EDSGN100 Design Project #2
Final Design Report
Recycling of Advanced High Strength Steel
Introduction to Engineering Design
EDGSN 100 Section 014
Fiddle Stix Design Co.
Team 1
Aaron Toldi, http://www.personal.psu.edu/ajt5354, ajt5354@psu.edu
Kody Belli, http://www.personal.psu.edu/kjb5505, kjb5505@psu.edu
Ahmed Alamoudi, http://www.personal.psu.edu/ama5753, ama5753@psu.edu
Submitted to: Prof. Berezniak
Date: 04/26/2012
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Recycling of Advanced High Strength Steel
Executive Summary
Table of Contents
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
Introduction……………………………………………………………………….………….
Project Background.……………………………………………………………………….
Project Objectives.………………………………..………….………………..………….
Project Requirements……………………………………….…………….….………….
Design Constraints/Assumptions….……….…………….…………..…………….
5.1 Economic…………………………………………………..…………..…….…….
5.2 Environmental……………………………….……..……..…………………….
5.3 Sustainability……………….…………………….…………………..…….…….
5.4 Technical/Manufacturing……………………….…………...…………….
5.5 Social and Political……………………………………….………..…………….
5.6 Public Health and Safety………….……………………..……….…..…….
5.7 Legal/Ethical……………………………..…………………………….………….
5.8 Critical Assumptions………………..…………………………….………….
Codes and Standards……………………………………..……………………..……….
Conceptual Design..….………………………..………………………..…………….….
Final Design..….………………………………………………….……………………….….
Results……………………………………………………………………………………………
Conclusions……………………………………………………………………………………
References………………………………………………….…………………………………
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List of Figures
Figure 1
Figure 2
Figure 3
Scrap Process …………………………………………………….………..… Page 6
Process-Flow Diagram….…………………………………….………..… Page 7
Alloy Tester .……………………………………………………….………..… Page 7
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Abstract (Executive Summary)
The objective of this project was to design a sustainable and efficient process to recycle steel
metal scrap from used automobiles. As a team, we were to design a system that would
separate the steel components of the car by the different alloys used in each part. We created
an alloy tester that sends electric current through the steel and identifies the alloy used by the
charge produced when a hot and cold current are sent through opposite sides, using a method
called the Thermoelectric Effect. Our total process is completely sustainable, by extracting the
toxic substances from the automobile and disposing of the non-steel parts, scrapping the
remaining parts, then finally testing the steel to be separated by alloy and sent to the required
factory to be recycled into future steel making.
1.0 Introduction
The project is to come up with a design to better recycle new high strength steel alloys and
keep it separate from other steel scrap throughout the scrap cycle. Our design team realized
the best way to separate the AHSS from other steel scrap was during the car scrapping process.
This method is the most efficient and cost effective. It utilizes what already exist with just some
minor alterations to get the job done.
2.0 Project Background
ArcelorMittal, as a customer, has asked us to redesign the steel recycling process. We are to
create a process that will separate the steel by alloy to recycle it back to the steel
manufacturers. The company is looking for a cradle-to-cradle process that will limit those
natural resources taken from the earth. While there are large known quantities of these
resources, they are finite and will eventually run out. ArcelorMittal is asking for a sustainable
recycling process that will follow environmental and socioeconomic constraints, as well as being
completely efficient. Right now, 30% of new steel is recycled. As we progress into the future,
this percentage should increase so that as much new steel as possible is made from scrap steel.
3.0 Project Objectives
The objective of this project is to develop a process to effectively recycle AHSS. The process
developed must be cost and socioeconomically effective, and environmentally friendly.
4.0 Project Requirements
The main requirement of this project is the effective separation of AHSS from line pipe steel.
This is important as the alloy products in line pipe pieces can cause an off chemistry heat and
those alloys could be in a heat to make more high alloy steel.
5.0 Design Constraints/Assumptions
5.1 Economic
Seeing as salvage yards currently remove recyclable materials from the vehicles, this
process won’t add much more cost to implement. Some new costs will include thermoelectric
metal detectors and perhaps a cutting device for the removal of AHSS from the regular steel.
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The separation of the two types of scrap may increase shipping costs slightly, but the same
weight of material would be moved either way.
5.2 Environmental
The process of breaking down the vehicle should be entirely indoors in order to prevent
run off of toxic chemicals. The toxic chemicals in the vehicle should all be drained prior to
disassembling the vehicle, and then reclaimed. All chemicals drained should be stored in
collection barrels. Spills which impact soil, surface water or ground water should be reported to
the appropriate authority. All salvage yards should meet EPA regulations, hopefully their own
standards exceed the EPA standards.
5.3 Sustainability
The design enables effective recycling of all vehicle parts. There is no part of this process
that creates waste which does not already exist. No part of this process requires a large amount
of energy or new materials. This process is very sustainable.
