electronic product design in the context of polymer recycling gary stevens · electronic product...
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Electronic Product DesignElectronic Product DesignIn the Context of Polymer RecyclingIn the Context of Polymer Recycling
Gary StevensGary Stevens
gnosysgnosysukuk,, University of SurreyUniversity of Surrey
IeMRCIeMRC--SUMEEPnet EcoSUMEEPnet Eco--Design WorkshopDesign Workshop
Loughborough University, 27 March 2007
Presentation OutlinePresentation Outline
•• Market and Regulatory InfluencesMarket and Regulatory Influences
•• WEEE and ELV CommonalitiesWEEE and ELV Commonalities
•• Market Opportunity for EcoMarket Opportunity for Eco--designdesign
•• Potential Areas of BenefitPotential Areas of Benefit
•• Examples Examples –– Design for RecyclingDesign for Recycling
•• Recycled Plastics QualificationRecycled Plastics Qualification
•• OutlookOutlook
•• Plastics widely used in electrical/electronics industryPlastics widely used in electrical/electronics industry
•• Design for endDesign for end--ofof--life management is poorlife management is poor
•• Many plastics contain labile and hazardous chemicalsMany plastics contain labile and hazardous chemicals
•• Product life <1yr to >15yrsProduct life <1yr to >15yrs
•• EEP waste product in UK is >1million tonnes/yrEEP waste product in UK is >1million tonnes/yr
•• Current recycling/reuse methods are inefficientCurrent recycling/reuse methods are inefficient
•• RecyclatesRecyclates can acquire higher economic valuecan acquire higher economic value
•• Need to retrieve more value by recyclate qualificationNeed to retrieve more value by recyclate qualification
•• Development of tools for rapid identification, separation and Development of tools for rapid identification, separation and qualification is requiredqualification is required
•• Design for Design for ““lifelife--extensionextension”” and recycling is essentialand recycling is essential
EEE Plastics Market BackgroundEEE Plastics Market Background
Vehicle EE Equipment TrendsVehicle EE Equipment Trends
•• Number of UK ELVs ~ 2.2M p.a. and growing Number of UK ELVs ~ 2.2M p.a. and growing
•• EEE intensity in vehicles is growingEEE intensity in vehicles is growing
•• In car EE technology extends from In car EE technology extends from consumer consumer electronics, to control, monitoringelectronics, to control, monitoring and and instrumentationinstrumentation to to telematicstelematics,, power systems and power electronicspower systems and power electronics
•• Trends in EEE weight fraction, total mass and value Trends in EEE weight fraction, total mass and value unknown (unknown (not in public domainnot in public domain))
•• Hazardous substance use and management in Hazardous substance use and management in AutoEEEAutoEEEshould parallel should parallel RoHSRoHS requirements for WEEE requirements for WEEE
Regulatory Influences on DesignRegulatory Influences on Design
•• WEEE Directive WEEE Directive –– UK implementation 1 January 2007UK implementation 1 January 2007–– network of designated collection facilities (registered)network of designated collection facilities (registered)
–– Declarations of compliance expected 30 August 2007Declarations of compliance expected 30 August 2007
–– Designated waste streams Designated waste streams
–– 4kg per person target too easy 4kg per person target too easy –– 14 kg achieved in Sweden 14 kg achieved in Sweden
•• RoHSRoHS Directive Directive –– established in UK July 2006, in advance of WEEE established in UK July 2006, in advance of WEEE legislationlegislation
•• EuPEuP Directive Directive –– 2005/32/EC on the Eco2005/32/EC on the Eco--design Requirements for Energydesign Requirements for Energy--using Products using Products –– working plan expected July 2007working plan expected July 2007
•• Chemicals Directive Chemicals Directive –– REACH REACH –– negotiations ongoingnegotiations ongoing
Design with Common Threads Design with Common Threads in WEEE and ELV in Mindin WEEE and ELV in Mind
•• Both come under Producer Responsibility and Integrated Both come under Producer Responsibility and Integrated Product Policy Product Policy –– & Waste Directive definitions & influence& Waste Directive definitions & influence
