new frontiers seminar: closing the loop: conserving resources through sustainable design and...

Knowledge Transfer NetworksAccelerating business innovation;a Technology Strategy Boardprogramme


Closing the Loop:Conserving resources through

sustainable design and chemistryMike PittsChemistry Innovation


content

• Chemistry and Industry (who uses it?)• Chemistry and Sustainability (issues?)• Chemistry and Sustainable Design

(examples)• Sustainable Design Guide


Chemistry-Using Industries

Source: 2009 R&D Scoreboard of Top 850 UK Companies - published by BIS

Chemical Manufacture

Process Technology

Product Development

Application &Formulation Skills

£113 bn

£226 bn

£523 bn

CUIs contributetowards £270 bn GVA

to the UK

Chemistry

Engineering

Biotechnology


Chemists and Sustainability

Green Chemistry: Theory & Practice, Anastas & Warner, 1998


RSC Roadmap

Sustainable Designis a RSC Roadmap‘Top Ten’ Challenge

www.rsc.org/roadmap


For every tonne of household wastethat we throw away, there's a further 5

tonnes of materials that have beenused in the manufacturing of the

products consumed

Don't throw anything away. There is no 'away' - Shell advert

90% of all products are waste within 6 months of purchase


Oil

•• The world consumes 84 million barrels of oil a day.The world consumes 84 million barrels of oil a day.•• We consume two barrels of oil for every barrelWe consume two barrels of oil for every barrel

discovered.discovered.•• It took us 125 years to use the first trillion barrels of oil.It took us 125 years to use the first trillion barrels of oil.

WeWe’’ll use the next trillion in 30.ll use the next trillion in 30.•• The world has been finding less oil than itThe world has been finding less oil than it’’s been usings been using

for twenty years now.for twenty years now.•• In 20 years the world will consume 40% more oil than itIn 20 years the world will consume 40% more oil than it

does today.does today.•• The oil and gas weThe oil and gas we’’ve been finding is coming fromve been finding is coming from

places that are tough to reach.places that are tough to reach.•• Peak oil production passed?Peak oil production passed?


Renewable Chemicals

“natural”, “naturederived”, “renewable”etc.do not equate with“less impact onenvironment”

Need to consider:scale, energyintensity, competingland requirements ,etc.

Source: JLS Consulting


Water

by 2020 we will need 17% moreby 2020 we will need 17% morewater than is currently availablewater than is currently available

‘‘water is the oil of the 21st centurywater is the oil of the 21st century’’Dow CEO Andrew LiverisDow CEO Andrew Liveris

‘embedded’water

content (litres)1 pair of shoes 1 cotton T-shirt 1 hamburger 1 glass of milk 1 cup of coffee 1 microchip (2 g)

80004100240020014032

Source: World Council, UNESCO, DEFRA

about how much adishwasher uses

in a year


Endangered Elements


• As much gold in 1 tonneof computer scrap as in17 tonnes of gold ore

• Concentration ofplatinum in the dust onthe streets ofBirmingham is higherthan in the ore it camefrom

• More copper above theground in use that left inviable supplies


Sustainable Design

Reducing the overall environmental impact, whilstmaintaining or improving economic, technical andsocial performance

A shift in thinking: from unit operation to whole system from plant/product to whole life cycle from process and product to service


From unitoperation towhole system


Development of a Green Route toViagra™

ProblemSildenafil citrate development route was inefficientand used large amounts of toxic materials.

Technical SolutionNew, convergent route was designed with a cleancyclisation as the final step, eliminating purification processes.

Benefits nine-fold increase in yield organic waste reduced 15 fold aqueous waste reduced 5 fold highly volatile solvents eliminated toxic metal steps avoided no reaction step involved an extraction reduced energy and waste disposal costs

source: Sustainable Technologies Roadmap

New Route – lower yield but less resource demand


Whole system thinking



From plant/productto whole life cycle


Product Life-Cycle

materials

manufacture

distribution & retail

disposal

use of product


Lifecycle Analysis

for each pint of milk:

Source: DEFRA


Improved Efficiency

70

80

90

100

110

120

130

140

150

160

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

Year

Re

lati

ve

In

de

x (

19

90

= 1

00

)

Greenhouse Gas Emissions

Energy Consumption

Production

source: CEFIC/European Environment Agency

EU Chemicals Industry (incl. pharma)


Low-Carbon Solutions

For every unit of GHG emitted directlyand indirectly by the chemical industry,this industry enabled 2-3 units ofemission savings via the products andtechnologies provided to other industriesand consumers.

