Fluid Management component improvement for Back up fuel cell systems
Deliverable 6.3 [End - of - Life Assessment]
Version 2.0 Report submission date: 25/11/14 Dissemination level: Work Package: WP6 [Market preparation and Environmental sustainability assessment] Work Package Leader: FHa Contributors: FHa, UL
This project is co-financed by funds from European Commission under Fuel Cell and Hydrogen Joint Undertaking Aplication Area: Stationary Power Generation & CHP Topics: Component improvement for stationary power applications FCH-JU-2011-1 Grant Agreement Number: 301782
Fluid Management component improvement for Back up fuel cell systems
Contact details Project Coordinator Ilaria Rosso, Electro PS email: Ilaria.rosso@electrops.it
Document prepared by Lorenzo Castrillo, FHa Email: lcastrillo@hidrogenoaragon.org Mitja Mori, UL Email: mitja.mori@fs.uni-lj.si
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Table of contents 1 TASKS AND GOALS
6
2 INTRODUCTION
7
3 REVISION OF THE CURRENT ENVIRONMENTAL LEGISLATION AND FUTURE TRENDS
8
3.1 3.2 3.3 3.4
INTRODUCTION 7TH ENVIRONMENT ACTION PROGRAMME EU LAWS FUTURE TRENDS IN EU LAWS
8 9 12 13
4 IDENTIFICATION OF MATERIALS USED IN 3 KW UPS AND ENVIRONMENTAL IMPACT OF MATERIALS
15
4.1 MATERIALS USED IN THE UPS SYSTEM 4.2 COMPARISON OF USED MATERIALS REGARDING ENVIRONMENTAL IMPACT 4.3 VALORIZATION OF THE MATERIALS REGARDING HAZARD
15 17 20
5 REVERSE LOGISTICS FOR HAZARDOUS AND NOT HAZARDOUS ITEMS.
22
5.1 5.2 5.3 5.4 5.5
22 22 23 26 27
INTRODUCTION REASONS TO CARRY OUT PROCESS IN REVERSE LOGISTICS MATERIALS IN REVERSE LOGISTIC REVERSE LOGISTICS IN FLUMABACK
6 LAYOUT OF SPECIFICATIONS FOR DISASSEMBLY/DISPOSAL OF PARTS AND COMPONENTS
29
6.1 6.2 6.3 6.4
31 32 32 35
FUEL CELL STACK DISASSEMBLY RETURNED PRODUCTS TO EPS END OF LIFE SCENARIOS OF 3 KW UPS SYSTEM RECOMMENDATIONS REGARDING PACKAGING, TRANSPORT AND INFORMATION DISPLAY
7 CONCLUSIONS
39
8 BIBLIOGRAPHY
41
9 SOURCES
42
10 ANNEX: LCIA – MATERIALS USED IN LCA MODEL
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Figures Figure 1. 7th EAP logo. .................................................................................................................................... 9 Figure 2. Circular economy. ...................................................................................................................... 14 Figure 3. Masses and materials presented in 3 kW UPS FluMaBack system......................... 15 Figure 4. The shares of materials used in 3 kW FluMaBack UPS system................................ 16 Figure 5. Abiotic depletion of 1 kg used materials in UPS. ........................................................... 17 Figure 6. Acidification of 1 kg used materials in UPS. .................................................................... 18 Figure 7. Eutrofication of 1 kg used materials in UPS. ................................................................... 18 Figure 8. Global warming of 1 kg used materials in UPS............................................................... 19 Figure 9. Human toxicity of 1 kg used materials in UPS. ............................................................... 19 Figure 10. Ozone layer depletion of 1 kg used materials in UPS. ............................................... 19 Figure 11. Integrated supply chain view (dashes line: reverse logistic; continuous line: direct logistic)[15]. ...................................................................................................................................... 23 Figure 12. Example reverse logistics functions and flows [16]. ................................................. 25 Figure 13. Combination of Generic Logistics Network actors’ with grouped Generic Treatment activities [13]. .......................................................................................................................... 27 Figure 14. Initial Panasonic’s round trip. ............................................................................................ 28 Figure 15. Final Panasonic’s round trip. .............................................................................................. 28 Figure 16. EPS reverse logistic map. ..................................................................................................... 29 Figure 17. End-of-life options [18]. ....................................................................................................... 30 Figure 18. EPS returned products. ......................................................................................................... 32
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Tables Table 1. List of regulations which must be applied. ........................................................................ 13 Table 2. Masses of materials in FluMaBack 3 kW UPS system.................................................... 16 Table 3. Classification of materials used in UPS system. ............................................................... 20 Table 4. Classification of polymers used in the FluMaBack UPS system................................. 21 Table 5. Classification of BoP components / parts /processes regarding materials ......... 21 Table 7. External heat exchanger EOLA scenarios. ......................................................................... 33 Table 8. Humidifier EOLA scenarios ..................................................................................................... 33 Table 9. Battery EOLA scenarios ............................................................................................................ 33 Table 10. FC stack EOLA scenarios ........................................................................................................ 33 Table 11. Hydrogen blower EOLA scenarios ..................................................................................... 33 Table 12. Air blower EOLA scenarios ................................................................................................... 34 Table 13. UPS Assembly EOLA scenarios ............................................................................................ 34 Table 14. List of norms approved by EU Commission according Directive 94/62/EC, [21]. ............................................................................................................................................................................. 37 Table 15. Masses of materials in LCA model of ONDA External climate. ................................ 43 Table 16. Masses of materials in LCA model of Tubiflex humidifier. ....................................... 43 Table 17. Masses of materials in LCA model of Fiamm battery.................................................. 43 Table 18. Masses of materials in LCA model of fuel cell stack. ................................................... 44 Table 19. Masses of materials in LCA model of hydrogen blower. ............................................ 44 Table 20. Masses of materials in LCA model of air blower........................................................... 45 Table 21. Masses of materials in LCA model of assembly process and components needed in Turin. ............................................................................................................................................ 46
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1 Tasks and goals Tasks and goals are defined in description of work document on page 94, [1]: “As for common daily hardware, the necessary actions for disposal of the fuel cell system at its end of useful lifetime have to be foreseen. This study implies a revision of the current environmental legislation and future trends, a thorough classification of the components regarding their materials and its level of environmental hazard, the potential of valorisation of the materials, the reverse logistics for hazardous and not hazardous items, lay out of specifications for the works of disassembly and disposal of parts and components, as well as recommendations regarding packaging, transport, and information display for the final users.�
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2 Introduction The end-of-life of a product is an important step, the last one which can become the first of a new item. Unfortunately it is no common to find procedures, regulations and any information related to disposal and reuse of different products. And high technology products, like fuel cells, have no difference. Furthermore, the environmental impact of a product does no finish when its use ends. And, in some cases, it is considered the step that has more effect over environment. Regarding to this, new policies are hoped to be published. It will help to impulse the reduction of waste, reutilization and recycling of materials. And with this document, FluMaBack pretends to show all the steps, its influence and procedure for the end-of life of the products here developed. An identification of materials was done regarding masses and types of materials used in the system. Three stage hazardous scale was set up to identify all hazardous materials and their presence in the components. That was done with the help of LCA model from task 6.2, where manufacturing phase is modelled in detail. Possible end of life scenario is defined for 3 kW UPS system. Final user, dealers, and anyone who work, or use, this product, can be whose manage the end-of-life. So, a complete explanation has to be done for all of them. And the aim of this document is to offer all this information.
