Scrap tires to crumb rubber: feasibility analysis for processing facilities

Crumb rubber can be produced from scrap tires in a wide range of particle sizes and quality levels. Ideally, the revenue stream includes tipping fees paid to receive the raw materials; sales of variously-sized crumb products to different end-user markets; and potential sales of scrap metal and fiber contained within the tires. General demand has been increasing, and submarkets for crumb products are growing in size and variety. However, the optimistic expectations of potential investors and government agencies contrast sharply with the experiences of many current and former producers. Production planning and operation is complex, real-dollar crumb prices have fallen, and many producers recount difficulties finding stable markets and competing against newer, state-subsidized competitors. This paper examines the engineering economics of crumb rubber facilities. Following a literature review and interviews with producers, a financial model of a nominal processing operation was created to aid the analysis of different market, crumb size, and production scenarios. The profitability of a crumb facility appears to be particularly sensitive to crumb rubber prices, operating costs, and raw material availability. Better analysis of market and production impacts on financial viability for proposed processing facilities would aid overall market efficiency.     

An environmental assessment of food supply chains: a case study on dessert apples

The contemporary food system provides consumers with convenience, extensive choice, and the year-round availability of fresh produce. In this paper these achievements are recognized within the context of the associated environmental impacts. While many analyses have considered the energy and material efficiency of various options for food production and packaging, very few studies have investigated the environmental impacts of the transport components of food supply chains. This is surprising, given that the global sourcing of food produce, centralized distribution systems, and shopping by car have become prevalent in recent decades and have contributed to an increase in the distance between producer and consumer or “food miles.” In a case study the transport energy consumption is calculated for all possible ways in which dessert apples can be supplied to the UK consumer. The aim is to assess the environmental performance of the predominant fresh produce supply chains and to investigate claims that localized systems are more environmentally efficient. The main criteria used to compare the environmental efficiency in alternative food supply chains are the transport-related fossil-fuel energy consumption and associated carbon dioxide emissions. Analysis of the empirical data shows that transportation is now responsible for a considerable fraction of the total energy consumption in the life cycle of fresh apples, and in most cases exceeds the energy consumed in commercial apple cultivation. By developing local production and marketing systems for fresh products, transport demand can be reduced and many of the environmental impacts associated with existing supply chains can be avoided. The results of the study are then discussed in relation to the wider issues of transport policy, international trade, food security, and product-related environmental information for consumers.     

Assessing the potential of yield improvements, through process scrap reduction, for energy and CO2 abatement in the steel and aluminium sectors

Targets to cut 2050 CO₂ emissions in the steel and aluminium sectors by 50%, whilst demand is expected to double, cannot be met by energy efficiency measures alone, so options that reduce total demand for liquid metal production must also be considered. Such reductions could occur through reduced demand for final goods (for instance by life extension), reduced demand for material use in each product (for instance by lightweight design) or reduced demand for material to make existing products. The last option, improving the yield of manufacturing processes from liquid metal to final product, is attractive in being invisible to the final customer, but has had little attention to date. Accordingly this paper aims to provide an estimate of the potential to make existing products with less liquid metal production.Yield ratios have been measured for five case study products, through a series of detailed factory visits, along each supply chain. The results of these studies, presented on graphs of cumulative energy against yield, demonstrate how the embodied energy in final products may be up to 15 times greater than the energy required to make liquid metal, due to yield losses. A top-down evaluation of the global flows of steel and aluminium showed that 26% of liquid steel and 41% of liquid aluminium produced does not make it into final products, but is diverted as process scrap and recycled. Reducing scrap substitutes production by recycling and could reduce total energy use by 17% and 6% and total CO₂ emissions by 16% and 7% for the steel and aluminium industries respectively, using forming and fabrication energy values from the case studies. The abatement potential of process scrap elimination is similar in magnitude to worldwide implementation of best available standards of energy efficiency and demonstrates how decreasing the recycled content may sometimes result in emission reductions.Evidence from the case studies suggests that whilst most companies are aware of their own yield ratios, few, if any, are fully aware of cumulative losses along their whole supply chain. Addressing yield losses requires this awareness to motivate collaborative approaches to improvement.     

