Vehicle Recycl ing

10 11

General overview of the recycling

Airbag collectionand recycling

Airbag

Hood (Steel)→Vehicle parts, general steel products

Wiring harness (Copper)→Copper products, engines (cast aluminum reinforcement)

Engine oil (Oil)→Alternative fuel for boilers and incinerators

Radiator (Copper, aluminum)→Gunmetal ingots, aluminum products

Coolant (Alcohol)→Alternative fuel for boilers and incinerators

Bumper (Resin)→Interior parts, tool boxes, etc.

Battery (Lead)→Batteries

Transmission (Steel, aluminum)→General steel products, aluminum products Tire (Rubber)→Raw materials, alternative fuel for cement, etc.

Engine (Steel, aluminum)→Engines, aluminum products

Window (Glass)→Tiles, etc.

Suspension (Steel, aluminum)→General steel products, aluminum products

Gear oil (Oil)→Alternative fuel for boilers and incinerator

Catalytic converter (Rare metal)→Catalytic converters

Door (Steel)→Vehicle parts, general steel products

Tire (Rubber)→Raw materials, alternative fuel for cement, etc.

Bumper (Resin)→Interior parts

Trunk (Steel)→Vehicle parts, general products

Seat (Urethane foam, fiber)→ Soundproofing materials for vehicles Body (Steel)→Vehicle parts, general steel products

Dismantlingcompanies

Collectingcompanies

Engines, transmissions, catalysts, tires,batteries, oils, fuels, flons, airbags, etc.

17～19％

40～60％

Approx. 3.6 million units/year

Shreddingcompanies

ASR recyclingcompanies

20～45％

Ferrous,nonferrous metal

Soundproofing products,copper, slag, electricity, etc.

ASR

Sorting

Recycling

Removal

Press

End-of-life vehicles

Exports ofused cars

End user

Dealers

Used cardealersServicecenters

Wheel (Steel, aluminum)→Vehicle parts, general steel products, aluminum products

ASR material composition (Wt%)

Resin33

1615

Urethane foamFabric

Combustible

Non-combustible

7Rubber

Iron 8

GlassWire harness Nonferrous metal

754

Paper2

Wood3

■Recycling/recovery route for end-of-life vehicles(Japan)■Examples of parts being recycled from end-of-life vehicles

ASR landfill,etc.

Vehiclerecycling/

recovery rate :over 99%＊2

＊1 ASR : Abbreviation of Automobile Shredder Residue.＊2 Recycling efficacy rate : Weight sent for recycling / total weight of end-of-life vehicles

End-of-life vehicles Removal of parts in good condition

Reuse as used parts, and as ferrous and non-ferrous metals

Press

Dismantling company Shredder company

Shredder

Recycling company

Reuse as materials

Sort into three

Ferrous Nonferrous metals Shredder residue（ASR＊1）

Bumper

CFC collection

Flon

Battery

Catalyst Power steering, 　etc.

Engine, transmission

Reuse as ferrous and non-ferrous metals

Reuse as energy

(Copper)

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life

Vehicle Recycl ing

12 13

Glass

High-strength, precise tiles

Landscape pavingResin within ASR

Development and use of ASR sorting technology

In 1993, Toyota started working jointly with Toyota Metal Co., Ltd. to develop ASR recycling technology. We built a unique recycling plant and started operating it in August 1998, recycling on a mass production basis (approximately 15,000 cars per month).

To use automobile shredder residue, leaving no residues, it is necessary to return it to the basic materials of products.That requires separation of constituents to raise their purity, so we developed special separation technologies for ASR recycling plants, using wind and magnetism, to make shredder residue reusable.

Toyota Metal Co., Ltd.

World’s firstmass production

process of shreddingand ASR recycling

ELV Shredder Plant（End of Life Vehicle）

ASR Recycling Plant（Automobile Shredder Residue）

Primary shredderMain shredder

Pneumatic sorting

Pneumaticsorting

Pneumaticsorting

Crushing

Trommel

ASR(Shredder dust)

Glass

Aluminum

Copper

Resin/rubber

Melt-solidification

Rotating sieve

Ferrous metal

Non-ferrous sorting

Magnetic sorter

Shredded ferrousmetal

Nonferrousmetal

Iron scrap (Toyota plants)

Press

Electric furnace heat source

＊ ASR ： Abbreviation of Automobile Shredder Residue.

●Toyota has established a technology to mix and 　heat ASR, reducing it to 1/5 of the volume.

●The amount of lead elution is reduced to 1/5 of 　the previous level, reducing the environmental 　load on landfill sites.

Recycle of glass

Technical development about landfill

We have developed technologies to recycle vehicle glass, making the most of its high-purity property.

