Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Grand Group Holding, Industrijska zona bb, Baka Palanka, Serbia, e-mail:
marko.rokvic@grandgroup.co.rs
b
Faculty of Technical Sciences, Department of Environmental Engineering, Trg Dositeja
Obradovia 6, Novi Sad, Serbia, e-mail: nemanjastanisavljevic@uns.ac.rs,
svjetlanajokanovic@uns.ac.rs
1. Introduction
Polyvinyl chloride, or PVC, is one of the most widely used polymers in the world. Due to its
versatile nature, PVC is used extensively across a broad range of industrial, technical and
everyday applications from window profiles and pipes to credit cards and blood bags. Made
from salt (57%) and oil (43%), PVC was first produced commercially in the late 1920s after
additives were blended into this mixture to create a plastic which quickly became popular for
its flexible, durable and cost-effective qualities.
Today, PVC is the third largest-selling commodity plastic in the world after polyethylene and
polypropylene. PVC's low cost, excellent durability and processability, make it the material of
choice for dozens of industries such as health care, IT, transport, textiles and construction.
A strategy to promote resource efficiency has been developed by PlasticsEurope, which
represents the European plastics producing industry. This is known as the Integrated
Approach and covers all stages of plastics usage from production to final disposal.
3. Waste management
Waste management is an integrated concept of different practices and treatment options
comprising prevention and collection strategies; separation steps for producing recyclables
or for subsequent processing using biological, physical, chemical, and thermal treatment
technologies; and different landfill types. [5]
The goals of modern waste management are to:
Protect human health and the environment
Conserve resources such as materials, energy, and space
Treat wastes before disposal so that they do not need aftercare when finally stored in
landfills
The last goal is also known as the final-storage concept and is part of the precautionary
principle: the wastes of todays generation must not impose an economic or ecological
burden to future generations. The aforementioned goals make it clear that the focus in waste
management is not necessarily on goods (paper, plastics, etc.) or on functions of materials
(e.g., packaging). The focus is on the nature of the substances.
Hazardous substances threaten human health. Hence, advanced waste-management
procedures are implemented to control and direct the disposition of substances at the
interface between the anthroposphere and the environment to achieve the following two
goals:
1. Materials that can be recycled without inducing high costs or negative substance
flows should be recycled and reused. Negative flows can appear as emissions or byproducts during the recycling process. The recycling process itself can also lead to
enrichment of pollutants in goods and reservoirs. For example, the recycling process
can increase heavy metal contents in recycled plastics, or it can lead to accumulation
of metals in the soil when sewage sludge is applied to agricultural fields.
2. Nonrecyclables should be treated to prevent the flow of hazardous substances to the
environment. A tailor-made final sink defined as a reservoir where a substance
resides for a long period of time (>10,000 years) without having a negative impact on
the environment should be assigned for each substance. [7]
MFA is a valuable tool in substance management because it can cost-efficiently determine
the elemental composition of wastes exactly. This information is crucial if the goal is to assign
a waste stream to the best-suited recycling/treatment technology and to plan and design new
waste-treatment facilities.
4. Tarkett doo
Tarkett DOO is a productive organization with a seat in Baka Palanka, Republic of Serbia,
which produce PVC hardfloor covering and multilayer parquet. In production facility Tarkett
DOO PVC-4m, nonhomogenic PVC floor covering is being produced. Technological process
consist of several phases: preparation of raw materials and semi-finished product (lacquer),
preparation and homogenization of paste, preparation of colors for printing, Coating I (with
Grund layer), Coating II (with Shaum layer with white Bach), printing on nine-color machine
for deep print, Coating III (with transparent layer), Coating IV (with back-paste or chemical
foam with yellow Bach), expansion of foamy layer in high-temperature channel, Coating V
(with compact layer), mechanical engraving, Coating with UV lacquer, back print, finished
product control classification, rolling and packing of product, finished goods warehouse,
final control of goods, audit of finished goods and recycling unclassified products.
Normal production at Tarkett DOO causes a lot of waste materials, with significant percent of
hazardous waste. The goal of the study is to define the most critical types of waste, to
estimate the amount of those types in the period of 2013 2017, and to define alternative
strategies for waste management.
5. Methodology
MFA begins with the definition of the problem and of adequate goals. Then relevant
substances and appropriate system boundaries, processes, and goods are selected. Next,
mass flows of goods and substance concentrations in these flows are assessed.
MFA consist of several steps. Process, storage, inputs, outputs and interflows were defined.
Next step was to create a graphic model using software STAN, as in [3]. In graphic model, all
known data were entered (mass flow, stocks, inputs, outputs). All uncertainties were also
entered, so software could have calculated other unknown data (some flows are often
unknown before the analysis).
