Session: DFMLC-01-01: Life Cycle, Human Factors, Supply Chain, and Circular Economy

Paper Number: 143585

143585 - Recycling Automotive Shredder Residue: A Techno-Economic Analysis 

This study presents a novel "sorter-at-shredder" business model for the pyrolysis of Automotive Shredder Residue (ASR) plastics, addressing the challenge of low plastic recycling rates in end-of-life vehicles (ELVs). ASR comprises 25% of ELV material, and ASR consists of about 43% polypropylene (PP) and polyethylene (PE) plastics, which can be separated using sink-float sorting technology and pyrolyzed into olefin-rich product. The “sorter-at-shredder” business model strategically places small-scale pyrolysis plants that process up to 280 tons per day at existing shredders, integrating with ferrous and non-ferrous processing chains and enabling daily processing of ASR plastics. The model focuses on PP and PE plastics, creating olefin-rich product that can be re-entered into the supply cycle. Economic analysis reveals a yearly revenue of $46.1M for olefins-rich product, and a promising payback period of 6.3 years for the shredder, falling within acceptable ranges. The model uses Dallas, Texas, to capitalize on regulatory, economic, and geographical advantages, including proximity to a cluster of 5 shredders which process 165 tons of PP and 119 tons of PE each day, and proximity to oil refineries which can purchase olefin-rich product from the shredder. Future work involves optimizing sorting and pyrolysis technologies, ensuring the model's success and contributing to a sustainable automotive industry.

Presenting Author: Amber Velez Massachusetts Institute of Technology

Presenting Author Biography: Amber Velez studies mechanical engineering at MIT, focused in design and sustainability. She has worked on automotive recycling, devices for methane capture, and built a small-scale, energy-efficient tractor for small farms in resource-constrained areas. Outside of the lab, she enjoys blacksmithing and writing sci-fi/fantasy novels. She is excited to pursue a master’s in mechanical engineering at MIT this fall.

Authors:

Luke Chapman Massachusetts Institute of Technology
Amber Velez Massachusetts Institute of Technology
Ashley English Massachusetts Institute of Technology
Melanie Gavilanes Massachusetts Institute of Technology
Hung Huynh Massachusetts Institute of Technology
Emily Welsh Massachusetts Institute of Technology
Amos Winter Massachusetts Institute of Technology