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MARASMaterial Recycling and Sustainability
MARASMaterial Recycling and Sustainability
Dr. ir. Antoinette van Schaik
MARAS, The Hague, The Netherlands
Design
for
Recycling
© MARAS
Design for Recycling and Resource Efficiency
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Dismantling/shredding/sortingDesign Metallurgical processing
Design for waste stream sorting
Design for disassembly
Design for shredding/liberation
Design for recovery in final treatment processing
Design for sorting
How can we define DfR rules to optimise Resource Efficiency?
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10 Design Rules and Simulation Derived Guidelines
Fundamental DfR rules
1. DfR rules are product and recycling system specific; oversimplification of recycling bydefining general DfR rules will not produce the intended goal of resource efficiency
2. DfR needs model and simulation based quantification
3. Design data should be accessible/available in a format which is compatible with the detailrequired to quantify and optimise recycling performance of products for all metals,materials and compounds present
4. Economically viable infrastructure and rigorous tools must be in existence for realizing industrial DfR rules and methodologies
5. CAD/Design tools must be linked to recycling system process simulation tools to realisetechnology based, realistic and economically viable DfR
Note : All DfR rules/guidelines are subject to a mindful consideration of product/component
functionality and should not impair these
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10 Design Rules and Simulation Derived Guidelines
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Possible DfR guidelines – Derived from Fundamental DfR Rules
Iteratively checked by simulation and validity
6. Identify and minimize the use of materials which will cause losses and contaminations inrecycling due to material characteristics and behaviour in sorting
7. Identify components/clusters in a product, which will cause problems and losses inrecycling due to combined and applied materials
8. Design clusters or sub-units in products that can be easily removed and which match withthe final treatment recycling options (i.e. Metal Wheel)
9. Labelling (including carefully considered standardisation) of products/components basedon recovery and/or incompatibility for easy identification (and removal) from recyclatesand waste streams
10. Be mindful of liberation of materials in design (Design for Liberation)
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DESIGN FOR RECYCLING RULES
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DfR Rule 1 : DfR is product specificDfR rules are product and recycling system specific - each product has a unique recyclability profile
RecyclatesMulti-material particles and flows
Connected
materials
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DfR Rule 1 : DfR is product specific Each product has a recyclability profile and a set of product and recycling system specific DfR guidelines
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DfR Rule 1 : No oversimplificationOversimplification of recycling by defining general DfR rules will not produce the intended goal of resource efficiency
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DfR Rule 2 : QuantificationQuality of recyclates : design, shredding and sorting determines recoverability and recycling of product and components (example on Printed Circuit Board)
Ferrous recyclate PCB recyclate Plastics recyclate Residue fraction
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Different appearances of PCB in (PCB) recyclates
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Steel
Cu, Ni, Sn, Pb,
Zn, PGM, PM
Cu, Pb, PM
Aluminium
Cu, PGM, PM
Various others
Variousseparationprocesses/
routes
Dismantling/depollution Final treatment/metallurgyShredding/liberation Sorting/separation
DfR Rule 2 : QuantificationDfR needs model and simulation based quantification of recycling performance
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DfR Rule 3 : Design dataDesign data on product composition and construction should be available in a consistent format that matches with the detail required to quantify and optimise recycling
Material usage and materialcombinations in products
