Transport Model Sheets by IAI SAWG UI Design & Code by James Campbell

NON OWC Version Sheet Revision 1.3 7/14/2008

Click on the button to the right to launch the transport model. You then will need to fill in data for each of the four stages, clicking finish to end and view the results.

If you need to access the orignal spreadsheet calculations you can do this by clicking on the sheet in interest at the bottom of the Excel window.

Transport Model Sheets by IAI SAWG UI Design & Code by James Campbell

NON OWC Version Sheet Revision 1.3 7/14/2008

Data entry
1 Specification of the vehicle and the component Component Mass of vehicle (kg) Number of vehicles per series Mass of component (kg) Portion of the component (%) gained from aluminium sheet with continous heat treatment gained from aluminium sheet w/o continous heat treatment ...gained from extruded aluminium ...gained from forgings ...gained from castings produced from untreated flat mild steel ...produced from hot-dip galvanized flat mild steel produced from untreated long and special steel produced from hot-dip galvanized long and special steel Percentage of indirect mass savings (%) car 2000 1 Aluminium 20.00 0% 0% 0% 0% 100%

All fields, if not stated differently, must be filled out.

Name the relevant component e.g. bumper, motor block, body in white. Weight of the vehicle before light-weighting Number of vehicles that will be produced in total (this field is optional) Steel is used as an acronym for steel and cast iron Mass of the component made out of aluminium Mass of the component made out of steel Information on the component, whether it is sheet, extrusion, casting and/or forging. Total must be 100% E.g. Body sheet - AlMgSi (AW-6xxx) E.g. Body sheet - AlMg alloys (AW-5xxx) E.g. bumper E.g. wheels E.g. motor block E.g. Bumper E.g. Body sheet - state-of-the-art E.g. Seamless tubes (components other then sheet out of high strength steel) E.g. Body sheet out of high strength steel Additional light-weighting of other components are possible. E.g. reducing the motor. These may vary from 0 to 100%. If no information is available 23% is used as an average.

Steel 40.00

0% 100% 0% 0% 0% 0%

23%

2 Production stage Percentage of generated process scrap from forming and machining operations Process scrap from forming and machining operations amount of scrap that is generated when producing a final product from a semi-product. E.g. a producing a door from a metal sheet. Enter the ...from rolled products 0% 0% E.g. 50% for a steel or aluminium body-in-white, 5% for a steel bumper from extruded products 0% E.g. 5% for a bumper fom forgings 0% 0% E.g. 5% for wheels from castings 5% 5% E.g. 5% for castings 3 Use stage Energy consumption of vehicle per 100 km Litres gasoline Litres Diesel Percentage biofuel in gasoline or diesel Nm3 natural gas or LPG MJ electric energy Designation of electricity grid Percentage air friction Life time driving distance (km) 4 End-of-life stage Percentage of vehicles collected for recycling 0% Aluminium 0% 0% 0% 0% 5% 1% 5% 1% 5% 0% 100% 0% Steel 0% 0% If the vehicle is landfilled and not recycled please set this value to 0% 0.0 35 0% 0 0 Global 40% 200,000 Average gasoline consumption before light-weighting Average diesel consumption before light-weighting

Average natural or liquid petrol gas consumption Average electric energy consumption Specify your electricity grid. If no information is available use the global grid. For road and rail vehicles there are four resistance factors, namely the rolling resistance, the gradient resistance, the acceleration resistance and the aerodynamic resistance. The three first resistance factors are proportional with Average driving distance during the operating life

Percentage of components dismantled Percentage of dismantled components shredded Percentage of shredded components EM sorted Expected metal loss from dismantling # from shredding of dismanteled parts and sorting from electromagnetic sorting from car shredding and sorting from sink float sorting ...from refining/EAF remelting - process Refining/EAF remelting - value correction Recovered Al scrap for refining (for castings) Total recycling rate

0% 5% 5% 5% 0%

Vehicles often undergo a dismantling stage, where pieces are dismantled before shredding the vehicle in order to get a better price for the scrap. This does not include pieces for re-use. Larger pieces that were dismantled are shredded in order to reduce their size and make them fit into the melting furnace If there are magnetizable and non-magnetizable pieces in the dismantled and shredded scrap then a magnet will be installed after the shredder. Processing (dismantling, shredder etc.) losses for aluminium and steel are usually around 5%. Remelting losses around 4% Losses from dismantling are usually 0%

Metals can be recycled over and over again without loss of quality if the scrap is processed appropriately. In case the remelted metal from scrap is of lower quality than primary metal then it is possible to add a correction factor a Aluminium can be remelted in a "refining" and a "remelting" furnace. The end product of a refining furnace is a casting alloy and of a remelting furnace is a wrought alloy. The two furnace types have different energy needs. See total recycling rate for your information.

0%

e. The three first resistance factors are proportional with the mass of the vehicle. The aerodynamic resistance (air friction) factor depends on the dimensions and the form of the vehicle and not on the mass of the vehicle. For passenger vehicles the air friction factor is between 25% and 50%. If you do not have any data please use 40% as an average.

ary metal then it is possible to add a correction factor accordingly. It is advised to study the primary and recycled metal prices. E.g. if you enter 10% it means that the quality of the recycled metal is about 90% of that of primary metal. e two furnace types have different energy needs.

Result
1 Product information
A Type of component B Mass of Al component (kg) C Mass of steel component (kg) D Mass difference (kg) E Percentage indirect mass F Effective mass of steel component (kg) G Total weight savings aluminium vs steel (kg) car 20.00 40.00 20.00 23% 44.60 24.60 calculated automatically data taken from "calculations" data taken from "data entry"

2 Environmental loads per component

From ingot to finished product Use stage - additional loads End-of-life recycling Substitution of lost material Total 0 2840 3445 Primary energy (MJ) Aluminium Steel 605 159 20783 0 1128 22070 0 208 241 Greenhouse gas emissions (kg CO2e) Aluminium Steel 33 11 1514 0 90 1615

3 Primary energy and GHG savings

Savings related to component under study Savings per kg aluminium used Savings per car series Primary energy (MJ) 18625 931 18,625 Greenhouse gas emissions (kg CO2e) 1374 69 1,374

4 Carbon Footprint of component

Carbon Footprint, excluding use stage Carbon Footprint, use stage Carbon Footprint, total

Carbon Footprint (kg CO2e) Aluminium Steel 241 101 1231 1472 2744 2845

5 Total recycling rate

Total recycling rate (%) Aluminium Steel ...excluding refining/remelting 0% 0% including refining/remelting 0% 0%