Under 2030 scenarios, this could reach4:1

The most significant savings came from:marine antifoulingcoatingssynthetic textilesautomotive plasticslow-temperaturedetergentsplastics used in piping

insulating foamsagrochemicalslightingplasticpackagingengineefficiency

Source: www.icca-chem.org


Design for lifecycle



From process andproduct toservice


Closed-loop business models

Key materials• scarce elements• recyclable polymers• all metals

Managing Molecules Service Models

sunlight

Globalresources

Deliveredbenefit

Focus on• delivered benefits• customer service• efficient delivery


Closed-loop business models

Key materials• scarce elements• recyclable polymers• all metals

Separationtechnologie

s

Globalresources

Deliveredbenefit

Chemicalmanageme

nt

‘Chemicalleasing’

Consumertakeback

Design forrecycling

Design forreuse

renewables

Intelligentdesign

Consumereducation

Near netshapemanuf

Customised

products

Reducedresourceintensity

Efficientprocessdesign

Managing Molecules Service Models

Focus on• delivered benefits• customer service• efficient delivery


Design for recycle and re‑use(closed-loop)



Design for service



Sustainable Design Guide

Shows chemistry-usingorganisations how to buildsustainable thinking intotheir innovation processes

A collection of best practicewith a process for how todo it

Linked supporting resources

www.chemistryinnovation.co.uk/sdg


Workbook Content



Supporting Information



Roadmap website

www.chemistryinnovation.co.uk/stroadmap

www.chemistryinnovation.co.uk/stroadmap


‘Today's problems cannot be solved if we still think theway we thought when we created them’ - Albert Einstein

www.chemistryinnovation.co.uk/stroadmapwww.chemistryinnovation.co.uk/sdg

[email protected]

Closing the Loop

Ian Holmes

C-Tech Innovation

Environmental Sustainability KTN

Starter for 10

• What has;

• 20 different types of fastener

• Complex mixture of 25 or more chemical compounds

• Is the fastest growing source of waste in the EU

• Has no current commercial recycling or recovery process?

Average TV screen Size is now 32”

Liquid Crystal Displays

• Electronic items containing LCDs has been identified as one of thefastest growing sources of waste in the EU, increasing by 16-28%every five years (and predictions are expected to be conservative).

• The future volumes per year of LCD TVs in WEEE for the UK alone,have been estimated at around;

Predicted Disposal Statistics for LCD Telev isions in the UK

Year 2004 2005 2006 2007 2008 2009 2010 Total

Units(1000) 39 39 74 109 134 305 770 1,470

Mass(MT) 1,050 1,050 1,650 2,250 3,125 5,500 10,900 25,525

Avg Unit Mass kg/Unit 27 27 22 21 23 18 14

Reflated

Project Objectives

• Development of semi automated methods for LC glass panel disassembly,

• Guidelines for integration of LCD recycling with general WEEE reprocessing,

• Active disassembly designs for LCD displays (both casings and LC panels) andother electronics,

• Development of a process for recovery of the LC, Indium and glass from LC displays,

• The re-use of the recovered materials

• The development of new applications for recovered materials as well as direct re-use.

The REFLATED process aimed to recover maximum value from LCD waste . Based on thismaterial offsetting virgin production, savings may be achieved. LCA and economic analysisindicated, a saving of 960kg of CO2 emissions and cost saving of £1,500 per tonne may beachieved if materials are recovered rather than land filled.

LiquidCry stal

Glass

Dismantle

Indium

WasteStream

Project Goals

• Recovery of metals already in short supply

• Recovery of liquid crystal material

• Development of disassembly techniques for LCD containing equipment

• Recycling of high quality glass

• Development of new markets for liquid crystals.

• Diversion of waste LCDs from landfill (up to 10,000 tonnes of waste/year inthe UK )

LCD what’s inside?

