we innovate to close material loops - essensciaadmin.essenscia.be/upload/docs/2014 03 26_we innovate...

WE INNOVATE to close material loops

Herman Derache, Sirris

27.03.14 © sirris | www.sirris.be | [email protected] | 1

And we help you become factories of the future

Closing material loops: challenges

27.03.14

Necessary, rewarding

Complex, multidisciplinary, multi-stakeholder

Technical

Logistical

Juridical

Economical

Psychological (behaviour)

And these aspects are linked

© sirris | www.sirris.be | [email protected] | 2

Some technical challenges

27.03.14 3

Material characterisation (eg. waste streams)

Sorting technology

Recycling technology

(adaptation of) product design

New material properties (recycled versus virgin)

Design for recycling

Reuse (eg. modular design)

Production process adaptation

Assessing life cycle impact (LCA)

Standards & norms

© sirris | www.sirris.be | [email protected] |

Sirris’ contributions

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Identification and prioritization of opportunities

Matchmaking +

Composing multidisciplinary teams (together with

our partner network)

Setting up vertically integrated projects

Bringing in the required techological expertise

Project execution and coordination

Collective actions and knowledge build-up

Broader scope than typical Sirris (technological +)


Sirris’ expertise

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Product design and development:

selection, modeling and

simulation, testing

Manufacturing:

parameter optimisation,

simulation, characterisation,…

Mechatronics:

sorting technology, internet of

things

Multi-X projects


Sustainability

27.03.14 6 © sirris | www.sirris.be | [email protected] |

METALS

COMPOSITES

PLASTICS & HYBRIDS

COATINGS

NANOMATERIALS

ECO-MECHATRONICS

SENSORIZED FUTURE

MODEL BASED DESIGN

FACTORIES OF FUTURE

WORLD CLASS TECHNOLOGIES

ADDITIVE MANUFACTURING

SOFTWARE ENGINEERING

CLOUD COMPUTING

DATA INNOVATION

Focus on metals, plastics and coatings

Bottom-up and top-down


Systemic changes: need for holistic approach

Learning by doing need for small scale experiments

Case: baby bottle reborn


Baby bottles from maternities: from waste incineration to material recycling

https://www.google.be/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=IxkiCQ5Z-q305M&tbnid=-GVPCYv9O6oGOM:&ved=0CAYQjRw&url=https://www.voedingscentrum.nl/nl/mijn-kind-en-ik/flesvoeding.aspx&ei=aREoU7OVIYna0QXr24HoDQ&bvm=bv.62922401,d.ZGU&psig=AFQjCNGLNDIy4ZyRX1nAIFmXG9UmN-cZ3w&ust=1395221190905781

http://www.fostplus.be/

http://www.indaver.be/nl.html

http://www.vangansewinkel.be/

http://www.fdme.be/index.php?id=2824

http://www.kras-recycling.com/

http://www.google.be/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=0ZNp7EpcKqvZiM&tbnid=N4NCVTS-ArdC3M:&ved=0CAYQjRw&url=http://www.inspirerend-wonen.be/doe-het-zelf-2/diy-fiches-afwerking/afval-sorteren-goed-recycleren.html&ei=6xkoU5ahAdHK0AXVn4HoBQ&bvm=bv.62922401,d.ZGU&psig=AFQjCNGAZ0tyftJd4GUcxwnnp9sWcTrxgg&ust=1395223354167471

Case: Verimpex

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From discarded airplane tires to flooring mats.


Source: www.verimpex.be

http://www.verimpex.be/www/main.asp

http://www.verimpex.be/www/main.asp?MainItem=productgamma_details&productgamma_ID=TireGuard

Case: CycLED

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Recycling of critical metals in LEDs


Production

and manufac-

turing

Collection

of end-of-life

products

Raw

materials extraction

Use

Residues

Waste

prevention and industrial

symbiosis

Natural

resources

Production waste for

recycling (new scrap)

Assembling

Residues

Residues

Residues

Residues

Waste

prevention and industrial

symbiosis

Industrial

symbiosis

Waste

prevention and product reuse

Component

reuseProduct

reuse

Material recovery

Pre-

processing of waste

material

Residues

Legend: Existent material flow

Flow to be increasedFlow to be decreased

Reuse of waste

materials for production

www.cyc-led.eu

SIM: an opportunity for “circular” materials research

• ”Strategic Initiative Materials”

• Established in 2009 as a joint initiative by Flemish academia and the materials industry

• Virtual Organisation

own limited staff (lean)

research is subcontracted to Flemish universities & research centres (flexible)