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3 Revision of the current environmental legislation and future trends 3.1 Introduction Environmental legislation in the European Union (EU) is a set of decisions, regulations, directives, etc. which have to protect, regulate resources and safeguard the Union's citizens from environment-related pressures. The EU has put in place a broad range of environmental legislation due to an intense effort. Approximately 200 or so environmental laws cover most eventualities nowadays. For example the air quality directive limits pollutants and particles, forcing authorities to take action. Other directives, like urban waste water treatment directive, indicate necessary to set up systems to collect and purify wastewater and sewage, and the REACH chemicals legislation [2] obliges to demonstrate that chemical products are safe by producers. This has permitted to reduce significantly pollution from air, water and soil. The use of many toxic or hazardous substances has been restricted by chemicals legislation. Environmental law EU takes effort for application, but long-term benefits, both environmental and economic obtained. But not implement these laws could have adverse effects on human health, environment and industry. However, there are many challenges remaining that must be addressed together in a structured way. Therefore, regarding environmental policies, the EU has developed a framework which helps to group together different directives, regulations, etc. It is called Environment Action Programme, and currently it is in effect the 7th Environment Action Programme (7th EAP) [3]. 7th EAP will be working until 2020, guiding EU environment policy: “The Union has set itself the objective of becoming a smart, sustainable and inclusive economy by 2020 with a set of policies and actions aimed at making it a low carbon and resource efficient economy” Also this program aims to develop its objectives beyond this date, as it says: “In 2050, we live well, within the planet’s ecological limits. Our prosperity and healthy environment stem from an innovative, circular economy where nothing is wasted and where natural resources are managed sustainably, and biodiversity is protected, valued and restored in ways that enhance our society’s resilience. FluMaBack D 6.3
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Our low-carbon growth has long been decoupled from resource use, setting the pace for a safe and sustainable global society. “
3.2 7th Environment Action Programme The 7th EAP is exposed at Decision nº 1386/2013/EU of the European Parliament and of the Council of 20 November 2013 on a General Union Environment Action Programme to 2020 ‘Living well, within the limits of our planet’. 6th EAP ended in July 2012, and the final assessment concluded that the programme delivered benefits for the environment and for the environment policy of the EU. Moreover unsustainable trends still persist in the four priority areas identified in the 6th EAP, i.e.: climate change; nature & biodiversity; environment & health & quality of life; and natural resources & wastes. “A number of major environmental challenges still remain, and serious repercussions will ensue if nothing is done to address them” [4].
Figure 1. 7th EAP logo.
Therefore the 7th EAP has to continue and improving all those areas, identifying nine priority objectives: 1. To protect, conserve and enhance the EU’s natural capital. 2. To turn the EU into a resource-efficient, green, and competitive low-carbon economy. 3. To safeguard the EU’s citizens from environment-related pressures and risks to health and wellbeing. 4. To maximise the benefits of the EU’s environment legislation by improving implementation. 5. To increase knowledge about the environment and widen the evidence base for policy. 6. To secure investment for environment and climate policy and account for the FluMaBack D 6.3
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environmental costs of any societal activities. 7. To better integrate environmental concerns into other policy areas and ensure coherence when creating new policy. 8. To make the EU’s cities more sustainable. 9. To help the EU address international environmental and climate challenges more effectively. Focusing into the aim of the task, not all the objectives have the same impact. Only the main objectives are explained here in relation to the final project goals, mainly focused in the end-of-life assessment1. Priority objective 2: To turn the Union into a resource-efficient, green and competitive low-carbon economy. “Resource-efficient Europe” Flagship Initiative targets to support the move towards a new efficient economy with resources, energy, environmental impacts, etc. that enhances competitiveness through efficiency and innovation and promotes greater energy and resource security, including through reduced overall resource use. Turning waste into a resource, as called for in the Roadmap to a Resource Efficient Europe is also a part of this priority objective. Limiting energy recovery to non-recyclable materials, phasing out land filling of recyclable or recoverable waste, ensuring high quality recycling, where the use of recycled material does not lead to overall adverse environmental or human health impacts, and developing markets for secondary raw materials are also necessary to achieve resource efficiency objectives. Hazardous waste will need to be managed so as to minimise significant adverse effects on human health and the environment. Future trends given by 7th EAP indicates a fully implementing EU’s waste legislation. This legislation will include the waste hierarchy in accordance with the Waste Framework Directive [5] and the effective use of marketbased instruments and other measures to ensure that: (1) Land filling is limited to residual (i.e. non-recyclable and nonrecoverable) waste; (2) Energy recovery is limited to non-recyclable materials; (3) Recycled waste is used as a major, reliable source of raw material for the EU, through the development of non-toxic material cycles;
1
A detailed view of the Priority Objectives can be seen at Annex of 7th EAP [3].
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(4) Hazardous waste is safely managed and its generation is reduced; (5) Illegal waste shipments are eradicated, with the support of stringent monitoring; (6) Food waste is reduced;
Priority objective 6: To secure investment for environment and climate policy and address environmental externalities. The EU and its Member States will need to put in place the right conditions to ensure that environmental externalities are adequately addressed, including by ensuring that the right market signals are sent to the private sector, with due regard to any adverse social impacts. This will involve applying the polluter-pays principle more systematically, in particular through phasing out environmentally harmful subsidies and considering fiscal measures in support of sustainable resource use such as shifting taxation away from labour towards pollution. The private sector, in particular SMEs, should also be encouraged to take up opportunities offered under the new EU financial framework to step up its involvement in efforts to achieve environment and climate objectives, especially in relation to eco-innovation activities and the uptake of new technologies. Priority objective 9: To increase the Union’s effectiveness in addressing international environmental and climate-related challenges. “The EU should also leverage its position as one of the largest markets in the world to promote policies and approaches that decrease pressure on the global natural resource base. This can be done by changing patterns of consumption and production, including by taking the steps necessary to promote sustainable resource management at international level and to implement the 10-year Framework of Programmes on Sustainable Consumption and Production, [...] with a view to preventing environmental dumping� [3]. The EU should facilitate the transition towards an inclusive and green economy at international level, with the promotion of environmentally responsible business practices.
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3.3 EU Laws The FluMaBack project has to identify necessary actions for disposal of the fuel cell system. This waste generated by the fuel cell at the end of its life has to fit actual legislation. And the 7th AEP sets objectives to improve waste policies in the EU:
To reduce the amount of waste generated;
To maximize recycling and re-use;
To limit incineration to non-recyclable materials;
To phase out landfilling to non-recyclable and non-recoverable waste;
To ensure full implementation of the waste policy targets in all Member States.
These objectives can be founded in different directives, separated by areas:
Directive 2008/98/EC on waste [5].
Directive 94/62/EC on packaging and packaging waste [6].
Directive 1999/31/EC on the landfill of waste [7].
Directive 2000/53/EC on end-of-life vehicles [8].
Directive 2006/66/EC on batteries and accumulators and waste batteries and accumulators [9].
Directive 2012/19/EU on waste electrical and electronic equipment [10].
To manage the waste at the end of the life the directives to be taken into account are Directive 2008/98/EC, Directive 1999/31/EC, Directive 2006/66/EC and Directive 2012/19/EU. Accordingly to Directive 94/62/EC, this equipment has to be packed at least one time. Only Directive 2000/53/EC does not apply for fuel cells. Furthermore there are decisions, regulations and some directives which affect to the transport, disposal, emissions and classification of waste generated at the end of fuel cell’s life. In Table 1 there is a detailed list of current legislation at European level that applies to the Flumaback project objectives.
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“1999/816/EC: Commission Decision of 24 November 1999 adapting, pursuant to Articles 16(1) and 42(3), Annexes II, III, IV and V to Council Regulation (EEC) nº 259/93 on the supervision and control of shipments of waste within, into and out of the European Community (notified under document number C(1999) 3880) (Text with EEA relevance).” “Commission Decision of 3 May 2000 replacing Decision 94/3/EC establishing a list of wastes pursuant to Article 1(a) of Council Directive 75/442/EEC on waste and Council Decision 94/904/EC establishing a list of hazardous waste pursuant to Article 1(4) of Council Directive 91/689/EEC on hazardous waste (notified under document number C(2000) 1147) (Text with EEA relevance) (2000/532/EC).” “Commission Regulation (EC) nº 967/2009 of 15 October 2009 amending Regulation (EC) No 1418/2007 concerning the export for recovery of certain waste to certain non-OECD countries (Text with EEA relevance).” “Council Decision 97/640/EC of 22 September 1997 on the approval, on behalf of the Community, of the amendment to the Convention on the control of transboundary movements of hazardous wastes and their disposal (Basel Convention).” “Council Regulation (EU) nº 333/2011 of 31 March 2011 establishing criteria determining when certain types of scrap metal cease to be waste under Directive 2008/98/EC of the European Parliament and of the Council.” “Directive 2010/75/EU of the European Parliament and of the Council of 24 November 2010 on industrial emissions (integrated pollution prevention and control).” “Regulation (EC) no 1013/2006 of the European Parliament and of the Council of 14 June 2006 on shipments of waste.” “Regulation (EC) no 2150/2002 of the European Parliament and of the Council of 25 November 2002 on waste statistics (Text with EEA relevance).” Table 1. List of regulations which must be applied.