Anticipated Challenges

• Separation of screens from housing

• Extraction of liquid crystals from displays

• Recovery of Indium from ITO coated glass

• Markets for recovered materials

Disassembly of housing

• Myriad of designs and configurations

• Automated dismantling not feasibly• Number of tool changes required for screws• Large variation in sizes 10” – 42”• Cutting not feasible due to;

• Presence of backlights containing mercury• Most displays not labelled to show Hg present• Current Hg recovery systems not suited to CCFLs

Treatment of Panel

• No standard Panel within a display model• Different manufacturer• Different LCs used

• Film removal• Varity of adhesives used• Varied between same model of display• Responded differently to solvents / removal processes

• Identification of display type• Twisted Nematic (TN) [including STN, TFT-TN];• In-Plane Switching (IPS)• Vertically-Aligned Nematic (VAN).

Display Type

In-Plane Switching (IPS) Vertically Aligned Nematic (VAN) Twisted Nematic (TN)

OFF OFF OFFON ON ON

Electric field

Backlight Backlight Backlight

Electric field

CommonElectrode

PixelElectrode

Display Type

• The mode of action determines the nature of the liquid crystal mixture used in eachdisplay type.

• TN and IPS technologies require liquid crystal mixtures with positive dielectric, +Δε,VAN technology requires materials with negative dielectric, -Δε.

• If the LC recovered is to be used in electronically activated applications care must betaken not to mix TN and IPS LCD panels with VAN LCD panels.

• The type of screen is hard to identify and will present a significant problem in therecycling process if the intention is to recover and reuse the LC.

• In addition it is believed that some additional compounds are added for “confusion”

Glass Recovery

Thought to be lowest value material, but highest volume in wastestream.

• Original concept was that glass could be recycled into new displays• Logistics – manufactured in far east, to expensive to transport• Quality issues- very high specification for display glass

• Conventional recycling• Not suitable due to chemical properties and high melting temperature

• Possible route into insulation manufacture

Disassembly

• Manual process opted for• Faster and safer than an automated process• Best practice guidelines and training course developed

• Design and development of Active Disassembly fastenings

Thermal-Probe Release Screws

Thermally Reversible Polymers

Polariser Removal

• A host of solvents were tried

• Ethanol, Methanol, DCM

• Banana Oil! - Isoamyl acetate

• Orange juice / citric acid

• No perfect all rounder.

• Resorted to peeling films form whole screens• Not safe or practical for damaged screens

Liquid Crystal Recovery

Ideal was the use of super-critical CO2

• Not practical on larger scale at present

• 2 stage process1. “conventional” solvent removal from screens2. “Clean up” with super critical CO2

Data base complied of “common” LC components in order to see if therewere any “key stone” compounds to target for recovery

Process

Markets

• Liquid Crystal compounds-• Virgin material - $15 - $30/g• Recycled material – no market

• Deployment of recovered LC in other applications is still underinvestigation.

• Glass• Virgin material – high

• Indium – although rumoured to be in short supply current marketprice is dropping!• Not economically viable to recover at current price.

Recommendations

• Labelling• Identification of screen types• Identification of backlight types• Mark plastics by resin type

• Design for disassembly• Use fewer screws• Use uniform screws• Or adopt active disassembly fasteners• Developed “removable” adhesives• Make lamps easier to remove

• Develop Market for recovered products

Outputs

• Technology and knowledge to recover liquid crystal and Indium• Not currently economically viable

• Best practice guide and training course on manual handling anddismantling of LCD panels

• Possible route for LCD glass reuse• Would be significant reduction in waste to landfill

• New “active disassembly” fastening and construction prodcuts

• Recommendations to WRAP on recycling of LCDs

WEEE Recovery:Japan September 2005

BatteriesMay 2006

WEEE Recovery:Europe June 2006

Product LightweightingApril 2007

Life Cycle AssessmentAugust 2007

BioplasticsOctober 2007

Useful Reports

Retail WasteDecember 2007

Materials SecurityMarch 2008

Further InfoIan [email protected]

https://ktn.innovateuk.org/web/sustainabilityktn

Design for recyclingRoger Morton Director, Axion

Closed loop recycling

• A bit about Axion• Some practical examples of the issues

– Coat hangers– Game console– Milk bottles– Vinyl flooring– Carpets

• Actions for designers

The Axion Group

Axion Consulting• Develops and evaluates novel resource recovery

and manufacturing processes• Tests and operates innovative recyclable

collection systems• Business planning and financial analysis• Carbon footprinting for the industrial sector• Wide range of private and public sector clients• 31 staff - 20 chemical engineers, chemists &

environmental scientists

Axion Polymers• Leading UK re-processor of

plastics from WEEE and otherpost consumer waste

• High quality Axpoly® 100%recycled plastic compounds forinjection moulding & extrusion

