Katerina Swanson
The use of plastic fuel tanks in cars has been a growing trend since the mid-1980s, with the majority of vehicles in Europe adopting plastic tanks and North America not far behind. Plastic fuel tanks are made from high-density polyethylene, a robust material that is lighter, more flexible, and safer than traditional steel tanks. They offer improved fuel economy, enhanced safety due to their seamless design, and greater design freedom for manufacturers. However, concerns have been raised about the recyclability of plastic fuel tanks and the potential environmental impact of their disposal. Despite these challenges, the automotive industry continues to evolve, and plastic fuel tanks remain a significant aspect of modern car design.
| Characteristics | Values |
|---|---|
| Weight | Plastic tanks are about 30% lighter than steel tanks. |
| Shape | Plastic can be moulded into complex shapes, giving designers more freedom |
| Safety | Plastic tanks have no seams, making them less likely to rupture in a crash |
| Safety | Plastic tanks are better insulators in the event of a fire |
| Cost | Steel is cheaper than plastic. |
| Recyclability | Plastic tanks are harder to recycle than steel tanks. |
| Usage | Plastic tanks have been adopted by the majority of vehicles in Europe, with North America and the rest of the world following suit. |
| Types | High-density polyethylene (HDPE) is a common type of plastic used for fuel tanks. |
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What You'll Learn
Plastic tanks are safer and more efficient
Plastic fuel tanks are made from high-density polyethylene, or HDPE. They are typically about 30% lighter than steel tanks, which translates to better fuel economy and efficiency. This is because a car does not need to haul as much weight, and so sips fuel instead of guzzling it. The lighter weight of plastic tanks also contributes to better fuel efficiency, and plastic's versatility of form gives it a distinct advantage in vehicle design. Engineers can now design a blow-molded plastic fuel tank to conform to virtually any available space in the undercarriage, rather than having to design a vehicle around rigid steel tank shapes and fixed specifications.
Plastic tanks are also safer. They are seamless and thus not prone to failures in vulnerable seam areas. They are not a source of sparks, and they are more flexible than steel, in that they can spring back into shape after impact. When a steel tank absorbs impact energy, it crumples and often bursts at the seams, causing the volume to decrease and fuel to be ejected under pressure. Plastic tanks are also better insulators in the event of a fire beneath the vehicle, as the fuel inside takes longer to heat up and is less likely to rapidly pressurise and vent flammable vapour.
Plastic tanks also do not corrode or rust like metal tanks. Water vapour can cause metal tanks to rust from the inside out, but plastic tanks are immune to this. Plastic tanks are also cheaper to produce and maintain.
However, there are some drawbacks to plastic tanks. While plastic tanks are recyclable, the process is more complex than for steel tanks, as it is difficult to separate the different kinds of plastic used in multilayer tanks. Plastic tanks also ultimately melt in an under-car fire, which is far from ideal.
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They are also better for the environment
Plastic fuel tanks are better for the environment because they are typically about 30% lighter than steel tanks, which means better fuel economy. This is good news for the environment as it reduces the amount of fuel used and the subsequent hydrocarbons released. Plastic tanks are also moulded to fit snugly into a vehicle's design, leaving less room for fuel vapours to escape.
Another environmental benefit of plastic tanks is their rust resistance. Steel tanks can rust at the seams, whereas plastic tanks do not rust at all. This means that plastic tanks are less likely to leak, reducing the risk of fuel contamination. Plastic tanks also have fewer seams, thanks to blow-moulding techniques, making them even less prone to leaks.
In terms of production, plastic tanks are cheaper to produce and maintain than steel tanks. They are made from high-density polyethylene, a robust material that is flexible and durable. Plastic is also a less expensive material than steel, and plastic tanks are easier to produce. However, steel tanks have a longer lifespan, so they may be more cost-effective in the long run.
While plastic tanks have environmental benefits, there are also some concerns about their recyclability. Plastic tanks are made from multiple plastics bonded together, which can be difficult to separate when the car is dismantled for recycling. This is a challenge for auto dismantlers and could result in the tanks being landfilled instead of recycled. However, some automakers, such as General Motors, are addressing this issue by conducting careful studies of plastic versus steel tanks to consider the environmental performance of the whole life cycle of the material.
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Plastic tanks are harder to recycle
Plastic fuel tanks have become increasingly common in cars, replacing the heavier metal tanks of the past. These tanks are crafted from polyethylene, a robust material that is lighter, more flexible, and more fuel-efficient than steel. However, plastic tanks present challenges when it comes to recycling.
The recycling of plastic products is crucial in addressing the global issue of plastic waste. Unfortunately, the recycling rates for plastics are extremely low, with only about 9% of all plastic being recycled globally, and only 1% recycled more than once. This is due in part to the high cost of collecting, recycling, and reusing plastic waste, as well as the limitations of traditional mechanical recycling methods.
