Vehicle Recycle

Vehicle Recycling
Published by : Environmental Affairs Div., Toyota Motor Corporation
Published : April 2014
Contact : Environmental Affairs Div. TEL : +81-565 -28 -2121
T a b l e
o f
C o n t e n t s
・ Table of Contents
1
・ Introduction
2
・ Resource saving and recycling,
looking at the entire life cycle of vehicle
3
Development
and
Design
Development and design with the environment in mind
4
Easy to dismantle vehicle structure
5
Examples of efforts other than recycling
6
Development
and Design
・ Specific content of efforts
・Development and wider use of plastics derived from plants
Promotion of effective use of resources
7
Production
and Logistics
Production
and
Logistics
・Reduction of discarded materials from the plants
・Reduction of water usage
・Reduction of packaging and wrapping materials
End-of-life
8
Sales
Recycling at the Sale Stage
・Reuse of used parts
General overview of the recycling
10・11
Recycling of automobile shredder residue from
end-of-life vehicles
12・13
Research and development of recycling technologies
14∼16
Resource recycling of rare metal and rare earth
17∼21
・ Compliance with the domestic act for
promotion of use of recycled resources
22
・ Compliance with overseas recycling laws
23
・ Result of Toyota Group’
s Efforts
24
End-of-life
Sales
〈 Vehicle recycling 〉Character profiles
N a m e : Kurukuru
Gender : Unknown
Interest : Driving
(The most recommended place to go is
Toyota Automobile Museum.)
Search by "Toyota Automobile Museum"!
Horoscope : Virgo
1
Introduction
T O D A Y
Resource saving and recycling,
looking at the entire life cycle of vehicle
F O R
T O M O R R O W
It is necessary to consider recycling through the entire life cycle of a car,
from its production to the end of its usefulness.
Make effective use of
We also contribute
the earth’s limited resources,
to sustainable
Toyota is constantly
progress for society
working towards that goal
and the earth.
so the children of
the future can always
Toyota applies the following activities
within these stages,
●Repeatedly use reusable items.
s.
through the most advanced
live affluent lives.
●Suppress the generation of waste.
Development
and Design
Production
and Logistics
End-of-life
Sales
●Recycle waste.
It keeps going
round and round!
efforts in the field of
resource recycling.
which from the life cycle of vehicle
To make more effective use of limited resources, we feed the results back into the development and design stages,
Universal guiding principles
and policies
Toyota Environmental Action Plan system
Guiding Principles at Toyota
Life cycle of vehicle
Toyota Earth Charter (Environmental Basic Policies)
Development and Design
Establishing a
low-carbon society
Establishing a
recycling-based society
Ultimate Eco-Car
Significantly reduce GHG emissions
Enhancing recycling of resources through 3R
Working together with Society
FCHV
Alternative
fuel HV
Diesel
HV
Plug-in
HV
Promoting integrated
actions on CO2 reduction
( p h o t o: S m a r t H o u s e
collaboratively controls
home electric appliances,
cars and solar power to
use home energy more
effectively)
THS Ⅱ
Hybrid Technology
Further performance improvement through the
use of hybrid technology
Bio
fuel
Mid / long-term movement and direction
working on creating cars with recycling in mind.
Lean
burn
Common-rail
DI
EV
VVT- i
The right vehicle for the right place at
the right time
Alternative
fuel engines
Development/
Design
Production
Internal recycling
Recycling improvement design/
development of Ecological Plastic
Reduction of materials discarded
Production/
Logistics
Internal reutilization
Intra-process reutilization
Resource
input
Promoting use of Ecological Plastic for plastic parts
(Photo: Parts of the SAI where Ecological plastic is used)
Internal recycling
Products
Resource
input
Recycling for profits
Materials discarded
Waste at cost
Incineration of waste
Increasing use of returnable shipping containers
Landfill waste
Enhancing development of recycling technology
for effective reutilization of resources
(Fig. Resource flow)
D-4
DPNR
Synthetic
fuel
CNG
Development and Design
Toyota Global Vision
Diesel
engines
Gasoline
engines
Eco-driving enlightenment
activities (Photo: Monitor of
ESPO installed in SAI and
Prius α)
The Fifth
Toyota Environmental
Action Plan
2011 - 2015
Recycling
Electrical
energy
Development of next-generation vehicles using
electricity, and promoting combination of
different power sources in ways that maximise
the strengths of each
Environmental protection and establishing a society in
harmony with nature Receiving and continuing the
blessings of nature
Working together with Society
Establishing technology
aimed at recycling advancement
(photo: Exterior view of a recycling plant)
End-of-life
Recycling from end-of-life
vehicles
HV Batteries
Promoting initiatives on biodiversity
(Photo: Toyota’s approach to
biodiversity brochure)
Supporting activities in Japan and overseas
t h ro u g h t h e Toyo t a E n v i ro n m e n t a l
Activities Grant Program
HV Motors
Recycling of repair/
replacement parts
Used bumpers
replaced during
repair at dealers
Enhancing environmental education at
TOYOTA Shirakawa-Go Eco-Institute
＊
ASR
Engine
undercover
Sales
Pallets for
transport,
etc.
Luggage door trim
Luggage trim
Seat back board
Environmental management
＊ ASR ： Abbreviation of Automobile Shredder Residue. It is the residue left from shredding end-of-life vehicles.
