Truck & Off-Highway Engineering - October 2023 - 10

TECHNICAL INNOVATIONS
Sustainable Process: ArcelorMittal is supplying recycled and renewably
produced steel that offers significantly reduced CO2
emissions.
Sustainable Product: Nikola emphasized recycling and reuse when
developing its Tre FCEV.
40% with new tooling, or 8% with current tooling, and decreases
foam thickness by 50% to support styling aesthetics. The new
foam, the result of a joint development with materials partner
Covestro, also cuts raw material costs by 20% and volatile organic
compounds by 80% compared to the current polyurethane
foam in use, while retaining a high-quality feel and appearance.
The project began during the Covid-19 pandemic. " We set
out with a 25 percent weight-reduction target. With our first
trials in future production tools, we found that it exceeded
that target - that blew our socks off, " a Marelli representative
said at MBS. " The key metric to us was actually having it be
reverse-compatible to current tooling and programs so that
we can deploy this in the current vehicles. "
Runner-up: Ajedium PEEK slot liners developed by Solvay
Specialty Polymers can reduce battery-pack weight by 12 kg (36.4
lb.) and the e-motor by 4 kg (8.8 lb.). There is no requirement for
high-power dedusting equipment or climate-controlled storage to
prevent moisture uptake (reducing energy consumption), since
PEEK slot liners can be inserted using existing equipment.
Honorable Mention: WorldAutoSteel and engineering partner
Ricardo developed steel body structures for a fully-autonomous
vehicle concept that meets stringent crash requirements.
The concept features a 282-kg (622-lb) body structure
and a 25% mass reduction compared to an expected reference
vehicle, the organizations claim. It also has the potential
to reduce total lifecycle carbon emissions by 86%.
Honorable Mention: Michigan Technological University created
a steel e-motive side closure mechanism as part of the
Auto/Steel Partnership. The mechanism uses advanced highstrength
steel (AHSS) instead of aluminum, potentially cutting
carbon emissions by 3X while also reducing manufacturing costs.
10 October 2023
Sustainable Product
Winner (commercial vehicle): Nikola emphasized recycling
when developing its new Tre FCEV (fuel-cell electric vehicle)
- 100% of scrap from the production of pre-consumer batteries
was recycled and/or reused. In addition, 100% of hazardous
waste produced during production was safely recycled,
the company claims. A circular reuse program also was implemented
for all battery pallets, and the vehicle manufacturing
process consumed no water.
Winner (passenger vehicle): The 2024 Polestar 2 features
next-generation electric motors, quicker charging and longer
range - now up to 654 km (406 miles) as measured by the
Worldwide Harmonized Light Vehicle Test Procedure
(WLTP). The EV also has a reduced carbon footprint, with
some versions purportedly producing up to three tons less
CO2
compared to the model released in 2020. Polestar says
it uses blockchain technology within its supply chain to expand
raw material traceability and address social and environmental
issues.
Runner-up: Lucid Air has enjoyed the industry and EVenthusiast
accolades for its flagship Lucid Air sedan, which the
EV manufacturer claims has broken records for range, charging
speeds, aerodynamics and performance. With its core technology
designed and engineered in-house, the EV can add 300
miles (483 km) of range with 22 minutes of charging, has an
aerodynamic drag coefficient of 0.197, and includes trims with an
EPA-estimated range of up to 516 miles (830 km) and energy
efficiency of 4.6 miles (7.4 km) per kilowatt-hour.
Sustainable Process
Winner: ArcelorMittal was recognized for its commitment to
using biomass for carbon-neutral steelmaking. Its Port-Cartier
pellet plant in Quebec, Canada reportedly became the first in
the world to substitute pyrolytic oil for heavy fuel oil on a permanent
basis. By using this biofuel, produced locally by
BioÉnergie AE Côte-Nord Canada, ArcelorMittal reduces its
emissions and builds a regional energy ecosystem utilizing
local resources: iron and the forest.
" This is only the first step in the energy transition of mining in
Canada. Once we reach full potential, we will be able to reduce
our emissions by 200,000 tons per year, thus enabling the production
of more-sustainable steel, " an ArcelorMittal representative
said at MBS.
TRUCK & OFF-HIGHWAY ENGINEERING
FROM LEFT: NIKOLA; ARCELORMITTAL
Truck & Off-Highway Engineering - October 2023

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