NEW FRONTIERS SEMINAR: Closing The Loop: Conserving Resources Through Sustainable Design and Chemistry'.
2 likes1,467 views
The document discusses sustainable design and chemistry, specifically focusing on closing the material loop through recycling. It provides examples of challenges with recycling LCD screens, including separating different materials, extracting liquid crystals, and recovering indium from glass. The REFLATED project aimed to develop methods to disassemble, separate, and recover materials from LCD waste, including liquid crystals, glass, and metals. Key challenges included the variety of LCD designs, presence of mercury in backlights, and identifying screen types. The document discusses the project goals of recovering scarce materials and diverting waste from landfill.
![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).](https://image.slidesharecdn.com/newfrontiersclosingtheloopjul2010-100712115937-phpapp01/85/NEW-FRONTIERS-SEMINAR-Closing-The-Loop-Conserving-Resources-Through-Sustainable-Design-and-Chemistry-43-320.jpg)
NEW FRONTIERS SEMINAR: Closing The Loop: Conserving Resources Through Sustainable Design and Chemistry'.
- 1. Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 2. Closing the Loop: Conserving resources through sustainable design and chemistry Mike Pitts Chemistry Innovation Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 3. content • Chemistry and Industry (who uses it?) • Chemistry and Sustainability (issues?) • Chemistry and Sustainable Design (examples) • Sustainable Design Guide Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 4. Chemistry-Using Industries £113 bn £226 bn Chemistry Chemical Manufacture Process Technology Engineering Product Development Application & Biotechnology Formulation Skills £523 bn CUIs contribute towards £270 bn GVA to the UK Knowledge Transfer Networks Source: 2009 R&D Scoreb oard of Top 850 UK Companies - pub lished b y BIS Accelerating business innovation; a Technology Strategy Board programme
- 5. Chemists and Sustainability Knowledge Transfer Networks Accelerating business innovation; Green Chemistry: Theory & Practice, Anastas & Warner, 1998 a Technology Strategy Board programme
- 6. RSC Roadmap Sustainable Design is a RSC Roadmap ‘Top Ten’ Challenge www.rsc.org/roadma p Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 7. For every tonne of household waste that we throw away, there's a further 5 tonnes of materials that have been used 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 purchaseKnowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 8. Oil • The world consumes 84 million barrels of oil a day. • We consume two barrels of oil for every barrel discovered. • It took us 125 years to use the first trillion barrels of oil. We’ll use the next trillion in 30. • The world has been finding less oil than it’s been using for twenty years now. • In 20 years the world will consume 40% more oil than it does today. • The oil and gas we’ve been finding is coming from places that are tough to reach. Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board • Peak oil production passed? programme
- 9. Renewable Chemicals “natural”, “nature Need to consider: derived”, “renewable” scale, energy etc. intensity, competing do not equate with land requirements , “less impact on etc. environment” Knowledge Transfer Networks Source: JLS Consulting Accelerating business innovation; a Technology Strategy Board programme
- 10. Water ‘embedded’ about how much a water by 2020 we will need 17% more content (litres) dishwashercurrently available water than is uses 1 pair of shoes 8000 in a year 1 cotton T-shirt 4100 1 hamburger 2400 1 glass of milk 200 ‘water is the oil of the 21st century’ 1 cup of coffee 140 Dow CEO Andrew Liveris 1 microchip (2 g) 32 Knowledge Transfer Networks Source: World Council, UNESCO, DEFRA Accelerating business innovation; a Technology Strategy Board programme
- 11. Endangered Elements Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 12. • As much gold in 1 tonne of computer scrap as in 17 tonnes of gold ore • Concentration of platinum in the dust on the streets of Birmingham is higher than in the ore it came from • More copper above the ground in use that left in viable supplies Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 13. Sustainable Design Reducing the overall environmental impact, whilst maintaining or improving economic, technical and social performance A shift in thinking: from unit operation to whole system from plant/product to whole life cycle from process and product to service Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 14. From unit operation to whole system Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 15. Development of a Green Route to Viagra™ Problem Sildenafil citrate development route was inefficient and used large amounts of toxic materials. Technical Solution and New, convergent route was designed with a clean dem so urce cyclisation as the final step, eliminating purification processes. ss re ut le eld b Benefits nine-fold increase in yield wer yi organic waste reduced– fold lo oute 5 fold aqueous w R reduced 15 e waste Nvolatile solvents eliminated highly toxic metal steps avoided no reaction step involved an extraction reduced energy and waste disposal costs Knowledge Transfer Networks source: Sustainable Technologies Roadmap Accelerating business innovation; a Technology Strategy Board programme
