PROJECT DESCRIPTION
BACKGROUND
In 2015, transport was responsible for 25.8% of all greenhouse gases (GHG) emissions in the EU, with road transport accounting for almost 73% of these emissions. Of the road emissions 44.5% were produced by passenger cars, while 18.8% came from heavy-duty vehicles. Transport is the only major sector in the EU where greenhouse gas emissions are still rising. Between 1990 and 2017 the GHG emissions from the transport sector increased by more than 23%. To meet the 60% GHG emission reduction target of the 2011 Transport White Paper, emissions from the transport sector will need to fall by 68% by 2050.
To reach the target, it will be necessary to reshape policy to reduce transportation needs and introduce restrictions for individual transport. Public transport, the development of low-emission vehicles (e.g. electric cars) and the wider use of alternative fuels (biofuels, natural gas, etc.) should be encouraged. Reduction of emissions can also be achieved by changes to car design: more efficient engines, better aerodynamics and reduced weight of vehicle.
OBJECTIVES
The main objective of LIFE BIOBCOMPO was to reduce the environmental footprint of new vehicles through innovative low density thermoplastic composites derived from renewable (bio-based) sources, in order to meet the GHG emission reduction target of the 2011 EU Transport White Paper. To achieve this target, the project developed very low-density thermoplastic materials on an industrial scale that served as an alternative in the production of equipment and car parts. Specifically, the project aimed to:
- optimise bio-components that will be used for the production of innovative materials: the selection of the best matrices, fibres and additives, and the characterisation of the produced materials and their final tuning;
- optimise injection moulding process, the production and qualification of prototypes, the pre-industrial manufacturing of components made by bio-based composite and their installation on vehicles;
- develop a recycling process for the composite materials and verify its recycling potential;
- draw up a business plan and replicate analysis in other market sectors across Europe;
- monitor the project’s impact, and carry out dissemination and networking activities.
LIFE BIOBCOMPO also aimed to ensure that the production costs of the innovative lightweight composites are viable and that the new materials are fully recyclable at the end of their lifecycle. The project contributed to achieving the European Commission proposal to reduce transport sector-related GHG by lowering the emission target of new automotive vehicles to 95 g of CO2 per km from 2021.
RESULTS
The project has achieved all planned goals. The beneficiaries developed formulas of 12 bio-based materials in which glass fibres and talc were replaced by natural fibres. All innovative materials have been tested and two of them meet all the requirements of the automotive industry. These are the following materials: PP 20CF-10T (with the addition of 20% of the cellulose fibres and 10% of talc) and CF23 (with 23% of the cellulose fibres). Car parts made from these materials had the required properties: they were 8% lighter than parts made from conventional materials and were recyclable. Cars with parts made of innovative materials (Alfa Romeo Giulia and Lancia Ypsylon) were lighter and consumed less fuel, thanks to which their CO2 emissions were lower by about 11 g/km. Since the production of parts from innovative materials requires less energy (the production process requires lower temperatures), the reduction of greenhouse gas emissions also occurs at this stage.
The beneficiaries produced 102 000 innovative car parts, which were installed in over 30 000 vehicles. This made it possible to reduce greenhouse gas emissions by approx. 36.9 tons of CO2eq.
The beneficiaries intend to continue work on the production of parts from innovative materials in the coming years. According to the beneficiaries, in the next 3 years they will produce approx. 5 319 000 pieces of the lightweight car parts that would be installed in cars produced by the FCA (one of the project partners). They estimated that the value of production, 3 years after the project ending, would reach €31 754 000 and the cumulative earnings before interest, taxes, depreciation, and amortization (EBITDA) would be €2 222 780. The development of production will require the creation of new jobs, it is planned that 56 new jobs will be created over the next three years.
The beneficiaries will also work on the introduction of innovative materials for the production of parts used in other car brands. Tests carried out during the project have shown that they can be used in the following car brands: Maserati (Grecale), Ferrari, Seat (Ateca), Volkswagen (T-Cross). The beneficiary demonstrated the possibility of using innovative materials in the production of parts for New Holland T7 and T670 tractors.