3.4 Future trends in EU Laws The European Commission aims to create a new economic model related with products, named “Circular economy” [11]. Formally called “Towards a circular economy: A zero waste programme for Europe”, it’s at level of proposal for directive [12], and wants to join together all directives listed on point 3.3, as part of 7th AEP. This new vision wants to keep the added value of the products as long as possible, eliminating waste. When a product has reached the end of its life its parts, or whole system, can be used again and again and hence create further value.
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Figure 2. Circular economy.
The circular economy boosts recycling, secures access to raw materials and creates jobs and economic growth. And the main elements of the proposal include:
Recycling and preparing for re-use of municipal waste to be increased to 70 % by 2030;
Recycling and preparing for re-use of packaging waste to be increased to 80 % by 2030, with material-specific targets set to gradually increase between 2020 and 2030 (to reach 90 % for paper by 2025 and 60% for plastics, 80% for wood, 90% of ferrous metal, aluminium and glass by the end of 2030);
Phasing out landfilling by 2025 for recyclable (including plastics, paper, metals, glass and bio-waste) waste in non-hazardous waste landfills – corresponding to a maximum landfilling rate of 25%;
Promoting the dissemination of best practices in all Member States, such as better use of economic instruments (e.g. landfill/incineration taxes, pay-as-youthrow schemes, incentives for municipalities) and improved separate collection;
Improving traceability of hazardous waste;
Increasing the cost-effectiveness of Extended Producer Responsibility schemes by defining minimum conditions for their operation;
Simplifying reporting obligations and alleviating burdens faced by SMEs;
Improving the reliability of key statistics through harmonised and streamlined calculation of targets;
Improving the overall coherence of waste legislation by aligning definitions and removing obsolete legal requirements.
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4 Identification of materials used in 3 kW UPS and environmental impact of materials On the basis of the life cycle inventory analysis in manufacturing phase of UPS and LCA analysis presented in D6.2 document of FluMaBack steps are (1) Identification of all materials regarding their mass represented in the system. (2) Valorization of materials regarding their impacts to the human health and environment. (3) Proposal of end-of-life scenarios according to presented directive, legislation and technological possibilities;
4.1 Materials used in the UPS system In the chapter all masses and shares of material used are presented. From Figure 3 is clear that steel has the biggest share in the system (basic construction, etc.), with tinlead alloy from batteries next and aluminum following as main material in all components and parts. Brass
0,02
Platinum
0,02
Glass fiber
0,06
Silicon
0,23
Plastic bonded ferrite
0,45
Nafion
0,48
Electronic equipment
0,82
Sulfuric acid 96%
4,94
Copper
12,34
Polymers
14,62
Carbon + polymer
16,28
Aluminium
20,91
Tin-lead alloy
39,52
Steel
247,27 0,00
50,00
100,00
150,00
200,00
Mass, kg Figure 3. Masses and materials presented in 3 kW UPS FluMaBack system.
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0,23% 1,38% 3,45%
0,13%
0,13% 0,06%
0,02%
Steel
4,08%
Tin-lead alloy Aluminium
4,55%
Carbon + polymer Polymers
5,84%
Copper Sulfuric acid 96% 11,04%
Electronic equipment Nafion 69,08%
Plastic bonded ferrite Silicon Glass fiber
Platinum Brass
Figure 4. The shares of materials used in 3 kW FluMaBack UPS system.
Material Steel Tin-lead alloy Aluminium Carbon + polymer Polymers Copper Sulfuric acid 96% Electronic equipment Nafion Plastic bonded ferrite Silicon Glass fiber Platinum Brass
Quantity [kg] 247,27 39,52 20,91 16,28 14,62 12,34 4,94 0,82 0,48 0,45 0,23 0,06 0,02 0,02
Table 2. Masses of materials in FluMaBack 3 kW UPS system.
Detailed masses of materials in specific components or parts are presented in Annex: LCIA – Materials used in LCA model.
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First indicator is material mass since production of material is closelly linked to energy consumption and complex processes that have most of the impact to environment and human health.
But there are materials that requires much more process and manufacturing energy per unit mass in production stage of material and manufacturing process and therefore is more harmfull to environment and/or to human health. So second indicator is three stage scale that represent harmfulness of specific material through environmental indicators or/and human health impacts.
The third indicitor of environmental impact of specific material is its posible reuse and recycling options of materials. By that is imporatant how material is bonded into the system and what kind of possibilities of reuse and recycling exists.
If we look at the masses present in the system, we can see that almost 70 % is steel than can be easily reused and/or recycled. Steal in FluMaBack UPS can be also easily dismantled. 11 % is tin-lead alloy that is present in the Fiamm battery and for which good establish recycling paths are established. All other materials should be classified how complex are bonded in the system. That is done in next chapters.
4.2 Comparison of used materials regarding environmental impact To compare materials regarding environmental impact we compare environmental impacts in the form of impact criteria by CML2001 used also in deliverable 6.2. 1 kg of each material is used for comparison to evaluate AD, A, E, GW, HT, ODP, POC. With that approach we want to confirm the impact to environment of specific material and harmfulness of material. Abiotic Depletion (AD elements) [kg Sb-Equiv.] 1,00E-03 8,00E-04 6,00E-04 4,00E-04 2,00E-04 0,00E+00 Al
AD Share, %
Cu
FeO
Polyme rs
Steel
Glass fibers
Brass
H2SO4
El. comp.
Si
Alloy Sn-Zn
C
Pt
Nafion
1,32E-0 6,54E-0 1,71E-0 7,12E-0 1,77E-0 9,15E-0 6,75E-0 5,53E-0 1,28E-0 4,31E-0 1,06E-0 1,93E-0 2,36E+0 9,47E-0
0,00
0,00
0,01
0,00
0,00
0,00
0,03
0,00
5,15
0,00
0,04
Figure 5. Abiotic depletion of 1 kg used materials in UPS. FluMaBack D 6.3
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0,00
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We can see from the electronic equipment and platinum has the most impact in almost all categories. Platinum is in all cases of impact categories the most critical from environmental point of view what is already exposed in chapter 4.3 Acidification (A) [kg SO2-Equiv.] 0,15 0,13 0,11
0,09 0,07 0,05 0,03
0,01 -0,01
A Share, %
Al
Cu
FeO
Polymer s
Steel
Glass fibers
Brass
H2SO4
El. comp.
Si
Alloy SnZn
0,0270
0,0109
0,0771
0,0167
0,0017
0,0110
0,0037
0,0068
1,8952
0,0307
0,0305
0,00
0,00
0,00
0,00
0,00
0,00
0,00
0,00
0,06
0,00
0,00
C
Pt
Nafion
0,0001 3377,17 0,1423 0,00
99,93
0,00
C
Pt
Nafion
Figure 6. Acidification of 1 kg used materials in UPS.
Eutrophication (E) [kg Phosphate-Equiv.] 0,01000 0,00800 0,00600 0,00400 0,00200 0,00000 Al E Dele탑 [%]
Cu
FeO
Polymer s
Steel
Glass fibers
Brass
H2SO4
El. comp.
Si
Alloy SnZn
0,00421 0,00912 0,02654 0,00184 0,00016 0,00138 0,00021 0,00008 3,30005 0,00325 0,00256 0,00007 197,0478 0,02341 0,00
0,00
0,01
0,00
0,00
0,00
0,00
0,00
1,65
0,00
0,00
Figure 7. Eutrofication of 1 kg used materials in UPS.