2
3
Ve h i c l e R e c y c l i n g
Specific content of efforts
Development and Design
Development and Design
Development and design with the environment in mind
Easy to dismantle vehicle structure
In 1998, Toyota was the first in the auto industry to introduce ISO14001＊1 in its design and development division. Since then, it has been assessing
recyclability in advance, at the vehicle development stage. From 2005, we introduced the“Eco-VAS”＊3 comprehensive environmental assessment
system, which is based on the approach of LCA＊2 (Life Cycle Assessment), through the entire vehicle development process.
■ Wire
harness
Using pull tab-type ground terminals
Environmental performance
Assembled condition
・Customer needs
・Cost
・CE＊4 concept
harness layout innovation
The wiring harness can be stripped out
without interfering with other components.
When dismantled
Pull-off
direction
Development
and Design
・Fuel economy improvement
・Reduction of exhaust gas, noise, and
environmental load substances
・Recycle
・LCA
■ Wire
Separates at
thinner areas
Setting targets that reconcile environmental
performance with customer needs
Design and prototyping
Target attainment
Before the production start
Final confirmation of
environmental performance
■
Production
and Logistics
Vehicle planning
Instrument panel removal
The positioning of the V grooves makes it easy to
Assessment using the“Eco-VAS”environmental assessment system
Use of "Easy to
dismantle mark"
remove the instrument panel by pulling it strongly.
Sales
■
“Disassembly facilitation
marks”are added to show
Information
disclosure to
customers
Points at which the load required for peeling door
Removal of heavy parts of batteries
from hybrid cars
trim off can be reduced by 30% were identified,
Component removal times for the Prius are further
and marked with easy to dismantle mark.
reduced.
■
Door trim peeling
■
End-of-life
key points for disassembly
＊1 ISO14001 : The international standard for environmental management systems
Toyota was the first in the auto industry to introduce it in 1998.
＊2 Life Cycle Assessment (LCA) : The product’
s impact on the environment is assessed in each process,
from development to disposal, as a way of selecting production methods, alternative raw materials,
and other options with lower environmental burdens.
＊3 Eco-VAS : Eco-Vehicle Assessment System
＊4 CE : Chief Engineer
tasks.
New easy to dismantle mark
is a d d e d , s o t h at h eav y
components can be hoisted
with good balance.
4
5
Ve h i c l e R e c y c l i n g
Development and Design
Production and Logistics
■ The Ecological plastic CO2
circulation concept
Examples of efforts other than recycling
Promotion of effective use of resources
CO2
Development and wider use of plastics derived from plants
CO2
Production
Photonic
synthesis
Toyota is suppressing CO2 emissions by other methods besides recycling, to prevent global warming.
CO2
CO2
Reduction of discarded materials from the plants
Petroleum-based plastics
Toyota researched how to use plastics
made from plants in cars!
Plant-based
materials
Heat recovery
We promote resource loss reduction activities to cut waste from the plants.
In particular, we are tackling yield improvement measures and waste reduction to steadily cut down the amounts of waste output by the company.
■ Environment Center
■ Resource Flow
・Suppress CO2 emissions to prevent global warming
Development
and Design
Plastics derived from plants
The Toyota Environment Center is an energy recovery plant that is
・Helping to reduce the usage of oil resources
Automobile
parts
Raw materials
Internal recycling
Internal reutilization
Intra-process reutilization
■ Record of use in cars
adjacent to the Motomachi plant. The Center generates electricity
and steam by burning combustlble waste and functions as the
Use of Ecological plastic in the“Raum”in May 2003
Use of Ecological plastic＊1 in cars
World
first
Resource
input
Products
Recycling for profit
Waste at cost＊1
Use of new Ecological plastic in the“CT200h”in Jan. 2011
Bio-PET＊2 derived from sugar cane is used
in new Ecological plastic＊3.
World
first
Materials discarded (Waste
not processed within Toyota)
Incineration of waste
Landfill waste
Production
and Logistics
energy source for the Motomachi plant.
・The Center had been completely shut down due to decrepit facilities and resumed its operation in April 2009 after the renewal.
Managing combustion drastically reduced the emissions of
substances of concern in the exhaust gas.
・Incinerated ash shall be recycled outside
80
Usage has reached
% of the surface area of all
interior decor components.
mponents.
Used in
mass-produced cars!!
Parts which require high wear resistance
... Seat covers, floor carpets, etc.
Sales
of Toyota as materials for cement or
Use in components that are difficult with previous Ecological plastic
Reach the same level as petroleum-based plastics,
includingg component
p
costs.
pavement , etc.
Reduction of water usage
We are constantly working on ways to use water effectively in the plants, with particularly thorough attention
End- of-life
Use of new Ecological plastic for interior surfaces
in the“SAI”in Nov. 2011
to management in car assembly plants, which use large volumes, to reduce overall water usage
Logistics
SAI
CT200h
Reduction of packaging and wrapping materials
Usage is reduced by simplification of wrapping
specifications, including slimmer bumper wrapping,
and wider use of returnable shipping containers.
：Areas where Ecological plastic is used
(approximately 80% of interior decor surface area)
Sugar cane
＊1 Ecological plastic : The general name for plastics developed by Toyota for use in vehicles, which include plants as raw material and achieve better heat
resistance, impact resistance, and other properties than general plant-derived plastics
＊2 Bio-PET : PET that is manufactured by replacing the monoethylene glycol that is one of the raw materials of polyethylene terephthalate with biological
raw material derived from sugar cane
＊3 New Ecological plastic : Plastic that provides far better heat resistance, durability, expansion and contraction resistance, and other properties, than other
general plastics derived from plant materials
6
Topics
Increasing
lean
specifications
for wrapping,
etc.
