NEW FRONTIERS SEMINAR: Closing The Loop: Conserving Resources Through Sustainable Design and Chemistry'.

Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board
programme

Closing the Loop:
Conserving resources through
sustainable design and chemistry
Mike Pitts
Chemistry Innovation
programme

content

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

programme

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

Source: 2009 R&D Scoreb oard of Top 850 UK Companies - pub lished b y BIS Accelerating business innovation;
programme

Chemists and Sustainability

Green Chemistry: Theory & Practice, Anastas & Warner, 1998 a Technology Strategy Board
programme

RSC Roadmap

Sustainable Design
is a RSC Roadmap
‘Top Ten’ Challenge

www.rsc.org/roadma
p

programme

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
programme

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

• Peak oil production passed? programme

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”

Source: JLS Consulting Accelerating business innovation;
programme

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
Source: World Council, UNESCO, DEFRA Accelerating business innovation;
programme

Endangered Elements

programme

• 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
programme

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

programme

From unit
operation to
whole system

programme

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
source: Sustainable Technologies Roadmap Accelerating business innovation;
programme

Whole system thinking

programme

From plant/product
to whole life cycle

programme

Product Life-Cycle

distributio
n & retail use of
manufacture
product

materials disposal

programme

Lifecycle Analysis

for each
pint of milk:

Source: DEFRA Accelerating business innovation;
programme

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
source: CEFIC/European Environment Agency Accelerating business innovation;
programme

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;
programme

Design for lifecycle

programme

From process and
product to
service

programme

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

programme

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

programme

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

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Design for service

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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
www.chemistryinnovation.co.uk/sdg a Technology Strategy Board
programme

Workbook Content

programme

Supporting Information

programme

Roadmap website

www.chemistryinnovation.co.uk/stroadmap

www.chemistryinnovation.co.uk/stroadmap a Technology Strategy Board
programme

‘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

programme

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 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

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.

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

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 )

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)
Common
Electrode

Electri
Electri
c field
c field

OFF ON OFF ON OFF ON
Pixel
Electrode
Backlight Backlight Backlight

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”

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

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 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

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.

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 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

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

Further Info
Ian Holmes
ian.holmes@ctechinnovation.com

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

Design for recycling
Roger 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

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 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

Axion Polymers

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

Axion Polymers’ Process

REMOVE NON-PLASTICS
INPUT WASTE MATERIAL

COMPOUND & BLEND
WASTE

USER
POLYMER
SPECIFIC
SEPARATION
PRODUCT

METALS

20+ separation steps in full process

Axion Polymers

Polymer
product
from
extruder

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

Axion Polymers

Washing
machine
component
made from
Axpoly

Axpoly PS13 – Closed Loop

garment hanger
shred – complex mix

We convert the shred
to 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 – 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

PS3 casing disassembled

Stickers

ABS

PC

a Rubber Metal Foam

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

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

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

UK Collectable Flooring Tonnage

How is the PVC recycled?
• Off cuts back into
production of new
flooring including
safety

• Uplifted flooring to
road cone bases etc

Collection logistics

Material collected by
manufacturers using:
Backloads
Diversion of vehicles
Consolidation at:
 waste transfer stations
 distributors

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

Carpet recycling

UK carpet waste tonnes/yr

Half UK carpet waste is PP
Wide range of
constructions:
• Tufted, looped, tiled
• PP, jute, polyester,
nylon scrim
• Rubber, bitumen,
PVC backed

Recovery to polymer

Extrusion
Shredding Feed extruder

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

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

rmorton@axionconsulting.co.uk

Tudor House
2 Meadway
Bramhall
SK7 2DG
0161 426 7731

NEW FRONTIERS SEMINAR: Closing The Loop: Conserving Resources Through Sustainable Design and Chemistry'.

NEW FRONTIERS SEMINAR: Closing The Loop: Conserving Resources Through Sustainable Design and Chemistry'.

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