The quantity of waste from end-of-life vehicles is increasing with an increase in the number of scrapped internal combustion engine vehicles owing to international trends such as carbon neutrality and particulate matter reduction. The recycling rate must be ≥95%; however, the average recycling rate remains at approximately 89%. Therefore, the improvement of the recycling of automobile shredder residues (ASR) is gaining attention. In this study, four types of products (interlocking, clay, and lightweight swelled ceramic (LSC) bricks, and asphalt paving aggregate (APA)) were manufactured using ASR melting slag (ASRMS). Environmental performance, quality standards, and technology were evaluated to assess the recyclability of the manufactured bricks. The interlocking brick substituted melting slag for sand and stone powder as an aggregate. As melting slag content increased, absorption decreased and bending strength increased. Clay brick was manufactured by replacing kaolin and feldspar with melting slag that substituted for 20%. The quality of clay bricks mixed with over 15% melting slag was not better than standard. Asphalt paving aggregate was used to investigate the optimum condition of slag content in mixed asphalt; the mixture ratio showed that 61% broken stone of 13 mm, 6% screenings, 10% melting slag, 15% sand and 8% filler was most effective. A lightweight swelled ceramic brick was manufactured by using melting slag, front glass, and so on. Specific gravity and compressive strength ranged from 0.38 to 0.51 and from 339.7 to 373.6 N/cm². ASRMS exhibited an environmental performance suitable for recycling and the manufactured bricks satisfied the quality standards. The recyclability of ASR was also assessed in terms of waste usage, conformance to quality standards, market size, and demand prediction. APA showed the best results followed by interlocking, clay, and LSC bricks.

In this study, we investigated the applicability of an automobile shredder residue (ASR) as an energy and recycling resource. First, ASR gasification was conducted in a fixed-bed reactor (throughput = 1 kg/h) at different temperatures (800, 1000, and 1200 °C) and an equivalence ratio of 0.1–0.5. Clay bricks were prepared with the solid residue obtained from the gasification process to address the issue of solid-residue production in pyrolysis. The syngas (H₂ + CO) from ASR gasification had maximum and minimum yields of approximately 86 and 40 vol.%, respectively. Furthermore, the yield of syngas increased with the temperature and equivalence ratio (ER); therefore, the optimum conditions for the ASR gasification were determined to be a temperature of 1200 °C and an ER of 0.5. In addition, solid residues, such as char and ash, began to melt due to thermal heating in the range of 1300–1400 °C and were converted into melting slag, which was subsequently used to manufacture clay bricks. The absorption ratios and compressive strengths of the clay bricks were compared to those set by Korean Industrial Standards to evaluate the quality of the clay bricks. As a result, the manufactured clay bricks were estimated to have a compressive strength of over 22.54 N/mm² and an absorption ratio of less than 10%. Additionally, greenhouse gas (GHG) emissions from the melting–gasification process were estimated and compared with those from ASR incineration, calculated using the greenhouse gas equations provided by the Korean Ministry of Environment. As a result, it was revealed that the GHG emissions from the combined melting–gasification process (gasification, melting system, and clay-brick manufacturing) were approximately ten times higher than those from the ASR-incineration process. Thus, in terms of operation cost on the carbon capture process for GHG reduction, the combined melting–gasification process would be a more efficient process than that of incineration.