Mechanical recycling, the most common form of plastic recycling, involves collecting, cleaning, sorting, shredding, and melting down plastic waste to create new products. However, this process is not effective for plastic products contaminated with oil and grease, such as food packaging and motor oil bottles, which are difficult to recycle and require alternative methods like chemical recycling.
Chemical recycling breaks down plastic waste to the molecular level, allowing contaminants to be filtered out and the plastic to be recycled. This method can address the challenges of multi-layer plastic products that are not suitable for mechanical recycling. However, it still faces obstacles due to the lack of infrastructure in some parts of the world and the need for supportive policies to encourage investment in chemical recycling.
Plastic fuel tanks in cars contribute to the complexity of recycling. These tanks are often made of multiple layers of different types of plastic bonded together, making it difficult for auto dismantlers to separate the various plastics during the recycling process. As a result, many plastic fuel tanks end up in landfills, creating a disposal issue that needs to be addressed by product designers and automakers.
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They are more flexible and durable
Plastic fuel tanks are more flexible and durable than their steel counterparts. They are typically crafted from polyethylene, a robust material that is flexible and durable. This flexibility allows for the expansion of vapors and bending during an accident. The lack of seams in plastic tanks, made possible by blow-moulding techniques, makes them less prone to leaks and rupture upon impact.
The durability of plastic fuel tanks is evident in their ability to withstand wear, weathering, and deterioration. They are not susceptible to corrosion and rust, which can affect metal tanks, and can withstand a wide range of temperatures without cracking. Plastic tanks are also lighter in weight, which improves fuel economy and allows for more efficient vehicle design.
The flexibility of plastic fuel tanks is advantageous in maximizing space in vehicle design. The mouldable nature of plastic allows designers to create complex shapes that fit snugly into a vehicle's design, leaving less room for fuel vapors to escape. This flexibility also enables customization, ensuring plastic tanks can be tailored to fit specific spots in a vehicle's complex undercarriage.
While plastic tanks offer enhanced flexibility and durability, it is important to consider the challenges they pose during recycling. The multi-layered structure of plastic tanks, composed of multiple plastics bonded together, can be difficult to separate for recycling. This has led to concerns about the proper disposal of plastic tanks as vehicles reach the end of their lifespan.
Overall, the flexibility and durability of plastic fuel tanks contribute to their popularity in modern vehicles, offering improved safety, efficiency, and design possibilities.
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Plastic tanks are more cost-effective
Plastic fuel tanks are more cost-effective than their steel counterparts. Firstly, plastic tanks are typically about 30% lighter, which translates to better fuel economy, benefiting both the environment and drivers' wallets. The reduced weight means that cars consume less fuel, improving fuel efficiency. This is particularly significant given the rising fuel prices and growing environmental concerns.
Secondly, plastic can be moulded into complex shapes, allowing designers to maximise space within the vehicle and enhance design freedom. This is especially advantageous given the odd saddle-shaped tanks used in some modern vehicles. Plastic tanks also have no seams, reducing the chance of rupture upon impact and improving safety. The absence of seams also makes plastic tanks less prone to leaks, which is a common issue with steel tanks at the seams.
Thirdly, plastic tanks are cheaper to produce and maintain. They are formed by blowing a thick continuous tube of HDPE within a mould, which costs less than the machined steel dies used for steel tanks. Plastic tanks are also corrosion-resistant, whereas steel tanks require stainless steel to achieve the same level of corrosion resistance, increasing costs.
Finally, plastic tanks have the ability to fit snugly into a vehicle's design, reducing the escape of fuel vapours and improving the environmental performance of the car. While recycling plastic tanks can be challenging, General Motors and Tier 1 automotive supplier Delphi Automotive Systems are addressing this issue upfront in their product design.
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Frequently asked questions
Plastic fuel tanks are typically about 30% lighter than steel tanks, which results in better fuel economy. Plastic can also be moulded into complex shapes, giving designers more freedom to maximise space. Plastic tanks also have fewer seams, making them less prone to leaks and less likely to rupture in a crash.
Plastic fuel tanks are made from high-density polyethylene, or HDPE.
Plastic fuel tanks are very tough and are a better insulator in the event of a fire beneath the vehicle. This means that the fuel inside the tank takes longer to heat up, reducing the likelihood of rapid pressurisation and flammable vapour venting. However, plastic tanks will eventually melt in a fire.
Plastic fuel tanks are common in Europe and North America. MTS manufactures plastic fuel tanks for Chevy Trucks, Ford Trucks, Jeeps and SUVs. Plastic fuel tanks are also used in Chrysler's LH series and Viper sports car, as well as in Ford's six-layer fuel tanks.