5.4 Technical/Manufacturing
If the salvage vehicle is broken down effectively, it is almost entirely recyclable. Any
waste can be separated and properly disposed of. There should only be short term storage of
materials prior to shipping them to the appropriate facility to be processed. The AHSS scrap will
be stored and shipped separately from the other steel. After the AHSS is stripped from the
vehicle, the frame can be crushed and shredded.
5.5 Social and Political
If done entirely indoors the public and environment will not be negatively impacted by
the process. The air can be filtered to collect any dust or chemicals. This process has the
potential to create more jobs. Considering it is also about recycling and saving money, it should
be well received by the public.
5.6 Occupational Health and Safety
As potentially toxic materials exist in cars, it is necessary for personnel scrapping them
to wear the appropriate PPE. The PPE can also protect personnel from physical harm in the
industrial workplace. There are some hazards associated with the vehicle scrapping process but
proper training and equipment will drastically reduce the risk of these.
5.7 Legal/Ethical
There are many chemicals and other materials recovered from the salvage vehicles
which must be handled within government regulations. One of the more notable chemicals is
the refrigerant in the air conditioner. Refrigerant recovery equipment must be certified by an
independent testing organization to meet EPA standards. The EPA prohibits venting refrigerant
to the atmosphere. Refrigerants also have special storage and labeling requirements. All
salvage yards should already be meeting these standards. The only addition our process creates
is the cutting out of AHSS. This may create emissions from cutting the metal, the emissions
from which are not monitored by the EPA but by OSHA, because they are potentially toxic to
the workers.
5.8 Critical Assumptions
The first critical assumption is that most salvage yards which fully or near fully recycle
vehicles already exists. The second is that there will be some incentive for the salvage yards to
separate the AHSS from the regular steel.
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6.0 Codes and Standards
Most states have salvage laws which require the buyer of the salvage vehicle to keep a record
of the seller and contact law enforcement and the NMVTIS with vehicle information. This is to
prevent the sale of stolen property. Many recycling laws already exist and will not be violated
by this process. There are many laws regarding the environmental and occupational safety of
salvage yards. If interested in researching these laws, check out the resources.
7.0 Conceptual Design
The mass separation of shredded scrap is not feasible. The high alloy steel must be separated
from the other steel prior to it arriving at the steel mill. This must be accomplished when
scrapping the vehicle. There are a few ways to accomplish this. The first way would be to have a
computer readily available with information about which car parts contain AHSS so these can
be removed from the rest. A person with more experience with the specific type of vehicle
could do this more quickly. So it seems that an effective method would be for some company or
companies to recycle vehicles on a much larger scale than currently being done. Another
method would involve using some a method of detection to find which metals are AHSS at
existing scrap yards. It appears a thermoelectric metal tester would be the fastest way to
accomplish this, but just researching which parts are made of AHSS might be as effective.
8.0 Final Design
Our final design involves taking existing salvage yards and having them separate the AHSS from
the other steel. Our design is a process which involves cutting out the AHSS as part of the
recycling process. The ideal way this process works is part of the way which cars are already
recycled. First, all chemicals are drained from the vehicle. Then any parts with hazardous or
precious materials are removed. Next the tires, glass any other rubber, all the cables and
engine. Then the interior parts are removed, such as the dash and seats. After all those parts
are removed the AHSS can then be cut out. The way to identify which parts are AHSS and which
are not could be done either by researching which parts are AHSS or using an electric alloy
detector. The AHSS is then kept separate from the regular steel throughout the scrap cycle.
The rest of the car can then be crushed and shredded as per usual. (see Figure 1)
10.0 Results
The design here isn’t reinventing the wheel but it seems to be the most effective way to
separate the steel scrap. To visualize our process refer to figures 1 and 2. By using this process,
we can better separate the scrap and recycle the steel by its alloy make-up. This method will
help to increase the percentage of new steel that is made from recycled scrap. The process is
effective, efficient, and sustainable.
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11.0 Conclusions
This project was a great success. The process we developed enables the full recycling of
vehicles, and met the requirements for this project. It uses a very sustainable, environmentally
friendly process. It enables the separation of AHSS from other scrap to alloy the alloys to be
reused to reduce the cost of new alloys and it won’t affect the chemistry of other heats.
12.0 References
“ScrapLaws.com - Laws, Resources, Prices and News for Recyclers of Metal, Paper, Plastic, Etc." ScrapLaws.com.
2011. Web. 20 Apr. 2012. <http://www.scraplaws.com/>.
"World Auto Steel." - Steel Is Green. Web. 20 Apr. 2012. <http://www.worldautosteel.org/>.
“Environmental Compliance Guide for Motor Vehicle Salvage Yards.” Ohio EPA. Web. 20 Apr. 2012.
< http://www.epa.ohio.gov/portals/41/sb/publications/salvageguide.pdf>.
ArcelorMittal Project Statement
Figures
Figure 1
Scrap Process. Process of car being broken down at scrap yard into its separate components.
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Figure 2
Process-Flow Diagram. Flow diagram breakdown of where each step will take place.
Figure 3
Alloy Tester. Uses the Thermoelectric Effect to use heat currents to test for the charge of the alloy used.
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