Use as substitute fuelThe resin that is the largest ingredient of ASR, by weight, is used as alternative fuel.

Electric steel furnaces use heat sources and carbon additives when then melt ferrous scrap to turn it into steel.

By adding an appropriate amount of the resin sorted out from ASR, it has become possible to achieve a heating efficiency usable as a heat source and also to use the resin as an alternative to the recar-burizer.

The Automobile Recycling Law calls for the ASR recycling rate to be raised to 70% by 2015, but Toyota already reached that target in 2007.

Use of resin as a heat source for electric steel furnaces

Resin within ASR

Iron scrap

Steel and components for vehicles

Substitutionfor heat sourcesand carbonadditives

Dissolution

Joint technical developmentwith Aichi Steel Corporation

in Jan. 2005

Joint research with Sanei Corporationand in use since April 1999

This technology enables effec-tive use of l ight materials of low calori f ic value, such as mixed resin, which were previ-ously difficult to recycle.

Electric steel furnace

Recycling of automobile shredder residue (ASR＊1)from end-of-life vehicles

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life

Urethane foam/fibers

Vehicle Recycl ing

14 15

Automobile Recycle Technical Center

Removing a wire harness＊3 with heavy scrapping equipment

＊1 Urban mines : The valuable rare metals contained in vehicles, electrical appliances, etc. that are discarded as garbage in urban areas are seen mine resources.＊2 Neodymium and dysprosium : Rare earths used in the production of powerful permanent magnets＊3 Wire harness : The bundled electric wires that supply electricity within the vehicle.

Before scrapping

Heavy scrapping equipment

Motor removal Motor disassembly

After scrapping

Before scrapping After scrapping

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life vehicle recycling researchToyota has to date conducted extensive research to enhance the dismantlability of end-of-life vehicles and the recyclability of parts. To further advance dismantling and recycling technologies and commercialize and incorporate them in vehicle designs based on the technologies and expertise gained from this research, Toyota established the Automobile Recycle Technical Center within Toyota Metal Co., Ltd. in 2001.

Toyota Motor Corporation Dismantling and shredding industries, etc.

Component and material manufacturers, etc. Tool and instrument manufacturers, etc.

Positioning of the Automobile Recycle Technical Center

Automobile RecycleTechnical Center

・・Research into vehicle structures that are easy to recycle・Research into efficient scrapping technologies・Development of appropriate and efficient recycling technologies

Proposing easy torecycle vehicle designs

Proposing efficientdismantling technologies

Technical developmentfor recycling rare metal andrare earth resources

Disclosure ofinformation on dismantling

technologies, etc.

Disclosure ofinformation on dismantling

technologies, etc.

Technical developmentfor recycling rare metal andrare earth resources

Research into technologies for disassembling parts that use noble metals

R&D on resource recycling

We are researching technologies for the efficient dis-assembly of electronic circuit boards and sensors etc., which are viewed as urban mine resources＊1, and technologies for the removal of components containing noble metals.

Research into technologies for disassembling parts that use rare earthsWe are researching efficient dismantling technologies for the magnets used in devices such as hybrid vehicle drive motors which use neodymium and dysprosium＊2.

Research into efficient removal and recovery technologiesWe are researching dismantling technologies that are efficient when used with widely used heavy dismantling equipment, and easy to dismantle vehicle structures.

Development of appropriate and efficient recycling technologiesWe are researching and developing technologies for the recycling and appropriate treatment of parts disassembled from end-of-life vehicles, including methods for their appropriate and efficient disassem-bly and reuse.

■O2sensor

■Engine ECUWorld'shighestlevel

End-of-life

Research and development of recycling technologies

Vehicle Recycl ing

16 17

Workshop for disassembly and removal of hybrid vehicle batteries

Vehicle resin parts

Rare earth

China97%

India 2%Brazil 1%

Other0%

Chile34%

Peru 8%U.S.A 8%

Other50%

Chile41%

Australia24%

China13%

Other 22%

Russia19%

Indonesia13%Canada 13%

Other55%

Copper

Lithium

Nickel

Source: Annual report on the environment in Japan 2010

Toyota is working on rare metals to provide its customers with stable supply of good vehicles

Resin recycling researchWe are considering the possibility of reusing resin vehicle parts recovered from end-of-life vehicles, as a way of promoting the wider recycling of resin. E.g.) Bumper material from end-of-life vehicles→Reused in resin body componentsWe are also working on R&D towards future realiza-tion of bumper to bumper recycling.