- 16. Whole system thinking Knowledge Transfer Networks source: Sustainable Technologies Roadmap Accelerating business innovation; a Technology Strategy Board programme
- 17. From plant/product to whole life cycle Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 18. Product Life-Cycle distributio n & retail use of manufacture product materials disposal Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 19. Lifecycle Analysis for each pint of milk: Knowledge Transfer Networks Source: DEFRA Accelerating business innovation; a Technology Strategy Board programme
- 20. Improved Efficiency 160 EU Chemicals Industry (incl. pharma) Production 150 140 Relative Index (1990 = 100) 130 120 110 Energy Consumption 100 90 80 Greenhouse Gas Emissions 70 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Year Knowledge Transfer Networks source: CEFIC/European Environment Agency Accelerating business innovation; a Technology Strategy Board programme
- 21. Low-Carbon Solutions For every unit of GHG emitted directly and indirectly by the chemical industry, this industry enabled 2-3 units of emission savings via the products and technologies provided to other industries and consumers. Under 2030 scenarios, this could reach 4:1 insulating foams marine antifouling The most significant savings came from: agrochemicals coatings lighting synthetic textiles plastic automotive plastics packaging low-temperature engine detergents efficiency plastics used in piping Knowledge Transfer Networks Source: www.icca-chem.org Accelerating business innovation; a Technology Strategy Board programme
- 22. Design for lifecycle Knowledge Transfer Networks source: Sustainable Technologies Roadmap Accelerating business innovation; a Technology Strategy Board programme
- 23. From process and product to service Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 24. Closed-loop business models Global Delivered resources benefit Key materials Focus on • scarce elements • delivered benefits • recyclable polymers • customer service • all metals • efficient delivery sunlig ht Managing Molecules Service Models Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 25. Closed-loop business models Reduced resource intensity Consumer renewable Near net s shape Customis education manuf ed products Global ‘Chemical Delivered resources leasing’ benefit Key materials Focus on • scarce elements • delivered benefits Intelligent design • recyclable polymers Separation • customer service Consumer • all metals technologie • efficient delivery takeback Efficient s process design Chemical manageme Design for nt Design for recycling reuse Managing Molecules Service Models Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 26. Design for recycle and re‑use (closed-loop) Knowledge Transfer Networks source: Sustainable Technologies Roadmap Accelerating business innovation; a Technology Strategy Board programme
- 27. Design for service Knowledge Transfer Networks source: Sustainable Technologies Roadmap Accelerating business innovation; a Technology Strategy Board programme
- 28. Sustainable Design Guide Shows chemistry-using organisations how to build sustainable thinking into their innovation processes A collection of best practice with a process for how to do it Linked supporting resources Knowledge Transfer Networks Accelerating business innovation; www.chemistryinnovation.co.uk/sdg a Technology Strategy Board programme
- 29. Workbook Content Knowledge Transfer Networks Accelerating business innovation; www.chemistryinnovation.co.uk/sdg a Technology Strategy Board programme
- 30. Supporting Information Knowledge Transfer Networks Accelerating business innovation; www.chemistryinnovation.co.uk/sdg a Technology Strategy Board programme
- 31. Roadmap website www.chemistryinnovation.co.uk/stroadmap Knowledge Transfer Networks Accelerating business innovation; www.chemistryinnovation.co.uk/stroadmap a Technology Strategy Board programme
- 32. ‘Today's problems cannot be solved if we still think the way we thought when we created them’ - Albert Einstein www.chemistryinnovation.co.uk/stroadmap www.chemistryinnovation.co.uk/sdg mike.pitts@ciktn.co.uk Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme
- 33. Closing the Loop Ian Holmes C-Tech Innovation Environmental Sustainability KTN
- 34. 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?
- 35. Average TV screen Size is now 32”
- 36. Liquid Crystal Displays • Electronic items containing LCDs has been identified as one of the fastest 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
- 37. 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) and other 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.
- 38. The REFLATED process aimed to recover maximum value from LCD waste . Based on this material offsetting virgin production, savings may be achieved. LCA and economic analysis indicated, a saving of 960kg of CO2 emissions and cost saving of £1,500 per tonne may be achieved if materials are recovered rather than land filled. Waste Liquid Stream Cry stal Glass Dismantle Indium
- 39. 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 in the UK )
- 41. Anticipated Challenges • Separation of screens from housing • Extraction of liquid crystals from displays • Recovery of Indium from ITO coated glass • Markets for recovered materials
- 42. 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
- 43. 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).
