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

Slides 3 – Material flow analysis Step 5: Flowchart Pre-treatment Priming/ Painting DryingAir filterCleaningSteam generator Balance limit

Slides 3 – Material flow analysis Step 5: Flowchart Pre-treatment Priming/ Painting DryingAir filterCleaningSteam generator Balance limit Oily parts l Parts with paint Parts clean Parts wet Thinner Waste thinner Air and thinner Air, paint, thinnerAir, thinner Filter, paint Paint, thinner, filler, tape, film, air, container filter Tools Dust containers Water, detergent

Slides 3 – Material flow analysis  Input = output for the whole system  Input = output for the single steps Step 6: Balances

Slides 3 – Material flow analysis Step 5: Flowchart Pre-treatment Priming/ Painting DryingAir filterCleaningSteam generator Balance limit E1 A1 E11 A6 A4, A7 A3 E3, E4, E5, E6, E7 E8, E9, E 10, A4, A5, A8, A9 E2 A2

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): Conventional35-50% HVLP50-70% Airless40-75% Electrostatic50-85% Rotating disc75-90% Dipping90% Pouring95% Rolling98%

Slides 3 – Material flow analysis Evaluation of a material flow analysis

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) q = 0,31 h 2g tan o o 2,5

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  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.) Recommendations – 2 for a material flow analysis