Research done by Jaguar Land Rover has found how an innovative recycling process could upcycle aluminium waste from every day drinks cans, bottle tops and old vehicles into the premium vehicles of the future and by doing so reduces production CO2 emissions by up to an impressive 26 per cent.
An imprortant part of Jaguar Land Rover’s Destination Zero mission to reduce carbon emissions and its effort to make societies safer and environments cleaner through persistent innovation is the innovative REALITY aluminium project. Engineers were able to constructively use the recycled aluminium parts and mix it with a lower amount of primary aluminium to form a new, tested and decent prototype alloy, similar to the existing Jaguar Land Rover grade and quality.
Jaguar Land Rover further close the loop on its manufacturing and use of raw materials due to the fact that this recycling and manufacturing process will reduce alloy production CO2emmissions by a whapping 26 percent when compared to the recent automotive grade.
Aluminium is one of the most widely recycled materials in the world and can be melted down and reformed repeatedly without losing quality. Post-consumer recycled aluminium appears in everyday goods such as drinks cans, aerosols, foil food trays and bottle tops but is not widely used for high-end applications such as automotive manufacturing. Nearly 75 per cent of all aluminium produced in the USA and EU is still in use today while the creation of recycled aluminium uses around 90 per cent less energy than raw material production*.
By improving the high-quality automotive-grade aluminium used to manufacture vehicles, Jaguar Land Rover can re-use the premium properties as part of a blend, minimizing the need for virgin aluminium in their vehicle productions. Typically, old vehicle scrap is exported overseas where it can be re-used for low-end applications, but the new advanced separation technology has allowed it to be upcycled back into the automotive process once again, assisting to close the loop and reduce the impact these manufacturing progress has on the environment.
The Lead Project Manager for REALITY at Jaguar Land Rover, Gaëlle Guillaume, said: “This project has allowed us, for the first time, to recover premium automotive-grade aluminium from scrapped vehicles and re-use its unique properties. The potential of this on the production process is a reduction in CO2 impact as well as helping us re-use even more aluminium.
“As we move into an autonomous, connected and electrified future, with the potential of shared fleets being de-commissioned en masse, it could allow Jaguar Land Rover to engineer this closed loop recycling alloy into tight production schedules to further improve efficiency and environmental benefits.”
The project of £2 million, co-funded by Innovate UK and in partnership with Brunel University, is assisting Jaguar Land Rover to extend its aluminium closed loop and recycling projects and initiatives as part of Destination Zero. Jaguar Land Rover has already reduced its global operating CO2 emissions per vehicle since 2007 by 50.7 per cent and remains dedicated to an ongoing decarbonisation process. Between September 2013 and March 2020, around 360,000 tonnes of closed-loop scrap was processed back into the brand’s lightweight aluminium intensive architecture, across all its vehicle lines including the Jaguar XE.
For more information about Destination Zero please visit: https://www.jaguarlandrover.com/2019/destination-zero