Material usage, chemical compounds and combinations in components and its variations
Connection of complex components to structural parts/materials
Chemical composition and compounds in e.g. electrical components and its variations
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DfR Rule 4 : Infrastructure and toolsRobust metallurgical infrastructure should be in place to ensure maximum recovery
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DfR Rule 4 : Infrastructure and toolsRigorous tools for recycling simulation and DfR
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SIMULATION DERIVED GUIDELINES
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Guideline 6 : Material characteristicsIdentify and minimize the use of materials which will cause losses in recycling due to material characteristics and behaviour in sorting
Concrete in
washing machines
Colored PrintedWire Boards
Glass in fridges Isolation materials
Losses of PCB to other recyclates -contamination of PCB fraction
Pro
ble
ma
tic m
ate
ria
ls
ind
esig
n
Contaminates recyclate fractions -material losses
Process waste,decreases recycling performance
Difficult to dismantle & distributes over recyclate fractions
Pro
ble
ms/co
nse
qu
en
ce
s
in s
ort
ing
/se
pa
rati
on
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Guideline 7 : (In) compatibility of combined materialsIdentify and minimize the use of materials which will cause losses due to combined & applied materials
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ZnRLE/Fume
CuSmelt/Refine
MnTRIP SteelAustenitic
Ni/CrStainless
Steel
FeSteel (BOF&EAF)
SnSmelt/Refine
REHydro-
metallurgy
AlRemeltRefine
MgHydro Metallurgy
Remelt
LiHydro&PyroMetallurgy
TiPyroMetallurgyRemelt
©van SchaikReuter
PbSmeltRefine
RESpecial BatteryRecycling
Metallurgical
Infrastructure
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Guideline 7 : (In) compatibility of combined materialsSociety’s Essential Carrier Metals: Metal recycling products, by products & residues
Metal
Slag, Slime, Speiss, Dust
Off gas / Low Value Products
Carrier metals : Primary and recycling metallurgy
infrastructures
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Metals in Printed Circuit Board Destination (recovery/losses) of elements PCB
Guideline 7 : (In) compatibility of combined materials Recovery&losses determined by quality and destination/processing route of recyclate/component
Cu2O
Pt
Pd
REOsREs
Ta2O5
Br
Sn
REs
Ta2O5
Bi
Pb
Zn
Hg
TiO2
ZrO2
PNa
K
REOs
As
Sb
CaO
Al2O3
Cu2O
FeOx
MgO
Ga2O3
ThO2
Th
V2O5
Cu
BaO
SiO2
MnO
SrO
Ag
Co
Ni
Au
PtPd
Mo
Cl
Sn
Cd
Bi
Sn
Sb
AuPt
Ga
Co
Cd
CuCaO
Al2O3
FeOx
SiO2
Au
Ag
Al2O3
FeOx
Cu
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Guideline 7 (In) compatibility of combined materials Compatibility tables for a first quick screening – based on Metal Wheel
Al 2 1 2 2 2 2 2
Cu 3 2 1 1 0 0 0
Pd 3 3 1 2 3 0 0
Sb 3 3 2 1 0 0 0
Materials in input streams
(from WEEE materials)
To Remelting, Smelting,
Hydrometallurgy, Refining
Fe S
teel
(B
OF&
EAF)
Al R
emel
t/R
efin
e
Cu
Sm
elt/
Ref
ine
Zn R
LE/F
um
e
Pb
Sm
elt/
Ref
ine
Ni/
Cr
Stai
nle
ss S
teel
Rar
e E
arth
s
Hyd
rom
etal
lurg
y
Rar
e E
arth
s
Spec
ial B
atte
ry R
ecyc
ling
Society’s Essential Carrier Metals: Primary Product
Extractive Metallurgy’s Backbone
(primary and recycling metallurgy)
Materials in input streams
(from WEEE materials)
To Remelting, Smelting,
Hydrometallurgy, Refining
Fe S
teel
(B
OF&
EAF)
Al R
emel
t/R
efin
e
Cu
Sm
elt/
Ref
ine
Zn R
LE/F
um
e
Pb
Sm
elt/
Ref
ine
Ni/
Cr
Stai
nle
ss S
teel
Rar
e E
arth
s
Hyd
rom
etal
lurg
y
Rar
e E
arth
s
Spec
ial B
atte
ry R
ecyc
ling
Society’s Essential Carrier Metals: Primary Product
Extractive Metallurgy’s Backbone
(primary and recycling metallurgy)
Ag 3 3 1 0 0 0 0
Al 2 1 2 2 2 2 2
Al2O3 2 3 2 2 2 2 2
Au 3 3 1 1 0 0 0
Bi 3 0 1 1 0 0 0
Br 3 0 1 0 0 0 0
Cl 3 0 1 0 0 0 0
Cr 2 3 3 3 1 3 0
Cu 3 2 1 1 0 0 0
Cu2O 0 0 2 0 0 0 0
Fe 1 2 0 0 1 0 0
FeOx 2 0 2 2 2 2 2
Ni 2 2 1 0 1 0 1
Pb 2 2 1 1 2 0 0
Pd 3 3 1 2 3 0 0
Sb 3 3 2 1 0 0 0
Sb2O3 0 0 0 0 0 2 0
Si 2 2 0 0 0 0 0
SiO2 2 0 2 2 2 2 0
Sn 3 2 1 1 0 0 0
Zn 2 2 1 1 2 0 0
Elastomers 2 2 2 2 2 2 4
Thermosets 2 2 2 2 2 2 0
Thermoplastics (flame retardants etc.) 2 2 2 2 2 2 0
Epoxy 2 2 2 2 2 2
PCBA (washing machine/LHHA)
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Guideline 8 : Design matching with final treatmentDesign clusters or sub-units, which match with the final treatment recycling options (Metal Wheel) and that can be easily removed
