Increase Material Efficiency Research Articles

Digitalisation as Enabler Towards a Sustainable Circular Economy in Germany

The increasing use of digital networking in complex industrial processes opens up new potential for more sustainability. This paper delivers the first empirical findings on the relevance of digitalisation for improving material efficiency in German industry based on a unique dataset including nearly 600 manufacturing firms. The survey results indicate that the opportunities of digital networking for increasing material efficiency are only being used to a limited extent thus far, primarily for traditional efficiency-raising measures optimising manufacturing processes.

A new lightweight design method integrating shape optimization with life cycle assessment for extrusion dies

Extrusion dies, in which melted raw materials are forced continuously into a profile to produce various plastic products, are often empirically designed leading to overweight and waste in materials, energy and emissions. Lightweight design method has been applied to reduce weight and increase material efficiency of extrusion dies at design stage. However, the research work was often focused on weight reduction with function requirements as the design constricts. Environmental impacts (EIs) over the entire life cycle of dies are not considered, as a result, it may result in environmental burdens being shifted from design stage to other stages of life cycle of products. Aiming at it, a new lightweight design method is proposed to integrate life cycle assessment (LCA) with shape optimization. The optimization mathematic models for the proposed method are developed, in which the EIs of extrusion dies are modeled as a function of shape variables and processing parameters. An example of extrusion dies for plastic pipe was presented to illustrate the effectiveness of the proposed method. The results showed that 13% weight reduction whist achieving reduction in EIs over the life cycle of dies in comparison with 18% weight reduction yet 29% increase in EIs at manufacturing stage and resultant increase in EIs over the life cycle using conventional lightweight design method in which EIs are not taken into account. It indicated that the proposed lightweight method could have great potentials to reduce weight and prevent environmental burdens shift problem.

Advancing Formwork Systems for the Production of Precast Concrete Building Elements: from Manual to Robotic

The utilization of precast concrete offers significant benefits in terms of increased material efficiency, safety, labor productivity, and reduced time, cost and wastage over conventional on- site construction. In the meantime, challenges exist in the precast concrete production in the high requirements for dimensional accuracy of precast elements, flexibility and reusability of formwork, and stability of shuttering. Formwork systems are a critical component of the precast production line, which is also the key to innovation from manual to automated and robotic. Previous studies seldom examined the competitive features of such systems within the context of the building prefabrication process. The aim of this paper is to explore the future development directions of, and to identify transferable advanced technologies for, advanced formwork systems in the production of precast concrete building elements. The research was carried out by comparing the conventional and advanced approaches drawing on the case of high-rise buildings in Hong Kong. The results indicate that automation and robotic technologies offer unique advantages in the betterment of the formwork system. Besides gains in productivity, reliability and accuracy, the adoption of robotic systems also provide the great benefit of cost-effectiveness owing to the high labor cost and fast growing market in Hong Kong. However, there also exist barriers to advancing formwork systems for precast, including industry and culture reluctance, high capital costs and skill shortages. The findings should contribute to a better understanding of how automated and robotic technologies could advance the formwork systems in the precast production, which can further reap the benefits of prefabrication and facilitate innovation in building industry.

Decarbonising the energy intensive basic materials industry through electrification – Implications for future EU electricity demand

The need for deep decarbonisation in the energy intensive basic materials industry is increasingly recognised. In light of the vast future potential for renewable electricity the implications of electrifying the production of basic materials in the European Union is explored in a what-if thought-experiment. Production of steel, cement, glass, lime, petrochemicals, chlorine and ammonia required 125 TW-hours of electricity and 851 TW-hours of fossil fuels for energetic purposes and 671 TW-hours of fossil fuels as feedstock in 2010. The resulting carbon dioxide emissions were equivalent to 9% of total greenhouse gas emissions in EU28. A complete shift of the energy demand as well as the resource base of feedstocks to electricity would result in an electricity demand of 1713 TW-hours about 1200 TW-hours of which would be for producing hydrogen and hydrocarbons for feedstock and energy purposes. With increased material efficiency and some share of bio-based materials and biofuels the electricity demand can be much lower. Our analysis suggest that electrification of basic materials production is technically possible but could have major implications on how the industry and the electric systems interact. It also entails substantial changes in relative prices for electricity and hydrocarbon fuels.