•• Both require recovery and recycling to achieve maximum value Both require recovery and recycling to achieve maximum value for for EoLEoL productsproducts
•• Both contain hazardous substances which require Both contain hazardous substances which require EoLEoLmanagement to be at registered sitesmanagement to be at registered sites
•• Both are under increasing recycling targetsBoth are under increasing recycling targets
•• Trend in policy terms to ensure bonaTrend in policy terms to ensure bona--fide recycling to highest fide recycling to highest possible economic value not entailing adverse effects on the possible economic value not entailing adverse effects on the environmentenvironment
•• Both product sets contain significant electrical and electronic Both product sets contain significant electrical and electronic components that can be asset trackedcomponents that can be asset tracked
Possible Extension of WEEE to ELVsPossible Extension of WEEE to ELVs•• Anticipate growing pressure to maximise resource efficiency Anticipate growing pressure to maximise resource efficiency
under Integrated Product Policyunder Integrated Product Policy
•• Anticipate growing pressure to make full use of established Anticipate growing pressure to make full use of established recycling infrastructure and to maximise the return on recycling infrastructure and to maximise the return on investment from new facilitiesinvestment from new facilities
•• Common shredding facilities, Common shredding facilities, MRFsMRFs and secondary materials and secondary materials qualification qualification
•• Anticipate a future requirement to recycle ELV electrical and Anticipate a future requirement to recycle ELV electrical and electronic systems electronic systems –– as an ELV Directive refinement as an ELV Directive refinement –– totoensure alignment with WEEE ensure alignment with WEEE
•• Both could benefit from common approach to ecoBoth could benefit from common approach to eco--design design principles, methods, aids and software toolsprinciples, methods, aids and software tools
•• Mutual benefits from recycled materials qualificationMutual benefits from recycled materials qualification
Market Opportunity
UK WEEE Arisings Data for 1998 - ICER
Equipment Units (Millions) Weight (ktonnes) % of Total
Large Household Appliances 10 392 43
Small Household Appliances 15 30 3
IT Equipment 22 357 39
Telecoms 7 8 1
Radio, TV and Audio 12 72 8
Lamps 77 12 1
Medical No data
Monitoring and Control 8 8 1
Toys 8 8 1
Electronic & Electrical Tools 6 28 3
Automatic Dispensers No data
Total 165 915,000 100
Vaio Desktops Displays Flat panel LCDCRT Display VAIO NotebooksVAIO handheld Home projectorsPlasma TV LCD TVRear Projection TV LCD ProjectionTV CRT TV CRT othersTV Combo Digital TVDVD players Smart Engine VCR recordersAV Reciever DAV CD, Super Audio CD playerMD Home decks Cassette DecksRecievers Tuners/Amplif iersMidi systems FH systemsMicro systems LoudspeakersCD Tuners CD ChangerMicromv Handycam MiniDV HandycamD8 Handycam Hi8 HandycamDigital still camera DSC Digital still camera MavicaMD w alkman NW MS w alkmanCD w alkman Tape w alkmanRadi w alkman PlayStation2Playstation One
Thermoplastic Consumed Per Product CategoryTotal: ~ 30,000 t (based on sales in Western Europe in 2002)
CRT TV: 14,000 t (45%) thermoplastic
(MBA Polymers report, USA, 1999and ACCORD)
Typical Plastics in EEE and AutosTypical Plastics in EEE and Autos
Ferrous metal (65%)
Non-ferrous metal (8%)
Other(3.5%)
Other rubber (seals & hoses etc. 4%)
Polyurethane seat foam (2%)
Thermoset plastics (1.5%)
Thermoplastics (8%)
Tyres (3%)
Glass (3%)
Fluids(1%)
Battery (1%)
Automotive Materials Proportions
Nylon7%
Polycarbonate4%
Noryl2% PMMA (Acrylic)
2%
PC/PBT co-polymer1%
Others (inc.seatbelts) 9%
Polyethylene6%
PVC12%
ABS17%
Polypropylene40%
(MBA Polymers report, USA, 1999)
Typical Resin Proportions in ElectricalTypical Resin Proportions in Electricaland Electronic Devicesand Electronic Devices
Impact of Designin the Supply Chain
Design and Select MaterialsDesign and Select Materialswith Degradation in Mindwith Degradation in Mind
(Sharp Ltd.)
