3case Studies on Plastics-pet Bottles

8/4/2019 3case Studies on Plastics-pet Bottles

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3 Case study on Plastics : PET Bottle



Life Cycle of Plastics

ProductPolymer Crude 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 Industry Fiber Industry (wash, crash, melt, spin)

Bottle Industry Bottle 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 asa stakeholder

2. To accumulate knowledge/information of lifecycle from information suppliers

3. To interpret massive life cycle data withtransparency 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 Industry Fiber Industry (wash, crash, melt, spin)

Bottle Industry Bottle Industry (deporimerization)



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.



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.



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



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



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



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 ]



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



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.



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

ConsumptionDisposal

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


Bottle collection

recycling

Polymerization

Molding

Filling

Consumption

Disposal

Polymerization

Manufacturing

Consumption

Disposal


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

Fiber

Quality

demand

• • •

ResinBaleWasteBottle

Emptybottle

Bottle withdrinks

RecyclingWithdrawalSeparationCompositionFiber

manuf.



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

• • • • • •

• • •



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



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.



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



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


Recycler X

7,000t/yrRank D

CC 1Max: 34,000t/yrMin rank: D

Recycler Y


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



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



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



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 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



• 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

Documents

3case Studies on Plastics-pet Bottles