：Areas where new eEcological plastic is used
〈 Use of Ecological plastic in interior parts of partially redesigned SAI〉
■ Results of activities to reduce packaging and
wrapping materials (FY2012)
Increasing
returnable
containers
Before improvement :
Corrugated cardboard
After improvement :
Air bubble sheet (polyethylene)
Total
Products
Service
parts
Details
Reduction
(Thousand
tons/year)
Changing packaging specifications, reuse, etc.
1.6
Increasing lean specifications for wrapping
0.3
Production
parts
Improvement of storage capacity,
simplification of packing specifications, etc.
0.1
Service
parts
Expanding the use of returnable containers
(Expansion to more product types)
0.3
Production
parts
Expanding applications of returnable containers
(Expansion to more product types)
0.3
2.6
＊1 Waste at cost : Materials discarded that are recycled for a fee
7
Ve h i c l e R e c y c l i n g
Coffee
Break
Sales
Bumpers replaced
for repairs at car dealers
are recycled.
Recycling at the Sale Stage
Recycling in Changing Times, and Toyota’s Response
Collecting discarded bumpers from dealers and recycling
ng of plastics
1970∼
Discarded bumpers are made which allows easy recycling when they are discarded,
1990∼
2001
2002
2003
2004
2005
2006
2007
2008∼
such as grit adhering to bumpers
recycled material with end-of-life
● Quality acquisition through detailed
vehicle bumpers as the raw material.
adjustment of constituents
Deflector for
engine compartment
● Start of use in deflectors
We also established technologies that
New technology development towards use of recycled
allow eco-plastics and recycled plastics
plastic materials from discarded bumpers
to be used for 20% of all plastic components in 2013.
・Advance of the car
society
・Factory pollution
problems
→Rising environ mental
awareness
★1970∼
Established
Toyota Metal
Co., Ltd.
● Decision of the target components and track
of progress
・The 2000 EU ELV Directive＊1
・Recycling rate 95% in 2015
・Mandatory disclosure of disassembly information
・Enactment of the 2000 Basic Law for Establishing
the Recycling-based Society and the 3R Law＊2
・Demand for the promotion of recycling design
Started ASR
operations
World's
highest
level
● Removal of coating fragments etc., which reduce
★2001
★1998∼
Established Recycle
Technical Center
P12
P14
impact resistance
・2005 Act for promotion of Use of
Recycled Resources(Japan)
・Recycling rate 95% in 2015
・Mandatory removal of three items
(airbags, flon, ASR)
・Rising resource prices, rare metal shock
Expanded action towards securing resources
Development
and Design
up by recycling bumpers, developing a
・Growing momentum for promoting 3R
Advancing recycling technologies
(thermal＊3 → material＊4)
★2005
★2007
★2008
Implementation of
the Automobile
Recycling Law
Prepared
scenarios for
recycling
technologies in
2020
Established
the Resource
Recirculation
Committee
P17
Production
and Logistics
● Thorough removal of foreign material,
Towards the creation of a recycling-based society
Recycling design
efforts based on
recycling
technology
scenarios
Efforts for recycling design
(design for easy removal of components)
Sales
We have advanced the technology built
Changing times
so we actively collect them through Toyota dealers nationwide.
Handling of used parts began and extends
nationwide in 2001, using e-commerce
(electronic commercial transactions) to
■ How e-commerce works
Customer
Used parts
dealer A
Used parts
dealer B
Used parts
dealer C
Wants to use
used bumpers
make effective use of components,
through wider use of used parts, supply of
Repair consultation
and request
Shipping
instruction
Vehicle
repair
remanufacturing parts, etc.
＊1
■ Supply of rebuilt parts
(FY2012)
and new parts
Number supplied
Part name
Remanufacturing
parts
3,775
99
Power
steering
9,908
4,721
Used parts
3,758
5,766
46,135
ー
e-commerce
site
Toyota Metal Co., Ltd.
(Handa City, Aichi Prefecture)
Recycle Technical Center
(Toyota Metal Co., Ltd.)
Access
Dealer
Part
request
Delivery
ASR recycle plant
(Toyota Metal Co., Ltd.)
Product
(Delivery via parcel service)
Parts
distributor
Parts distributor : Company for the distribution and sale of car repair parts
and accessories, established with joint investment from
Toyota Motor Corporation and local dealers. 34 companies nationwide
＊1 Rebuilt parts : Parts that have been disassembled and cleaned, have had internal parts replaced etc., and are at the same standard as new parts
8
More advanced
recycling of resources
(rare earths, rare
metals, etc.)
Compliance with
the Automobile Recycling Law
Used parts and New parts
rebuilt parts
(reference)
Automatick
transmission
Torque
converter
Inventory
information
database
Search
and
order
End- of-life
Reuse of used parts
Toyota’
s Responses
Various recycling design points are extended to all new vehicles from the Raum
Raum
Prius
＊1 EU ELV Directive : Reduce waste output from end-of-life vehicles, recover materials for environmental protection, promote reuse and recycling.
It is legally binding.
＊2 3R (Reduce, Reuse, Recycle) : Reduce the amount of waste generated, reuse it, and then recycle it.
＊3 Thermal recycling : Rather than simply incinerating waste, use the heat and gases etc. that are generated by incineration.
