Slides 3 – Material flow analysis MATERIAL FLOW ANALYSIS Slides 3 – Material flow analysis Strategies for waste minimization Slides 3 – Material flow analysis What are materials? Goods/raw materials (e.g. wood, gravel, PVC) Elements (e.g. carbon, cadmium) Compounds (e.g. benzene, methane) Slides 3 – Material flow analysis What is a material flow analysis? A material flow analysis is a systematic reconstruction of the way a chemical element, a compound or a material takes through the natural and/or economic cycle. A material flow analysis is generally based on the principle of physical balance. Definition of the Commission of inquiry "Protection of human life and the environment" of the German Bundestag Slides 3 – Material flow analysis Initial situation in a paint shop Slides 3 – Material flow analysis Material flows in a car repair shop Slides 3 – Material flow analysis How does a balance work? Input mass = Output mass + Storage (Without chemical reaction) Slides 3 – Material flow analysis Material flow analysis and eco-balances Eco-balances Analyse the whole life-cycle of a product Analyse the ecological effects Assess the material and energy consumptions emerging during a life cycle and the arising environmental effects. Slides 3 – Material flow analysis Objectives of a material flow analysis Trace the flow of raw materials through the company to establish connections within the process Retrace waste and emissions to the point where they are generated Identify weak points (inefficiencies) Define the basis for evaluation Edit data in a decision-oriented way Set priorities for appropriate measures to minimize waste and emissions Slides 3 – Material flow analysis Criteria for the selection of a material Quantity of the material flow Costs of the material flow Toxicity of the material flow Legal aspects of the material flow Slides 3 – Material flow analysis How to carry out a material flow analysis? 1. Define the objectives and parameters to be monitored 2. Limit the balance scope 3. Limit the balance period 4. Identify and define the process steps 5. Draw the flowcharts: material flows – quality 6. Draw up the balances: material flows – quantity 7. Interpret the results and draw conclusions Slides 3 – Material flow analysis Material flow analysis of machine painting Slides 3 – Material flow analysis Step 1: Parameters monitored Paints, solvents, (all process materials) Step 2: Balance scope Painting chamber and drying Step 3: Balance period 1 year Slides 3 – Material flow analysis Step 4: Process steps of machine painting Process steps: Pre-treatment Priming, painting Drying Additional equipment: Steam generator Exhaust air filter Cleaning of spray gun and container Slides 3 – Material flow analysis Step 5: Flowchart Representing process steps by rectangles Representing material flows by arrows 3 – Material flow analysis Slides Step 5: Flowchart Air filter Pre-treatment Steam generator Priming/ Painting Drying Cleaning Balance limit 3 – Material flow analysis Slides Step 5: Flowchart Paint, thinner, filler, tape, filter film, air, container Filter, paint Air filter Air, thinner Air and thinner Air, paint, thinner Priming/ Painting Pre-treatment Oily parts l Parts clean Steam generator Tools Drying Parts wet Parts with paint Cleaning Water, detergent Balance limit Thinner Waste thinner Dust containers Slides 3 – Material flow analysis Step 6: Balances Input = output for the whole system Input = output for the single steps 3 – Material flow analysis Slides Step 5: Flowchart E8, E9, E 10, E3, E4, E5, E6, E7 A3 A4, A7 Air filter Priming/ Painting Pre-treatment E1 Drying A1 Steam generator Cleaning E2 Balance limit A2 E11 A6 A4, A5, A8, A9 Slides 3 – Material flow analysis Quantitative material flow analysis Slides 3 – Material flow analysis Quantitative material flow analysis Slides 3 – Material flow analysis Step 7: Interpretation By identifying parameters Calculation of the so-called “application efficiency": Dry surface film mass Efficiency = _______________________ Input solid state mass In this case for small pieces < 10% In this case on average < 20% State of the art? Slides 3 – Material flow analysis Typical efficiencies (application efficiency, expressed in % solids): Conventional 35-50% HVLP 50-70% Airless 40-75% Electrostatic 50-85% Rotating disc 75-90% Dipping 90% Pouring 95% Rolling 98% Slides 3 – Material flow analysis Evaluation of a material flow analysis Flowchart To illustrate material flows and process sequences Pie chart and histogram To illustrate ratios, distributions and compositions, Time-travel diagram For chronological illustrations Sankey diagram To visualize material flows true to scale Slides 3 – Material flow analysis Evaluation of a material flow analysis – 2 Possible parameters: Efficiency factors (ratio of use to costs) Quality factors (ratio of real efficiency factor to the theoretically possible efficiency factor) Linkage with costs Slides 3 – Material flow analysis Data sources Accounting Warehousing Collection of process data Operational accounting Personal information (e.g. methods engineer) Estimates Measurements Original documents ... Slides 3 – Material flow analysis Measuring water volumes Water meter Turbine wheel meter Rotameter Induction measuring instrument Ultrasonic flowmeter Weir Measuring at water consumers (stop watch, bucket) 2,5 q= 0,31 h o tan o 2g Slides 3 – Material flow analysis Recommendations 1 for a material flow analysis Carry out the material flow analysis in steps An estimate is better than doing nothing at all Even with estimates it is possible to improve 80 – 90% of accuracy is sufficient Use simple measuring instruments Use indicators If necessary, contact the supplier or plant manufacturer Slides 3 – Material flow analysis Recommendations – 2 for a material flow analysis It is not essential to follow the instructions or procedures in great detail, a creative approach is often helpful. Even by simply working with the balances you can sometimes achieve improvements. It is important to translate the results into the language of the respective target group (monetary units, kg, pictures, comparisons, etc.)