A Systemic and Systematic Approach to the Development of a Policy Mix for Material Resource Efficiency

Increasing material use efficiency is important to mitigate future supply risks and minimize environmental impacts associated with the production of the materials. The policy mix presented in this paper aims to contribute to reducing the use of virgin metals in the EU by 80% by 2050 without significant shifting of burdens to other material resources, environmental impacts, or parts of the world. We used a heuristic framework and a systems perspective for designing the policy mix that combines primary instruments designed to increase material efficiency, recycling and substitution of materials (a materials tax, the extended producer responsibility, technical regulations, and environmental taxes) and supportive instruments aimed to reduce barriers to implementing the primary instruments and to contribute towards the policy objectives (e.g., research and development support, and advanced recycling centers). Furthermore, instruments were designed so as to increase political feasibility: e.g., taxes were gradually increased as part of a green fiscal reform, and border-tax adjustments were introduced to reduce impacts on competitiveness. However, even in such a policy mix design ongoing ex-ante assessments indicate that the policy mix will be politically difficult to implement—and also fall short of achieving the 80% reduction target. Nonetheless, we suggest combining primary and supportive instruments into coherent and dynamic policy mixes as a promising step towards system reconfigurations for sustainability.

A performative definition of waste prevention

The increasing importance being placed on waste prevention in European waste governance raises the question of how waste prevention is defined in practice. This paper presents a qualitative analysis of a sample of fifty-one Swedish waste prevention initiatives with the purpose of identifying which kind of actions are imagined, promoted, and set into motion under the label of waste prevention. The analysis shows that despite their apparent variety, the initiatives in the sample boil down to three main types of actions: raising awareness about the need to prevent waste, increasing material efficiency, and developing sustainable consumption. In contradistinction to the formal definition of waste prevention in the European Waste Framework Directive (2008/98/EC), what emerges from analyzing the initiatives in the sample is a performative definition of waste prevention as something heterogeneous, contradictory, and evolving. Such a definition of waste prevention in practice provides an understanding of the organizational dynamics of waste prevention.

Investigating environmental management accounting in the chemical industry in South Africa

Environmental issues are of increasing concern to a variety of stakeholders in most countries all around the world. There is a growing consensus that conventional accounting practices simply do not provide adequate information to support decision-making in order to manage the environment. Environmental management accounting (EMA) is a combined approach that provides for the transition of data from financial accounting, cost accounting and mass balances to increase material efficiency, reduce environmental impacts and risks and, ultimately, lead to the reduction of environmental costs. This paper investigates the practise of EMA in the chemical industry. A questionnaire was administrated to a selected group of participants who are employees in the chemical industry in South Africa. Different functional roles from different types of chemical companies were identified to participate. The findings of this paper indicate that there is a good level of awareness of EMA in the South African chemical industry. Most organizations are applying sound environmental practices and are adopting environmental strategies and tools to improve their current status. Different levels of awareness exist between the different functional roles in the respective organizations. Operational and capital environmental information are disclosed and organizations do generate and record information on physical and monetary environmental management accounting

A framework for material flow assessment in manufacturing systems

Improving material efficiency is widely accepted as one of the key challenges facing manufacturers in the future. Increasing material consumption is having detrimental impacts on the environment as a result of their extraction, processing, and disposal. It is clear that radical improvements in material efficiency are required to avoid further environmental damage and sustain the manufacturing sector. Current resource management approaches are predominantly used to improve material consumption solely in economic terms. Meanwhile, environmental assessment methodologies can determine sources of significant environmental impact related to a product; however, a methodology to effectively assess material efficiency in production systems is currently not available. This paper highlights the benefits of material flow modeling within manufacturing systems to support advances in increased material efficiency, proposing a framework for “material flow assessment in manufacturing” that promotes greater understanding of material flow and flexibility to explore innovative options for improvement.

