Which parameters characterise the life time of fibres in paper for recycling?

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1 Which parameters characterise the life time of fibres in paper for recycling? Gert Meinl, PTS REFFIBRE Conference Munich, Germany September 8th,

2 Outline 1. Key parameters for characterising the lifetime of a fibre Who is (or should be) interested in these parameters? How they are defined? 2. How to calculate the key parameters in a given recycling system? Material Flow Analysis Formulas 3. What are recent results for European fibre flows? Mean Fibre Age / Mean Number of Material Uses Allocation factors (see presentation 5 ITENE/VTT) 4. Introduction of an online tool 2

3 1. Key parameters for characterising the lifetime of a fibre 3

4 Who is (or should be) interested? The individual paper mill: How old are the fibres in Paper for Recycling (PfR)? Selection of PfR grades; Design of stock preparation What will happen after consumption? Measures to guaranty recyclability of the paper product Associations, Society: Characterising resource efficiency of paper production Life Cycle Assessment (LCA); see presentation 5 ITENE/VTT 1. Key parameters for characterising the lifetime of a fibre 4

5 Consumption / Collection U Consumption / Collection R Co-funded by How many times a fibre was used before it enters the paper mill? ( Mean fibre age) Fibre flow (on paper mill level) Virgin pulp How many times a fibre will be used after it leaves the paper mill? ( Mean number of uses) 1-U L 1-R U: Utilization rate of paper for recycling R: Recycling rate L: Reject rate ( Losses ) Rejects Not recycled 1. Key parameters for characterising the lifetime of a fibre 5

6 The Past Nomenclature The Future Fibre Age (FA): Number of uses of an individual fibre from their extraction until now Fibre Age Distribution: Distribution of fibre age within a certain paper product X Mean Fibre Age (MFA(X)): Mean value of Fibre Age Distribution in a paper product X Number of Future Uses (NU): Number of future repeated uses of an individual fibre from now on Number of Future Uses Distribution: Distribution of Numbers of Future Uses within a certain paper product X Mean Number of Future Uses (MNU(X)): Mean value of Number of Future Uses Distribution in the paper product X 6

7 Key parameters for characterising the Lifetime of Fibres MFA(X): Mean fibre age within a paper product X (mean number of fibre uses including the actual paper product X)*,** MNU(X): Mean number of future uses of a paper product X (mean number of fibre uses from now until end of life )*,** MFA(X)+MNU(X)-1: Mean number of fibre uses from cradle to grave (when used at least one time in a paper product X)*,** U(X): Percentage of paper for recycling utilisation (for paper product X) compared to the total paper product X production R(X): Percentage of paper for recycling "utilisation + net trade" compared to the total paper product X consumption** L(X): Percentage of losses during production compared to the total paper product X production *) Counting starts with 1 **) Not available at mill level. Must be calculated on a more global level (regional, national, international) 1. Key parameters for characterising the lifetime of a fibre 7

8 2. How to calculate the key parameters in a given recycling system? 8

9 Material Flow Analysis Calculation of MFA, MNU and R based on a fibre mass flow chart Before building up a flow chart, some levels must be decided: 1. Level of regional differentiation: regional, multiple regional, national, multiple national, international 2. Level of differentiation into paper grades 3. Level of differentiation into processes 4. Level of differentiation into materials 5. Time scale 6. Static or dynamic modelling Procedure to establish a fibre flow chart: Material Flow Analysis Some examples should illustrate different static fibre mass flow charts. They yield different results concerning the key parameters (even for the same region) 2. How to calculate the key parameters in a given recycling system? 9

10 The following 3 examples of mass flow charts are already known from the presentation by Lydia Tempel 2. How to calculate the key parameters in a given recycling system? 10

11 Example 1: CEPI European level Only paper in general; no differentiation of paper products ( one recycling loop) High resolution of individual process steps including net trade No differentiation of materials (water, fibres, pigments, chemicals) Source: CEPI: Annual Statistics. European Pulp and Paper Industry" 2. How to calculate the key parameters in a given recycling system? 11

12 Example 2: France Source: Design and Management for Circularity the Case of Paper. White Paper, World Economic Forum 2016 National level 3 paper grades with two grades to be recycled (Graphic Papers, Packaging) and one not recycled (Tissue) Process steps: production, consumption, collection & sorting No differentiation of materials (water, fibres, pigments, chemicals) 2. How to calculate the key parameters in a given recycling system? 12

13 In detail: See next slide Co-funded by Example 3: REFFIBRE From OGPFrom CM From OP From NP From CM From OP NP OGP To SH To OGP To CM To OP To OPB To SH To NP To CM To OP To OPB From NP From OGPFrom OP From NP From OGPFrom CM CM OP To SH To NP To OGP To OP To OPB To SH To NP To OGP To CM To OPB From NP From OGPFrom CM From OP From NP From OGPFrom CM From OP SH 207 OPB National and European level 6 paper product sectors: NP: Newsprint, OGP: Other Graphic Papers CM: Case Materials OP: Other Packaging SH: Sanitary & Household OPB: Other Paper & Board Process steps: Production and consumption Paper products only of the sectors NP, OGP, CM and OP are recycled but reused in all 6 sectors No recycling of SH and OPB Material in the mass flow: Only fibres (including 10 generations) and pigments; no water and chemicals 2. How to calculate the key parameters in a given recycling system? 13

14 Example 3 Detail : The Case Material Loop (CEPI region, 2014) The proportions reflects the composition of total PfR used for CM production From NP From OGPFrom OP CM To SH To NP To OGP To OP To OPB Legend: xxxx xxxx xxxx xxxx xxxx xxxx xxxx xxxx Virgin fibres Fillers/ Pig. Product loop (Production, Paper for Recycling) PfR migration Rejects Losses (Incineration, Landfill, Longtime Usage) Net Trade (PfR) Net Trade (Products) * *) does also include net trade of paper & board and converted products 2. How to calculate the key parameters in a given recycling system? 14

