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3 Case study on Plastics : PET Bottle
3 Case study on Plastics : PET Bottle
Life Cycle of Plastics
ProductPolymerCrude Oil Use
Recovery Polymer Product Use
Waste
Overview of PET bottle recycling
Specified business entities
Local governments Consumers
Obligation to recycle
Selective collection and storage
Selective discarding
Containers and Packaging Recycling Law
Fiber IndustryFiber Industry(wash, crash, melt, spin)Bottle IndustryBottle Industry(deporimerization)
Players
Producersn Plant designersn Product designersn Energy suppliersn Related industrial sectors
ConsumersMunicipal and governmental authoritiesWaste treatment agencies
Role of KIH ‘configuration engine’
1. To inform players of their role in life cycle as a stakeholder
2. To accumulate knowledge/information of life cycle from information suppliers
3. To interpret massive life cycle data with transparency for rational decision making
Overview of PET bottle recycling
Specified business entities
Local governments Consumers
Obligation to recycle
Selective collection and storage
Selective discarding
Containers and Packaging Recycling Law
Fiber IndustryFiber Industry(wash, crash, melt, spin)Bottle IndustryBottle Industry(deporimerization)
Objective of this case study
To develop a ‘configuration engine’, which takes LCA as an environmental metric concurrently with an economic metric, for chemical process designer,
To clarify steps, tools and information in a form ofbusiness-model.
To show actual design procedure of PET bottle recycling processes using configuration engine.
Business-model development with IDEF0
Output:
Objects that areproduced by a function
Input:
Objects that are transformed into output
Control:Conditions required to produce correct output
Mechanism:
Means to perform a function
A0
Activity
IDEF0: Integration Definition for Function Modeling type0A method to model activities of an organization or a system.
Top activity A0: Design Chemical Process
DesignDesignChemical ProcessChemical Process
A0
Knowledge, database
Process simulator
LCA tools
Economic evaluation tools
Monte Carlo simulator
External constraints (law, etc)
Enterprise’s constraints (Resource, etc)
Technical constraints
Input Output
Mec
hani
sm
Con
trol
Desired functionof the process Optimal design
Evaluation tools,databases
Constraints
One layer-down from A0
Configure design
problemA1
Generatealternatives
A2
Analyzeprocess
A3
Evaluateprocess
A4
Optimizeprocess
A5
Process diagrams
Database,Knowledge Process simulator
Economic evaluation toolsLCA tools Monte Carlo simulator
Constraints Needs to change design configurations
Needs to regenerate alternatives
Needs to check parameters
Idea for options
Process to beoptimized
Optimaldesign
Input Output
Mec
hani
sm
Con
trol
Scope, Objectives, Constraints
Desired functionof the process
Process input/output
Changes of CO2 emissions by installationof the process
s-phase Poly-condensation
Bottle Manu-
facturingConsump-
tionIncine-ration
Oil D
rilling & M
onomer P
roduction
Esterifi-cation
EG
PTABHET
Trans Este-rificatoin
PETresin
Polymerization
BHET routeBHET route
PETBHET
Consump-tionFibering Incine-
rationPolymeri-
zationManu-
factuaringEG
DMTPETresin
DMTPTA
EGPETint
BHET
PTA routePTA route
Flaking+Washing
UsedBottles
Glycolysis+
Purification
Hydro-lysis
Methano-lysis Glycolysis
Methano-lysis Glycolysisint
BHET PETEG
DMT
DMT routeDMT route
Elec.
Process Input/OutputProcess Input/Output
10,000 10,000 t/yrt/yr
Multi-objective evaluation result
The Net Present Value [Billion Yen]
40
35
30
25
20
15
45
2.0 4.0 6.0 8.0 10 12 140
Better design
DMT routePTA route
BHET route
Red
uctio
n of
CO
2em
issi
ons
[kt]
Whole picture of the design procedure
Configure design
problemA1
Generatealternatives
A2
Analyzeprocess
A3
Evaluateprocess
A4
Optimizeprocess
A5
Optimaldesign
Desired functionof the process
Process input/output
Economic evaluation tools
LCA tools
Process to beoptimized
10,000 t/yr asused-PET inlet
BHET, DMT, PTAroute
BHET route withLNG or Heavy oil
Conclusion of this case study
IDEF0 model defines each step of the activitiesn systematic and transparent integration of tools
that are conventionally available but separately existing in each field.
Integration of these engines construct KIHn KIH for process designer may play significant role
in becoming the sustainable chemical industry with stakeholders of its products.
Configuration engine for MR system
LCA showed that material recycling (MR) system decrease environmental impact.Quality of plastics deteriorates by use, processing for recycling.Life cycle wide quality management is needed as configuration engine
Emergence of quality problem
Polymerization
Molding
Filling
Consumption
Disposal
Polymerization
Manufacturing
Consumption
Disposal
PET bottle life cycle PET fiber life cycle
Bottle collection
recycling
Emergence of quality problem
Polymerization
Molding
Filling
Consumption
Disposal
Polymerization
Manufacturing
Consumption
Disposal
PET bottle life cycle PET fiber life cycle
Bottle collection
recycling
Polymerization
Molding
Filling
Consumption
Disposal
Polymerization
Manufacturing
Consumption
Disposal
PET bottle life cycle PET fiber life cycle
Bottle collection
recycling
Quality information doesn’t flow across life cycle
Dialog between players is needed!