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0,00
98,32
0,01
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Global Warming (GW 100 years) [kg CO2-Equiv.] 15,00 13,00 11,00 9,00 7,00 5,00 3,00 1,00 -1,00
Polyme Steel rs
Al
Cu
FeO
GW
5,90
1,03
13,80
3,88
Dele탑 [%]
0,04
0,01
0,09
0,03
Glass fibers
Brass H2SO4
El. comp.
Si
Alloy Sn-Zn
0,60
1,97
0,54
0,26
251,65
4,97
4,21
0,03 14779,3 323,07
0,00
0,01
0,00
0,00
1,64
0,03
0,03
0,00
96,02
2,10
Pt
Nafion
C
Pt
Nafion
Figure 8. Global warming of 1 kg used materials in UPS.
Human Toxicity (HT) [kg DCB-Equiv.] 30,00
25,00 20,00 15,00
10,00 5,00 0,00 Al
Cu
FeO
Polymer s
Steel
Glass fibers
Brass
H2SO4
El. comp.
Si
Alloy SnZn
C
HT
24,57
7,44
22,54
2,32
0,03
0,05
0,30
0,04
1052,44
1,28
0,64
0,01
Share, %
0,03
0,01
0,03
0,00
0,00
0,00
0,00
0,00
1,47
0,00
0,00
0,00
98,41
0,04
C
Pt
Nafion
70418,86 25,41
Figure 9. Human toxicity of 1 kg used materials in UPS.
Ozone Layer Depletion (OD) [kg R11-Equiv.] 1,20E-07 1,00E-07 8,00E-08
6,00E-08 4,00E-08 2,00E-08 0,00E+00 Al OD
Share, %
Cu
FeO
Polymer s
Steel
Glass fibers
Brass
H2SO4
El. comp.
Si
Alloy Sn-Zn
1,04E-0 5,34E-0 1,79E-0 6,63E-0 1,25E-0 9,66E-1 8,92E-1 4,62E-1 2,65E-0 1,08E-0 8,24E-1 2,16E-0 1,12E-0 9,42E-0 0,00
0,00
0,02
0,00
0,00
0,00
0,00
0,00
0,25
0,00
0,00
0,00
Figure 10. Ozone layer depletion of 1 kg used materials in UPS.
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89,14
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4.3 Valorization of the materials regarding hazard On the basis of results of chapter 4.2 definitions and guidelines three stage scale is defined to define hazardousness of material and/or component or process. Three stage scale:
0 - Not classified as hazardous 1 - Slight/moderate hazardous 2 - Serious/severe Hazardous
What is hazardous material? “Hazardous wastes pose a greater risk to the environment and human health than nonhazardous wastes and thus require a stricter control regime. This is laid down in particular in Articles 17 to 20 of Directive 2008/98/EC. It provides additional labelling, record keeping, monitoring and control obligations from the "cradle to the grave", i.e., from the waste producer to the final disposal or recovery. In addition, mixing of hazardous substances is banned in order to prevent risks for the environment and human health�.
4.3.1 Materials Table 3. Classification of materials used in UPS system.
Material Steel Tin-lead alloy Aluminium Carbon + polymer Polymers Copper Sulfuric acid 96% Electronic equipment Nafion Plastic bonded ferrite Silicon Glass fiber Platinum Brass
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1 1 0 in Table 4 0 2 2 0 0 1 1 2 0
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Table 4. Classification of polymers used in the FluMaBack UPS system.
Material Polypropylene (PP) Polyvinylchloride (PVC) Polyethylene Linear Low Density Granulate (LDPE/PE-LD) Polyamide 6.6 fibers (PA 6.6) Polyurethane flexible foam (PU) Polyether ketone granulate (PEEK) Acrylonitrile-butadiene-styrene granulate (ABS) Epoxy resin Synthetic rubber Polyether polyol
Hazardous Level 0 1 0 0 1 0 0 1 1 0
From Table 3 and Table 4 we can see that most material used in UPS system has the level of 1 or 2 in three stage hazardous scale. Sulfuric acid, electronic equipment and platinum are considered as very hazardous material that requires special attention, additionally platinum is bonded in fuel cell. On the basis of upper tables we can quantify components in three stage hazardous scale. Since the mass of platinum is not big FC stack is not classified as very hazardous, nbut Fiamm battery and assembly process (due to many electronics parts) is still very hazardous. In Table 5 relevant data for each component/part/process is presented with hazardous level also labeled.
4.3.2 Components Components were put in three stage scale regarding materials used and mass of materials used. Table 5. Classification of BoP components / parts /processes regarding materials
Component / part / process External heat exchanger Humidifier Battery Fuel cell Hydrogen blower Air blower Assembly, Turin
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Hazard level 0 0 2 Sulfuric acid (4936 g), Tin-lead alloy (39520 g) 1 Platinum (17,6g) 0 Elec. Equip (75g) 1 Elec. Equip (250g), Glass fiber (58g), Epoxy resin (20g) 2 Elec. Equip (490g) + Synthetic rubber (1500g) + PVC (527,5g) + Silicon (230g)
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5 Reverse logistics for hazardous and not hazardous items. 5.1 Introduction According to the European Working Group on Reverse Logistics, Reverse Logistics is: “The process of planning, implementing, and controlling flows of raw materials, in-process inventory, and finished goods, from a manufacturing, distribution or use point to a point of recovery or point of proper disposal”. It can be understood how the process of moving goods from their typical final user destination with the aim of capturing value, or proper disposal. And It is considered the best option for end-of-life products recovering [13].
5.2 Reasons to carry out Several reasons are involved to companies to use reverse logistics: 1) Companies can profit from reverse logistic; or/and 2) Companies have to; or/and 3) Companies “feel” socially motivated to do it. This reasons can be listed as these three driving forces [14]:
Economics ( direct and indirect)
Legislation
Corporate citizenship
5.2.1 Economics Reverse logistics have both direct and indirect gains. Which are listed below. Direct gains can be:
Raw materials for new products. From used products.
Some parts of the returned product can be recycled to manufacture new products. It reduces manufacturing cost.
Value added recovery.
Indirect gains can be:
Improved customer/ supplier relations
Anticipating/impeding legislation
Green image
Market protection
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5.2.2 Legislation Legislation allows to customers return the product to companies. And companies themselves should participate in recovery programs, to keep or to create a clean and green image. 5.2.3 Corporate citizenship The safe disposal or recycling of their products to maintain the environment safe are responsibility for many companies. Often companies create awareness among their customers and get involved in recovery and recycling programs.
5.3 Process in reverse logistics A typical reverse logistic process is shown in Figure 11.
1
Direct Resale
reuse
/ 4
Cannibalization Remanufacturing
2
Repair
5
Recycling
3
Refurbishing
6
Incineration / Landfilling
/
Figure 11. Integrated supply chain view (dashes line: reverse logistic; continuous line: direct logistic)[15].
Customers return the products for several reasons. Products once bought may be returned due to physical damage, dissatisfaction with the functionality of the product, discovery an alternative product, sometimes customers misuse the return policy and return it without any reason, etc. A distinction should be made between different categories of returns:
1. Commercial Returns Returns for which there is an immediate demand at another market location or segment. Possible causes: customer dissatisfaction, catalogue sales, overstocks etc. Commercial returns occur in the sales phase or shortly after. FluMaBack D 6.3
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2. Repairable Returns Defects and suspect components (modules/parts) from field (exchange) repair activities or products under warranty. Customer is entitled to a replacement product. 3. End-of-use Returns Returned products/components which are not of longer use to the original owner, but for which new customers can be found. Reasons: end-of-season, end-of-lease, trade-in, product replacements etc. 4. End-of-life Returns Items of no remaining use. These returns are often collected and processed according to legislative obligations. 5. Recalls Products recalled by the manufacturer due to a condition or defect that could affect its safe operation. Work on a recall is completed at no cost to the product owner. Other types of returns, such as refillable units and reusable carriers, are not included in this study.