15 Composition of major PfR grades The migration of paper products between the various recycling loops is calculated based on a given composition of PfR grades. Assumed composition of PfR grades for CEPI region 2014 Composition of grades Mixed grades Corrugated / Kraft Newspapers / Magazines High grades Newsprint Other Graphic Papers Case Materials Carton Board 1.01/ % 43% 27% 19% 1.04/4.x 0% 4% 65% 32% % 63% 0% 3% 2.x/3.x 20% 76% 0% 4% predefined values calculated according to paper consumption 2. How to calculate the key parameters in a given recycling system? 15

16 The next 3 examples of mass flow charts will be used to demonstrate how to calculate MFA and MNU 2. How to calculate the key parameters in a given recycling system? 16

17 Example 4: One Parameter Model No differentiation between paper products. Only one paper product X and one recycling loop. a a: PfR utilisation rate a X Source: Papermaking Science Technology Book 7. Product MFA MNU U R X 1 1 a 1 1 a a a 2. How to calculate the key parameters in a given recycling system? 17

18 Example 5: Two Parameter Model* * Introduced by Hunold and Göttsching (Das Papier, 10A/1993) as 2-Parameter-Model but indeed it is a 3-Parameter-Model X c b Y a Source: Papermaking Science Technology Book 7 A primary paper product X, fully based on virgin fibres and a secondary paper product Y, using recycled paper products X and Y. a: PfR utilisation rate for paper product Y b: Portion of (recycled) paper product Y within PfR used for production of paper product Y c: Recycling rate of paper product X Product MFA MNU U R X 1 1 c + c ab Y 1 + a 1 ab 1 1 ab 1 + ab 0 c 1 1 ab a ab 2. How to calculate the key parameters in a given recycling system? 18

19 Example 6: REFFIBRE case (see Example 3) For more complex recycling systems (multiple connected loops) a transformation of the mass flow chart into an oriented weighted graph is useful. Nodes for Virgin pulp input (the Sources ), for Material Output due to production/sorting losses, Net Trade, Landfill/Incineration (the Sinks ) and for paper products (the Inner nodes) are introduced The calculation of MFA(X) resp. MNU(X) of fibres in a product X is replaced by calculation of mean path lengths from any source to the node X resp. from node X to any sink. A more detailed description of the method will be presented at the 11 th Research Forum on Recycling (Sep Jacksonville USA) 2. How to calculate the key parameters in a given recycling system? 19

20 Example 6: REFFIBRE case (2) From OGPFrom CM From OP From NP From CM From OP NP OGP NP OGP To SH To OGP To CM To OP To OPB To SH To NP To CM To OP To OPB From NP From OGPFrom OP From NP From OGPFrom CM CM OP To SH To NP To OGP To OP To OPB To SH To NP To OGP To CM To OPB Transformation into an oriented weighted graph CM SH OPB OP From NP From OGPFrom CM From OP From NP From OGPFrom CM From OP SH 207 OPB Source : Fibre Input (Virgin Fibres) Sink : Material Output (Rejects, Net Trade, Landfill/Incineration) (Inner) Node : Paper product 2. How to calculate the key parameters in a given recycling system? 20

21 3. What are the recent results for European fibre flows? 21

22 CEPI 2014: Fibre Age / Number of Material Uses Distributions Newsprint Other Graphic Gapers Case Materials Other Packaging 3. What are the recent results for European fibre flows? 22

23 Key parameters (CEPI region 2014) Paper products ** * ** MFA MNU U R Ash NP 2,00 4,20 0,97 0,89 9% OGP 1,14 3,01 0,13 0,75 19% CM 3,02 3,09 0,93 0,87 14% OP 1,85 2,79 0,46 0,90 17% *) Beside incineration or landfill disposal a certain portion of fibres (about 10% in CEPI region) are used at life's end for composting and other treatments. This should be assumed (according to EU waste legislation) as an additional life cycle but is not taken into account at the moment. **) The MFA and MNU values depend solely on the mass balance that was derived from data reported by the national associations to CEPI. Some additional assumptions had to be made to fill those gaps, where no information was available. However, due to inconsistencies these assumptions need further research and can lead to changes in MFA and MNU values. 3. What are the recent results for European fibre flows? 23

24 Consumption / Collection U=93% Consumption / Collection R=87% Co-funded by Results for an average case material mill (based on CEPI region data) MFA = 3.02 Virgin pulp MNU = U L=7% 1-R U: Utilization rate of paper for recycling R: Recycling rate L: Reject rate ( Losses ) Rejects Not recycled 3. What are the recent results for European fibre flows? 24

25 4. Introduction of an Online Tool* *) Will be available soon at 25

26 Some Basics of the Online Tool 3 paper grades (Graphic Paper, Packaging Paper, Sanitary & Household / Other Paper & Board); basically the same as example 2 User interface for automatic (CEPI data) or manually input of mass flow data Output of MFA, MNU and in terms of distributions for every paper grade 4.. Introduction of an Online Tool Conceptual scheme 26

27 User Interface 4.. Introduction of an Online Tool 27

28 Distributions of Fibre Age and Number of Uses 4.. Introduction of an Online Tool 28

29 Many thanks for your attention! Dr. Gert Meinl +49 (0) PTS Heidenau Pirnaer Str Heidenau Acknowledgement: The research leading to these results has received funding from the European 's Seventh Framework Programme under grant agreement n

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