UK Electronics Supply ChainUK Electronics Supply Chain
(EIGT 2015 report, DTI, 2004)
UK Electronics Value ChainUK Electronics Value Chain
(EIGT 2015 report, DTI, 2004)
Eco-designand
good materials selectionare
Essential
Life Cycle Design is EssentialLife Cycle Design is Essential
(Dillon et al, University of Massachusetts, 2000)
Design for EndDesign for End--ofof--Life ProcessingLife Processing
(Waste Watch: Plastics in the UK Economy, 2003)
Motivation in the electronics industry
Plastics: Large VolumeTo reach WEEE recycling targets:⇒ How to deal with plastic fraction
Valuable material fraction
Made from fossil resources
Increase use ofrecycled materials
Definition ofrecycling standards
WEEE
Continuousimprovement
PLASTICS
metals8%PWB
7%
glass70%
plastics15%
TV material mix (1998 models)
plastics35%
metals 33%
PWB26%
others 6%
PS2
Product Composition:
Increased percentage of plasticsfor smaller products
Recycling of Plastic – Market Competition
Market for recyclates
Specifications for recyclates to be used in designed products
Competition with virgin material
Goal – highest possible value while meeting design needs
Plastics Supply Chain Flow Diagram
Source: Enviros Report, Aug. 2003
Design for Cascades of Material Uses
WASTE
USE 3
etc.
Re-use
WASTE
USE 3
etc.
Re-process Cascade
Re-use
Recycle
RESOURCE
USE 1
Process
Manufacture 1
Extract
Manufacture 2
USE 2 Re-process
Re-process
Usually, Use 2 has lower
performance than Use 1
Mellor, Wright, Clift, Azapagic and Stevens (2002)
Resource
Extraction &
Processing Polymerisation
Blending &
Forming Use
Disposal
Fuel
Energy Recovery
Chemical Recycling & Pyrolosis
Depolymerisation
Mechanical Recycling
Re-Use
An industrial Ecology for Polymers
Need for materials qualification
Mellor, Wright, Clift, Azapagic and Stevens (2002)
Qualification of Recycled Plasticsfor Various Applications
Application 1
Application 2
Application ...
.
.
.
.
.
.
Qua
lific
atio
n C
riter
ia
Polymer material pj
Degree ofQualification gj
Mellor and Stevens (2003)
Design for WEEE Thermoplastic Recycling
To reapply qualified recycled plastics from WEEE in products, we need some deliverables:
• QA & QMS for recycled thermoplastics• Cost saving by using recycled plastics• Volume and reliability of supply
Action Items:• Identify suitable materials streams• Identify future plastic requirements • Define eco-efficiency boundaries• Set up quality management system for recycled plastics• Gain support for use of recycled material – include design
An example of a possible future market - PET
Recycling of PET – Sony Experience
Bales Of Collected PET Mouldings using original material HiPS and the equivalent part in Pet
There are issues: increased weight, injection more difficult, tool mod required
However there is an overall cost saving !
Sony Tape Walkman, WM-FX202/WM-EC1All cabinet, Total 85g
DVD Player, DVP-NS999ESFront Panel, 123g
AIBO Accessory, ERF-210AW06JMarker base, Total 133g
AIBO, ERS-7Foot &others, Total 254g
Other Electronic Product Applications
Recycling - Directions for Design
Cost reduction for future waste begins with product design & material selection, but has to consider not only today's material and production cost, but also future
technologies and the likely cost of recycling!