Economics and GHG emission reduction of a PLA bio-refinery system—Combining bottom-up analysis with price elasticity effects

This paper analyses energy savings, GHG emission reductions and costs of bio-refinery systems for polylactic acid (PLA) production. The systems comprise ‘multi-functional’ uses of biomass resources, i.e. use of agricultural residues for energy consumption, use of by-products, and recycling and waste-to-energy recovery of materials. We evaluate the performance of these systems per kg of bio-based polymer produced and per ha of biomass production. The evaluation is done using data of Poland assuming that biomass and PLA production is embedded in a European energy and material market. First, the performance of different bio-refinery systems is investigated by means of a bottom-up chain analysis. Second, an analysis is applied that derives market prices of products and land depending on the own-price elasticity of demand. Thus, the costs of bio-refinery systems depending on the demand of land and material are determined. It is found that all PLA bio-refinery systems considered lead to net savings of non-renewable energy consumption of 70–220 GJ/(ha yr) and net GHG emission reductions of 3–17 Mg CO_2eq/(ha yr). Most of these PLA bio-refinery systems lead to net costs for the overall system of up to 4600 €/(ha yr). PLA production from short rotation wood leads to net benefits of about 1100 €/(ha yr) if a high amount of a high value product, i.e. fibres, is produced. Multi-functionality is necessary to ensure the viability of PLA bio-refinery systems from biomass with regard to energy savings and GHG emission reduction. However, the multi-functional use of biomass does not contribute much to overall incomes. Multifunctional biomass use – especially the use of biomass residues for energy consumption – contributes significantly to savings of non-renewable energy sources. Own-price elasticity of the demand for materials influences the overall costs of the bio-refinery system strongly. The own-price elasticity of land demand markets could become important if bio-refineries are introduced on a large scale.     

Evaluation of recycling efforts of aircraft companies in Wichita

The number of manufactured aircraft has been continuously increasing worldwide because of the high demand for airline transportation. During manufacturing, many advanced materials and devices are used to build various sizes and shapes of aircraft. However, most of these materials and devices require considerable energy and labor to produce, so reusing these at any life stage of the aircraft offers many economic and environmental benefits, and is considered lucrative and environmentally responsible. Several recyclable materials—composites, metals and alloys, wires, wood, paper, plastics, electronics, and avionics—emerge as waste streams during the manufacturing of aircraft. Many aircraft companies have been recycling these materials to remanufacture aircraft parts or other products for more sustainable production. In the present study, we evaluated the recycling efforts of local aircraft companies in Wichita, KS. These efforts were considered in terms of recycling efficiency/rate and environmental benefits. These included cradle-to-gate (CTG) life-cycle inventory analysis of the materials, carbon dioxide emissions, virgin material replacement with recycled materials, and natural resources usage. Our findings show that there exists a significant potential for contributions to sustainability as well as environmental and health benefits in the region from recycling by aircraft manufacturing plants.     

Efficient use of energy and materials: progress and policies

There is a growing awareness of the serious problems associated with the provision of sufficient energy to meet human needs and to fuel economic growth world-wide. This has pointed to the need for energy and material efficiency, which would reduce air, water and thermal pollution, as well as waste production. Increasing energy and material efficiency also have the benefits of increased employment, improved balance of imports and exports, increased security of energy supply and adopting environmentally advantageous energy supply. A large potential exists for energy savings through energy and material efficiency improvements. Technologies are not now, nor will they be, in the foreseeable future, the limiting factors with regard to continuing energy efficiency improvements. There are serious barriers to energy efficiency improvements, including unwillingness to invest, lack of available and accessible information, economic disincentives and organizational barriers. A wide range of policy instruments, as well as innovative approaches have been tried in some countries in order to achieve the desired energy efficiency improvements. These include: regulation and guidelines; economic instruments and incentives; voluntary agreements and actions; information, education and training; and research, development and demonstration. An area that requires particular attention is that of improved international co-operation to develop policy instruments and technologies to meet the needs of developing countries. Material efficiency has not received the attention that it deserves. Consequently, there is a dearth of data on the qualities and quantities of final consumption, thus, making it difficult to formulate policies. Available data, however, suggest that there is a large potential for improved use of many materials in industrialized countries.     

