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 ?