＊4 Material recycling : Process the waste produced by used products, and use it as materials or raw materials for new products.
9
Ve h i c l e R e c y c l i n g
End-of-life
Reuse as used parts, and as ferrous and non-ferrous metals
Nonferrous metals
Reuse as ferrous and non-ferrous metals
■ Recycling/recovery route for end-of-life vehicles(Japan)
■ Examples of parts being recycled from end-of-life vehicles
Collecting
companies
Body (Steel)→
Vehicle parts, general steel products
Window (Glass)→Tiles, etc.
Wiring harness (Copper)→
Copper products, engines (cast aluminum reinforcement)
Engine oil (Oil)→
Alternative fuel for boilers and incinerators
Radiator (Copper, aluminum)→
Gunmetal ingots, aluminum products
Coolant (Alcohol)→
Alternative fuel for boilers and incinerators
Bumper (Resin)→Interior parts, tool boxes, etc.
Battery (Lead)→Batteries
Transmission (Steel, aluminum)→
General steel products, aluminum products
10
Trunk (Steel)→
Vehicle parts, general products
Dealers
Bumper (Resin)→Interior parts
Tire (Rubber)→
Raw materials,
alternative fuel for cement, etc.
Door (Steel)→
Vehicle parts, general steel products
Catalytic converter (Rare metal)→
Catalytic converters
End user
Hood (Steel)→Vehicle parts, general steel products
Engine (Steel, aluminum)→Engines, aluminum products
Shredder residue（ASR＊1）
End- of-life
Power steering, etc.
Ferrous
Sales
(Copper)
Engine, transmission
Seat (Urethane foam, fiber)→ Soundproofing materials for vehicles
Reuse as energy
Battery
Airbag
Catalyst
Sort into three
Used car
dealers
Service
centers
Exports of
used cars
Dismantling
companies
Approx.
3.6 million
units/year
Shredding
companies
17∼19％
ASR recycling
companies
ASR landfill,
etc.
ASR
ASR material composition (Wt%)
Wire harness
Vehicle
recycling/
recovery rate :
over 99%＊2
40∼60％
20∼45％
Non-combustible
Paper
2
5
4
7
Resin
33
Iron 8
Combustible
Rubber
7
Gear oil (Oil)→Alternative fuel for boilers and incinerator
Suspension (Steel, aluminum)→General steel products, aluminum products
Nonferrous metal
Glass
Recycling
Flon
Reuse as materials
Sorting
Bumper
Shredder
Press
Airbag collection
and recycling
Press
Removal
CFC collection
Removal of parts in good condition
Recycling company
End-of-life vehicles
End-of-life vehicles
Shredder company
Production
and Logistics
Dismantling company
Development
and Design
General overview of the recycling
Fabric
Engines, transmissions, catalysts, tires,
batteries, oils, fuels, flons, airbags, etc.
Ferrous,
nonferrous metal
Soundproofing products,
copper, slag, electricity, etc.
Wood
3
15
Urethane
foam
16
Wheel (Steel, aluminum)→Vehicle parts, general steel products, aluminum products
Tire (Rubber)→Raw materials, alternative fuel for cement, etc.
＊1 ASR : Abbreviation of Automobile Shredder Residue.
＊2 Recycling efficacy rate : Weight sent for recycling / total weight of end-of-life vehicles
11
Ve h i c l e R e c y c l i n g
End-of-life
＊1
Recycling of automobile shredder residue (ASR )
from end-of-life vehicles
Use of resin as a heat source
for electric steel furnaces
Joint technical development
with Aichi Steel Corporation
in Jan. 2005
Electric steel furnaces use heat sources
and carbon additives when then melt
ferrous scrap to turn it into steel.
In 1993, Toyota started working jointly with Toyota Metal Co., Ltd.
Iron scrap
to develop ASR recycling technology. We built a unique recycling
Substitution
for heat sources
and carbon
additives
By adding an appropriate amount of the
plant and started operating it in August 1998, recycling on a mass
resin sorted out from ASR, it has become
production basis (approximately 15,000 cars per month).
possible to achieve a heating efficiency
usable as a heat source and also to use
the resin as an alternative to the recar-
Dissolution
burizer.
Resin within ASR
To use automobile shredder residue, leaving no residues, it is necessary to return it to the basic materials of products.
The Automobile Recycling Law calls for
That requires separation of constituents to raise their purity, so we developed special separation technologies for
the ASR recycling rate to be raised to 70%
This technology enables effec-
ASR recycling plants, using wind and magnetism, to make shredder residue reusable.
by 2015, but Toyota already reached that
tive use of light materials of
target in 2007.
low calorific value, such as
ELV Shredder Plant
ASR Recycling Plant
（End of Life Vehicle）
（Automobile Shredder Residue）
Trommel
mixed resin, which were previously difficult to recycle.
Main shredder
Pneumatic
sorting
Aluminum
Sales
Recycle of glass
T h e resi n t h at is t h e l a rgest
We have developed technologies to recycle vehicle
ingredient of ASR, by weight, is
glass, making the most of its high-purity property.
used as alternative fuel.
Non-ferrous
sorting
Urethane foam/
fibers
Ferrous metal
(Shredder dust)
Use as substitute fuel
Joint research with Sanei Corporation
and in use since April 1999
Pneumatic
sorting
Magnetic sorter
End- of-life
Crushing
ASR
Steel and components for vehicles
World’
s first
mass production
process of shredding
and ASR recycling
Primary shredder
Pneumatic sorting
Electric steel furnace
Production
and Logistics
Development and use of ASR sorting technology
Glass
Development
and Design
Toyota Metal Co., Ltd.