Reverse Logistics is a complex subject with many supply chain actors, internally and externally, with their own (often contradictory) objectives. Not all reverse logistic will be similar and generic. The functions and flows of each reverse logistic will also be dependent on the product life cycle, industry, and design. Depending on maturity of the product it’s reverse logistic may be more focused on processing stages, while less mature products will develop networks for initial aggregation and collection. An example set of functions is shown in Figure 12 that takes into consideration various activities, inputs, outputs, and mechanisms (and overall system).
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Figure 12. Example reverse logistics functions and flows [16].
In summary, the major reverse logistic functional phases can include Collection, Separation, Disassembly, Compaction and Outbound Logistics [13]:
Collection is the accumulation of materials from the waste stream (including returned products, used products, etc.) for eventual introduction back into the forward manufacturing and supply chain.
Separation and inspection is the classification of materials from one another (e.g. reusable equipment, re-manufactural equipment, recyclable material) for shipment to an appropriate intermediate processor or end user. Sortation and separation can make reverse logistics activities very labour intensive and cost inefficient.
Disassembly processing may be needed for materials that need to be separated or components that may be reusable and saved.
Densification or compaction may include shredding or grinding. Densification attempts to increase the recyclable material’s density to reduce transport costs and for ease of transportation.
Outbound logistics, the last step in the process, could include delivery and integration. Where the reverse logistic materials that have flowed through the chain are finally utilized and delivered to the manufacturing process for new products or to disposal it.
The majority of the infrastructure for reverse logistics is managed through a third party relationship. The three main participants in the reverse logistics activities can be given as: FluMaBack D 6.3
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Forward supply chain actors (supplier, manufacturer, wholesaler and retailer)
Specialized reverse chain players (jobbers, recycling specialists etc...)
Opportunistic players (such as charity organizations)
It is commonly involve two or more of these players. Usually, one or two of these participants play the major role while others operate as intermediate junctions. Reclamation and recycling process for materials are mostly carried by scrap yards, waste processors or municipal organizations. Newer and continuously changing product markets may require greater flexibility in reverse logistics networks to handle continuous new product developments. These industries may also have less well established reverse logistics networks due to a lower relative value and utility of returned materials. “Concerning the reverse supply chain design field, more research is needed to develop a systems approach to business instead of a narrower local optimization approach of operation research” [13].
5.4 Materials in reverse logistic What is actually being returned is an important viewpoint on reverse logistics. The main characteristics in this regard are:
Composition
Deterioration
Use-pattern
5.4.1 Composition Differences in materials, its unions, its hazard, etc. have to keep in mind the material composition of the products at design step, which is called design for recovery. Not all parts of a product can be easily recycled or disposed, so use unrecyclable materials have to be minimized as possible. When elements are dangerous due to toxicity, radioactivity, etc. its management gets difficult and, like unrecyclable materials, it has to be minimized as possible. The cost for recovery increases as the size of the product increases, because most of the times the recovery value is less than the cost for recovery. 5.4.2 Deterioration Deterioration, which eventually cause a lack of performance of the product, also determine if there is enough left functionality to further use of the product, whether in whole or as parts. Often, manufacturers have to deal with questions such as if the product will age during use, if it will age all parts equally or if the value of products decline rapidly. FluMaBack D 6.3
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5.4.3 Use-pattern An important role when thinking about recovery is the use-pattern of the product. This affects the reusability of the parts or whole product in various degrees. Books are another example for varied usage. Use-pattern is not only affected by number of users but also the duration of usage.
5.5 Reverse logistics in FluMaBack The round trip for the FluMaBack products has several important factors, but location of final user must be one of the most important. This has effects over transportations and communications over retailer/producer. Avoiding this issue, the reverse logistics can have multiples pathways. At A. El Korchi and D. Millet paper [13], it can seen 18 different ways to carry out reverse logistics. At this document, that provides different reverse logistics channels, it disposal an assessment to choose proper one. Eliminating not applicant parts, only is needed the “choice of potential generic RLC structure�. This part comprises different assessments: feasibility assessment, economic assessment environmental assessment and social assessment. It gives the best structures which has the lowest costs, lowest environmental impact, and highest job creation.
Figure 13. Combination of Generic Logistics Network actors’ with grouped Generic Treatment activities [13]. FluMaBack D 6.3
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This has a high job to achieve the proper pathway. And as an example, Panasonic company improve its round trip processes [17] improving several aspects: Ability to control the information required in real time, removed manual processing between retailer & supplier, reduced contact points in goods movement, etc. Initially Panasonic had a traditional return process (Figure 14) with a lot of steps. And the integration of an efficient process (Figure 15) a new pathway let manufacturer the state of products in real time to get on with reuse, recycle, disassembly or disposal of products.
Figure 14. Initial Panasonic’s round trip.
Figure 15. Final Panasonic’s round trip. FluMaBack D 6.3
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5.5.1 Reverse logistics EPS Despite big enterprises, EPS has an extremely lean reverse logistics process. It only involves four actors:
Customer
Retailer (usually EPS itself)
EPS Customer service
Local contractor
Customer Contacts
Retailer
EPS product
Alert 3° party
Is it EPS or 3° party? Shipped to
Withdraws
EPS
EPS
EPS
Contractor
Alert
Figure 16. EPS reverse logistic map.
6 Layout of specifications for disassembly/disposal of parts and components The end-of-life starts when the equipment has served its useful life and/or when technological obsolescence renders it unusable or is no longer functional. It was understood as landfill that was the usual method for the disposal of post-use equipment. More options are now available for the disposal. At End-of-life the disposal options are: reuse, recycling and remanufacturing.
Reuse, involves continued use for the purpose for which it was built.
Re-manufacturing is a viable option at a lower cost than that of manufacturing new equipment.
Recycling recovers materials from equipment, to be used in the production of new equipment (closed-loop recycling) or in other products (open-loop recycling).
There are two more options: waste-to-energy (incineration of elements to obtain energy) and landfilling which are the most undesirable options. FluMaBack D 6.3
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In Figure 17 there is a short diagram with all the possible options for the end-of-life of equipment.
Figure 17. End-of-life options [18].
The disassembly process is defined as the systematic removal of the required parts from an assembly [2]. It can be classified into two types of disassembly process: manual and automated. Manual disassembly has proved to be the most efficient method, due to the high variety of products collected by recycling yards and the unfavourable design of products. The disassembly design it is a step usually avoided into the design process. Manual disassembly begins with an operator carrying and lifting the unit or part to be disassembled to a workbench. Normally used tools are chisel, tongs, screwdrivers, etc. This first part separated elements and hazardous components are removed intact and visually inspected for possible reuse. This creates a flow that contains intact plastic and steel cases, printed circuit boards, etc. and hazardous waste, such as batteries and capacitors. It is done prior to shredding in order to:
Remove components containing hazardous materials Selectively destroy or recover proprietary parts Reduce contamination in downstream volume reduction (shredding) and separation operations Extract valuable components or metals.
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6.1 Fuel cell stack disassembly 6.1.1 Membrane Economic and environmental terms prefer re-use than other processes. But there are barriers to re-use, like membrane dehydration and pin-holing. More feasible than re-use is recycling. Dissolution of the membrane and re-casting as a polymer film is one possible method of membrane recycling. With a high toxic smoke (i.e. HF), incineration is not a favourable option. It has been necessary a costly HF recovery plant. Dissolving the membrane out of the MEA is therefore the alternative preferred to incineration or re-use. 6.1.2 Platinum/ruthenium electro-catalysts The value of platinum and ruthenium in a 3 kW stack is around 100 ₏ at precious metal prices 32 ₏/g [20]. The environmental argument for recycling platinum is strong. Emissions of sulphur dioxide (SO2) are decreased by a factor of 100, and the primary energy demand is reduced by a factor of 20, when the platinum is recycled in comparison to its production from primary sources. Platinum recycling is crucial to the sustainable future of PEMFCs due to limited platinum reserves, coupled with the saving in energy by a factor of 20 in comparison to extraction from the ore. 6.1.3 Bipolar plates Economically, the only practical end-of-life option for a graphite plate is to incinerate it for energy recovery. At cell’s end-of-life re-use would not be possible, because it is probable that the design of the bipolar plate will be obsolete. The likely two options for the end-of-life management of the carbon composite bipolar plates are recycling, and incineration to generate energy. The future European Union directive [12] will push the manufacturer to recycle rather than incinerate. 6.1.4 Ancillary components The ancillary components of the fuel cell stack are the non-repeat items. They are significant when considering recycling. They consist of the polypropylene and polyethylene housing and insulators, the cupper tie-rods and an important mass of aluminium alloy for different purposes. These parts are melted and mechanized again.