An analysis of variables influencing the material composition of automobiles

The use of materials is studied broadly, because of the environmental problems related to extraction, production, consumption and waste treatment. The use and substitution of materials in products is therefore a relevant issue for environmental policy making. Studies have been done to describe the material flow or to measure the impact of materials or products on the environment. However, these studies do not often consider economic, substitution and dynamic aspects of material flows. Other studies on material flows analyse the relationship between the use of materials and economic growth, but they do not consider substitution between materials. For environmental policy making economic, technological and environmental aspects of the use of materials need to be considered. Especially, substitution of materials is important. In various countries material and product policies are imposed on a variety of materials and products. For evaluation of these policies their environmental and economic effects need to be examined in detail. This study aims to analyse the economic and technological factors influencing the use of materials and the substitution between different materials dynamically. The goal is to obtain an insight in the effect that material levies may have on the use and substitution of materials. The statistical analysis is performed on a specific product-group because decisions on the use of materials are taken on a product-level. The case study is performed on automobiles. The results show that the material use is largely an autonomous development. The price of aluminium has a positive, significant effect on the use of that material. The price of plastics has a positive, but not significant effect on the use of plastics. Reasons may be that the costs of a raw material are small relative to the processing costs, and that the production process can only be changed slowly. Other factors, like competitiveness and consumers' tastes, may be more important for substitution. This implies that levies or subsidies on certain materials is not a promising policy to change the use of materials. Besides time, there are two other factors that have a positive and significant relationship with the use of aluminium and plastics: the fuel efficiency, which is the distance driven divided by the energy used; and, the road tax, which depends on the weight of a car. However, these effects are caused by their positive relationship with time. The main conclusion of the case study is that imposing a levy on materials may not have the desired or expected effect of reduction in material use.     

Geological supply and economic demand: The unresolved equation

Whereas the ultimate world supply of minerals is controlled by geological factors, the actual supply at any particular time is controlled by economic factors. Mineral production is a function of investment in exploration, mining, and processing - and research in these fields. Given the long lead time between a decision to explore and actual production from any deposit found, the increasing difficulty of finding deposits in the well prospected parts of the world, the political barriers to exploration in the less developed countries, the energy barriers to mining and processing ever lower grade ores, and the lengthy time required to develop new exploration, extraction, and processing techniques, adjustments in supply in response to changes in demand cannot be assumed to be automatic.     

Integrating waste, manufacturing and industrial symbiosis: an analysis of recycling, remanufacturing and waste treatment firms in Texas

The continually increasing volume of the waste stream has led to numerous calls for strategies to close the loop on material use through industrial symbiosis strategies which direct used material and products (wastes) back to production processes. By use of a survey of recycling, remanufacturing and waste treatment firms in Texas, this paper asks if these firms can operate as a bridge between production and consumption/waste to efficiently increase the flow of used materials and products back to production processes at the local level. The results suggest that while most materials and used products are collected locally, only some can be re(consumed) locally. Moreover, the firms face negative perceptions about their activities from industry and the public at large that likely slow both the rate of entry of new firms into these markets and the expansion possibilities of existing firms. In addition, the types of conventions that characterize the interactions of more successful firms are not well developed in this sector(s). It is unlikely that recycling, remanufacturing and waste treatment firms can become central players in the production, consumption and waste cycle loop until society develops production design, marketing and consumption philosophies that include recycling and remanufacturing at a fundamental level.     

Integrating waste,manufacturing and industrial symbiosis: an analysis of recycling,remanufacturing and waste treatment firms in Texas

The continually increasing volume of the waste stream has led to numerous calls for strategies to close the loop on material use through industrial symbiosis strategies which direct used material and products (wastes) back to production processes. By use of a survey of recycling, remanufacturing and waste treatment firms in Texas, this paper asks if these firms can operate as a bridge between production and consumption/waste to efficiently increase the flow of used materials and products back to production processes at the local level. The results suggest that while most materials and used products are collected locally, only some can be re(consumed) locally. Moreover, the firms face negative perceptions about their activities from industry and the public at large that likely slow both the rate of entry of new firms into these markets and the expansion possibilities of existing firms. In addition, the types of conventions that characterize the interactions of more successful firms are not well developed in this sector(s). It is unlikely that recycling, remanufacturing and waste treatment firms can become central players in the production, consumption and waste cycle loop until society develops production design, marketing and consumption philosophies that include recycling and remanufacturing at a fundamental level.     

Evaluating opportunities to improve material and energy impacts in commodity supply chains

When evaluated at the scale of individual processes, next-generation technologies may be more energy and emissions intensive than current technology. However, many advanced technologies have the potential to reduce material and energy consumption in upstream or downstream processing stages. In order to fully understand the benefits and consequences of technology deployment, next-generation technologies should be evaluated in context, as part of a supply chain. This work presents the Materials Flow through Industry (MFI) supply chain modeling tool. The MFI tool is a cradle-to-gate linear network model of the US industrial sector that can model a wide range of manufacturing scenarios, including changes in production technology and increases in industrial energy efficiency. The MFI tool was developed to perform supply chain scale analyses in order to quantify the impacts and benefits of next-generation technologies and materials at that scale. For the analysis presented in this paper, the MFI tool is utilized to explore a case study comparing three lightweight vehicle supply chains to the supply chain of a conventional, standard weight vehicle. Several of the lightweight vehicle supply chains are evaluated under manufacturing scenarios that include next-generation production technologies and next-generation materials. Results indicate that producing lightweight vehicles is more energy and emission intensive than producing the non-lightweight vehicle, but the fuel saved during vehicle use offsets this increase. In this case study, greater reductions in supply chain energy and emissions were achieved through the application of the next-generation technologies than from application of energy efficiency increases.     

