A case study on the improvement of eco-efficiency ratios: application to a composite processing industry

The World Business Council for Sustainable Development (WBCSD) defines Eco-Efficiency as follows: ‘Eco- Efficiency is achieved by the delivery of competitively priced-goods and services that satisfy human needs and bring quality of life, while progressively reducing ecological impacts and resource intensity throughout the life-cycle to a level at least in line with the earth’s estimated carrying capacity’. Eco-Efficiency is under this point of view a key concept for sustainable development, bringing together economic and ecological progress. Measuring the Eco-Efficiency of a company, factory or business, is a complex process that involves the measurement and control of several and relevant parameters or indicators, globally applied to all companies in general, or specific according to the nature and specificities of the business itself. In this study, an attempt was made in order to measure and evaluate the eco-efficiency of a pultruded composite processing company. For this purpose the recommendations of WBCSD [1] and the directives of ISO 14301 standard [2] were followed and applied. The analysis was restricted to the main business branch of the company: the production and sale of standard GFRP pultrusion profiles. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined according to ISO 14031 recommendations. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent eco-efficiency’s ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and ecoefficiency ratios were estimated taking into account the implementation of new proceedings and procedures, both in upstream and downstream of the production process, namely: a) Adoption of new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; b) Implementation of new software for stock management (raw materials and final products) that minimize production failures and delivery delays to final consumer; c) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. In particular, the last approach seems to significantly improve the eco-efficient performance of the company. Currently, by-products and wastes generated in the manufacturing process of GFRP profiles are landfilled, with supplementary added costs to this company traduced by transport of scrap, landfill taxes and required test analysis to waste materials. However, mechanical recycling of GFRP waste materials, with reduction to powdered and fibrous particulates, constitutes a recycling process that can be easily attained on heavy-duty cutting mills. The posterior reuse of obtained recyclates, either into a close-looping process, as filler replacement of resin matrix of GFRP profiles, or as reinforcement of other composite materials produced by the company, will drive to both costs reduction in raw materials and landfill process, and minimization of waste landfill. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Mix design process of polyester polymer mortars modified with recycled GFRP waste materials

In this study, the effect of incorporation of recycled glass fibre reinforced plastics (GFRP) waste materials, obtained by means of shredding and milling processes, on mechanical behaviour of polyester polymer mortars (PM) was assessed. For this purpose, different contents of GFRP recyclates, between 4% up to 12% in weight, were incorporated into polyester PM materials as sand aggregates and filler replacements. The effect of the addition of a silane coupling agent to resin binder was also evaluated. Applied waste material was proceeding from the shredding of the leftovers resultant from the cutting and assembly processes of GFRP pultrusion profiles. Currently, these leftovers as well as non-conform products and scrap resulting from pultrusion manufacturing process are landfilled, with additional costs to producers and suppliers. Hence, besides the evident environmental benefits, a viable and feasible solution for these wastes would also conduct to significant economic advantages. Design of experiments and data treatment were accomplish by means of full factorial design approach and analysis of variance ANOVA. Experimental results were promising toward the recyclability of GFRP waste materials as partial replacement of aggregates and reinforcement for PM materials, with significant improvements on mechanical properties of resultant mortars with regards to waste-free formulations.

Sustainable waste recycling solution for the glass fibre reinforced polymer composite materials industry

In this paper the adequacy and the benefit of incorporating glass fibre reinforced polymer (GFRP) waste materials into polyester based mortars, as sand aggregates and filler replacements, are assessed. Different weight contents of mechanically recycled GFRP wastes with two particle size grades are included in the formulation of new materials. In all formulations, a polyester resin matrix was modified with a silane coupling agent in order to improve binder-aggregates interfaces. The added value of the recycling solution was assessed by means of both flexural and compressive strengths of GFRP admixed mortars with regard to those of the unmodified polymer mortars. Planning of experiments and data treatment were performed by means of full factorial design and through appropriate statistical tools based on analyses of variance (ANOVA). Results show that the partial replacement of sand aggregates by either type of GFRP recyclates improves the mechanical performance of resultant polymer mortars. In the case of trial formulations modified with the coarser waste mix, the best results are achieved with 8% waste weight content, while for fine waste based polymer mortars, 4% in weight of waste content leads to the higher increases on mechanical strengths. This study clearly identifies a promising waste management solution for GFRP waste materials by developing a cost-effective end-use application for the recyclates, thus contributing to a more sustainable fibre-reinforced polymer composites industry.