• Material cost at time of product design
• Can secondary materials be used• Simpler set of virgin materials • Technologies applied in products
and technology changes(e.g. CRT => LCD => OLED)
• Product design – ease of recycling / material recovery
• Legal requirements for new products at time of recovery
• Material demand and price at time of recovery, resource availability
• Qualification and specification of secondary materials – fitness for purpose
• Recycling technology & process changes, reformulation
• Recycling operational cost (energy, labour, transport, disposal)
• Legal requirements for recycling operations
Design Factors Recycling Factors
Feedback from Recyclers to Design
Ensure that feedback from recycling is reflected in the design of new products
Action Items:• Produce eco-design guidance for:
• Mechanical design, electrical design, printed circuit board design, product planning and parts & procurement
• Facilitate feedback from recyclers to product designers• Training for product designers• Introduce standards and some form of control
Eco design guidance and tools – industry wide
Improved End-of-Life Management
Improved Processing Developments
Epoxy Based PCB Waste Processing OptionsCuring Agent Application
Acid Anhydrides Electrical CastingsPowder Coatings
White pigmented Can coatingsComposites
Aromatic and Cylcoaliphatic Polyamines Powder CoatingsMoulding powders
Adhesives
Dicyandiamides Printed Circuit BoardsPowder Coatings
Moulding PowdersCompositesAdhesives
Imidazoles Potting CompoundsPowder Coatings
Moulding Powders
Boron Halide Compounds Electrical Machine InsulationCompositesAdhesives
Blocked isocyanates Electrodeposited automotive primersPowders
Polyamines and polyamide resins Maintenance PaintsMarine PaintsDIY Adhesives
Industrial FlooringCivil Engineering Adhesives
Construction Industry Mortars and Grouts
Polyisocyanates Paints (with good acid resistance)
Polymercaptans Fast Curing Adhesives
Rapid Qualification MethodsRapid Qualification Methods
•• Wide wavelength spectroscopy provides rapid Wide wavelength spectroscopy provides rapid identification, condition assessment and qualification of identification, condition assessment and qualification of recyclate materialsrecyclate materials
•• Portable, robust onPortable, robust on--line measurement capabilityline measurement capability
•• FibreFibre--optics based visibleoptics based visible--near infrared spectroscopy is near infrared spectroscopy is suitablesuitable
•• Multivariate statistical analysis (MVSA) for rapid onMultivariate statistical analysis (MVSA) for rapid on--line line material property evaluationmaterial property evaluation
Spectroscopy and MVSASpectroscopy and MVSA
•• Visible spectral range (electronic transitions): Visible spectral range (electronic transitions): information relating to colour variationinformation relating to colour variation
•• NearNear--infrared (NIR) spectral range (overtones and infrared (NIR) spectral range (overtones and combinations of molecular vibrations) : information combinations of molecular vibrations) : information relating to presence of specific functional groupsrelating to presence of specific functional groups
•• MVSA: MVSA: ““UnscramblesUnscrambles”” all spectral information; all spectral information; regression of spectral data against known materials regression of spectral data against known materials parametersparameters
•• FibreFibre--optic probes designed for sampling in the fieldoptic probes designed for sampling in the field
•• NonNon--destructive and fast techniquedestructive and fast technique
Measurement Technique: TRANSPECMeasurement Technique: TRANSPECTMTM
TRANSPECTRANSPECTMTM SystemSystem
Scoping Study of Enclosure PlasticsScoping Study of Enclosure Plastics
•• Electronic housings inspected Electronic housings inspected spectroscopicallyspectroscopically
•• Principal Components Analysis (PCA)Principal Components Analysis (PCA)
•• Colours varying from light to dark greyColours varying from light to dark grey
•• Discrimination of materials by source was possibleDiscrimination of materials by source was possible
CRTs
HP dj 950
HP lj 1200
flat screens
PCs
keyboards
floppy disks
CRTs
HP dj 950
HP lj 1200
flat screens
PCs
keyboards
floppy disks
PCA, Plastic Enclosure Materials: PC2 v PC3PCA, Plastic Enclosure Materials: PC2 v PC3
Visible-NIR Spectra of Plastic Materials