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6.2 Returned products to EPS After receiving the returned product, disassembling is operated by EPS. Depending on the reason of product demission, components follow different paths showed in the following schematic:
Figure 18. EPS returned products.
6.3 End of life scenarios of 3 kW UPS System Various disassembly line layouts can be found at existing remanufacturing facilities. They can be divided in three different configurations [18].
After receiving units from the receiving dock, the operator disassembles them on a workstation and puts the disassembled parts into their respective bins around the table.
Products arrive into the sorting and staging area on the conveyor. Products are then sorted and scheduled for disassembly, as opposed to the first configuration, where products are disassembled without any prior sorting.
Similar to prior one except for the addition of a conveyor for disassembled parts. An operator disassembles units at a workstation adjacent to the conveyor belt.
Once final equipment has been disassembled and sorted, each part must be checked to reuse, re-manufacture or landfill. In tables below EOLA scenarios are presented in accordance with manufacturer’s data, end-of-life processes, legislation and guidelines. FluMaBack D 6.3
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Table 6. External heat exchanger EOLA scenarios.
Material Mass Part Reuse Recycle Waste Possible Question Copper 2.3 kg Tubes 1 OK Aluminium 2.2 kg Fins 1 OK Steel 11.5 kg Casing 1 OK Copper 1.5 kg Fan (1) 1 ? motor? PVC 2.4 kg Fan 1 OK blades? Steel 2.1 kg Fan (1) 1 ? motor case? PVC 1.0 kg ? Table 7. Humidifier EOLA scenarios
Material ABS ABS ABS Polyurethan Polysulfone Stainless steel
Mass 0.420 0.470 0.550 0.180 0.175 0.180
kg kg kg kg kg kg
Part Reuse Recycle Waste Possible Question inlet header 1 OK outlet header 1 OK case 1 OK sealing 1 OK hollow fibers 1 OK connectors 1 OK -
Table 8. Battery EOLA scenarios
Material Mass Part Reuse Recycle Waste Possible Question Tin-lead alloy 39.52 kg Lead grids 1 OK PP 5.47 kg Case 1 OK Sulfuric acid 96% 4.94 kg Electrolyte 1 OK Table 9. FC stack EOLA scenarios
Material Mass Carbon + polymer 16.28 Copper 1.3 Aluminium 9.0 Polypropylene PP 0.7 Polyethylene LDPE 0.22 Nafion 0.4824 Platinum 0.0176
kg kg kg kg kg kg kg
Part Bipolar plates Tie-rods Housing Housing Insulator PEM PEM
Reuse Recycle Waste Possible Question 1 W 1 OK 1 OK other? 1 OK 1 OK other? 1 (1) ? 1 (1) ?
Table 10. Hydrogen blower EOLA scenarios
Material Steel Steel Copper Aluminium Aluminium FluMaBack D 6.3
Mass 0.397 0.006 0.120 0.976 0.053
kg kg kg kg kg
Part Rotor, stator Other Wire - stator Covers, housing, volute Impeller, other 33
Reuse
Recycle 1
Waste 1
1 1 (1)
1
Possible ? OK ? OK ?
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Plastic bonded ferrite PA 6.6 PEEK Synthetic rubber Electronic equipment
0.031 0.060 0.160 0.008 0.075
kg kg kg kg kg
Magnet ring - rotor Stator, return channel Motor protection O-rings Boards
(1) 1 1 (1)
1 1
? W OK W ?
Table 11. Air blower EOLA scenarios
Material Steel Copper Aluminium Aluminium Brass Plastic bonded ferrite PA 6.6 PA 6.6 Epoxy resin Glass fiber Electronic equipment
Mass 0.640 0.079 0.566 0.384 0.017 0.047 0.098 0.048 0.020 0.058 0.250
kg kg kg kg kg kg kg kg kg kg kg
Part Reuse Recycle Waste Possible Rotor, stator, other 1 ? Wire - stator 1 ? Covers, housing, volute 1 OK Impeller, Return channel (1) 1 ? Rotor end cap 1 W Magnet ring - rotor (1) ? Housing 1 OK Stator, return channel 1 W ? 1 W ? 1 W Boards (1) 1 ?
Table 12. UPS Assembly EOLA scenarios
Material Mass Part Reuse Recycle Waste possible Steel 140 kg Cabinet 1 OK Synthetic rubber 1.5 kg Cabinet sealing 1 OK Al, Cu, PP, Fe 1,5 kg compr./pumps/fans 1 (1) ? Cu, Fe, Si, Al, 8.18 kg DC/DC converter 1 (1) ? ele. eq., PP Aluminium 1.12 kg Control panel (Housing ?) 1 OK ABS, electronic eq. 0.28 kg Control panel 1 W Copper 3.6 kg Wiring 1 OK PVC 0.4 kg Wiring insulation 1 OK Aluminium 2 kg Cooling fan (blades ?) 1 OK Steel 2 kg Cooling fan (m. housing ?) 1 OK Copper 1 kg Cooling fan (motor ?) (1) 1 ? Al, Cu, PVC 0.55 kg Presure regulator 1 (1) ? Fe, PVC, CU 3 kg Valves/Fittings/Pipings 1 OK
Most of them are metal made, so according to [19], once re-use is rejected, materials have to be transformed into basic metals. These components are: cabinet, compressors, pumps, fans, DC/DC converter, control panel, wiring, cooling fan, pressure regulator, valves-fittings-piping, external heat exchanger.
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6.4 Recommendations regarding packaging, transport and information display 6.4.1 Packaging and transport As can be seen at European Parliament and Council Directive 94/62/EC of 20 December 1994 on packaging and packaging waste [6], ‘packaging’ shall mean all products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of goods, from raw materials to processed goods, from the producer to the user or the consumer. ‘Non-returnable’ items used for the same purposes shall also be considered to constitute packaging. A further study of functions and uses of package means more than this definition. It lets to know about the protected product and takes effect over resources consumption and waste generation. Protection • Prevent spoilage (barrier to moisture, gases, light, flavours and aromas) • Increase shelf life • Prevent contamination, tampering and theft • Prevent breakage (mechanical protection) Convenience • Product storage • Product preparation and serving • Portioning Information • Product identification • Product preparation and usage • Nutritional and storage data • Safety warnings • Contact information • Opening instructions • End of life management Promotion • Description of product • List of ingredients • Product features & benefits • Promotional messages and branding FluMaBack D 6.3
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Unitisation • Provision of consumer units • Provision of retail and transport units Handling • Transport from producer to retailer • Point of sale display Waste reduction and recycling and reuse of by-products • Enables centralised processing and re-use of by-products • Facilitates portioning and storage • Increases shelf life • Reduces transport energy Directive 94/62/EC makes a framework that facilitates the free movement of packaging and/or packaged goods throughout the EU. It aims to reduce the environmental impact of packaging through supporting systems for the collection of waste packaging, ensure recovery and recycling targets for packaging, etc. The essential requirements can be identified with keeping package’s weight and volume to the minimum amount needed for the safety, hygiene and consumer’s approval of the packed product. Other requirement has to keep toxic and/or hazardous constituents to a minimum. And other requirement must be to ensure that packaging can be reused and/or recovered once it has been used. By an European Commission Communication [21] a suite of standards are prepared to provide a practical and effective route to fulfilment the Directive [6]: ESO
Reference and title of the harmonised standard (and reference document)
CEN
EN 13427:2004 Packaging — Requirements for the use of European Standards in the field of packaging and packaging waste
CEN
EN 13428:2004 Packaging — Requirements specific to manufacturing and composition — Prevention by source reduction
CEN
EN 13429:2004 Packaging — Reuse
CEN
EN 13430:2004 Packaging — Requirements for packaging
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recoverable by material recycling CEN
EN 13431:2004 Packaging — Requirements for packaging recoverable in the form of energy recovery, including specification of minimum inferior calorific value
CEN
EN 13432:2000 Packaging — Requirements for packaging recoverable through composting and biodegradation — Test scheme and evaluation criteria for the final acceptance of packaging
Table 13. List of norms approved by EU Commission according Directive 94/62/EC, [21].
