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8/4/2019 3case Studies on Plastics-pet Bottles
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3 Case study on Plastics : PET Bottle
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Life Cycle of Plastics
ProductPolymer Crude Oil Use
Recovery Polymer Product Use
Waste
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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 Industry Fiber Industry (wash, crash, melt, spin)
Bottle Industry Bottle Industry (deporimerization)
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Players
Producersn Plant designersn Product designersn Energy suppliersn Related industrial sectors
ConsumersMunicipal and governmental authoritiesWaste treatment agencies
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Role of KIH ‘configuration engine’
1. To inform players of their role in life cycle asa stakeholder
2. To accumulate knowledge/information of lifecycle from information suppliers
3. To interpret massive life cycle data withtransparency for rational decision making
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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 Industry Fiber Industry (wash, crash, melt, spin)
Bottle Industry Bottle Industry (deporimerization)
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Objective of this case study
To develop a ‘configuration engine’, which takes LCAas an environmental metric concurrently with aneconomic metric, for chemical process designer ,
To clarify steps, tools and information in a form ofbusiness-model.
To show actual design procedure of PET bottlerecycling processes using configuration engine.
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Business-model development with IDEF0
Output:Objects that are
produced 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 type0 A method to model activities of an organization or a system.
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Top activity A0: Design Chemical Process
DesignDesignChemical ProcessChemical Process
A0
Knowledge, databaseProcess simulator
LCA tools
Economic evaluation tools
Monte Carlo simulator
External constraints (law, etc)
Enterprise’s constraints (Resource, etc)
Technical constraints
Input Output
M e c
h a n
i s m
C o n
t r o l
Desired function
of the process Optimal design
Evaluation tools,databases
Constraints
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One layer-down from A0
Configuredesign
problemA1
Generatealternatives
A2
Analyzeprocess
A3
Evaluateprocess
A4Optimizeprocess
A5
Process diagrams
Database,Knowledge Process simulatorEconomic 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
M
e c
h a n
i s m
C o n
t r o l
Scope, Objectives, Constraints
Desired functionof the process
Process input/output
Ch f CO i i b i ll i
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Changes of CO 2 emissions by installationof the process
s-phase Poly-condensation
BottleManu-facturing
Consump-tion
Incine-ration
Oi l D r i l l i n
g & M
on
om
er P r o
d u c t i on
Esterifi-cation
EG
PTA BHETTrans Este-
rificatoinPETresin
Polymerization
BHET route BHET route
PETBHET
Consump-
tionFibering Incine-
ration
Polymeri-
zation
Manu-
factuaring
EG
DMT
PET
resin
DMTPTA
EGPET
int
BHET
PTA route PTA route
Flaking+Washing
UsedBottles
Glycolysis+
Purification
Hydro-lysis
Methano-lysis Glycolysis
Methano-lysis Glycolysisint
BHET PETEG
DMT
DMT route DMT route
Elec.
Process Input/OutputProcess Input/Output
10,00010,000 t/yr t/yr
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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 route
PTA route
BHET route
R e
d u c t
i o n o
f C O
2 e m
i s s
i o n s
[ k t ]
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Whole picture of the design procedure
Configuredesign
problemA1
Generatealternatives
A2
Analyzeprocess
A3
Evaluateprocess
A4Optimizeprocess
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, PTA
route BHET route withLNG or Heavy oil
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Conclusion of this case study
IDEF0 model defines each step of theactivities
n systematic and transparent integration of toolsthat are conventionally available but separatelyexisting in each field.
Integration of these engines construct KIHn KIH for process designer may play significant role
in becoming the sustainable chemical industrywith stakeholders of its products.
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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
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Emergence of quality problem
Polymerization
Molding
Filling
ConsumptionDisposal
Polymerization
Manufacturing
Consumption
Disposal
PET bottle life cycle PET fiber life cycle
Bottle collection
recycling
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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!
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Matrix Model
Functions
•Transferring of quality information throughout the life-cycle
•Translating information into comprehensible quality terms
Fiber
Quality
demand
• • •
ResinBaleWasteBottle
Emptybottle
Bottle withdrinks
RecyclingWithdrawalSeparationCompositionFiber
manuf.
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Model Structure
DenierDEDT
Shrinking Rate
Dyeing capacityColor
DenierDEDT
Shrinking Rate
Dyeing capacityColor
FiberIV
Moisture rateDEG
Acid valueColor
PVC contamMetal, sand contam
Other contam
IVMoisture rate
DEGAcid value
Color
PVC contamMetal, 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
manufacturingDehydrationHeating& pushing-out
Pre-filteringMetal-filteringFiber-spinning
Wind roll…
DehydrationHeating& pushing-out
Pre-filteringMetal-filteringFiber-spinning
Wind roll…
Correlation Matrix
Quality demand
• • • • • •
• • •
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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 strongcorrelation
Nocorrelation
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Model Calculation
0 0 Squashing Squashing 0.192Washing
0.448Tape adhesion
0.448Plastic mixing
0.512Can separation
0.6464 0.6464 Cap separation Cap separation
0,384Label separation
Low broken threadSeparation
Cap separation affects the
most on low broken thread.
Squashing does not affect at all.
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PET fiber
P ol y m
er
F i b
er
S al e
s
C on
s um
p t i on
D i s
p o s al
PET Bottle
P ol y m
er
B o t t l e
B o t t l i n g
S al e
s
C on
s um
p t i on
D i s
p o s al
RecoveryTreatment
Lifecycle wide quality controlbetween sectors, consumers
Requirements
Control
NewControl
Control
Lifecycle Wide QualityManagement
Requirements
Conventional quality
controlsin individual sectors
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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 andSupply 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/yr
RankA
CC 3
Consumer’s attitude should beinvolved in the management ofsupply chain
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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
E n v
i r o n m e n
t a l I n d i c a
t o r
Economic Indicator
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Conclusion of this case study
• ‘Configuration engine’ for quality conscious lifecycle system design
• Q-model for every stakeholders in plastics life
cycle as a ‘configuration engine’, to eliminate thecommunication barrier regarding lifecycle-widequality improvements. – Propagation function – Interpretation function – Accumulation and integration of
knowledge/information about life cycle quality issues
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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
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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 toincorporate life cycle view – Q-model with LCA for stakeholders in plastics
recycling system
• Possible framework of KIH and its potential tocontribute to realize less-unsustainableresource-productive society
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• Collaborative partnership among stakeholders isthe first step to take effective and productiveaction against environmental problems.
• Application of KIH enables to constrainadversarial relationship and enhance moreproductive dialogue among various stakeholders.
• The research demonstrates the new function ofgovernmental agencies as the facilitator topromote the exchange knowledge andinformation.
Possible policy implications