Level monitoring system for waste oil containers: an EPS@ISEP project

Waste oil recycling companies play a very important role in our society. Competition among companies is tough and process optimization is essential for survival. By equipping oil containers with a level monitoring system that periodically reports the level and alerts when it reaches the preset threshold, the oil recycling companies are able to streamline the oil collection process and, thus, reduce the operation costs while maintaining the quality of service. This paper describes the development of this level monitoring system by a team of four students from different engineering backgrounds and nationalities. The team conducted a study of the state of the art, draw marketing and sustainable development plans and, finally, designed and implemented a prototype that continuously measures the container content level and sends an alert message as soon as it reaches the preset capacity.

Mechanical behaviour analysis of polyester polymer mortars modified with recycled GFRP waste materials

In this study the effect of incorporation of recycled glass-fibre reinforced polymer (GFRP) waste materials, obtained by means of milling processes, on mechanical behaviour of polyester polymer mortars was assessed. For this purpose, different contents of recycled GFRP waste powder and fibres, with distinct size gradings, were incorporated into polyester based mortars as sand aggregates and filler replacements. Flexural and compressive loading capacities were evaluated and found better than unmodified polymer mortars. GFRP modified polyester based mortars also show a less brittle behaviour, with retention of some loading capacity after peak load. Obtained results highlight the high potential of recycled GFRP waste materials as efficient and sustainable reinforcement and admixture for polymer concrete and mortars composites, constituting an emergent waste management solution.

Optimization process of polyester polymer mortars modified with recycled GFRP waste aggregates – application of factorial experiment design-

Glass fibre-reinforced plastics (GFRP), nowadays commonly used in the construction, transportation and automobile sectors, have been considered inherently difficult to recycle due to both: cross-linked nature of thermoset resins, which cannot be remolded, and complex composition of the composite itself, which includes glass fibres, matrix and different types of inorganic fillers. Presently, most of the GFRP waste is landfilled leading to negative environmental impacts and supplementary added costs. With an increasing awareness of environmental matters and the subsequent desire to save resources, recycling would convert an expensive waste disposal into a profitable reusable material. There are several methods to recycle GFR thermostable materials: (a) incineration, with partial energy recovery due to the heat generated during organic part combustion; (b) thermal and/or chemical recycling, such as solvolysis, pyrolisis and similar thermal decomposition processes, with glass fibre recovering; and (c) mechanical recycling or size reduction, in which the material is subjected to a milling process in order to obtain a specific grain size that makes the material suitable as reinforcement in new formulations. This last method has important advantages over the previous ones: there is no atmospheric pollution by gas emission, a much simpler equipment is required as compared with ovens necessary for thermal recycling processes, and does not require the use of chemical solvents with subsequent environmental impacts. In this study the effect of incorporation of recycled GFRP waste materials, obtained by means of milling processes, on mechanical behavior of polyester polymer mortars was assessed. For this purpose, different contents of recycled GFRP waste materials, with distinct size gradings, were incorporated into polyester polymer mortars as sand aggregates and filler replacements. The effect of GFRP waste treatment with silane coupling agent was also assessed. Design of experiments and data treatment were accomplish by means of factorial design and analysis of variance ANOVA. The use of factorial experiment design, instead of the one factor at-a-time method is efficient at allowing the evaluation of the effects and possible interactions of the different material factors involved. Experimental results were promising toward the recyclability of GFRP waste materials as polymer mortar aggregates, without significant loss of mechanical properties with regard to non-modified polymer mortars.

Experiments on new polymer based mortars filled with FRP waste recyclates - a quantitative analysis

Glass fibre-reinforced plastics (GFRP) have been considered inherently difficult to recycle due to both: cross-linked nature of thermoset resins, which cannot be remolded, and complex composition of the composite itself. Presently, most of the GFRP waste is landfilled leading to negative environmental impacts and supplementary added costs. With an increasing awareness of environmental matters and the subsequent desire to save resources, recycling would convert an expensive waste disposal into a profitable reusable material. In this study, efforts were made in order to recycle grinded GFRP waste, proceeding from pultrusion production scrap, into new and sustainable composite materials. For this purpose, GFRP waste recyclates, were incorporated into polyester based mortars as fine aggregate and filler replacements at different load contents and particle size distributions. Potential recycling solution was assessed by mechanical behaviour of resultant GFRP waste modified polymer mortars. Results revealed that GFRP waste filled polymer mortars present improved flexural and compressive behaviour over unmodified polyester based mortars, thus indicating the feasibility of the waste reuse in polymer mortars and concrete. © 2011, Advanced Engineering Solutions.