• Produced to ISO9001 qualitystandards

• First UK polymer to achieveCarbon Footprint label

• 30 staff, running on 3 shifts

Axion Polymers

Polymer recycling factory 40,000sq.ft.Salford, Manchester

Axion Polymers’ Process

INPUT WASTE M

ATERIAL

REMO

VE NON-PLASTICS

WASTE

POLYMER SEPARATION

METALS

COM

POUND & BLEND

USERSPECIFICPRODUCT

20+ separation steps in full process

Axion Polymers

Polymerproductfromextruder

The Full Story :-Primary Fridge Treatment -

Shredded Plastic

Plastic Recycling, At Axion Polymers,

Manchester UK

Injection MouldingWhite Goods Part

Washing Machine Manufacturer

Waste white goods

New white goods

Axion Polymers

Washingmachinecomponentmade fromAxpoly

Axpoly PS13 – Closed Loop

garment hangershred – complex mix

We convert the shredto produce Axpoly PS13 for resale back into garment hangers

Why China?

• “Demand is Huge”• OEM brands made there already• Axion has scrap material sources in UK• Labour & operating costs lower• ʻWork withʼ not ʻCompete againstʼ• Opportunity to ʻstretch the loopʼ....

Extended closed-loop – retailgarment hanger

• Success proven in UK – hanger-to-hanger• Major volume is moulded in China• Export to Chinese compounding partner• Sell local resin to Chinese hanger moulder• Hangers exported back to UK / USA

Traceable – Quality – Price

SONY PlayStation 3 Recycling

a

PS3 casing disassembled

Foam

PC

MetalRubber

Stickers

ABS

Pellets from a 99%-1% blendof PS3 casing and foam

Plastic strand after removing onlymetal from the PS3 casings

Pellets after removing all non-PCcomponents from PS3 casings

HDPE milk bottle design forrecycling

• Supports UK dairy andretail industry CourtauldCommitment

• Maximise theavailability and qualityof food grade recycledHDPE for closed looprecycling

HDPE recycling flowsheet

HDPE bottle categories

A B CEasy torecycle withgood yield inclosed loopusing existingtechnology

Tricky torecyclebutachievablewithreducedyield

Notsuitablefor closedlooprecycling

Recycling PVC flooring

UK Collectable Flooring Tonnage

What do we accept?

How is the PVC recycled?

• Off cuts back intoproduction of newflooring includingsafety

• Uplifted flooring toroad cone bases etc

Collection logistics

Material collected bymanufacturers using:BackloadsDiversion of vehiclesConsolidation at:

waste transfer stationsdistributors

Environmental tradeoff

Maximise resourceefficiency

Use recycled polymer• Oil-based raw material

re-used• Legacy additives

appear in new products

Eliminate persistentchemicals

Use virgin polymer &modern additives

• No chemical impact• Carbon impact of virgin

polymer 10 x recycledPVC

Carpet recycling

UK carpet waste tonnes/yr

Half UK carpet waste is PP

Wide range ofconstructions:

• Tufted, looped, tiled• PP, jute, polyester,

nylon scrim• Rubber, bitumen,

PVC backed

PP carpet identification

Recovery to polymer

Shredding Feed extruderExtrusion

Trial results

Trial resultsPhysical properties

testUnits

Recycledcarpet

Virgin PP used forinjection moulding

MFI (at 230°C, 2.16kg) 19.5 12

Tensile strength MPa 17 32Impact strength kJ/m2 3.96 3.5

Elongation @ Yield % 7.3 10

Elongation @ Break % 15

Density g/cm3 1.09 0.905

Ash % 17 0

Actions for designers• Consider end of life right from the start• Work with the supply chain to keep end of

life product out of general waste• Treat end of life product as a resource• Use carbon footprint to guide design choices

•Talk to the recyclers!

Axion Consulting

[email protected]

Tudor House2 MeadwayBramhallSK7 2DG0161 426 7731

new frontiers seminar: closing the loop: conserving resources through sustainable design and...

Design

barrels of oil

content chemistry

rsc roadmapsustainable

tonne of household waste

world council

fold increase

e waste nvolatile solvents

convergent route