Research into technology for the removal and recovery of batteries from hybrid vehiclesEnd-of-life hybrid vehicle battery units basically remain at high voltage and, if they are damaged during the removal process, they can cause sparks, fire, and fluid leakage accidents, so safe removal is required. Therefore, we are collaborating with the Japan ELV＊1 Recycler’s Association to run training sessions nation-wide on the safe and appropriate removal of hybrid vehicle batteries.

Manuals for the disassembly and removal of hybrid vehicle batteries are also available on the Toyota Motor Corporation official site (http://www.toyota.co.jp/).

In recent years, vehicles have come to use numerous motors and circuit boards. Compared to previous vehicles, hybrid vehicles, in particular, have increasing numbers of components, such as batteries and motors that use rare metals＊1 and rare earths＊2.

Coffee Break Periodic table of the elements1

1

(Period)

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18(Group)

Hydrogen

1

H

Lithium

3

Li

Sodium

11

Na

Potassium

19

K

Rubidium

37

Rb

Cesium

55

Cs

Francium

87

Fr

Helium

2

He

Neon

10

Ne

Argon

18

Ar

Krypton

36

Kr

Xenon

54

Xe

Radon

86

Rn

Beryllium

4

Be

Magnesium

12

Mg

Calcium

20

Ca

Strontium

38

Sr

Barium

56

Ba

Radium

88

Rg

Lanthanum

57

LaCerium

58

CePraseodymium

59

PrNeodymium

60

NdPromethium

61

PmSamarium

62

SmEuropium

63

EuGadolinium

64

GdTerbium

65

TbDysprosium

66

DyHolmium

67

HoErbium

68

ErThulium

69

TmYtterbium

70

YbLutetium

71

Lu

Scandium

21

Sc

Yttrium

39

Y

LanthanideSeries

57～71

ActinideSeries

89～103

Titanium

22

Ti

Zirconium

40

Zr

Hafnium

72

Hf

Vanadium

23

V

Niobium

41

Nb

Tantalum

73

Ta

Chromium

24

Cr

Molybdenum

42

Mo

Tungsten

74

W

Manganese

25

Mn

Technetium

43

Tc

Rhenium

75

Re

Iron

26

Fe

Ruthenium

44

Ru

Osmium

76

Os

Cobalt

27

Co

Rhodium

45

Rh

Iridium

77

Ir

Nickel

28

Ni

Palladium

46

Pd

Platinum

78

Pt

Copper

29

Cu

Silver

47

Ag

Gold

79

Au

Zinc

30

Zn

Cadmium

48

Cd

Mercury

80

Hg

Boron

5

B

Aluminum

13

Al

Gallium

31

Ga

Indium

49

In

Thallium

81

Tl

Carbon

6

C

Silicon

14

Si

Germanium

32

Ge

Tin

50

Sn

Lead

82

Pb

Nitrogen

7

N

Phosphorus

15

P

Arsenic

33

As

Antimony

51

Sb

Bismuth

83

Bi

Oxygen

8

O

Sulfur

16

S

Selenium

34

Se

Tellurium

52

Te

Polonium

84

Po

9

17

35

53

85

FluorineF

ChlorineCl

BromineBr

IodineI

AstatineAt

Rare metalRare earth

LanthanideSeries

Hybrid vehicle motors Hybrid vehicle batteries

Ni Nickel

Li Lithium

Cu Copper

Nd Neodymium

Dy Dysprosium

Procurement risks

●The potential extraction period is short●Production is concentrated in a few countries.●Procurement is easily affected by economic 　and political changes.●Prices are extremely volatile.

Countermeasures

●Reduce the quantities used of materials subject to procurement risks.●Stabilize procurement by opening up new routes.●Recycle resources from “urban mines”.

■Leading producing countries of non-ferrous metal resources(2009)

＊1 Rare metal : Metals difficult to obtain. Lithium, cobalt, nickel, etc.＊2 Rare earth : Rare-earth 17 metals of similar chemical properties, included in the rare metals

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life

Resource recycling of rare metal and rare earth

This is one of the factors that can have a major impact on the production and sale of cars in the future

＊1 ELV : End-of-life

Vehicle Recycl ing

18 19

Dismantler : Consolidation with recovered catalysts

③

Reverse logistics of supply deliveries

④

Distributor : Part supply and return service

③

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life

Resource recycling of rare metal and rare earth Recycling of nickel＊1 included in batteriesIn October 2010, Toyota started the world’s first “battery to battery” recycling operation, in partnership with other related companies. It extracts nickel from used nickel-metal hydride batteries and recycles it as raw material for batteries. Total recycling of rare metals has moved into the final validation phase＊2.