Recycling of pultrusion production waste into innovative concrete-polymer composite solutions

In this study, the added value resultant from the incorporation of pultrusion production waste into polymer based concretes was assessed. For this purpose, different types of thermoset composite scrap material, proceeding from GFRP pultrusion manufacturing process, were mechanical shredded and milled into a fibrous-powdered material. Resultant GFRP recyclates, with two different size gradings, were added to polyester based mortars as fine aggregate and filler replacements, at various load contents between 4% up to 12% in weight of total mass. Flexural and compressive loading capacities were evaluated and found better than those of unmodified polymer mortars. Obtained results highlight the high potential of recycled GFRP pultrusion waste materials as efficient and sustainable admixtures for concrete and mortar-polymer composites, constituting an emergent waste management solution.

GFRP waste reinforced polymer mortars: a new waste management solution for GFRP scrap material

To date, glass fibre reinforced polymer (GFRP) waste recycling is very limited and restricted by thermoset nature of binder matrix and lack of economically viable enduse applications for the recyclates. In this study, efforts were made in order to recycle grinded GFRP waste proceeding from pultrusion production scrap, into new and sustainable composite materials. For this purpose, GFRP waste recyclates, a mix of powdered and fibrous materials, were incorporated into polyester based mortars as fine aggregate and filler replacements, at different load contents (between 4% up to 12% of total mass) and particle size distributions. Potential recycling solution was assessed by mechanical behaviour of resultant GFRP waste modified polymer mortars. Test results revealed that GFRP waste filled polymer mortars present improved flexural and compressive behaviour over unmodified polyester based mortars, thus indicating the feasibility of GFRP waste reuse in concrete-polymer composites.

Waste collection routing-limited multiple landfills and heterogeneous fleet

This article deals with a real-life waste collection routing problem. To efficiently plan waste collection, large municipalities may be partitioned into convenient sectors and only then can routing problems be solved in each sector. Three diverse situations are described, resulting in three different new models. In the first situation, there is a single point of waste disposal from where the vehicles depart and to where they return. The vehicle fleet comprises three types of collection vehicles. In the second, the garage does not match any of the points of disposal. The vehicle is unique and the points of disposal (landfills or transfer stations) may have limitations in terms of the number of visits per day. In the third situation, disposal points are multiple (they do not coincide with the garage), they are limited in the number of visits, and the fleet is composed of two types of vehicles. Computational results based not only on instances adapted from the literature but also on real cases are presented and analyzed. In particular, the results also show the effectiveness of combining sectorization and routing to solve waste collection problems.

Electromagnetism based approach to Sector design in Waste Collection

For efficient planning of waste collection routing, large municipalities may be partitioned into convenient sectors. The real case under consideration is the municipality of Monção, in Portugal. Waste collection involves more than 1600 containers over an area of 220 km2 and a population of around 20,000 inhabitants. This is mostly a rural area where the population is distributed in small villages around the 33 boroughs centres (freguesia) that constitute the municipality. In most freguesias, waste collection is usually conducted 3 times a week. However, there are situations in which the same collection is done every day. The case reveals some general and specific characteristics which are not rare, but are not widely addressed in the literature. Furthermore, new methods and models to deal with sectorization and routing are introduced, which can be extended to other applications. Sectorization and routing are tackled following a three-phase approach. The first phase, which is the main concern of the presentation, introduces a new method for sectorization inspired by Electromagnetism and Coulomb’s Law. The matter is not only about territorial division, but also the frequency of waste collection, which is a critical issue in these types of applications. Special characteristics related to the number and type of deposition points were also a motivation for this work. The second phase addresses the routing problems in each sector: new Mixed Capacitated Arc Routing with Limited Multi-Landfills models will be presented. The last phase integrates Sectoring and Routing. Computational results confirm the effectiveness of the entire novel approach.

