Demonstration/Exploitation event of H2020 CarE-Service project about the circularity on techno-polymers, describing recycling processes and results obtained during the project

1. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851

2. Please mute your microphone and open it only to ask questions in
the dedicated discussion slots
Use the chat to submit comments during the entire workshop
Raise your virtual hand if you want to ask a question in the
dedicated discussion slots
Presentations will be available for download in the CarE-
Service project website (www.careserviceproject.eu)
Connection recommendations

3. Next appointments  www.careserviceproject.eu

4. Automotive polyamide circularity?
Yes it’s feasible!
Experts from RadiciGroup’s High Performance Polymers Business Area

5. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

6. This project has received funding from the European Union’s Horizon 2020 research and innovation
programme under grant agreement No 776851
Automotive polyamide circularity?
Yes it’s feasible!
Riccardo Galeazzi
June 29th 2021

7. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

8. Organizational structure
Personnel
3,100 employees
2020 Sales
1,019 million €
Network 30+
production and sales units in Europe;
North and South America, and Asia

9. A global presence

10. From RadiciGroup Vision & Mission
to High Performance Polymers Facts

11. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

12. Circular Economy Business Models for innovative hybrid and
electric mobility through advanced re-use and re-manufacturing
technologies and services.
Duration: 42 Months
Program: H2020-CIRC-2017
15 Partners
European Project
This project has received funding from the European Union’s Horizon 2020 research and innovation
programme under grant agreement No 776851

13. Concept

14. Key points
Smart mobile
modules
Disassembly + Testing
ICT Platform
Supply and offer
connection
Car Sharing

15. Partnership
• 15 Partners
• 7 Countries
• Costs: 7,7 mln€
• EU Funding: 6,2 mln€
• From June 2018 to
May 2021 (3 years)
• Coordinator:
Giacomo Copani
(CNR-STIMA)

16. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

17. Recycling process
Sample
production
Mechanical
Characterization
Property
comparison
Recycled material characterization
Formulation
tuning
Compound
Production
Metal (ferrous)
separation
Raw material
Analysis
Raw material characterization
Drying
• Polymer
composition
• Moisture content
• Not adapt materials
• Etc…
Disassembly
procedure
Grinding
Cleaning and
metal sep.
Raw material
pre-treatments
QUALITY
CONTROL
POINT
continuous extruder

18. EOL recycled components
Airbags
Wheel covers
Polyamides
bases components
SET-UP AND SCALE-UP
Rear wipers
Door handles
Polyesters
bases components
PROCESS VALIDATION

19. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

20. … enjoy the video!!!
Let’s discover the details…
https://www.radicigroup.com/it/news-
media/video/car-e_service-project-63903

21. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

22. Furniture application
Adjustable desk actuator components
Gear box; gear box cover; bottom cover
PA66 – GF30 WITH post-consumer airbags content
• Good processability
• Good aesthetic surface finishing
• Dimension stability after cooling
• Good assembly;
• Dimensional tolerances
respected
• Good ultrasonic weldability
• Aesthetics welding not so good
(minor issue)
Test
Reference

23. Automotive application
Electric engine bottom cover
PA66 – GF25 Flame retardant WITH post-consumer airbags content
• In comparison to the reference material,
the cycle time slightly increased
• White stripes are present on the all parts
• Dimension stability after cooling
Mold Ref. material
Post-cons. material
REFERENCE
POST-CONSUMER

24. Automotive E-Mobility application
Recharge connectors components
PA66 - GF25 Flame retardant laser markable WITH post-cons. airbags content
• Good processability
• Dimension stability after cooling
• Excellent laser markability
15mm
15mm

25. Ribbed beam
PBT-PET – GF20 WITH
post-consumer rear wiper
and door handles content
PA66 – GF15MD10 WITH post-
consumer wheel cover content
• Good processability
• Good aesthetic surface finishing
• Dimension stability after cooling
• Dimensional tolerances respected
• Possible inclusion due to the wheel cover source

26. Fatigue Wohler curves - preliminary results
ISO527-1A Samples made of
PA66 – GF35 WITH post-consumer airbags content

27. 3D printing: Wormhole; Open box; Air spinner;
Wormhole
Gear box; gear box cover; bottom cover
PA66 – GF30 WITH post-consumer airbags content
• Good
processability
• Good
geometry
definition;
• Absence of
post-molding
warpage
Air spinner
Open box
Wormhole

28. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

29. Environmental Impact
[*] In agreement with ISO14040 Life
Cycle Assessment standard

30. Hot topics in the techno-polymer value chain
Component’s
selection
Separation of
the non adapt
materials
Cleaning
phase
Quality control
in imput
Variability intra
lot and lot by lot
Properties
characterization in
output
Material modeling
Validation Environmental
sustainability
Economic
sustainability

31. Conclusion
 Thanks to the European CarE-Service project, we were able to work more in
depth on the themes of recycling, the circular economy and sustainability in
the automotive sector.
 The CarE-Service project showed how teamwork among the various players
in the supply chain is a winning strategy for a more sustainable future.
 RadiciGroup contributed its expertise in the formulation and production of
engineering polymers with high technical and environmental performance.

32. This project has received funding from the European Union’s Horizon 2020 research and innovation
programme under grant agreement No 776851
Thank you for your attention!
Let’s team up!