High-strength, precise tiles
Rotating sieve
Glass
Copper
Resin/rubber
Shredded ferrous
metal
Nonferrous
metal
Melt-solidification
Iron scrap (Toyota plants)
＊ ASR ： Abbreviation of Automobile Shredder Residue.
12
Landscape paving
Technical development about landfill
Electric furnace heat source
Press
Resin within ASR
●Toyota has established a technology to mix and
●The amount of lead elution is reduced to 1/5 of
heat ASR, reducing it to 1/5 of the volume.
the previous level, reducing the environmental
load on landfill sites.
13
Ve h i c l e R e c y c l i n g
End-of-life
Research and development of recycling technologies
R&D on resource recycling
End-of-life vehicle recycling research
Toyo t a h a s to d a te co n d u c te d e x te n si v e re s e a rc h to
Development of appropriate and
efficient recycling technologies
Research into technologies for
disassembling parts that use rare earths
enhance the dismantlability of end-of-life vehicles and the
We are researching and developing technologies for
We are researching efficient dismantling technologies
recyclability of parts. To further advance dismantling and
the recycling and appropriate treatment of parts
for the magnets used in devices such as hybrid vehicle
recycling technologies and commercialize and incorporate
disassembled from end-of-life vehicles, including
drive motors which use neodymium and dysprosium＊2.
them in vehicle designs based on the technologies and
methods for their appropriate and efficient disassem-
expertise gained from this research, Toyota established the
bly and reuse.
Automobile Recycle Technical Center
Research into technologies for
disassembling parts that use noble metals
We are researching technologies for the efficient dis-
Positioning of the Automobile Recycle Technical Center
Proposing efficient
recycle vehicle designs
dismantling technologies
Disclosure of
information on dismantling
World's
highest
level
and technologies for the removal of components
containing noble metals.
Research into efficient removal and
recovery technologies
We are researching dismantling technologies that are
■Engine ECU
efficient when used with widely used heavy dismantling
Sales
Dismantling and shredding industries, etc.
Proposing easy to
Motor disassembly
assembly of electronic circuit boards and sensors
etc., which are viewed as urban mine resources＊1,
Toyota Motor Corporation
Motor removal
Production
and Logistics
Co., Ltd. in 2001.
Development
and Design
Automobile Recycle Technical Center within Toyota Metal
equipment, and easy to dismantle vehicle structures.
technologies, etc.
End- of-life
Technical development
for recycling rare metal and
rare earth resources
Before scrapping
After scrapping
■O2sensor
Automobile Recycle
Technical Center
・Research into vehicle structures that are easy
to recycle
・Research into efficient scrapping technologies
Heavy scrapping
equipment
・Development of appropriate and efficient
recycling technologies
Technical development
Disclosure of
for recycling rare metal and
information on dismantling
rare earth resources
technologies, etc.
Component and material manufacturers, etc.
Tool and instrument manufacturers, etc.
Before scrapping
After scrapping
Removing a wire harness＊3 with
heavy scrapping equipment
＊1 Urban mines : The valuable rare metals contained in vehicles, electrical appliances, etc. that are discarded as garbage in urban areas are seen mine resources.
＊2 Neodymium and dysprosium : Rare earths used in the production of powerful permanent magnets
＊3 Wire harness : The bundled electric wires that supply electricity within the vehicle.
14
15
Ve h i c l e R e c y c l i n g
End-of-life
Resin recycling research
Resource recycling of
rare metal and rare earth
We are considering the possibility of reusing resin
vehicle parts recovered from end-of-life vehicles, as a
Hybrid vehicle motors
Hybrid vehicle batteries
Li
Nd
Lithium
Neodymium
way of promoting the wider recycling of resin.
E.g.) Bumper material from end- of-life vehicles→
In recent years, vehicles have come to use numerous motors and circuit boards.
Reused in resin body components
Compared to previous vehicles, hybrid vehicles, in particular, have increasing numbers
＊1
of components, such as batteries and motors that use rare metals
We are also working on R&D towards future realiza-
Ni
Nickel
Cu
＊2
and rare earths .
Dy
Copper
Dysprosium
tion of bumper to bumper recycling.
Development
and Design
Toyota is working on rare metals to provide its customers
with stable supply of good vehicles
■ Leading producing countries of non-ferrous metal resources(2009)
Procurement risks
Source: Annual report on the environment in Japan 2010
●The potential extraction period is short
●Prices are extremely volatile.
End-of-life hybrid vehicle battery units basically remain
Manuals for the disassembly and removal
at high voltage and, if they are damaged during the
of hybrid vehicle batteries are also available
removal process, they can cause sparks, fire, and fluid
on the Toyota Motor Corporation official site
leakage accidents, so safe removal is required.
(http://www.toyota.co.jp/).
Australia
24%
Copper
Countermeasures
Nickel
Other
50%
●Reduce the quantities used of materials subject
to procurement risks.
Russia
19%
Chile
34%
Other
55%
Indonesia
13%
Peru 8%
U.S.A 8%
●Stabilize procurement by opening up new routes.
●Recycle resources from“urban mines”
.
Sales
This is one of the factors that can have
a major impact on the production and
sale of cars in the future
Chile
41%
China
13%
China
97%
Vehicle resin parts
Research into technology for the removal and
recovery of batteries from hybrid vehicles
Other
22%
Canada
13%
End- of-life
●Procurement is easily affected by economic
and political changes.
