MATERIAL FLOW ANALYSIS

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MATERIAL FLOW ANALYSIS
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Strategies for waste minimization
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What are materials?

• Goods/raw materials (e.g. wood, gravel, PVC)
• Elements (e.g. carbon, cadmium)
• Compounds (e.g. benzene, methane)

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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

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Initial situation in a paint shop
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Material flows in a car repair shop
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How does a balance work?

• Input mass
• Output mass
• Storage
• (Without
• chemical
• reaction)

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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.

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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

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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

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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

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Material flow analysis of machine painting
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Step 1 Parameters monitored

• Paints, solvents, (all process materials)

Step 2 Balance scope
Painting chamber and drying
Step 3 Balance period
1 year
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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

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Step 5 Flowchart

• Representing process steps by rectangles
• Representing material flows by arrows

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Step 5 Flowchart
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Step 5 Flowchart
Paint, thinner, filler, tape, film, air,
container
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Step 6 Balances

• Input output for the whole system
• Input output for the single steps

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Step 5 Flowchart
A2
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Quantitative material flow analysis
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Quantitative material flow analysis
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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 lt 10
• In this case on average lt 20
• State of the art?

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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
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Evaluation of a material flow analysis
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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

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Data sources

• Accounting
• Warehousing
• Collection of process data
• Operational accounting
• Personal information (e.g. methods engineer)
• Estimates
• Measurements
• Original documents
• ...

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Measuring water volumes

• Water meter
• Turbine wheel meter
• Rotameter
• Induction measuring instrument
• Ultrasonic flowmeter
• Weir
• Measuring at water consumers
• (stop watch, bucket)
  

2,5
0,31 h 2g
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tan o
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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

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Recommendations 2 for a material flow analysis

• It is not essential to follow the instructions or
  procedures in great detail, a creative approach
  is often helpful.
• Even by simply working with the balances you can
  sometimes achieve improvements.
• It is important to translate the results into the
  language of the respective target group (monetary
  units, kg, pictures, comparisons, etc.)