0
0.5
1
1.5
2
2.5
400 600 800 1000 1200 1400 1600 1800 2000 2200wavelength/nm
Abs
orba
nce
ABS sheet (red colour)polycarbonate/ABS sheet (purple colour)polycarbonate sheet (unpigmented)pure polycarbonate pelletspure polystyrene pellets
UV-vis-NIR spectra of base polymers
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0 500 1000 1500 2000 2500 3000wavelength/nm
abso
rban
ce (o
ffset
)
PCPSPANPB
2ν(CH)+δ(CH)
3ν(CH) 2ν(CH)
ν(CH)+ν(C=C)
ν(CH)+ν(CC)ν(CH)+δ(CH)
ν(CH)+δ(=CH)
ν(CH)+ν(C≡N)
3ν(C=O)
Spectroscopic Assignment of VibrationalSpectroscopic Assignment of VibrationalOvertones and CombinationsOvertones and Combinations
ABS content:ABS content:accurate to ~1%accurate to ~1%
over 0over 0--100% content100% content
FR content:FR content:accurate to <0.2%accurate to <0.2%over 0over 0--7% content7% content
Copolymer and Br Flame Retardant ContentCopolymer and Br Flame Retardant Content
Effect of Processing and Environmental Effect of Processing and Environmental Ageing of Thermoplastic CopolymersAgeing of Thermoplastic Copolymers
•• ABS and PC/ABS selected as most common enclosure ABS and PC/ABS selected as most common enclosure materials for processingmaterials for processing
•• 1010--pass injection moulding used as mechanical processing pass injection moulding used as mechanical processing scheme for both plasticsscheme for both plastics
•• UV 500 hr weathering scheme for both plasticsUV 500 hr weathering scheme for both plastics
•• Intermediate property evaluation between passes/exposure Intermediate property evaluation between passes/exposure times:times:
–– Melt flow rate (MFR)Melt flow rate (MFR)
–– Tensile modulusTensile modulus
–– Stress and elongation measurementsStress and elongation measurements
-4
-2
0
2
4
6
8
10
-15 -10 -5 0 5 10 15
PC1
PC2
ABS2_extrudedABS2_UVagedABS_virginABS_FRPCABS_extrudedPC_FRPCABS_UVagedPCABS_virginPCABS_FR
3 grades of virgin ABS3 grades of virgin ABS
Cluster Analysis Cluster Analysis –– PC1 v PC2PC1 v PC2colourcolour--coded by polymer, ageing processes and flame retardant contentcoded by polymer, ageing processes and flame retardant content
-6
-5
-4
-3
-2
-1
0
1
2
3
4
-4 -2 0 2 4 6 8 10
PC2
PC3
ABS2_extrudedABS2_UVagedABS_virginABS_FRPCABS_extrudedPC_FRPCABS_UVagedPCABS_virginPCABS_FR
Cluster AnalysisCluster Analysis -- PC2 PC2 vsvs PC3PC3colour coding by polymer, ageing and flame retardant presence colour coding by polymer, ageing and flame retardant presence
0
200
400
600
0 100 200 300 400 500 PCABS_PCR_02, (Y-var, PC): (UVexposure,3)
Elements :Slope:Offset:Correlation:RMSEC:SEC:Bias:
160.96051111.306330.98005630.5704331.57301
1.907e-06
Measured Y
Predic ted Y
0
0.1
500 1000 1500 2000 25 PCABS_PCR_02, PC(X-expl,Y-expl): 1(74%,45%) 2(23%,48%) 3(2%,0%)
X-variables
X-loadings
““PredictedPredicted”” versus versus ““ActualActual”” and regression coefficientand regression coefficientUV exposure for UVUV exposure for UV--Aged PC/ABSAged PC/ABS
Error of prediction: ~32 hours (2Error of prediction: ~32 hours (2σσ))
2150
2200
2250
2300
2350
2150 2200 2250 2300 2350 PCABS_PCR_02, (Y-var, PC): (Tens ileMod,3)
0.000 100.000 200.000 300.000 400.000 500.000
Elements :Slope:Offset:Correlation:RMSEC:SEC:Bias:
150.835964376.57910.88198526.8998926.479168.318734
Measured Y
Predic ted Y
-5
0
5
500 1000 1500 2000 25 PCABS_PCR_02, (Y-var, PC): (Tens ileMod,3) B0 = 2631.751221
X-Variables
Regress ion Coefficients (B)
““PredictedPredicted”” versus versus ““ActualActual”” Tensile Modulus Tensile Modulus for UVfor UV--Aged PC/ABS, colour coded by UV exposure time Aged PC/ABS, colour coded by UV exposure time
Error of prediction: ~26 Error of prediction: ~26 MPaMPa (2(2σσ))
““PredictedPredicted”” versus versus ““ActualActual”” and regression coefficientand regression coefficientMFR for mechanically and UVMFR for mechanically and UV--Aged PC/ABSAged PC/ABS
Error of prediction: ~0.7 g/10 min. (2Error of prediction: ~0.7 g/10 min. (2σσ))
Summary for ABS and PC/ABSSummary for ABS and PC/ABS
•• Plastic type and grade can be identifiedPlastic type and grade can be identified•• Polymer type concentration of blends can be determinedPolymer type concentration of blends can be determined•• FR content can be determined to better than 0.2% FR content can be determined to better than 0.2% b.wb.w. : . :