Projeto de uma ETAR para a freguesia de Canelas, Penafiel

O tratamento das águas residuais domésticas surge com o intuito de degradar os poluentes presentes, para que as águas residuais tratadas não prejudiquem o ambiente nem a saúde pública. O presente trabalho teve como objetivo a conceção e o dimensionamento de uma Estação de Tratamento de Águas Residuais (ETAR) na freguesia de Canelas com a finalidade de substituir a já existente e permitir a ampliação da área da rede de saneamento da freguesia. Foram considerados dois tipos de ETAR’s, compacta e convencional, para tratar águas residuais domésticas de aproxidamente 2000 habitantes, com um caudal médio de 400 m3/dia e um caudal de ponta de 1136,7 m3/dia. Das duas opções optou-se pela convencional uma vez que acarreta um menor investimento, no valor de 187 232 €, e se considera também mais adequada às características do efluente a tratar. O tratamento escolhido inclui inicialmente uma gradagem, com uma grade constituída por sete barras com um espaçamento de 20 mm entre elas, seguida de um tamisador rotativo com uma abertura de malha de 3 mm. Depois do tamisador, optou-se por um sistema de desarenação/desengorduramento com um volume do tanque de 3,95 m3 e um fluxo de ar de 17,9 m3/h. Na fase seguinte considerou-se um tratamento biológico por lamas ativadas em regime de arejamento prolongado num tanque de arejamento de volume igual a 245,8 m3 com um arejador submerso, seguindo-se um decantador secundário de volume 33,3 m3. Por último, escolheu-se um sistema de desinfeção por ultravioleta e, a montante do mesmo, um filtro rápido para eliminar pequenas partículas que o efluente ainda possa conter. Para a desinfeção foram consideradas duas secções com cinco módulos de duas lâmpadas cada, ou seja, vinte lâmpadas ultravioleta. Dos resíduos produzidos pelo tratamento da água residual, os gradados e as areias serão encaminhados para aterro, enquanto que as lamas serão enviadas para a ETAR das Termas de S.Vicente, para que sofram o tratamento adequado e sejam encaminhadas para o destinal final adequado (aplicação em solos agrícolas, compostagem ou em alternativa para aterro). No caso da ETAR covencional foi ainda avaliada a possível reutilização de um decantador da ETAR de Milhundos uma vez que esta se encontrava em fase de desativação. Desta avaliação, concluiu-se que não seria economicamente viável o seu reaproveitamento. Mestrado em Engenharia Química – Tecnologias de Proteção Ambiental Para além disso realizou-se também um levantamento dos principais problemas que ocorrem na maioria das ETAR’s e foram apresentadas as respetivas sugestões de resolução. A realização de um inquérito permititu concluir que os odores são o problema que mais causa incómodo à população.

Estudo da Resistência Mecânica do Betão com Agregado Cerâmico Vermelho

Os sectores da construção e demolição de edifícios são responsáveis por um elevado volume de produção de resíduos. Estes resíduos são normalmente direcionados para aterros, que se encontram, neste momento, sobrelotados. Esta falta de capacidade de receção de resíduos tem como consequência imediata o aumento dos valores monetários associados ao depósito destes materiais excedentários. Com a elevada produção destes resíduos torna-se importante a sua reciclagem e reutilização. No caso da Engenharia Civil, uma grande produtora de resíduos, seria ainda mais interessante o seu reaproveitamento imediato na área. Nesta investigação, pretendeu-se avaliar o desempenho mecânico de betões com diferentes percentagens de agregados cerâmicos vermelhos. Essa investigação passou numa fase inicial pelo estado fresco do betão, de forma a analisar a sua trabalhabilidade. Na fase seguinte, analisou-se no estado endurecido, a resistência à compressão e resistência à tração por compressão diametral. Para concretização deste objetivo produziram-se três tipos de betões: um de referência (areia fina e brita fina), um betão com incorporação de agregados finos e grossos de cerâmica vermelha, juntamente com a areia fina e a brita fina, e o terceiro, um betão com a substituição total da areia fina por cerâmica fina. A realização desta investigação, demostrou que os betões com a incorporação de agregado cerâmico vermelho apresentam resultados de boa qualidade, sendo plausível a sua utilização em estruturas.