Lithium
Other
0%
Brazil 1%
India 2%
Production
and Logistics
Rare earth
●Production is concentrated in a few countries.
＊1 Rare metal : Metals difficult to obtain. Lithium, cobalt, nickel, etc.
＊2 Rare earth : Rare-earth 17 metals of similar chemical properties, included in the rare metals
Therefore, we are collaborating with the Japan ELV＊1
Recycler’s Association to run training sessions nationwide on the safe and appropriate removal of hybrid
vehicle batteries.
B
Coffee
(Group)
re a k
1
Periodic table of the elements
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
(Period)
1
2
H
1
He
Hydrogen
3
Helium
4
5
Li
2
Lithium
11
Be
Sodium
19
K
4
Potassium
37
Ca
Calcium
Rubidium
55
Sr
Strontium
7
Workshop for disassembly
and removal of
hybrid vehicle batteries
Barium
88
Ti
Titanium
Y
Yttrium
Lanthanide
Series
24
V
Vanadium
41
Zr
Zirconium
72
25
Cr
Chromium
42
Nb
Niobium
73
26
Mn
Mo
Tc
75
Co
Iron
44
Molybdenum Technetium
74
Fe
Manganese
43
28
27
Ru
Ruthenium
Ni
Cobalt
Nickel
46
45
76
29
Rh
Rhodium
Cu
Pd
Zinc
48
Ag
Palladium
31
Silver
79
Ga
Ge
Germanium
Cd
50
In
Cadmium
P
Tin
82
Sulfur
34
As
Arsenic
51
Sb
Antimony
Ar
Chlorine
Argon
36
Br
Bromine
Te
Kr
Krypton
54
53
I
Tellurium
84
Neon
Cl
Se
Selenium
Ne
18
35
52
83
F
Fluorine
17
S
Phosphorus
Sn
Indium
81
O
Oxygen
16
33
Gallium
49
80
Silicon
32
Zn
Copper
47
78
77
30
10
Xe
Iodine
Xenon
86
85
Hf
Ta
W
Re
Os
Ir
Pt
Au
Hg
Tl
Pb
Bi
Po
At
Rn
Hafnium
Tantalum
Tungsten
Rhenium
Osmium
Iridium
Platinum
Gold
Mercury
Thallium
Lead
Bismuth
Polonium
Astatine
Radon
89∼103
Fr
Rg
Francium
Radium
57
Lanthanide
Series
23
40
57∼71
Ba
Cesium
87
Sc
Scandium
39
56
Cs
6
22
9
N
Nitrogen
15
Si
Aluminum
21
38
Rb
5
Al
Magnesium
20
Carbon
14
Mg
8
C
Boron
13
Na
7
B
Beryllium
12
3
6
Actinide
Series
58
59
60
La
Ce
Pr
Lanthanum
Cerium
Praseodymium
61
Nd
62
Pm
Neodymium Promethium
63
64
65
66
67
68
69
70
71
Sm
Eu
Gd
Tb
Dy
Ho
Er
Tm
Yb
Lu
Samarium
Europium
Gadolinium
Terbium
Dysprosium
Holmium
Erbium
Thulium
Ytterbium
Lutetium
Rare metal
Rare earth
＊1 ELV : End-of-life
16
17
Ve h i c l e R e c y c l i n g
Wo
r
first ld
!
End-of-life
Recycling of nickel＊1 included in batteries
In October 2010, Toyota started the world’s
partnership with other related companies. It
receives collection requests nationwide. This system is able
extracts nickel from used nickel-metal hydride
to recover over 90% of used batteries (record for FY2010).
batteries and recycles it as raw material for
batteries. Total recycling of rare metals has
This system also increases consolidation on the returning deliv-
Removal of
hybrid vehicle batteries
End-of-life
hybrid vehicle
Hybrid vehicle
production
moved into the final validation phase＊2.
Dismantling
companies
Customers
ery trucks of Toyota service parts, reduce CO2 emissions. In
future, we plan to build a global recycling system, covering
Until now
North America, Europe, and elsewhere.
Recycled as scrap for raw
material of stainless steel.
Toyota HV
Call Center
Toyota
system
PEVE
Toyota
Chemical
Engineering
（Primearth EV
Energy）
Production of
hybrid vehicle batteries
Stainless
Outline of the Whole Collection Network
Rare earth
recycler
Development of advanced sorting
and extraction technologies
In future
Dealers
③Transportation
(reverse logistics of service
parts delivery)
③ Dismantler :
Aggregate
② Recovery request
① Collection request
Toyotsu Recycle
Corporation
Distributors
＊1 HV : Abbreviation of Hybrid Vehicle
③ Distributor :
④Transportation
(reverse logistics of service
parts delivery)
Toyota Chemical
Engineering Co., Ltd.
Sumitomo Metal Mining
Co., Ltd.
④ Reverse logistics of
supply deliveries
Nickel
Part supply and
return service
Part supply transportation
company
⑤Reduction process
Toyota HV call center
(24 hours a day)
Consolidation with
recovered catalysts
Product
③Transportation
(consolidated with
catalysts)
Battery raw material
manufacturing
Transition to complete recycling. Removal
of nickel, cobalt＊3,
and rare earths
Hybrid vehicle battery recycling process
Dismantling companies
Discarded battery reception
Collection and transportation
instructions
Development
and Design
collection of used batteries, and the Toyota HV＊1 Call Center
Hybrid vehicle
purchase
Reduction,
crushing and sorting
Sumitomo Metal
Mining Co., Ltd.