In order to minimize waste generation and improve Sustainability an holistic approach along the entire packaging value chain is needed.
6.4.2 Raw material sourcing Management strategies have to be established. It includes the base materials and the converted stock in the product cycle. A better known process to use waste materials shall be done based on the common principles for resource management, conservation and restoration. 6.4.3 Packaging material manufacture and conversion Inefficient production of packaging causes greater environmental impact. Sustainable production can reduce costs and contributes to improving the environmental performance of products. Therefore packaging manufacturers have implemented environmental management systems [21] that continuously help to reduce operational costs. 6.4.4 Distributing Sustainability in logistics and distribution is primarily about preventing damage to goods and ensuring that use of transport resources (e.g. trucks, trains, short sea shipping and storage facilities) is optimised. For example, trucks should carry their maximum volume capacity, normally achieved through modifications of pack dimensions so that they closely fit the pallet. That optimisation may be limited by the load carrying capacity of the pallet and truck. The use of standardized systems can help improve inefficient cube utilisation caused by irregular height pallets on mixed product shipments.
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6.4.5 Retailing Designing a pack that is robust enough to resist distribution stresses, easy to open and easily displayed on shelf while minimising environmental impact represents a great challenge. A challenge to packaging is to be attractive, consistent with the brand and minimize their environmental impact. This balance requires hard work on the part of manufacturers, but will be rewarded by consumers, retailers and the authorities. 6.4.6 Collection of post-use packaging When package reaches its ending all recovery systems must work to achieve high collection rates of packaging waste. But that depends on a range of factors outside the packaging supply chain’s control, so at this point manufacturers have short action capacity. According to EUROPEN [22] there is a specific actions related to package: •
“Standing still is falling behind – sustainability is a competitive issue”.
•
“It is best practice to foster improvements though the whole product life cycle”.
•
“Packaging sustainability targets should not be set in isolation – packaging should be part of a product’s sustainability profile which in turn contributes to a company’s sustainability goals”.
•
“Targets should be SMART – specific, measurable, achievable, realistic and time based”.
•
“Senior management engagement is crucial to support delivery of these targets”.
•
“Communicate information on packaging and recycling on the package”.
•
“Eliminate components that add weight or complexity whenever possible”.
•
“Commit to reducing the environmental impact of packaging, without jeopardising the safety, quality or consumer acceptance of its contents”.
•
“Minimise headspace within packages”.
•
“Use the lowest possible weight packaging systems (providing they can be suitably managed when emptied)”.
•
“Decrease packaging waste at all stages, including package manufacturing, utilisation and disposal”.
•
“Avoid the use of substances that can adversely impact the environment during packaging production and disposal”.
•
“Develop a holistic approach that considers packaging performance and environmental impact across the supply chain. Select and develop packaging and
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packaging formats that fulfil the needs of the supply chain and do not create extra waste and environmental impact elsewhere”. •
“Maximise the use of recycled material in place of virgin material for secondary and tertiary packaging and where appropriate for primary packaging”.
•
“Maximise opportunities for recovery through reuse, recycling, energy recovery from waste to avoid disposal to landfill”.
•
“Increase the recycle-ability and compatibility of packages with existing waste management schemes”.
•
“Take into account new packaging materials and processes that reduce the impact on the environment”.
“Support industrial and governmental efforts to promote integrated waste management”.
•
“Develop and track changes in SP for inclusion in CSR reporting”.
•
“Maximise the use of renewable materials from sustainably managed sources where appropriate”.
7 Conclusions Nowadays, for FluMaBack project’s aim, the listed norms at point 3.3 have to be applied for the different parts of the fuel cell. But the develop of circular economy [12] may change the situation soon. It’s important to pay attention to publication of new directives. It means that all actions developed at this point have to fit all these directives. Identification of waste, shipment of waste, disposal, export of waste to certain non-OECD countries have to be studied with the knowledge of all the rules described at directives, regulations, etc. However, all these rules are going to be modified, including the idea of circular economy [11]. When it will appear at the Official Journal of the European Union it will becomes a legal rule that have to be complied. So, all procedures have to be revised to comply with the current environmental legislation and future trends. Reverse logistics has an inherent difficulty, associated with all steps which have to be done, and which have been analyzed at previous points. But in the other hand, there are several points to carry out reverse logistics. This are:
Compliance with environmental legislation.
Economic benefits
Recovering raw materials difficult to obtain.
Customer Service and guarantees.
Social responsibility.
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
Competitive Advantage.
The final destination of materials must be determined to maximize, in a broad sense, the performance that can be obtained, or to minimize the social and environmental impact generated. Creating reverse logistics strategies and considerations on the environmental impact of disposal and recycling products at end-of-life lead to a change in design criteria and in industrial processes. Logistics has become an indispensable tool for companies to be efficient, profitable and competitive in the current market demands. Materials used in manufacturing FluMaBack UPS system were identified on the basis of constructed LCA model of manufacturing phase. Environmental impacts in form of environmental indicators by the CML2001 methodology for given materials were analysed. On the basis of results 3 stage scale was defined in order to get clearer view on materials hazard. At the end EOLA scenarios for each component of the system was presented. Many of the aspects of the minimization of environmental impact are open for companies to develop according to their own views, but there are certain fundamental principles that must be respected. These required elements are contained in the legislation. Any part of the planning phase should specifically refer back to this legislation to ensure that these requirements are met. The Essential Requirements are set out in EU Directive 94/62 / EC [6] on packaging and packaging waste, and must ensure compliance. On the contrary companies are free to choose how to demonstrate compliance with the essential requirements. Standards on Packaging and Environment, contained in [21] are not mandatory, but its implementation automatically assumes that meets the essential requirements.