Material Efficient Manufacturing of Three-Dimensional Components Using Metal Knitting

The high investment cost and long lead-time to design and manufacture a forming tool is a major obstacle for local manufacturing of products in sheet metal. To minimize resource consumption large efforts are put into increase material efficiency by reducing the thickness of the sheet and move towards production methods with less scrap percentage. Nevertheless, the scrap portion is still high, in the automotive industry often as high as 50%. This paper discuss the possibilities of introducing knitting of metal wire into metal engineering industry to manufacture scrap free, light-weight three dimensional components in metal. Knitting could be a way of obtaining material efficient production within metal engineering industry especially for small and medium sized enterprises, SME. A knitting machine is able to produce large amounts of products at low price with moderate investments costs. For certain products knitting offer a simplified production of ready formed, 3D components. Experiments with knitting stainless steel wire were performed in order to establish the possibilities and limits of knitting today as well as identify development possibilities. The experiments covered improving the stiffness of the metal knit-wear by using different knitting techniques as well as introducing subsequent manufacturing steps such as surface treatment and joining. Demonstrators where produces for a number of geometries; squares, rectangles, boxes, hour-glass like in 2D and tubular, conical and T-tube shaped in 3D. For two geometries produced with knitting and sheet metal forming the material efficiency was compared. The first geometry used 32 % less material in the knitted product compared to the sheet metal component. The second geometry used 72 % less material in the knitted component compared to the sheet metal component. However, properties like strength and stiffness will be considerable less for a knitted component than for a sheet metal component. Today applications for the knitted materials have to be chosen carefully to take advantage of the potential of the material. With further development of both the knitting technique and subsequent operations the process will open new possibilities of material efficient and light-weight manufacturing.

The potential contribution of sustainable waste management to energy use and greenhouse gas emission reduction in the Netherlands

Future limitations on the availability of selected resources stress the need for increased material efficiency. In addition, in a climate-constrained world the impact of resource use on greenhouse gas emissions should be minimized. Waste management is key to achieve sustainable resource management. Ways to use resources more efficiently include prevention of waste, reuse of products and materials, and recycling of materials, while incineration and anaerobic digestion may recover part of the embodied energy of materials. This study used iWaste, a simulation model, to investigate the extent to which savings in energy consumption and CO2 emissions can be achieved in the Netherlands through recycling of waste streams versus waste incineration, and to assess the extent to which this potential is reflected in the LAP2 (currently initiated policy). Three waste streams (i.e. household waste, bulky household waste, and construction and demolition waste) and three scenarios compare current policy to scenarios that focus on high-quality recycling (Recycling+) or incineration with increased efficiency (Incineration+). The results show that aiming for more and high-quality recycling can result in emission reductions of 2.3MtCO2 annually in the Netherlands compared to the reference situation in 2008. The main contributors to this reduction potential are found in optimizing the recycling of plastics (PET, PE and PP), textiles, paper, and organic waste. A scenario assuming a higher energy conversion efficiency of the incinerator treating the residual waste stream, achieves an emission reduction equivalent to only one third (0.7MtCO2/year) of the reduction achieved in the Recycling+ scenario. Furthermore, the results of the study show that currently initiated policy only partially realizes the full potential identified. A focus on highest quality use of recovered materials is essential to realize the full potential energy and CO2 emission reduction identified for the Netherlands. Detailed economic and technical analyses of high quality recycling are recommended to further evaluate viable integrated waste management policies.