Development of advanced sorting and extraction technologies

Until now

Stainless

In future

＊1 Nickel : Rare metal＊2 Validation phase : Studying the problems of a newly-developed product or technology, etc. by using it in real situations, as preparation for practical use＊3 Cobalt : Rare metal

ToyotaChemicalEngineering

Toyota

PEVE（Primearth EV

Energy）

Sumitomo MetalMining Co., Ltd.

Rare earthrecycler

Nickel Rare earth

Reduction process, crushing and sorting

Refining andprocessing

Production of hybrid vehicle batteries

Hybrid vehicle production

Materials from battery recycling

Nickel battery raw materials Hybrid vehicle battery Hybrid vehicle

Product

Sumitomo MetalMining Co., Ltd.

Toyota MotorCorporation

Primearth EVEnergy Co., Ltd.

Toyota ChemicalEngineering Co., Ltd.

Hybrid vehicle battery recycling process

We have built a collection network, unique to Toyota, for the collection of used batteries, and the Toyota HV＊1 Call Center receives collection requests nationwide. This system is able to recover over 90% of used batteries (record for FY2010).

This system also increases consolidation on the returning deliv-ery trucks of Toyota service parts, reduce CO2 emissions. In future, we plan to build a global recycling system, covering North America, Europe, and elsewhere.

＊1 HV : Abbreviation of Hybrid Vehicle

Outline of the Whole Collection Network

Dismantling companies Dealers

Aggregate

① Collection request

② Recovery request

③Transportation 　(consolidated with 　catalysts)

Toyotsu RecycleCorporation Distributors

Part supply transportationcompany

Sumitomo Metal MiningCo., Ltd.

Toyota ChemicalEngineering Co., Ltd.

③Transportation 　(reverse logistics of service 　parts delivery)

④Transportation 　(reverse logistics of service 　parts delivery)

⑤Reduction process

Toyota HV call center(24 hours a day)

Customers Dismantlingcompanies

systemsystemsystem

Toyota HVCall Center

Removal ofhybrid vehicle batteries

Discarded battery receptionCollection and transportation

instructions

Hybrid vehicleproduction

Production ofhybrid vehicle batteries

Battery raw materialmanufacturing

Ni and Co refining

Rare earthcompounds

Materials frombattery recycling

NEW

Nickelhydroxide

Cathode material Anode material

NEW

Rare earth compounds

Recycled as scrap for raw material of stainless steel.

Transition to complete recycling. Removal of nickel, cobalt＊3, and rare earths

End-of-lifehybrid vehicle

Hybrid vehicleHybrid vehiclepurchasepurchase

Hybrid vehiclepurchase

Reduction,crushing and sorting

Worldfirst!

Vehicle Recycl ing

20 21

Lithium battery

＊1 Neodymium/dysprosium : Rare earths used in the production of powerful permanent magnets.

Recycle loop of carbide product waste (tungsten)● With the cooperation of Sumitomo Electric Indus-tries, Ltd. and Toyota Motor Corporation, the world’s first and forefront system for recycling tungsten (rare metal) from carbide product waste in domestic reflow has been established.

● 100% recovery and recycling of tungsten from carbide product waste has been achieved.

● This activity is being extended 　 in Toyota Group (16 companies).

Toyota(Scrap sorting)

Chips, etc.

Tungsten powder

Rotating tools,etc.

Carbidechips

Carbidedrills

Development

and Design

Production

and Logistics

Sales

End-of-life

End-of-life

Resource recycling of rare metal and rare earth

Development of systems for vehicle-to-vehicle recycling of magnets

Development of motors with less rare earths wherever possible.

Rare earth resource recyclingNeodymium and dysprosium＊1, which are rare earths, are essential for the magnets used in devices such as hybrid vehicle drive motors.

Copper resource recyclingHVs and electric vehicles use copper in their motor cables and battery electrodes, as well as in the wiring harnesses.

Resource recycling of copper, aluminum, rare metal, and non-ferrous metalCompared to nickel metal hydride batteries, lithium batteries use less metal resources to produce the same battery capacity. Toyota is developing technologies to recycle rare metals, non-ferrous metals and other elements of lithium batteries in the same way as from nickel metal hydride batteries.

■Toyota's Goal of Magnets Vehicle-to-Vehicle Recycling

Toyota’s Responses

Extracting magnetsNew car

manufacturing

Recycling ofResourcesMagnets

New carScrappingDismantling

S

N

S

N

S

N

S

N

Rare earth

Motor wires

Wire harnesses

●Development of sorting technologies

●Parts evaluation tests

●Development of manufacturing methods　and other fields are R&D topics.

Copper

Group company of Sumitomo Electric Industries,Ltd.

(Material recycling)

Group company ofSumitomo Electric Industries,Ltd.(Carbide product manufacturing)