An Experimental Approach towards Sustainable Solution for Material Recycling of ELV Plastic Bumpers and EV Batteries

The automotive industry in India generates a significant amount of waste and pollution through end-of-life vehicles (ELVs). This paper addresses the current state and challenges of ELV recycling in India and presents a sustainable solution for recycling waste bumpers and electric vehicle (EV) batteries. With the Indian domestic passenger vehicle sales reaching 3.9 million units in 2022-2023, the need for effective recycling measures is becoming increasingly critical. The study estimates that in FY 2023-24 alone, the Indian automotive passenger vehicle industry will produce approximately 2.9 million tons of scrap, with 0.1 million tons attributed to plastic materials. Considering the 15-year end-of-life period for vehicles and the historical sales figures, this scrap generation is expected to grow exponentially each year. To address this issue, the paper proposes a comprehensive recycling approach that focuses on two key aspects: plastic recycling and the recovery of precious metals from xEV Li-ion batteries. The plastic recycling component primarily targets polypropylene (PP) from bumpers and other vehicle components. Additionally, the paper emphasizes the importance of recycling precious metals such as lithium, cobalt, nickel, and manganese from EV batteries. By recycling ELVs, including their plastic components, batteries, catalytic converters, and critical technology parts, the environmental impact can be reduced, and valuable raw materials can be conserved. To evaluate the long-term viability and potential of ELV recycling, the paper conducts a SWOT analysis and a life cycle assessment (LCA) to assess the environmental impact and carbon footprint. Experimental pilot lines were established and validated through lab testing to analyze changes in physical properties. Furthermore, the paper discusses the progress and challenges associated with achieving carbon neutrality and circular economy objectives in the automotive industry. The findings of this study provide insights into sustainable material developments, such as utilizing long cellulose fibers reinforced polypropylene resin for bumpers and ensuring the reusability of raw materials in automobile parts manufacturing without compromising quality requirements. This research aims to facilitate rational decision-making and policy formulation for ELV recycling in India, ultimately contributing to a sustainable and environmentally responsible automotive sector.