Life cycle assessment of Italian citrus-based products. Sensitivity analysis and improvement scenarios

Though many studies concern the agro-food sector in the EU and Italy, and its environmental impacts, literature is quite lacking in works regarding LCA application on citrus products. This paper represents one of the first studies on the environmental impacts of citrus products in order to suggest feasible strategies and actions to improve their environmental performance. In particular, it is part of a research aimed to estimate environmental burdens associated with the production of the following citrus-based products: essential oil, natural juice and concentrated juice from oranges and lemons. The life cycle assessment of these products, published in a previous paper, had highlighted significant environmental issues in terms of energy consumption, associated CO₂ emissions, and water consumption. Starting from such results the authors carry out an improvement analysis of the assessed production system, whereby sustainable scenarios for saving water and energy are proposed to reduce environmental burdens of the examined production system. In addition, a sensitivity analysis to estimate the effects of the chosen methods will be performed, giving data on the outcome of the study. Uncertainty related to allocation methods, secondary data sources, and initial assumptions on cultivation, transport modes, and waste management is analysed. The results of the performed analyses allow stating that every assessed eco-profile is differently influenced by the uncertainty study. Different assumptions on initial data and methods showed very sensible variations in the energy and environmental performances of the final products. Besides, the results show energy and environmental benefits that clearly state the improvement of the products eco-profile, by reusing purified water use for irrigation, using the railway mode for the delivery of final products, when possible, and adopting efficient technologies, as the mechanical vapour recompression, in the pasteurisation and concentration of juice.     

Enhanced recycling through a materials tax

This article attempts to evaluate whether an appropriate consumption-based tax is likely to be successful in reducing demand for certain exhaustible resources, thereby curtailing their rate of depletion and increasing the demand for, and utilization of, secondary materials. The nature of such a tax and anticipated effects (including environmental impact) of its imposition on certain primary materials are considered, concentrating here on one metal, aluminium. The study concludes that a tax based on the exhaustible resources and energy used in the production of a good is likely to create more savings for fossil fuels than for other exhaustible resources.     

Life cycle assessment of hot mix asphalt and zeolite-based warm mix asphalt with reclaimed asphalt pavement

A comprehensive life cycle assessment of asphalt pavements was conducted including hot mix asphalt (HMA), warm mix asphalt (WMA) with the addition of synthetic zeolites, and asphalt mixes with reclaimed asphalt pavement (RAP). The environmental impacts associated with energy consumption and air emissions were assessed, as well as other environmental impacts resulting from the extraction and processing of minerals, binders and chemical additives; asphalt production; transportation of materials; asphalt paving; road traffic on the pavement; land use; dismantling of the pavement at the end-of-life and its landfill disposal or recycling. Monte Carlo simulations were also conducted to take into account the variability of critical input parameters. Taking into account the entire life cycle, the impacts of zeolite-based WMA pavements were almost equal to the impacts of HMA pavements with the same RAP content. The reduction in the impacts of WMA resulting from the lowering of the manufacturing temperature was offset by the greater impacts of the materials used, especially the impacts of the synthetic zeolites. Moreover, by comparing asphalt mixes with different RAP contents, it was shown that the impacts of asphalt mixes were significantly reduced when RAP was added. All endpoint impacts as well as climate change, fossil depletion and total cumulative energy demand were decreased by 13–14% by adding 15% RAP. A key advantage of WMA is the potentially greater use of RAP. Thus, the decrease in the impacts achieved by adding large amounts of RAP to WMA could turn these asphalt mixes into a good alternative to HMA in environmental terms.     

Energy Consumption in the Turkish Industrial Sector

Turkey's primary energy resources seem limited as indigenous energy production meets nearly 31 % of the total primary energy demand. But the growth of Turkey's industry gives rise to a substantial increase in energy demand. Final energy consumption grew from 52.6 Mtoe (million tons of oil equivalent) in the year 1990 to 78.4 Mtoe in the year 2002. Industrial demand accounts for about 41.6 % of the final energy demand in Turkey. Basic metal industries, non-metallic material products and chemical and petroleum products have the highest energy consumption in industrial sector. In this work, industrial energy consumption and energy consumption of different indsutrial subsectors in Turkey are investigated.     