Experimental Research on Static Behavior of Stiffened Square Concrete-Filled Steel Tubular Columns Subjected to Axial Load

Square concrete-filled steel tubes (CFSTs) are gaining increasing usage in modern construction practice, offering improved mechanical properties and increased material efficiency compared with the individual steel and core concrete components. However, the cross-section slenderness of the encasing steel is, although more inflexible than a comparable hollow steel tube, restrained due to local buckling. A number of innovative kinds of reinforcement stiffeners have been put forward particularly for the square CFSTs with slender sections of encasing steel. To investigate the mechanical effect of the reinforcement stiffeners and compare them with traditional ones in practice, four square CFSTs welded with various reinforcement stiffeners and one reference CFST have been tested, and are presented in this paper. The mechanical behaviors such as the resistance, ductility and failure mode investigated during the test were also studied in the theoretical research, which was carried out to predict and summarize the comprehensive properties of the specimens.

Static behaviors of reinforcement-stiffened square concrete-filled steel tubular columns

Square concrete-filled steel tubes (CFSTs) are gaining increasing usage in modern construction practice, offering improved mechanical properties and increased material efficiency compared with the individual steel and core concrete components. However, the cross-section slenderness of the encasing steel is, although more inflexible than a comparable hollow steel tube, restrained due to local buckling. A number of innovative kinds of reinforcement stiffeners have been put forward particularly for the square CFSTs with slender sections of encasing steel. To investigate the mechanical effect of the reinforcement stiffeners and compare them with traditional ones in practice, four square CFSTs welded with various reinforcement stiffeners and one reference CFST have been tested, and are presented in this paper. The mechanical behaviors such as the resistance, ductility and failure modes investigated during the test were also studied in the theoretical research, which was carried out to predict and further summarize the comprehensive properties of the specimens. A numerical analysis program was written and verified with related scholars’ experimental data, and extensive parametric analysis was conducted to investigate the influencing parameters on mechanical properties. Design recommendation for the cross-section strength has been put forward based on the test results and previous research.

Determinants of eco-innovations by type of environmental impact — The role of regulatory push/pull, technology push and market pull

Empirical analyses of eco-innovation determinants have rarely been able to distinguish between different areas of environmental impact. The present paper tries to close this gap by employing a new and unique dataset based on the German Community Innovation Survey, conducted in 2009. The main purpose of this paper is to test whether different types of eco-innovation (according to their environmental impacts) are driven by different factors. Beside a complex set of different supply, firm-specific, and demand factors, the literature on determinants of eco-innovation accentuates the important role of regulation, cost savings and customer benefits. We find that current and expected government regulation is particularly important with regard to pushing firms to reduce air (e.g. CO2, SO2 or NOx) as well as water or noise emissions, avoid hazardous substances, and increase recyclability of products. Cost savings are an important motivation for reducing energy and material use, pointing to the role of energy and raw material prices as well as taxation as drivers for eco-innovation. Customer requirements are another important source of eco-innovations, particularly with regard to products with improved environmental performance and process innovations that increase material efficiency, and reduce energy consumption, waste and the use of dangerous substances. Firms confirm a high importance of expected future regulations for all environmental product innovations.

Drivers and barriers of effective industrial material use

The long-term goal of the European Union is to become a recycling society that uses waste as a resource (COM, 2005, p. 666). The basic objectives of current EU waste policy are to prevent waste and promote re-use, recycling and recovery so as to reduce negative environmental impact. In this paper we focus on drivers and barriers for increasing material efficiency by using industrial by-products instead of raw material.Environmental legislation, which includes both traditional categories such as environmental protection, pollution control, environmental assessment and waste, and new categories such as emissions trading, is one of the main drivers in improving material efficiency, but it may also become one of the main barriers (2008/98/EC). We find that the most important barriers for environmentally friendly innovations seem to be the cost of investment and the high risk involved in committing capital to unproven technology. Other drivers, like corporate social responsibility, stakeholder pressure and general public pressure, will also affect the final decision. The EU encourages member states to increase the use of a combination of regulatory and economic instruments. An important mental barrier is still the lack of realisation that there is an opportunity to choose, and that there is no obligatory need for a change and no sanctions for operating in a traditional way. Such a realisation might only come from legislation.