- 44. Display Type In-Plane Switching (IPS) Vertically Aligned Nematic (VAN) Twisted Nematic (TN) Common Electrode Electri Electri c field c field OFF ON OFF ON OFF ON Pixel Electrode Backlight Backlight Backlight
- 45. Display Type • The mode of action determines the nature of the liquid crystal mixture used in each display 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 be taken 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 the recycling process if the intention is to recover and reuse the LC. • In addition it is believed that some additional compounds are added for “confusion”
- 46. Glass Recovery Thought to be lowest value material, but highest volume in waste stream. • 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
- 47. 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
- 48. 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
- 49. Liquid Crystal Recovery Ideal was the use of super-critical CO2 • Not practical on larger scale at present • 2 stage process 1. “conventional” solvent removal from screens 2. “Clean up” with super critical CO2 Data base complied of “common” LC components in order to see if there were any “key stone” compounds to target for recovery
- 50. Process
- 51. Markets • Liquid Crystal compounds- • Virgin material - $15 - $30/g • Recycled material – no market • Deployment of recovered LC in other applications is still under investigation. • Glass • Virgin material – high • Indium – although rumoured to be in short supply current market price is dropping! • Not economically viable to recover at current price.
- 52. 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
- 53. Outputs • Technology and knowledge to recover liquid crystal and Indium • Not currently economically viable • Best practice guide and training course on manual handling and dismantling 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
- 54. Useful Reports WEEE Recovery: Batteries WEEE Recovery: Product Lightweighting May 2006 April 2007 Japan September 2005 Europe June 2006 Bioplastics Retail Waste Materials Security Life Cycle Assessment August 2007 October 2007 December 2007 March 2008
- 56. Design for recycling Roger Morton Director, Axion
- 57. 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
- 58. The Axion Group
- 59. 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
- 60. Axion Polymers • Leading UK re-processor of plastics from WEEE and other post consumer waste • High quality Axpoly® 100% recycled plastic compounds for injection moulding & extrusion • Produced to ISO9001 quality standards • First UK polymer to achieve Carbon Footprint label • 30 staff, running on 3 shifts
- 61. Axion Polymers Polymer recycling factory 40,000sq.ft. Salford, Manchester
- 62. Axion Polymers’ Process REMOVE NON-PLASTICS INPUT WASTE MATERIAL COMPOUND & BLEND WASTE USER POLYMER SPECIFIC SEPARATION PRODUCT METALS 20+ separation steps in full process
- 64. The Full Story :- Waste white goods Primary Fridge Treatment - Shredded Plastic Plastic Recycling, At Axion Polymers, Manchester UK Injection Moulding White Goods Part Washing Machine Manufacturer New white goods
- 66. Axpoly PS13 – Closed Loop garment hanger shred – complex mix We convert the shred to produce Axpoly PS13 for resale back into garment hangers
- 67. 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....
- 68. Extended closed-loop – retail garment 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
- 69. SONY PlayStation 3 Recycling
- 70. PS3 casing disassembled Stickers ABS PC a Rubber Metal Foam
- 71. Plastic strand after removing only metal from the PS3 casings Pellets from a 99%-1% blend of PS3 casing and foam Pellets after removing all non-PC components from PS3 casings
- 72. HDPE milk bottle design for recycling • Supports UK dairy and retail industry Courtauld Commitment • Maximise the availability and quality of food grade recycled HDPE for closed loop recycling
- 74. HDPE bottle categories A B C Easy to Tricky to Not recycle with recycle suitable good yield in but for closed closed loop achievable loop using existing with recycling technology reduced yield
- 76. UK Collectable Flooring Tonnage
- 77. What do we accept?
- 78. How is the PVC recycled? • Off cuts back into production of new flooring including safety • Uplifted flooring to road cone bases etc
- 79. Collection logistics Material collected by manufacturers using: Backloads Diversion of vehicles Consolidation at: waste transfer stations distributors
- 80. Environmental tradeoff Maximise resource Eliminate persistent efficiency chemicals Use recycled polymer Use virgin polymer & • Oil-based raw material modern additives re-used • No chemical impact • Legacy additives • Carbon impact of virgin appear in new products polymer 10 x recycled PVC
- 81. Carpet recycling UK carpet waste tonnes/yr
- 82. Half UK carpet waste is PP Wide range of constructions: • Tufted, looped, tiled • PP, jute, polyester, nylon scrim • Rubber, bitumen, PVC backed
- 84. Recovery to polymer Extrusion Shredding Feed extruder
- 85. Trial results
- 86. Trial results Physical properties Recycled Virgin PP used for Units test carpet injection moulding MFI (at 230°C, 2.16kg) 19.5 12 Tensile strength MPa 17 32 Impact 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
- 87. 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!
- 88. Axion Consulting rmorton@axionconsulting.co.uk Tudor House 2 Meadway Bramhall SK7 2DG 0161 426 7731