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Guideline 9 : Labelling/SortingLabelling and marking for Waste stream Sorting and (Automated) Disassembly & Sorting
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CFL versus LED lampsTa capacitors – color/identification based labelling & easy to break connections
Compressors - Marking of tapping point Standardisation of marking/identification (incl. position)
of cooling liquid/gas for fluid system and foam
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Guideline 10 : Design for LiberationAvoid bolts/rivets of dissimilar materials (e.g. Fe bolts) as these produce generally a liberation problem therefore creates cross-contamination of the different recyclate fractions
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Guideline 10 : Design for Liberation Minimize the use of non reversible adhesives for incompatible/undesired material combinations
Glass glued to steel mask
Shrink films
Sealed batteries PUR glued to steel, Al, plasticsGlued wood/plastic
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Guideline 10 : Design for LiberationParticulate quality – an impression of un-liberated & multi-material particles
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SIMULATION EXAMPLE
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A Simulation Example : QuantificationQuantification of Recycling Rate, Mass flows and quality/composition of flows
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A Simulation Example Quantification of Recycling Rate, Mass flows and quality/composition of flows
A Simulation Example : QuantificationDistribution/dispersion of elements/compounds can be traced – example on Gold
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A Simulation Example : Redesign and recycling routeRemoval/sorting of PCBs & Ta capacitors through design changes by e.g. labelling and identification options for sorting
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A Simulation Example : Redesign and recycling route Removal/sorting of PCBs & Ta capacitors through design changes by e.g. labelling and identification options for sorting – distribution of Gold
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A Simulation Example : Design for LiberationEffect of construction/connections of Printed Wire Board in product – improved liberation of Al heat sinks and Fe containing components/bolts
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CONCLUDING REMARKS & RECOMMENDATIONS
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Recycling & recovery rates + losses/emissions(Product and recycling system specific)
Environmental Impact Analyses(Product /system specific )
Recycling system process simulation toolsCAD/Design (BOM/FMD/etc)
DfR Rule 4 & 5 : Recycling Simulation linked to DesignRecycling process simulation tools, including environmental footprint must be linked to CAD/Design tools to realise technology based, realistic and economically viable DfR & Ecodesign
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Recommendations
(Policy) targets for Recycling and Eco-design
• should remain within what is technologically (physically and thermodynamically) and economically possible and be based on recycling process simulation tools and knowledge;
• must be set in ways that account for the inevitable losses of materials due to mixing in products for product functional specifications;
• should stimulate Best Available Technology/Techniques (recycling and metallurgicalinfrastructures)
• should reflect the interest and expertise of all stakeholders in the product and recycling system and stimulate interaction;
• should respect the dynamic (time-varying) product characteristics and recycling profile over time.
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Acknowledgements
• Coolrec bv
• Remondis Electrorecycling GmbH
• Alba Service GmbH
• Indaver nv
• Sims Recycling Solutions
• Van Dalen / De Ruiter Schroot bv
• Markus Reuter (Outotec Oyj and Aalto University)
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Contact
Dr. ir. Antoinette van Schaik
MARAS - Material Recycling and Sustainability -
Rijsbes 46
2498 AS Den Haag
The Netherlands
Tel.: +31 6 53836042
www.marasustainability.nl
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