Hanneke Agterhuis

April 14th 2015

The Circle Economy

Van GansewinkelDesign for recycling

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Contents

1. Introduction

2. Recycling in practice

3. Design for recycling

Introduction

The business of recycling

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4

Two drivers for business in recycling:

LegislationMaterial value

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Recycling for value

EFW to reduce volume

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1985

1987

1989

1991

1993

1995

1997

1999

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2005

2007

2009

2010

Recycling other

Recyclingorganics

Energy fromWaste

Disposal

Legislation for separate collection of organics

Legislation drives breakthroughs in recycling

Processing of Dutch household waste. Figures from “Compendium voor de leefomgeving”

Legislation on WEEE recycling Legislation makes

recycling financiallyfeasible

This is part of the business of recycling

Legislation on car recycling

Taxes on disposal increased

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Material value and legislation determine recycling process

Material quality

Material

quantityProcessing

costsRecovery steps

Optimization by design

for recycling

Recycling in practice

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Basic steps in recycling

End processors,

f.e.xsmeltersSource: Van Schaik et al, 2010

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Material separation:

Based on physical properties :

o Magnetism

o Density & shape

o Density + electric conduction

o Optical properties

o Conductivity, density

Mixed particles pose a problem…

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Finally, processors make input material or final products

Examples:

• Plastic remelting

• Metal smelters

• Glass furnaces

• Road foundation constructors

���� Pose demands on their input materials���� Depend on successful physical separation

Design for recycling

Reduce, reuse, recycle

• Design for repair

• Design for upgrading

• Design that lasts

Different business models needed!

Light bulb cannot be replaced!

Modular smartphone (Phonebloks)

Sturdy and simple

Guidelines for designers:

Do not design entire product for dismantling.

Instead:

� Enable dismantling of dangerous parts

�Enable dismantling of high value parts

Herman Miller C2C chair

Design for dismantling? Design for shredding!

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Mixing two recyclable materials does not necessarily mean that the final product is recyclable

(M.B. Castro, 2005)

Consider which materials you combine

Guidelines for designers

Iron scrap

+>1% copper

Smelter

Low strength steel

Only tensile applications

Virgin iron ore needed to upgrade

1515Guidelines for designers

When connecting 2 non compatible materials: avoid irreversible connections, such as:

Instead : snap fit

Glue Many small bolts

Instead:

1 large bolt of right material

Composites, laminates

Consider the use of connections!

Instead:

?

1616Guidelines for designersLimit the number of materials- less is more!

Source: UNEP (2012): Metal Recycling; opportunities, limits, infrastructure

4 materials =

4 separation steps!

Disruptive technologies?Complete change of the system to phase out material use?

Case studies

Design for recycling

Case study: “Smartbin 2.0”

• Frame is 1 material: steel

• No plastics wheels

• Snap fit instead of stain steel bolts

• Toxin free powder coating, which does not affect steel quality in recycling

• Trial and error for finding right recycled plastic, while using same injection mold

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ReWorkWear

• Clothing is leased

• No harmful chemicals used

for dyes

• Lower energy and water use

• Fully Recyclable

Philips SensEco

• Challenge:

o Food grade plastics v/s recycled plastics

o Philips wanted guarantees about product origins

• One off solution: use material fromrecall actions

o 50% of plastic content is recycled material

o 50% of stainless steel is recycled material

• Next step: using our generic recycled plastics for non visible components

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Questions?

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Guidelines for designers & material engineers

• If possible, avoid combinations that reduce

recyclability or recoveryA

BS

ABS B

FR

HIP

S

HIP

S B

FR

PET

PC

PM

MA

PC/A

BS P

FR

HIP

S/P

PE P

FR

G

G G

Y Y G

Y Y G G

O O O O G

G G O O G G

O O O O Y O G

G R O R R G O G

O O G G R O O Y G

G

Y

O

R

Resonabile miscibility (contamination=2-5%, properties>80%)

Limited miscibil ity (contamination=0.1-2%, properties>80%)

Bad miscibility (contamination<0.1%, properties<80%)

HIPS/PPE PFR

PC/ABS PFR

Good miscibility (contamination>5%, properties>80%)

ABS

HIPS BFR

HIPS

ABS BFR

PMMA

PC

PET