• Funded by the Flemish Government

SIM SIBO programme structure and

• Phase 1: call for strategic programmes within SIM themes, using long-term industrial roadmaps, presented and managed by an industrial consortium (demand driven)

• Phase 2: call for projects within the approved programmes

• Final budget allocation by SIM depending on available budget and SIM’s KPIs

• Essentially two types of projects:

– Strategic Basic Research (SBO)

– Industrial Cooperative Research (ICON)

SIM Themes

Sustainable Cradle2Cradle

Materials

for

Energy

& Light

Durable &

Sustainable

Structural

Materials

Market

Technology

Tailored Nanomaterials

Sustainable materials

Recyclable

Materials

Predictive Modeling & Advanced Material Characterization

Closing the materials cycle loop

1. In SIM’s current programmes sustainability is a crucial criterium (conditio sine qua non)

2. Within the additive manufacturing programme recyclability of raw materials (mainly plastics) is one of the major topics

3. Phase 1 programme call “recyclable materials” is open!

Closing date June 2nd 2014

www.sim-flanders.be/call/call-11-recyclable-materials

Conclusions


Source : Ellen MacArthur foundation

http://www.google.be/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=rBzTgvIFJByohM&tbnid=LFm0Kqr6rUKeyM:&ved=0CAYQjRw&url=http://www.ellenmacarthurfoundation.org/case_studies/desso&ei=i08oU--uAoaN7AaNwIGoBg&bvm=bv.62922401,d.ZGU&psig=AFQjCNFKH8PWamIfZ9cBgMT7nMK3D4GIcg&ust=1395236977202264

Critical succes factors

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1. Stop the fragmentation

2. Top-down: smart specialization based on local

strengths and roadmaps (BE + EU)

1. EIP Raw Materials, KIC Raw Matters,…

3. Facilitate bottom-up experiments

1. Non-technological barriers & transition aspects

2. Continue to stimulate ecodesign and life cycle

thinking within manufacturing industry


18

Welke transformaties zijn nodig opdat

productontwikkeling & productie

samen een duurzame toekomst hebben

in Vlaanderen

ondanks de context van hogere kosten?

UITDAGING?

FABRIEK VAN DE TOEKOMST (FVT)

Producten en diensten

met een toegevoegde

waarde x 2

Kennisgedreven jobs

op alle niveaus

Energieverbruik

< 50%

Materiaalverbruik

< 50%

World class productiesystemen

flexibiliteit x2

Time to market 2 x sneller

Globale

markt Fabriek van de

Toekomst

http://www.printableworldmap.org/index.htm

20

EXCELLEREN NAAR FVT DOOR

7 GEÏNTEGREERDE TRANSFORMATIES

SMART PRODUCTION

ECO-PRODUCTION NETWORKED FACTORY HUMAN-CENTERED PRODUCTION

DIGITAL FACTORY WORLD-CLASS PRODUCTION

TECHNOLOGIES

SIMULTANEOUS PRODUCT & PRODUCTION DEVELOPMENT

0,0

1,0

2,0

3,0

4,0

5,0

T1 WORLD CLASSPRODUCTIEMIDDELEN

T2 SIMULTANE PRODUCT- ENPRODUCTIEONTWIKKELING

T3 DIGITALE FABRIEK

T4 HUMAN CENTEREDPRODUCTIE

T5 GENETWERKTE FABRIEK

T6 ECO-PRODUCTIE

T7 SLIMME FABRIEK

Tenneco Factory of the Future

21

1. Intake / Ambitieniveau

2. Nulaudit

3. Ontwerp nieuw productieproces IWT 3 mio €

4. Start uitvoering 6. Concurrentie-

positie versterkt

5. FvT Audit

0,0

1,0

2,0

3,0

4,0

5,0

T1 WORLD CLASSPRODUCTIEMIDDELEN

T2 SIMULTANE PRODUCT- ENPRODUCTIEONTWIKKELING

T3 DIGITALE FABRIEK

T4 HUMAN CENTEREDPRODUCTIE

T5 GENETWERKTE FABRIEK

T6 ECO-PRODUCTIE

T7 SLIMME FABRIEK

Tenneco Factory of the Future

AANPAK TRANSFORMATIE?

+32 498 91 93 95

[email protected]

Herman Derache, directeur

27.03.14 © sirris | www.sirris.be | [email protected] |

hermanderache

hermanderache

http://www.sirris.be

#sirris

http://www.linkedin.com/company/sirris

27.03.14

http://techniline.sirris.be


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