SummaryAlloying elements in steel add a wide range of valuable properties to steel materials that are indispensable for the global economy. However, they are likely to be effectively irretrievably blended into the steel when recycled because of (among other issues) the lack of information about the composition of the scrap. This results in the alloying elements dissipating in slag during steelmaking and/or becoming contaminants in secondary steel. We used the waste input-output material flow analysis model to quantify the unintentional flows of alloying elements (i.e., chromium, nickel, and molybdenum) that occur in steel materials and that result from mixing during end-of-life (EOL) processes. The model can be used to predict in detail the flows of ferrous materials in various phases, including the recycling phase by extending steel, alloying element source, and iron and steel scrap sectors. Application of the model to Japanese data indicates the critical importance of the recycling of EOL vehicles (ELVs) in Japan because passenger cars are the final destination of the largest share of these alloying elements. However, the contents of alloying elements are rarely considered in current ELV recycling. Consequently, the present study demonstrates that considerable amounts of alloying elements, which correspond to 7% to 8% of the annual consumption in electric arc furnace (EAF) steelmaking, are unintentionally introduced into EAFs. This result suggests the importance of quality-based scrap recycling for efficient management of alloying elements.

Steel is not elemental iron but rather a group of iron-based alloys containing many elements, especially chromium, nickel, and molybdenum. Steel recycling is expected to promote efficient resource use. However, open-loop recycling of steel could result in quality loss of nickel and molybdenum and/or material loss of chromium. Knowledge about alloying element substance flow is needed to avoid such losses. Material flow analyses (MFAs) indicate the importance of steel recycling to recovery of alloying elements. Flows of nickel, chromium, and molybdenum are interconnected, but MFAs have paid little attention to the interconnected flow of materials/substances in supply chains. This study combined a waste input-output material flow model and physical unit input-output analysis to perform a simultaneous MFA for nickel, chromium, and molybdenum in the Japanese economy in 2000. Results indicated the importance of recovery of these elements in recycling policies for end-of-life (EoL) vehicles and constructions. Improvement in EoL sorting technologies and implementation of designs for recycling/disassembly at the manufacturing phase are needed. Possible solutions include development of sorting processes for steel scrap and introduction of easier methods for identifying the composition of secondary resources. Recovery of steel scrap with a high alloy content will reduce primary inputs of alloying elements and contribute to more efficient resource use.

Even for metals, open-loop recycling is more common than closed-loop recycling due, among other factors, to the degradation of quality in the end-of-life (EoL) phase. Open-loop recycling is subject to loss of functionality of original materials, dissipation in forms that are difficult to recover, and recovered metals might need dilution with primary metals to meet quality requirements. Sustainable management of metal resources calls for the minimization of these losses. Imperative to this is quantitative tracking of the fate of materials across different stages, products, and losses. A new input-output analysis (IO) based model of dynamic material flow analysis (MFA) is presented that can trace the fate of materials over time and across products in open-loop recycling taking explicit consideration of losses and the quality of scrap into account. Application to car steel recovered from EoL vehicles (ELV) showed that after 50 years around 80% of the steel is used in products, mostly buildings and civil engineering (infrastructure), with the rest mostly resided in unrecovered obsolete infrastructure and refinery losses. Sensitivity analysis was conducted to evaluate the effects of changes in product lifespan, and the quality of scrap.

There has been a sharp increase in the production of automobiles over the past decade. In 2010, one billion automobiles were in circulation worldwide. The automobile industry is one of the largest metals consumers and plays an important role in their sustainable use. Steel materials, including alloy steels that contain alloying elements (AEs) such as manganese, chromium, nickel, and molybdenum, are the main component of automobiles. The recycling of end-of-life vehicles (ELVs) significantly affects the cycling of iron, steel, and AEs. Currently, ELV recycling is performed using the electric arc furnace (EAF). In this method, losses of AEs are likely to occur because their presence is rarely considered. This study evaluated the environmental and economic benefits of alternative ELV recycling schemes, which allow more efficient utilization of AEs found in ELV-derived steel scrap (ELV-dSS). The AE contents in ELV-dSS (as car-parts) were estimated by means of a waste input-output material flow analysis (WIO-MFA) model extended for the detailed analysis of automobile composition. Using Japanese data, it was found that sorting ELV-dSS by parts can result in a significant recovery of AEs; more specifically, a 10fold saving in AEs was achieved by sorting exhaust parts. The recoverable mass of AEs from sorted ELV-dSS was found to correspond to 8.2% of the annual consumption of AEs in Japan, as virgin resources in EAF steelmaking. ELV-dSS sorting was found to be significantly effective in the conservation of AE resources.

Metals can in theory be infinitely recycled in a closed-loop without any degradation in quality. In reality, however, open-loop recycling is more typical for metal scrap recovered from end-of-life (EoL) products because mixing of different metal species results in scrap quality that no longer matches the originals. Further losses occur when meeting the quality requirement of the target product requires dilution of the secondary material by adding high purity materials. Standard LCA usually does not address these losses. This paper presents a novel approach to quantifying quality- and dilution losses, by means of hybrid input-output analysis. We focus on the losses associated with the recycling of ferrous materials from end-of-life vehicle (ELV) due to the mixing of copper, a typical contaminant in steel recycling. Given the quality of scrap in terms of copper density, the model determines the ratio by which scrap needs to be diluted in an electric arc furnace (EAF), and the amount of demand for EAF steel including those quantities needed for dilution. Application to a high-resolution Japanese IO table supplemented with data on ferrous materials including different grades of scrap indicates that a nationwide avoidance of these losses could result in a significant reduction of CO(2) emissions.