Recycling Devalued is now Revalued

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Solvay—Plastic Car Engine Pushing the envelope in developing plastic-based car parts is not new— designers and engineers are on a constant search for innovations and new applications that will save weight, improve safety, offer savings, simplify manufacturing and increase flexibility. Few parts in a car have not been altered or improved with plastics technology— save the wood and leather found in some luxury vehicles. Polimotor—a plastic-based motor engine—was developed by American Engineer Matti Holtzberg in the early 1980s and was then successfully raced around the world in a LolaT616 racecar. Solvay Specialty Polymers is currently developing Polimotor 2, a next generation plastic-based engine, with the objective of introducing new innovative polymers and processing technologies, demonstrating light-weighting possibilities and showcasing C02 reduction technologies. The Polimotor 2, announced in May 2015, will be based upon a 2-liter, 4-cylinder Ford engine with double-overhead CAMs—and it too will be destined for a racecar. The expected output of the engine is 375—400 horsepower and will also deliver a 40 percent reduction in weight. Polymer components in Polimotor 2 will include: • nCylinder block • nCylinder head • nCam cover • nIntake manifold (plenum) • nAir duct (runner) • nOil pan • nCam sprocket • nWater inlet/outlet • nThrottle body • nFuel rail • nOil pump • nOthers to come Solvay believes its polymer engine will be circling Europe and U.S. racing circuits, including Watkins Glen, Daytona and others in 2017. A. COMPONENT: Air Intake Runner MATERIAL: KetaSpire ® KT-820 CF 30 G. COMPONENT: E-Water Pump MATERIAL: Ryton ® R-4-220 B. COMPONENT: Air Intake Plenum MATERIAL: Sinterline ® PA6 H. COMPONENT: Cam Cover MATERIAL: Radel ® R-5100 BK C. COMPONENT: Throttle Body MATERIAL: KetaSpire® KT-820 CF 30 I. COMPONENT: CAC Housing MATERIAL: Amodel ® A-4145 HH D. COMPONENT: Fuel rail MATERIAL: Ryton ® XK-2340 J. COMPONENT: Cam Sprockets MATERIAL: Torlon ® 7130 E. COMPONENT: Fuel injector o-ring MATERIAL: Tecnoflon ® VPL K. COMPONENT: Cylinder head gasket MATERIAL: Tecnoflon ® F. COMPONENT: Water inlets/outlets MATERIAL: AvaSpire ® AV-621 GF30 L. COMPONENT: Oil Scavenger Line MATERIAL: KetaSpire ® KT-820 CF 30 12 PLASTICS MARKET WATCH: DEVALUED IS NOW REVALUED SPI: The Plastics Industry Trade Association
CAFE Standards To meet these new mileage standards, EPA and NHTSA expect automakers to use a range of efficient and advanced technologies to transform their vehicle fleets, including advanced gasoline engines and transmissions, vehicle weight reduction, lower tire rolling resistance, improvements in aerodynamics, diesel engines, more efficient accessories and improvements in air conditioning systems. Federal Corporate Average Fuel Economy (CAFE) standards have guided the designs and engineering of vehicles for more than 40 years. The forwardlooking standards set by the U.S. Environmental Protection Agency (EPA) and National Highway Traffic Safety Administration (NHTSA) have set the course for lighter vehicles and more fuel conserving engines and drivetrains for all manufacturers. The standards are intended to reduce petroleum consumption, increase and diversify alternatively fueled vehicles, lower greenhouse gas emissions and promote the advancement of innovative technologies. In 2012, the Obama Administration updated the CAFÉ standards to 54.5 mpg for cars and light-duty trucks by Model Year 2025. When combined with previous standards set by the Administration, the move will nearly double the fuel efficiency of cars and trucks in nine years compared to vehicles currently on the roads. Today, manufacturers are under the CAFE standards for cars and light trucks for Model Years 2011– 2016 which requires the equivalent of 35.5 mpg. The new CAFE standards have broad support among manufacturers and environmental groups—13 major automakers that account for more than 90 percent of all vehicles sold in the United States endorsed the standards. To meet these new mileage standards, EPA and NHTSA expect automakers to use a range of efficient and advanced technologies to transform their vehicle fleets, including advanced gasoline engines and transmissions, vehicle weight reduction, lower tire rolling resistance, improvements in aerodynamics, diesel engines, more efficient accessories and improvements in air conditioning systems. The CAFE program also provides incentives for early introduction and adoption of new advanced technologies like electric vehicles, plug-in hybrid electric vehicles, fuel cell vehicles and natural gas vehicles. These next generation vehicles are employing plastics technology, including carbon fiber for interior and exterior components. BMW, which has invested hundreds of millions of dollars into developing carbon fiber components, is using CFRP in a wide range of vehicles, from its i3 electric city car and i8 hybrid models, to its flagship 7 Series sedan. For new entrants into the automotive sector, like Tesla, identifying the best material for its undercarriage and body panels was a priority. Tesla tested its lightweight carbon fiber/epoxy composite for two years before finalizing its formula. Tesla weaves long, thin carbon fiber strands into a fabric that are molded with plastics or resins. SPI: The Plastics Industry Trade Association PLASTICS MARKET WATCH: DEVALUED IS NOW REVALUED 13
Page 1 and 2: WATCHING: Automotive A SERIES ON EC
Page 3 and 4: Automotive Recycling: Devalued is n
Page 7 and 8: Plastics make up about 50% of a mod
Page 11 and 12: Plastics Growing Role in Auto Manuf
Page 13 and 14: It would be hard to get into a 2016
Page 15: turers to adopt modular assembly pr
Page 21 and 22: Current Automotive Recycling— Veh
Page 23 and 24: We are looking at larger parts that
Page 27 and 28: Recycled Plastics in Automobile Par
Page 29 and 30: European Circular Economy We try to
Page 31 and 32: automakers to connect with environm
Page 33 and 34: According to Sue Kozora, Manager—
Page 37 and 38: Research and Work Underway for Plas
Page 39 and 40: Carbon fiber is an expensive materi
Page 41 and 42: Bioplastics—in cars now and in th
Page 45 and 46: The plastics industry and recycling
Page 47 and 48: A SERIES ON ECONOMIC-DEMOGRAPHIC-CO

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