of resourcesAluminumAluminum19%19%Lead Lead 70%70%PlatinumPlatinum41%41%RubberRubber>60%>60%IronIron35%35%SteelSteel14%14%Why Care About Automobile RecyclingWhy Care About Automobile RecyclingWhat is Steel?What is Steel?2%1%How Do We Make Steel?Steel is Iron with a small Steel is Iron with a small amount of Carbon (~<1%)amount of Carbon (~<1%)Iron makes up 5% of Iron makes up 5% of earth's crustearth's crustSteel first used ~1400 BC Steel first used ~1400 BC by Chalybes, SE of Black by Chalybes, SE of Black SeaSeaTwo major steps:Two major steps:Make IronMake IronBlast FurnaceBlast FurnaceMake SteelMake SteelBasic Oxygen FurnaceBasic Oxygen FurnaceBOFBOFIron Ore LimestoneCokeBlast FurnaceLimeScrapIronBasic Oxygen FurnaceSteelHow Do We Make Steel?How Do We Make Steel?Making Steel Step One - Blast Furnace Raw MaterialsRaw MaterialsIron OreIron OreUsually iron oxidesUsually iron oxidesCokeCokeLimestone Limestone (and/or other fluxes)(and/or other fluxes)What is happening?What is happening?Carbon in coke serves Carbon in coke serves as reducing agentas reducing agentFeFe22OO33+ 3CO => 2Fe + + 3CO => 2Fe + 3CO3CO22 Blast Air 1300Fuel 50Slag 300Iron 1000Top Gas 2300Ore 1600Coke 450Limestone 190Blast FurnaceInputs (kg) Outputs (kg)Making Steel Step One - Blast Furnace Making Steel Step One - Blast Furnace Making Steel Step Two - Basic Oxygen Furnace Must reduce the Must reduce the amount of carbon in the amount of carbon in the ironironRaw MaterialsRaw MaterialsPig IronPig IronFrom blast furnaceFrom blast furnaceScrapScrapLimestoneLimestoneand other fluxesand other fluxesDissolved carbon is Dissolved carbon is oxidizedoxidizedReleases about Releases about .25g particulates/ kg .25g particulates/ kg steelsteelSlag Steel 1000Top Gas ~150(CO2)Iron 865Scrap 170Limestone 80Inputs (kg) Outputs (kg)OxygenBOFMaking Steel Step Two - Basic Oxygen Furnace Making Steel Step Two - Basic Oxygen FurnaceHow Do We Make Aluminum?Aluminum makes up 8% Aluminum makes up 8% of the earth's crustof the earth's crustAl production process Al production process discovered in 1886discovered in 1886Bauxite is the primary oreBauxite is the primary ore40-60% Alumina40-60% AluminaTwo major steps:Two major steps:Extract Alumina from Extract Alumina from BauxiteBauxiteBayer ProcessBayer ProcessElectrolytically reduce Electrolytically reduce Aluminum from AluminaAluminum from AluminaHall-Heroult ProcessHall-Heroult ProcessBauxite LimestoneNaOHBayer ProcessCarbon AnodesAlF3AluminaHall-Heroult ProcessAluminumAluminumAluminumMaking Aluminum Step One - Bayer ProcessBecause bauxite contains Because bauxite contains mamany minerals, the ny minerals, the alumina must be alumina must be extracted.extracted.Alumina is preferentially Alumina is preferentially dissolved in NaOHdissolved in NaOHAl(OH)Al(OH)33is precipitated outis precipitated outAl(OH)Al(OH)33is calcined to is calcined to AlAl22OO33 Remaining caustic sludge Remaining caustic sludge is referred to as red mudis referred to as red mudIron oxides give reddish Iron oxides give reddish colorcolorTo Produce 1000kg of AlBauxite4-5000 kgLimestone90 kgNaOH400 kgBayer ProcessAl2O31900kgper Kg Al2O3per Kg AlParticulates 100g 200gRed Mud 1.75kg 3.5kgProcess ReleasesBayerBayerMaking Aluminum Step Two - Hall-Heroult ProcessAluminum in alumina is electrolytically reducedAluminum in alumina is electrolytically reducedAnodes are made of carbonAnodes are made of carbonElectrolyte, called cryolite, is mixture ofElectrolyte, called cryolite, is mixture ofAlFAlF3 3 & Na& Na33AlFAlF66per Kg AlCO2 1.6kgParticulates 1.4gSO2 8gNOx 3gHF .25gFluorocarbons someElectricity 60MJProcess ReleasesTo Produce 1000kg of AlAlumina1900kgCryolite20kgC Anodes450kgHall-Heroult ProcessAluminum1000kgElectrolysisElectrolysisEmissions per kg of productEmissions per kg of productKilograms released for each kilogram producedKilograms released for each kilogram producedCO2 SO2 NOx NM VOC