Ni and Co refining
Production
and Logistics
first“battery to battery”recycling operation, in
Materials from
battery recycling
NEW
Rare earth
Nickel
hydroxide
Rare earth
compounds
Cathode material
Anode material
Toyota Chemical
Engineering Co., Ltd.
Sumitomo Metal
Mining Co., Ltd.
Primearth EV
Energy Co., Ltd.
Toyota Motor
Corporation
Reduction process,
crushing and sorting
Refining and
processing
Production of hybrid
vehicle batteries
Hybrid vehicle
production
Materials from
battery recycling
Nickel battery raw
materials
Hybrid vehicle battery
Hybrid vehicle
Sales
We have built a collection network, unique to Toyota, for the
End- of-life
Resource recycling of rare metal and rare earth
NEW
Rare earth compounds
＊1 Nickel : Rare metal
＊2 Validation phase : Studying the problems of a newly-developed product or technology, etc. by using it in real situations, as preparation for practical use
＊3 Cobalt : Rare metal
18
19
Ve h i c l e R e c y c l i n g
End-of-life
Resource recycling of rare metal and rare earth
Rare earth resource recycling
■ Toyota's Goal of Magnets Vehicle-to-Vehicle Recycling
＊1
Resource recycling of copper, aluminum,
rare metal, and non-ferrous metal
Compared to nickel metal hydride batteries, lithium batteries use less metal
Neodymium and dysprosium , which are rare
resources to produce the same battery capacity.
earths, are essential for the magnets used in
Toyota is developing technologies to recycle rare metals, non-ferrous metals
and other elements of lithium batteries in the same way as from nickel metal
New car
Scrapping
Dismantling
hydride batteries.
Lithium battery
S
Recycle loop of carbide product waste (tungsten)
N
N
New car
manufacturing
Extracting magnets
● With the cooperation of Sumitomo Electric Industries, Ltd. and Toyota Motor Corporation, the
world’s first and forefront system for recycling
S
tungsten (rare metal) from carbide product waste
S
Toyota
(Scrap sorting)
Production
and Logistics
Development of systems for
vehicle-to-vehicle recycling of magnets
Development
and Design
Development of motors with less
rare earths wherever possible.
S
Toyota’
s Responses
devices such as hybrid vehicle drive motors.
in domestic reflow has been established.
Copper resource recycling
N
Magnets
● 100% recovery and recycling of tungsten from
Recycling of
Resources
carbide product waste has been achieved.
HVs and electric vehicles use copper in their motor cables
and battery electrodes, as well as in the wiring harnesses.
Rare earth
Chips, etc.
Rotating tools,
etc.
Sales
N
● This activity is being extended
in Toyota Group (16 companies).
●Development of sorting technologies
Motor wires
Group company of
Sumitomo Electric Industries,Ltd.
(Material recycling)
End- of-life
Group company of
Sumitomo Electric Industries,Ltd.
(Carbide product manufacturing)
●Parts evaluation tests
●Development of manufacturing methods
and other fields are R&D topics.
Copper
Wire harnesses
Carbide
chips
Carbide
drills
Tungsten powder
＊1 Neodymium/dysprosium : Rare earths used in the production of powerful permanent magnets.
20
21
Ve h i c l e R e c y c l i n g
Compliance with the domestic act for
promotion of use of recycled resources
Compliance with overseas
recycling laws
The Automobile Recycling Law, which came into effect in January 2005, mandates an appropriate division of
Compliance with overseas automobile recycling laws
roles between automakers and other involved parties, to promote the recycling and appropriate processing of
end-of-life vehicles.
In line with the Act for Promotion of Use of Recycled Resources, Toyota collects CFCs, airbags, and ASR from
end-of-life vehicles and actively uses them for recycling and other applications.
All EU member states have enacted automobile recycling laws based on EU ELV Directive of 2000, and as of
January 2007 automakers started to take back end-of-life vehicles (ELVs) in most member states. In cooperation
with TME and distributors in various member states, Toyota has completed construction of a network ELV collection
of the 28 EU member states, and is proceeding with the necessary action in the remaining four member states in
Outline of the Law for recycling of end-of-life vehicles (Automobile Recycling Law)
(in effect since January 1st, 2005)
accordance with government authorization of dismantlers.
In other countries around the world, Toyota is diligently pursuing similar responses, working closely
with its distributors to ascertain local regulatory trends and studying local infrastructure in each country.
■ System for collection and recycling under the Automobile Recycling Law
Targets: 4-wheel passenger vehicles(including mini-vehicles) and 4-wheel commercial vehicles(standard, small, mini-trucks and buses)
Status
Fund management corporation
Recycling fee
Payment
Final owner
Return of vehicle
weight tax
Information management center
End-of-life
vehicle
Designated recycling support organization
Collection company
(dealer, vehicle maintenance company, etc.)
Outsourced/
payment
Japan Auto
Recycling
Partnership
(JARP)
Fluorocarbon
destruction
company
Collection of flon,
etc.