Environmental benefits of substituting talc by sugarcane bagasse fibers as reinforcement in polypropylene composites: Ecodesign and LCA as strategy for automotive components

The auto industry is compelled to improve its environmental performance, namely by making use of renewable materials and cleaner manufacturing processes with lower energy intensity, and at the end-of-life of the auto, recyclable products and materials are desirable specifications that need to be considered at an earlier design stage, i.e., promoting the ecodesign. This paper provides an analysis of such a strategy for a material that is used extensively in the auto industry, namely polypropylene composites, as we have quantified the environmental impacts when sugarcane bagasse-reinforced polypropylene substitutes for talc-filled polypropylene (PP). To achieve these goals, a comparative Life Cycle Assessment (LCA) was performed for the two alternatives, from raw extractions to the end-of-life (EOL) phase of sugarcane bagasse-PP and talc-PP composite, where data gathered in different industries in Brazil were included in the LCA GaBi software. Our analysis shows that in addition to similar mechanical performance, natural fiber composites showed superior environmental performance throughout the entire life cycle. This superior performance is because: (1) in the cultivation phase, sugarcane absorbs carbon through the photosynthesis process while growing, thus reducing the global warming impact of the materials used; (2) the production process is cleaner; (3) sugarcane bagasse-reinforced composites are lighter for equivalent performance, which reduces the amount of polypropylene used; and (4) the economic reuse proposed for the EOL sugarcane bagasse-PP composite was the best alternative to minimize environmental impacts.     

Sheep's wool insulation: A sustainable alternative use for a renewable resource?

Material selection in manufacturing may be characterized as a series of trade-offs between characteristics, properties, environmental impacts, sustainability, availability, and economics. Societal concerns about the environmental impacts of construction practices and materials have been expressed through an increase in the demand, production and use of “green” building products. This, combined with a desire to integrate more bioproducts and natural and renewable resources into the construction industry, has extended to the production and promotion of insulation made from sheep's wool.Although substantial literature exists on the insulation properties and other benefits of wool, less is known about the economics and manufacturing processes of sheep's wool insulation at varying scales of production. This paper contributes to this field of enquiry through presentation of the preliminary results of a wool insulation manufacturing pilot project, in which the scale and economics of the production of sheep's wool insulation were considered. Processing techniques, the impact of sheep breed, yield, energy use, and manufacturing costs were also examined. The results of the pilot project indicate that, while sheep's wool insulation produced at a smaller, or artisanal scale shows some potential, scale of operation and volume of production need to be carefully considered in order to ensure long-term sustainability of the operation. Using the least expensive sheep's wool available for the manufacture of wool batt insulation (and thereby reducing production costs) did not, in this pilot study, have a negative impact on productivity or product performance. Diversion of this waste stream of currently less marketable, and consequently less valuable wool, into the production of a green building material may offer small but significant benefit to sheep producers and the broader agricultural community, as well as consumers.     

Energy and carbon balances of wood cascade chains

In this study we analyze the energy and carbon balances of various cascade chains for recovered wood lumber. Post-recovery options include reuse as lumber, reprocessing as particleboard, pulping to form paper products, and burning for energy recovery. We compare energy and carbon balances of chains of cascaded products to the balances of products obtained from virgin wood fiber or from non-wood material. We describe and quantify several mechanisms through which cascading can affect the energy and carbon balances: direct cascade effects due to different properties and logistics of virgin and recovered materials, substitution effects due to the reduced demand for non-wood materials when wood is cascaded, and land use effects due to alternative possible land uses when less timber harvest is needed because of wood cascading. In some analyses we assume the forest is a limiting resource, and in others we include a fixed amount of forest land from which biomass can be harvested for use as material or biofuel. Energy and carbon balances take into account manufacturing processes, recovery and transportation energy, material recovery losses, and forest processes. We find that land use effects have the greatest impact on energy and carbon balances, followed by substitution effects, while direct cascade effects are relatively minor.     

Linkage Effects and Environmental Impacts from Oil Consumption Industries in Taiwan

Input–output modeling and cluster analysis are used to assess the impacts of oil consumption industries on environmental quality and inter-industry relationships in Taiwan. Results indicate that fuel oil has the greatest impact on the environment. The transportation sector has grown rapidly with high energy intensity and severe pollution emission in Taiwan. Also, power generation, other industrial chemicals, paper products, non-metallic mineral products, petro-chemical materials, rubber products, cement and textiles are identified as the most significant industries causing serious pollution problems in Taiwan. Results of inter-industry linkages confirm that investment of the above-mentioned industries should be adjusted to better energy efficiency, environmental quality and economic bases. This study indicates that energy policy should integrate environmental policy, in addition to assuring energy and economical gains.