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MATERIAL FLOW ANALYSIS

MATERIAL FLOW ANALYSIS. Strategies for waste minimization. What are materials?. Goods/raw materials (e.g. wood, gravel, PVC) Elements (e.g. carbon, cadmium) Compounds (e.g. benzene, methane). What is a material flow analysis?.

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MATERIAL FLOW ANALYSIS

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  1. MATERIAL FLOW ANALYSIS

  2. Strategies for waste minimization

  3. What are materials? • Goods/raw materials (e.g. wood, gravel, PVC) • Elements (e.g. carbon, cadmium) • Compounds (e.g. benzene, methane)

  4. What is a material flow analysis? A material flow analysis is a systematic reconstruction of the way a chemical element, a compound or a material takes through the natural and/or economic cycle. A material flow analysis is generally based on the principle of physical balance. Definition of the Commission of inquiry "Protection of human life and the environment" of the German Bundestag

  5. Initial situation in a paint shop

  6. Material flows in a car repair shop

  7. How does a balance work? Input mass = Output mass + Storage (Without chemical reaction)

  8. Material flow analysis and eco-balances Eco-balances • Analyse the whole life-cycle of a product • Analyse the ecological effects • Assess the material and energy consumptions emerging during a life cycle and the arising environmental effects.

  9. Objectives of a material flow analysis • Trace the flow of raw materials through the company to establish connections within the process • Retrace waste and emissions to the point where they are generated • Identify weak points (inefficiencies) • Define the basis for evaluation • Edit data in a decision-oriented way • Set priorities for appropriate measures to minimize waste and emissions

  10. Criteria for the selection of a material • Quantity of the material flow • Costs of the material flow • Toxicity of the material flow • Legal aspects of the material flow

  11. How to carry out a material flow analysis? 1. Define the objectives and parameters to be monitored 2. Limit the balance scope 3. Limit the balance period 4. Identify and define the process steps 5. Draw the flowcharts: material flows – quality 6. Draw up the balances: material flows – quantity 7. Interpret the results and draw conclusions

  12. Material flow analysis of machine painting

  13. Step 1: Parameters monitored Paints, solvents, (all process materials) Step 2: Balance scope Painting chamber and drying Step 3: Balance period 1 year

  14. Step 4: Process steps of machine painting Process steps: • Pre-treatment • Priming, painting • Drying Additional equipment: • Steam generator • Exhaust air filter • Cleaning of spray gun and container

  15. Step 5: Flowchart • Representing process steps by rectangles • Representing material flows by arrows

  16. Air filter Priming/ Painting Pre-treatment Drying Steam generator Cleaning Balance limit Step 5: Flowchart

  17. filter Filter, paint Air, thinner Air and thinner Air filter Air, paint, thinner Priming/ Painting Pre-treatment Drying Oily parts l Partswet Partsclean Parts with paint Tools Steam generator Cleaning Water,detergent Balance limit Thinner Dustcontainers Wastethinner Step 5: Flowchart Paint, thinner, filler, tape, film, air, container

  18. Step 6: Balances • Input = output for the whole system • Input = output for the single steps

  19. E8, E9, E 10, A3 E3, E4, E5, E6, E7 A4, A7 Air filter Priming/ Painting Pre-treatment Drying E1 A1 Steam generator Cleaning E2 Balance limit E11 A4, A5, A8, A9 A6 Step 5: Flowchart A2

  20. Quantitative material flow analysis

  21. Quantitative material flow analysis

  22. Step 7: Interpretation By identifying parameters Calculation of the so-called “application efficiency": Dry surface film mass Efficiency = _______________________ Input solid state mass In this case for small pieces < 10% In this case on average < 20% State of the art?

  23. Typical efficiencies (application efficiency, expressed in % solids):

  24. Evaluation of a material flow analysis

  25. Evaluation of a material flow analysis – 2 Possible parameters: • Efficiency factors (ratio of use to costs) • Quality factors (ratio of real efficiency factor to the theoretically possible efficiency factor) Linkage with costs

  26. Data sources • Accounting • Warehousing • Collection of process data • Operational accounting • Personal information (e.g. methods engineer) • Estimates • Measurements • Original documents • ...

  27. Measuring water volumes • Water meter • Turbine wheel meter • Rotameter • Induction measuring instrument • Ultrasonic flowmeter • Weir • Measuring at water consumers (stop watch, bucket) 2,5 0,31 h 2g o q = tan o

  28. Recommendations 1for a material flow analysis • Carry out the material flow analysis in steps • An estimate is better than doing nothing at all • Even with estimates it is possible to improve • 80 – 90% of accuracy is sufficient • Use simple measuring instruments • Use indicators • If necessary, contact the supplier or plant manufacturer

  29. Recommendations – 2for a material flow analysis • It is not essential to follow the instructions or procedures in great detail, a creative approach is often helpful. • Even by simply working with the balances you can sometimes achieve improvements. • It is important to translate the results into the language of the respective target group (monetary units, kg, pictures, comparisons, etc.)

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