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8 Bibliography [1] [2]
[3] [4] [5] [6] [7] [8] [9] [10] [11] [12]
[13] [14] [15] [16]
“Fluid Management component improvement for Back up fuel cell systems FluMaBack. Annex I - ‘Description of Work’.” 23-Mar-2012. “Regulation (EC) no 1907/2006, of 18 December 2006 concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH), establishing a European Chemicals Agency, amending Directive 1999/45/EC and repealing Council Regulation (EEC) No 793/93 and Commission Regulation (EC) No 1488/94 as well as Council Directive 76/769/EEC and Commission Directives 91/155/EEC, 93/67/EEC, 93/105/EC and 2000/21/EC,” 18-Dec-2006. “Decision no 1386/2013/EU of the European Parliament and of the Council of 20 November 2013 on a General Union Environment Action Programme to 2020 ‘Living well, within the limits of our planet.’” European Environment Agency, The European environment: state and outlook 2010 : synthesis. Luxembourg: Office for Official Publications of the European Union, 2010. “Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 on waste and repealing certain Directives.” “European Parliament and Council Directive 94/62/EC of 20 December 1994 on packaging and packaging waste.” “Council Directive 1999/31/EC of 26 April 1999 on the landfill of waste.” “Directive 2000/53/EC of the European Parliament and of the Council of 18 September 2000 on end-of life vehicles - Commission Statements.” “Directive 2006/66/EC of the European Parliament and of the Council of 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91/157/EEC.” “Directive 2012/19/EU of the European Parliament and of the Council of 4 July 2012 on waste electrical and electronic equipment (WEEE) Text with EEA relevance.” “Communicationfrom the commission to the European Parliament, the Council, the European Economic and Social Committee and the Committee of the Regions: Towards a circular economy: A zero waste programme for Europe.,” 02-Jul-2014. “Proposal for a Directive of the European Parliament and of the Council amending Directives 2008/98/EC on waste, 94/62/EC on packaging and packaging waste, 1999/31/EC on the landfill of waste, 2000/53/EC on end-of-life vehicles, 2006/66/EC on batteries and accumulators and waste batteries and accumulators, and 2012/19/EU on waste electrical and electronic equipment.,” 02-Jul-2014. A. El korchi and D. Millet, “Designing a sustainable reverse logistics channel: the 18 generic structures framework,” J. Clean. Prod., vol. 19, no. 6–7, pp. 588–597, Apr. 2011. M. Fleischmann, J. M. Bloemhof-Ruwaard, R. Dekker, E. van der Laan, J. A. E. E. van Nunen, and L. N. Van Wassenhove, “Quantitative models for reverse logistics: A review,” Eur. J. Oper. Res., vol. 103, no. 1, pp. 1–17, Nov. 1997. I. Fernández Quesada, “The concept of reverse logistics. a review of literature,” Annual Conference for Nordic Researchers in Logistics, NOFOMA’03, 2003. C. Bai and J. Sarkis, “Flexibility in reverse logistics: a framework and evaluation approach,” J. Clean. Prod., vol. 47, pp. 306–318, May 2013.
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[17] [18] [19] [20] [21] [22] [23] [24]
Philip Jayne, “Panasonic Case Study Reverse Logistics Association,” Las Vegas, EE.UU., 2011. M. Opalic, M. Kljajin, and K. Vuckovic, “Disassembly Layout in WEEE Recycling Process,” Strojarstvo, vol. 52, no. 1, pp. 51–58, 2010. Metal recycling: opportunities, limits, infrastructure. Nairobi: United Nations Environment Programme, 2013. “OroyFinanzas.com | Diario digital del dinero y las finanzas.” [Online]. Available: http://www.oroyfinanzas.com/. [Accessed: 18-Nov-2014]. “Commission communication in the framework of the implementation of the European Parliament and Council Directive 94/62/EC of 20 December 1994 on packaging and packaging wasteText with EEA relevance,” 19-Feb-2005. “EUROPEN - The European Organization for Packaging and the Environment.” [Online]. Available: http://www.europen-packaging.eu/. [Accessed: 21-Nov2014]. “GaBi 6 LCI documentation: GaBi Software.” [Online]. Available: http://www.gabi-software.com/support/gabi/gabi-6-lci-documentation/. [Accessed: 07-Nov-2014]. J. van Rooijen, A Life Cycle Assessment of the PureCellTM Stationary Fuel Cell System: Providing a Guide for Environmental Improvement. University of Michigan, 2006.
9 Sources http://io9.com/how-to-recognize-the-plastics-that-are-hazardous-to-you-461587850 https://blogs.baruch.cuny.edu/greenit/improve-it-energy-efficiency/e-waste/reducehazardous-materials/list-of-hazardous-materials/ http://www.espimetals.com/index.php/msds/815-tin-lead-alloy http://en.wikipedia.org/wiki/Sulfuric_acid#Safety
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10 Annex: LCIA – Materials used in LCA model In following tables all materials used in LCA models are presented in terms of masses od the shares of components in terms of masses of specific material in UPS. For exyample sulfur acid represented in Fiamm batery represents 100 % of sulfur acid used in total UPS since it is the only component with sulfur acid.
Table 14. Masses of materials in LCA model of ONDA External climate. External heat exchanger Quantity, g Share of material in UPS, % Steel Steel plate 13.600 5,50 Copper Copper sheet 3.800 30,79 Aluminium Aluminium sheet 2.200 10,52 Polymers Polyvinylchloride (PVC) 3.400 23,26 Total 23.000 6,43* *of total mass of UPS
Table 15. Masses of materials in LCA model of Tubiflex humidifier. Humidifier Quantity, Share of material in UPS, g % Steel Steel welded pipe 180 0,07 Polymers 1.825 12,48 Polyurethane flexible foam (PU) 180 Polyether polyol 175 Acrylonitrile-Butadiene-Styrene Granulate 1.470 (ABS) Total 2.005 0,56* *of total mass of UPS
Table 16. Masses of materials in LCA model of Fiamm battery. Battery Quantity, g Share of material in UPS, % Tin-lead alloy 39.520 100,00 Polymer Polypropylene (PP) 5.472 37,43 Sulphuric acid 96% 4.936 100,00 49.928 13,95* *of total mass of UPS FluMaBack D 6.3
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Table 17. Masses of materials in LCA model of fuel cell stack. Fuel cell stack Quantity, Share of material in UPS, g % Carbon + polymer 16.280,0 100,00 Copper Copper product manufacturing, avg. metal 1.300,0 10,53 working Aluminium Aluminium, production mix, cast alloy 9.890,0 47,30 Polymers 920,0 6,29 Polypropylene (PP) 700,0 Polyethylene Linear Low Density Granulate 220,0 (LLDPE) Nafion 482,4 100,00 Platinum 17,6 100,00 Total 28.890,0 8,07* *of total mass of UPS
Table 18. Masses of materials in LCA model of hydrogen blower. Hydrogen blower Quantity, g Share of material in UPS, % Steel Stainless steel white hot rolled coil (316) Non grain oriented silicon steel (dynamo steel) EAF Steel billet / Slab / Bloom Copper Copper Wire Aluminium Aluminium sheet Aluminium ingot Plastic bonded ferrite Polymers Polyamide 6.6 fibres (PA 6.6) Polyetherether ketone granulate (PEEK) Synthetic rubber Electronic equipment Total *of total mass of UPS
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410,6 126,0 279,0 5,6
0,17
120,0 1.069,0 201,0 868,0 31,0 220,9 52,9 160,0 8,0 75,0 1.926,5
0,97 5,11
6,84 1,51
9,20 0,54*
Fluid Management component improvement for Back up fuel cell systems
Table 19. Masses of materials in LCA model of air blower. Air blower Quantity, g Share of material in UPS, % Steel EAF Steel billet / Slab / Bloom Stainless steel Quarto plate (316) Non grain oriented silicon steel (dynamo steel) Stainless steel white hot rolled coil (304) Copper Copper Wire Aluminium Aluminium ingot Aluminium sheet Brass Plastic bonded ferrite Polymers Polyamide 6.6 fibres (PA 6.6) PE Epoxy resin PlasticsEurope Glass fiber Electronic equipment *of total mass of UPS
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659,1 156,9 2,4 460,2 39,6
0,27
78,8 970,5 537,5 433,0 17,3 47,0 165,0 145,0 20,0 58,1 250,0 2245,8
0,64 4,64
100,00 10,38 1,13
100,00 30,67 0,63
Fluid Management component improvement for Back up fuel cell systems
Table 20. Masses of materials in LCA model of assembly process and components needed in Turin. Assembly in Turin Quantity, Share of material in UPS, g % Steel EAF Steel billet / Slab / Bloom Non grain oriented silicon steel (dynamo steel) Steel UO pipe Steel product manufacturing, average metal working Copper Copper wire Copper product manufacturing, average metal working Wire drawing Aluminium Aluminium ingot Plastic bonded ferrite Polymers Synthetic rubber Polypropylene injection moulding part (PP) Acrylonitrile-butadiene-styrene granulate (ABS) Polyvinylchloride injection moulding part (PVC) Polyvinyl chloride film (PVC) Silicon Electronic equipment *of total mass of UPS
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2.32420 224.000 5.920 1.500 1.000
93,99
7.043 1.905 538
57,07
4.600 6.779 375 2.617,5 1.500,0 450,0 140,0 127,5 400,0 230 490 249.954,5
32,42 82,78 17,90
100,00 60,12 69,83