Economy-wide material flow indicators: Overall framework, purposes and uses and comparison of material use and resource intensity of the Czech Republic, Germany and the EU-15

Material flows induced by national economies can be regarded as indirect pressure indicators for environmental degradation. Economy-wide material flow analysis and indicators have been designed to monitor material and energy flows at the macroeconomic level and to provide indicators, which could contribute to management of resource use and output emission flows from both economic, environmental and broader sustainability points of view. These indicators can serve various purposes including monitoring the material basis of national economies and related environmental pressures, assessment of the material and resource productivity and monitoring the implications of trade and globalisation. The main part of this paper compares the material and resource use of the Czech Republic, Germany and the EU-15 by means of DMI and TMR indicators over the period of 1991–2004 (1991–2000 for EU-15). At the aggregate level both indicators in all three economies do not show any clear decreasing or increasing trends over the period considered. This means that environmental pressure related to use of materials for production and consumption purposes remains rather stable. All the economies however, recorded an increase in the efficiency of transforming the material/resource inputs into economic output. The analysis further revealed that most of the dynamics of DMI and TMR in the Czech Republic tended towards a higher similarity with Germany and the EU-15. In the future, further decreases in DMI as well as in TMR of fossils fuels might be expected in the Czech Republic, which could be counteracted by increase in DMI and TMR of metal ores/metal resources and non-metallic minerals/non-metallic resources. The future development of total DMI, TMR and material/resource intensity in both the Czech Republic and Germany will depend on further shifts to less material intensive industries and services and on increasing material efficiency in production and consumption of particular products. This is not only a technological, but also a social challenge, as there are barriers in current mode of governance and in shaping of current economic and social systems to do so.

Determinants of Eco-innovations by Type of Environmental Impact: The Role of Regulatory Push/Pull, Technology Push and Market Pull

Empirical analyses of the determinants of environmental innovations were rarely able to distinguish between different areas of environmental impacts. The paper tries to close this gap by employing a new and unique dataset based on the German Community Innovation Survey conducted in 2009. The main purpose of the paper is to test whether different types of eco-innovations (according to their environmental impacts) are driven by different factors. Besides a complex set of different supply, firm specific and demand factors, the literature on the determinants of environmental innovations accentuates the important role of regulation, cost savings and customer benefits. We find that current and expected government regulation is particularly important for pushing firms to reduce air (e.g. CO2, SO2 or NOx) as well as water or noise emissions, avoid hazardous substances and increase recyclability of products. Cost savings are an important motivation for reducing energy and material use, pointing to the role of energy and raw materials prices as well as taxation as drivers for eco-innovation. Customer requirements are another important source for eco-innovations, particularly with regard to products with improved environmental performance and process innovations that increase material efficiency, reduce energy consumption and waste and the use of dangerous substances. Firms confirm a high importance of expected future regulations for all environmental product innovations.

Nuclear Energy in Europe: Uranium Flow Modeling and Fuel Cycle Scenario Trade-Offs from a Sustainability Perspective

The European nuclear fuel cycle (covering the EU-27, Switzerland and Ukraine) was modeled using material flow analysis (MFA).The analysis was based on publicly available data from nuclear energy agencies and industries, national trade offices, and nongovernmental organizations. Military uranium was not considered due to lack of accessible data. Nuclear fuel cycle scenarios varying spent fuel reprocessing, depleted uranium re-enrichment, enrichment assays, and use of fast neutron reactors, were established. They were then assessed according to environmental, economic and social criteria such as resource depletion, waste production, chemical and radiation emissions, costs, and proliferation risks. The most preferable scenario in the short term is a combination of reduced tails assay and enrichment grade, allowing a 17.9% reduction of uranium demand without significantly increasing environmental, economic, or social risks. In the long term, fast reactors could theoretically achieve a 99.4% decrease in uranium demand and nuclear waste production. However, this involves important costs and proliferation risks. Increasing material efficiency is not systematically correlated with the reduction of other risks. This suggests that an overall optimization of the nuclear fuel cycle is difficult to obtain. Therefore, criteria must be weighted according to stakeholder interests in order to determine the most sustainable solution. This paper models the flows of uranium and associated materials in Europe, and provides a decision support tool for identifying the trade-offs of the alternative nuclear fuel cycles considered.

