Slides 3 – Material flow analysis MATERIAL FLOW ANALYSIS.

Slides 3 – Material flow analysis

MATERIAL FLOW ANALYSIS

Slides 3 – Material flow analysisStrategies for waste minimization


What are materials?

Goods/raw materials (e.g. wood, gravel, PVC)

Elements (e.g. carbon, cadmium)

Compounds (e.g. benzene, methane)


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


Initial situation in a paint shop


Material flows in a car repair shop


How does a balance work?

Input mass = Output mass+ Storage

(Without chemical reaction)


Material flow analysis and eco-balances

Eco-balancesAnalyse the whole life-cycle of a

productAnalyse the ecological effects Assess the material and energy

consumptions emerging during a life cycle and the arising environmental effects.


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 evaluationEdit data in a decision-oriented waySet priorities for appropriate measures

to minimize waste and emissions


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


How to carry out a material flow analysis?

1. Define the objectives and parameters to be monitored

2. Limit the balance scope3. Limit the balance period4. Identify and define the process steps5. Draw the flowcharts: material flows – quality6. Draw up the balances: material flows –

quantity7. Interpret the results and draw conclusions


Material flow analysis of machine painting


Step 1: Parameters monitoredPaints, solvents, (all process materials)

Step 2: Balance scopePainting chamber and drying

Step 3: Balance period1 year


Step 4: Process steps of machine painting

Process steps:Pre-treatmentPriming, paintingDrying

Additional equipment:Steam generatorExhaust air filterCleaning of spray gun and container


Step 5: Flowchart

Representing process steps by rectangles Representing material flows by arrows


Step 5: Flowchart

Pre-treatmentPriming/Painting Drying

Air filter

CleaningSteam generator

Balance limit


Step 5: Flowchart


Air filter


Balance limit

Oily parts l Parts

with paint

Partsclean

Partswet

Thinner Wastethinner

Air and thinner

Air, paint, thinner

Air, thinnerFilter, paint

Paint, thinner, filler, tape, film, air, container

filter

Tools

Dustcontainers

Water,detergent


Input = output for the whole systemInput = output for the single steps

Step 6: Balances


Step 5: Flowchart


Air filter


Balance limit

E1A1

E11 A6

A4, A7A3E3, E4, E5, E6, E7

E8, E9, E 10,

A4, A5, A8, A9

E2

A2


Quantitative material flow analysis


Quantitative material flow analysis


Step 7: Interpretation

By identifying parametersCalculation 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?


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%


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


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


Data sourcesAccountingWarehousingCollection of process dataOperational accountingPersonal information (e.g. methods

engineer)EstimatesMeasurementsOriginal documents...


Measuring water volumes

Water meterTurbine wheel meterRotameterInduction measuring instrumentUltrasonic flowmeterWeirMeasuring at water consumers (stop watch, bucket)

q =0,31 h 2g

tan o

o2,5


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


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

Slides 3 – Material flow analysis MATERIAL FLOW ANALYSIS.

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