End-of-life
vehicle
Country/Region
Enacted
EU, EFTA※, Japan,
Taiwan, Korea, Turkey
Under study
Russia, India, China,
Mexico, Vietnam
Legend
Finland
Sweden
※ EFTA：4 member states of Switzerland, Norway, Iceland, and Liechtenstein
Estonia
Ireland
Airbag
recycling
company
Collection of
airbags
Netherlands
Belgium
Luxembourg
Contract
Shredding company
Outsourced/
payment
〈ART※〉
Poland
Germany
Czech Rep.
ASR recycling company, etc.
Metal, electricity,
etc.
Romania
Bulgaria
Croatia
Greece
Used parts, etc.
ASR
collection
Slovenia
Italy
Spain
Metals, etc.
Slovakia
Hungary
Austria
Disassembled
vehicle
〈TH team〉8 companies
(Toyotsu Recycle Corporation)
Toyota, Honda, Daihatsu, Hino,
VW, Audi, Peugeot, BMW
UK
Portugal
End-of-life
vehicle
Dismantling company
〈Collection management companies by team〉
Latvia
Denmark
Lithuania
Flon collecting company
Fee payment
Outsourced/
payment
■ EU member states
France
Payment
Outsourced/
payment
De-registration system
under the road vehicles act
Used car
Usable parts market/
Usable metal market
Automakers and importers (self implementation or outsourced)
Claim
Outsourced/
payment
■ Legislation status
New vehicle owner, etc.
Japan automobile recycling promotion center(JARP)
〈Three designated companies〉
Malta
Cyprus
＊1 The EU ELV Directive : A directive adopted in the EU in 2000. It is legally binding.
＊2 TME (Toyota Motor Europe) : the management company in overall control of Toyota’s European operations
Residue
Registration required
License required
Flow of materials
Flow of expenses
Certification required
Landfill
※ ART：Automobile shredder Residue recycling promotion Team
■ Transition in Toyota's vehicle recycling/recovery rate and ASR recycling/recovery rate
100
90
93%
94%
96%
97%
97%
80%
81%
80
97%
99%
99%
93%
94%
Toyota's recycling/recovery rate
(vehicle conversion value)
Toyota’
s ASR recycling/recovery rate
85%
76%
70
Legal standard for FY2015 : 70%
66%
60
50
57%
’
05
22
’
06
’
07
’
08
’
09
’
10
’
11
’
12 (FY)
23
Ve h i c l e R e c y c l i n g
＊1
Result of Toyota Group’
s Efforts
Milestone
Ye a r
Details
1970
Toyota Metal Co., Ltd. established to meet future demand for
responsible disposal of end-of-life vehicles
・First automaker to establish a recycling company
・Approx. 6.5 million vehicles recycled between 1972 and 2012
1973
Toyota Chemical Engineering Co., Ltd. established to process and
recycle cutting oil from Toyota production plants
・Established by Toyota Tsusho Corporation; 30,000 kL of waste oil
processed and recycled between 2008 and 2011
1985
Toyotsu Recycle Corporation established to recover and recycle
precious metals from exhaust gas catalysts
・Established by Toyota Tsusho Corporation; approximately
16 million catalysts recycled between 1985 and 2012
1992
Toyota Environment Committee established
・Chaired by TMC president
1996
Bumper recycling across Japan commences
・Approximately 10 million recycled between 1996 and 2012
1998
Automobile Shredder Residue (ASR＊2) recycling plant established
・Established at Toyota Metal Co., Ltd.
・World's first dedicated ASR plant
・ASR recycled into soundproofing materials for 22 million vehicles
between 1998 to 2012
End-of-life hybrid vehicle NiMH battery collection and recycling
commences
・Approximately 30,000 collected between 1998 and 2012
Automobile Recycle Technical Center established
・Established at Toyota Metal Co. Ltd.; first automaker to establish
an independent recycling research institute
Ecoline Corporation, a used parts sales network operator,
established
・Established by Toyota Tsusho Corporation; approximately 200,000
used parts handled annually
Parts e-commerce system introduced for Toyota parts distributors
throughout Japan
・Approx. 600,000 used parts sold between 2001 and 2012
Toyota Recycling Vision formulated
・Sets targets for 2015
"Raum" model launched
・Incorporates Toyota's proprietary "Design for Recycling" (DfR) features
Bio-plastics used in parts for the first time
・World-first
2005
Aluminum recycling business established at Toyota production
plants
・Expanded to 13 plants worldwide; approximately 2.5 million tons
recycled between 2005 and 2012
2007
95% vehicle recycling rate achieved
2009
Recycling guidance commences in countries where hybrid vehicles
are sold
・Aiming for development of NiMH battery collection systems
outside Japan
2010
Battery-to-battery recycling of hybrid vehicle NiMH batteries
commences
・World-first
Tungsten recycling system launched
・World-first; approximately 75 tons recycled between 2010 and
August 2013
2001
2003
2011
99% vehicle recycling rate achieved
2012
Magnet-to-magnet hybrid vehicle motor magnet recycling system
launched
・World-first
2013
System for reusing NiMH batteries in stationary rechargeable
batteries launched
・World-first
Redesigned "Sai" dedicated hybrid sedan launched
・Achieved 20 percent usage of Ecological Plastic and recycled resin
materials
Toyota wins JEMAI Rare Metal Recycling Award
・First automaker to win the award
Toyota wins Prime Minister's Prize in the 3Rs Awards
・First automaker to win the award
＊1 Toyota Motor Corporation, Toyota Tsusho Corporation, and their affiliates
＊2 ASR : Abbreviation of Automobile Shredder Residue. It is the dust left from shredding end-of-life vehicles.
24