33. Agenda
RadiciGroup High Performance
Polymers: company introduction
01.
Car-E Service Introduction
02.
Recycling process overview
in Car-E Service reality
03.
Automotive Polyamide Circularity?
Yes it’s feasible! (Video play)
04.
Demonstrative parts produced by
post-consumer recycled materials
05.
Environmental impact of the post-
consumer engineering polymers
06.
Operational Demonstration
Smart Mobile Module – Testing
07.

34. This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules
“Automotive Polyamide Circularity?
Yes, it’s feasible”
June 29th, 2021

35. This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Operational Demonstration
Smart Mobile Module – Testing
Matthias Goetze
IMA Dresden

36. Content
• Role in the Concept CarE-Service
• Inside the Business Models
• Techniques for Technopolymers
• Demonstration Event
• See you again soon

37. Role in the concept CarE-Service
CarE-Service Project an integrating Business Model
• Network of highly
specialized contributors
• Multinational in EU
Technopolymer Value Chain
… one of three

38. Role in the concept CarE-Service
Focus of the Value Chain of Technopolymers
• Material recovery on level (structural components) Radici Group
• Reliable quality of End of Life parts (post customer) CIA & IMA
• Revaluation of parts by approved attributes on the CarE-Service Marketplace
• Advanced procedure or technology on site
Typical parts made from Technopolymer
https://demo.ev.care/en/13-techno-polymers
C-Eco & Prodigentia

39. Role in the concept CarE-Service
Where is IMA coming from? – Evaluation of capabilities of products
to be alive under service conditions
Permanently observed state (laboratory)
Eddi current test
Visual inspection
Ultrasound
test
Magnetic particle
inspection

40. Role in the concept CarE-Service
Premise of Recovery
• Appropriate End of Life parts
• Proven characteristics
• Successfully passed
inspections
Challenge concerning
EV&HEVs
• Limited number of post-use
cars in this ramp-up phase
• Old fashioned car design

41. Disassembly Module
• DSS suggesting which components to disassemble
based on car sensors data, manufacturer product
data and market
• Disassembly guidelines
• Robotics cooperative disassembly
• Mechatronics tools
Inside the Business Models
Smart Mobile Modules – Why?
• Mobile services tailor made for sophisticated recovery
• Advanced technologies for on-site disassembly and testing
• Operation on demand
Testing Module
Functional, geometric, mechanical and electric
testing methods and technologies for:
• Evaluation of re-usable parts
• Testing of components and parts for remanufacturing
• Type / content of value-added materials for recycling

42. Inside the Business Models
Connected with ICT Platform
• Mobile services intermidiately affects the data base
Public domain
(non-associated trade)
Internal order and logistic
(part-/material flow)
Evaluation
(edit attributes)
SMM Testing

43. Attribute setting
Inside the Business Models
Purpose of parts
Take box by box
Decision

44. Inside the Business Models
Outcome for the Technoploymer Value Chain
• Boxes of parts allowed for production of structural parts
• Selected in Catagory 3 – Level-Cycling
Rubbish or undifferentiated flow of automotive waste
• that is recycled after the removal of hazardous
thorough shredding and chemical processes
EV&HEVs circular economy perspective

45. Techniques for Technopolymers
Purpose: Material Identification
Proven Conditions
• Nondestructive Inspection
• Several kinds of Nondestructive Tests
• Hierarchically by effort, beginning
with visual inspection DIN EN 13018:2016

46. Techniques for Technopolymers
Visual Inspection, standardised
• Precise defined task
• Limited time consumption
Local Visual Inspection
Qualification to reproducely
realize inspection tasks

47. Techniques for Technopolymers
Global Visual Inspection
• Confirm material composition by reading the mark

48. Techniques for Technopolymers
Global Visual Inspection
• Process control by JobCards, e.g. wheel cover
• Description, options of decision and time

49. Techniques for Technopolymers
Infrared Spectroscopy
• Mobile solutions
• Preconfigured analysis
• Material libraries
Laser
activated
LED
activated
Laser
activated
(production is
going to be
terminated)

50. Techniques for Technopolymers
Near Infrared reflective Spectroscopy
• Range 1400nm … 2500nm
• Less than 3s per capture
• Operation temperature 0°C ... 40°C
• Relative humidity up to 80%
Preconfigured espcecially for Technopolymeres

51. Techniques for Technopolymers
Near Infrared reflective Spectroscopy
Captured data set
Prompted result

52. Techniques for Technopolymers
Near Infrared reflective Spectroscopy

53. Techniques for Technopolymers
Near Infrared reflective Spectroscopy
One capture 5 Captures

54. Techniques for Technopolymers
When the job is done
• Parts successfuly passed keep members of lot
• Expectable change of amount of parts inside a lot

55. Demonstration Event

56. See You Again Soon
21st July (Demonstration)
“New solutions for disassembly,
remanufacturing and testing automotive
metal parts”
In the Metal demonstration event,
Fraunhofer IWU will show the technolo-
gies for disassembling and remanu-
facturing the metal components at the
End-of-life of vehicles for producing new
parts.
https://www.careserviceproject.eu/news-and-events/

57. This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules
“Automotive Polyamide Circularity?
Yes, it’s feasible”
June 29th, 2021