Methods, Tools & Processes for Circular Economy

This document, by the European Environment Agency (EEA), is a comprehensive report that examines the environmental impacts of battery electric vehicles (BEVs) throughout their entire life cycle, from raw material extraction to end-of-life processing.

The document is a proposal from the European Commission for a regulation by the European Parliament and the Council. The regulation focuses on circularity requirements for vehicle design and the management of end-of-life vehicles (ELVs).

The proposed regulation aims to modernize the EU's legislative framework for vehicle design and end-of-life management, promoting a circular economy and reducing the environmental footprint of the automotive sector. It introduces comprehensive requirements for vehicle manufacturers, waste management operators, and Member States to ensure sustainable practices throughout the vehicle lifecycle.

In the transition towards sustainable mobility, Circular Design principles are crucial. Electric Motors are subject to continuous innovation to improve efficiency, performance density and reduce externalities associated with their production. Therefore, the choice of technological solutions during design phase must guarantee optimal performance and minimal environmental impact throughout the entire product life cycle: production, use, and end-of-life. In the automotive sector, the use phase is particularly critical since the efficiency of the traction system is directly related to total energy consumption during the life cycle and, consequently, to its environmental impact. This research introduces a simulation-based approach to evaluate the use phase of an Axial Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high performance for electric traction motors, these magnets are composed of Rare Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw Materials (CRMs) due to limited availability and environmental concerns associated with extraction and processing. However, the high torque and power density of this motor technology can potentially reduce the use of CRMs compared to other design solutions. The primary objective of this study is to show a preliminary scalable model that allows designers to evaluate motor performance under different design choices and use scenarios, defined through standard or custom driving cycles, providing immediate feedback in terms of environmental impact. The latter is evaluated by analyzing the powertrain’s energy consumption and efficiency using a road vehicle model, compiling the use phase inventory quickly, and simplifying access to information. This preliminary model thus serves as a decision-support system to balance performance optimization and environmental sustainability during the design phase. This work is part of a framework aimed at improving circularity of industrial products, particularly in the automotive industry. Incorporating environmental factors in design phases encourages innovative solutions that enhance efficiency and decrease reliance on limited resources.