Matrix Model
Functions
•Transferring of quality information throughout the life-cycle
•Translating information into comprehensible quality terms
FiberQualitydemand
• • •
ResinBaleWaste Bottle
Empty bottle
Bottle with drinks
RecyclingWithdrawalSeparationCompositionFiber
manuf.
Model Structure
DenierDEDT
Shrinking RateDyeing capacity
Color
DenierDEDT
Shrinking RateDyeing capacity
Color
FiberIV
Moisture rateDEG
Acid valueColor
PVC contamMetal, sand contam
Other contam
IVMoisture rate
DEGAcid value
ColorPVC contam
Metal, sand contamOther contam
Resin
Low broken threadlow unevenness
High strengthHigh measure stability
Fine colorLess variation of properties
Low broken threadlow unevenness
High strengthHigh measure stability
Fine colorLess variation of properties
Fiber manufacturing
DehydrationHeating& pushing-out
Pre-filteringMetal-filteringFiber-spinning
Wind roll…
DehydrationHeating& pushing-out
Pre-filteringMetal-filteringFiber-spinning
Wind roll…
Correlation Matrix
Quality demand
• • • • • •
• • •
Matrix Structure
………High strengthLow unevennessLow broken thread
0.200Shrinking
0.600DT
0.800.2DE
01.00Dyeing
000Color
000Denier
Quality demandFiber
Numbers are obtained by…
• Investigation Data from manufactures / organizations
• Information from expertise
• Chemical / physical relationship
Very strong correlation
No correlation
Model Calculation
00SquashingSquashing
0.192Washing
0.448Tape adhesion
0.448Plastic mixing
0.512Can separation
0.64640.6464Cap separationCap separation
0,384Label separation
Low broken threadSeparation
Cap separation affects the most on low broken thread.
Squashing does not affect at all.
PET fiber
Polym
er
Fiber
Sales
Consum
ption
Disposal
PET Bottle
Polym
er
Bottle
Bottling
Sales
Consum
ption
Disposal
RecoveryTreatment
Lifecycle wide quality controlbetween sectors, consumers
Requirements
Control
NewControl
Control
Lifecycle Wide Quality Management
Requirements
Conventional quality controls
in individual sectors
Max: 34,00Min rank: D
Recycler X
7,000t/yrRank D
CC 1Max: 34,000t/yrMin rank: D
Recycler Y
Max: 34,000t/yrMin rank: D
Recycler Z
3,000t/yrRank B
CC 5
3,000t/yrRank B
CC 8
4,000t/yrRank A
CC 46,000t/yrRank B
CC 2
3,000t/yrRank A
CC 6
3,000t/yrRank D
CC 7
5,000t/yrRank B
CC 3
Consumers and
Supply Chain
Max: 34,000t/yrMin rank: D
Recycler X
7,000t/yrRank D
CC 1Max: 34,000t/yrMin rank: D
Recycler Y
Max: 34,000t/yrMin rank: D
Recycler Z
3,000t/yrRank B
CC 5
3,000t/yrRank B
CC 8
4,000t/yrRank A
CC 46,000t/yrRank B
CC 2
3,000t/yrRank A
CC 6
3,000t/yrRank D
CC 7
5,000t/yrRank B
CC 35,000t/yrRankA
CC 3
Consumer’s attitude should be involved in the management of supply chain
Pareto Analysis
Consumer’s Attitude Supply
-9.00
-8.00
-7.00
-6.00
-5.00
-4.00
-3.00
-2.00
-1.00
-1.250 -1.200 -1.150 -1.100 -1.050 -1.000 -0.950 -0.900 -0.850
u Base Casen Scenario 1
Quality
Env
ironm
enta
l Ind
icat
or
Economic Indicator
Conclusion of this case study
• ‘Configuration engine’ for quality conscious life cycle system design
• Q-model for every stakeholders in plastics life cycle as a ‘configuration engine’, to eliminate the communication barrier regarding lifecycle-wide quality improvements.– Propagation function– Interpretation function– Accumulation and integration of
knowledge/information about life cycle quality issues
Example of grouping of knowledge and information
RecycleSystemDesign
RecycleSystemDesign Material
SelectionSupport
MaterialSelectionSupport
ProductSelectionGuidance
ProductSelectionGuidance
ZeroEmission
ZeroEmission
ProcessSystemDesign
ProcessSystemDesign
Scenario-basedLCA
Scenario-basedLCA
ISO14000Type LCA
ISO14000Type LCA
Policy DesignPolicy Design
ProductDesign
ProductDesign
Concluding remarks
• Prototypes of ‘configuration engine’– Multi-agent-simulator (MAS) for stakeholders
involved in supply/demand chain of biomass wastes– Activity model for recycling process designer to
incorporate life cycle view– Q-model with LCA for stakeholders in plastics
recycling system
• Possible framework of KIH and its potential to contribute to realize less-unsustainable resource-productive society
• Collaborative partnership among stakeholders is the first step to take effective and productive action against environmental problems.
• Application of KIH enables to constrain adversarial relationship and enhance more productive dialogue among various stakeholders.
• The research demonstrates the new function of governmental agencies as the facilitator to promote the exchange knowledge and information.
Possible policy implications