visible region is particularly useful herevisible region is particularly useful here•• Polymer property variation can be determined to good Polymer property variation can be determined to good
accuracyaccuracy•• Amount of UV exposure can be determined Amount of UV exposure can be determined –– most of which most of which
occurs in the first 100 hrs and affects the surface area onlyoccurs in the first 100 hrs and affects the surface area only•• MFR (a bulk property) and MW can be determinedMFR (a bulk property) and MW can be determined•• Tensile strength is affected by UV and process ageing Tensile strength is affected by UV and process ageing •• Mechanical processing has a much more marked effect on Mechanical processing has a much more marked effect on
PC/ABS compared with ABSPC/ABS compared with ABS
Further WorkFurther Work•• Further population of data sets: Further population of data sets:
–– Further grade differentiationFurther grade differentiation
–– Additional injection moulding and reprocessing effectsAdditional injection moulding and reprocessing effects
–– Additional property data and weathering studies Additional property data and weathering studies
–– Different flame retardant types and concentrationsDifferent flame retardant types and concentrations
•• Investigation of carbonInvestigation of carbon--black filled polymers using high black filled polymers using high intensity NIR, midintensity NIR, mid--infrared, Raman and infrared, Raman and PhotoacousticPhotoacousticspectroscopyspectroscopy
•• Enhancing spectroscopic systems and probes (under Enhancing spectroscopic systems and probes (under development)development)
•• Investigate the use of imaging spectroscopy for online Investigate the use of imaging spectroscopy for online qualification and separationqualification and separation
DRIVEnetDRIVEnet--SUMEEPnetSUMEEPnet CollaborationCollaboration
EE33DesignDesignA Knowledge Based Engineering and Extended Life Cycle Approach tA Knowledge Based Engineering and Extended Life Cycle Approach to o
Sustainable Complex Product DesignSustainable Complex Product Design
•• Develop an holistic KBE based design support tool to assist Develop an holistic KBE based design support tool to assist materials selection and product design choices that can materials selection and product design choices that can address the requirements of new European environmental address the requirements of new European environmental legislation. legislation.
•• Provide the capability for informed decisionProvide the capability for informed decision--making at the making at the designdesign--development stage to achieve optimal use of materials development stage to achieve optimal use of materials and minimal energy use in the manufacture and use of and minimal energy use in the manufacture and use of mechanical and electronic systems in the automotive industry. mechanical and electronic systems in the automotive industry.
•• Prove the tools through scenarioProve the tools through scenario--based case studies of based case studies of automotive components and systemsautomotive components and systems..
OutlookOutlook
•• Imperative for lifeImperative for life--cycle design to include the design and cycle design to include the design and selection of polymers in electronics and other products.selection of polymers in electronics and other products.
•• There may be future regulatory changes that could There may be future regulatory changes that could extend WEEE requirements to ELV managementextend WEEE requirements to ELV management
•• Commonalities between WEEE and ELV offer Commonalities between WEEE and ELV offer opportunities to get the materials right and ensure opportunities to get the materials right and ensure product design accounts for endproduct design accounts for end--ofof--life managementlife management
•• There are likely to be significant benefits in using There are likely to be significant benefits in using common ecocommon eco--design guidance, design guidance, EoLEoL decision support and decision support and resource management tools.resource management tools.
•• New rapid qualification methods are being developed for New rapid qualification methods are being developed for WEEE and ELV polymers to raise their market value WEEE and ELV polymers to raise their market value ––are designers prepared to use these secondary are designers prepared to use these secondary materials ?materials ?