Competences for green development and leapfrogging in newly industrializing countries

Competences for green development and leapfrogging in Newly Industrializing Countries are becoming increasingly urgent from a global perspective. The integration of these innovations into the development process in the rapidly growing economies requires knowledge build-up and technology cooperation. The prospect of exporting sustainability technologies can add an incentive for them to move towards sustainability technologies. These issues also affect innovations to increase material efficiency, which are receiving increasing interest among sustainability innovations. The competences for green development are analyzed with an innovation indicator approach. The general innovation capabilities are evaluated using R&D indicators and survey results about general innovation capabilities. Technological competences in the sustainability fields are a key indicator for the absorptive capacity of sustainability technologies and for the ability to export them. International patents and publications, and successes in foreign trade indicate to what extent a country is already able to participate in global technology markets. The resulting pattern shows various strengths and weaknesses of the analyzed countries. In general, the knowledge build up in material efficiency strategies is above-average in the Newly Industrializing Countries. There is a strong need for strategic positioning of the countries and for coordination of the various policy fields involved.

Bipolar plates for PEM fuel cells

The bipolar plates are in weight and volume the major part of the PEM fuel cell stack, and are also a significant contributor to the stack costs. The bipolar plate is therefore a key component if power density has to increase and costs must come down. Three cell plate technologies are expected to reach targeted cost price levels, all having specific advantages and drawbacks. NedStack has developed a conductive composite materials and a production process for fuel cell plates (bipolar and mono-polar). The material has a high electric and thermal conductivity, and can be processed into bipolar plates by a proprietary molding process. Process cycle time has been reduced to less than 10 s, making the material and process suitable for economical mass production. Other development work to increase material efficiency resulted in thin bipolar plates with integrated cooling channels, and integrated seals, and in two-component bipolar plates. Total thickness of the bipolar plates is now less than 3 mm, and will be reduced to 2 mm in the near future. With these thin integrated plates it is possible to increase power density up to 2 kW/l and 2 kW/kg, while at the same time reducing cost by integrating other functions and less material use.

The use of Environmental Management Accounting (EMA) for identifying environmental costs

The Expert Working Group on “Improving the Role of Government in the Promotion of Environmental Management Accounting (EMA)” was set up by the United Nations Division for Sustainable Development (UN DSD) in cooperation with a number of government agencies and non-governmental experts to promote Environmental Management Accounting (EMA) through publications, pilot projects and by establishing an international forum for discussion on the role of governments in the promotion of EMA. EMA, Environmental management accounting represents a combined approach that provides for the transition of data from financial accounting, cost accounting and mass balances to increase material efficiency, reduce environmental impacts and risks and reduce costs of environmental protection. EMA is performed by private or public corporations, but not by nations and has a financial as well as a physical component. The core focus of environmental management accounting and of the EMA UN DSD methodology is assessment of total annual environmental expenditure on emission treatment, disposal, environmental protection and management. In addition, and that is new and challenging for most companies, the material purchase value of all non-product output and its production costs are added. This total sum often provides a frightening picture of total annual costs of inefficiency and gets companies to improve their information systems and material efficiency options, which is the goal in the light of cleaner production. The first book published by the Expert Working Group, Environmental Management Accounting—Procedures and Principles (Jasch, C., United Nations, New York, 2001), defines principles and procedures for EMA, with a focus on techniques for quantifying environmental expenditures or costs, as a basis for better controlling and benchmarking purposes. The methodology excludes costs external to the company (so-called externalities, e.g. environmental and social effects that occur to the general public), but focuses on comprehensive assessment of direct annual expenditure on emission treatment, environmental protection and management as well as wasted material and energy input (efficiency losses in production). Firstly, total annual expenditure is assessed, then improvement options, savings and investment projects as well as product prices can be (re-)calculated. The method is currently applied in several case studies. The following summary provides some of the core definitions and generic assessment tables.