The software STAN (subSTance flow ANalysis) is a new user-friendly freeware that supports
performing material flow analysis (MFA) according to the Austrian standard NORM S 2096
(MFA - Application in waste management) under consideration After building a graphical
model with predefined components (flows, processes, subsystems, system boundaries and
text fields), known data (mass flows, stocks, concentrations and transfer coefficients) with
corresponding physical units can be either entered or imported for different hierarchical
layers (good, substance, energy) and time periods. A graph of the model with flows displayed
as Sankey arrows (i.e. the width of a flow is proportional to its value) can be printed or
exported into various graphical formats of data uncertainties. [3, 6]
First model for year 2012, which was taken as point zero was too complex and confusing to
do any real benefit. Only process engineers could understand the model, while for the
management of the company, the model is of no use in business decisions. STAN is offering
a possibility of grouping process, so a model could be simplified, as well as more useful.
Processes considering preparation of raw materials were classified in one group, with the
name: raw material preparation. In second group, classified processes were: first coating of
paste on top, second coating of paste on top, revolving of the lane. Third group, Second
coating with paste consists of: third coating of paste on top, drying channel, waste gas,
waste paste and forth coating of paste on the back. Group Gelling and cooling consist of
two processes: channel for gelling and cooling. Final product preparation consists of:
cutting and rolling of finished goods, recycling, finished good warehouse. This is shown in
figure 1. Processes Nukem, RTO, chimney and condensate warehouse were classified in the
group Waste gas incinerators.
After making a simple model of process of PVC hardfloor covering production (see Figure 2),
it is been used for calculation of amount of waste materials in the period of 2013 2017. For
the study, an assumption of total production increase of 30% has been used.
Using the STAN model PVC facility, inputs are increased by 6% per year, while all other date
software calculated itself. After period of 5 years, result show the total amount of generated
waste condensate, waste PVC paste and PVC material sent on recycling. These results are
shown in table 1.
Table 1: Amount of pollutants in waste gases and amount of waste in specific period (t)
Pollutant
2012
2013
2014
2015
2016
2017
Total 2013-2017
VOC
320,41
339,67
358,54
377,95
397,2
416,5
2210,27
SO2
72,34
76,58
81
85,34
89,95
94
499,21
CO2
6328,4
6708,2
7087,7
7466,8
7847
8224,6
43662,62
CO
955,5
1009,9
1070,1
1127,4
1184,8
1242,1
6589,8
NOx
1108,1
1174,7
1241,1
1307,4
1373,9
1440,5
7645,74
TOC
175
185,5
196
206,5
217
227,5
1207,5
Waste condensate
80
84,8
89,6
94,4
99,2
104
552
15
15,75
16,8
17,1
17,33
18,3
85,28
Recycled PVC
3,060
3,22436
3,4212
3,6108
3,7944
3,975
21,114
Waste condensate is generated in PVC production facility during waste gas condensation.
Condensate is being kept in marked small cans and barrels on all condensate outputs in the
facility. After collecting the condensate in small vessels, it is being poured into waste IBC
containers, which are being previously used for raw materials storage. IBC containers are
temporarily being kept on the specified location in the company.
5.3. Waste PVC paste
During PVC hardfloor production, some amount of PVC paste can harden up, and become
useless. As such, it becomes hazardous waste, and requires adequate disposal and
treatment, as directed by law. This waste PVC paste is being stored in prepared packaging
(IBC containers with 1000L volume, or metal and plastic barrels).
Considering the fact that in Serbia there isnt any hazardous waste landfill and accredited
facility for treatment of hazardous waste are still in development. Tarkett d.o.o. as a
generator of waste is obliged to export this hazardous waste in a country where it is possible
to treat this waste in the safest way to the environment.
The price of hazardous waste export depends of following factors:
3. Hazardous characteristics of the waste
4. Amount of hazardous waste
5. Type of final treatment of waste (incineration/permanent landfill or other type of
treatment)
6. Type of packaging for waste
7. Transport
Price of hazardous waste export can vary depending on mentioned factors, and for the study,
average price of treatment were used, and they are: average price for waste condensate is
250,000 din/t, and for waste PVC paste 165,000 din/t.
Using these prices and calculated amount of generated waste, company cost were
calculated, and shown in tables 2 and 3.
Table 2: Costs for waste condensate treatment
Year
Amount (t)
2013
84,9
250.000
21.225.000
2014
89,6
250.000
22.400.000
2015
94
250.000
23.500.000
2016
99,2
250.000
24.800.000
2017
104
250.000
26.000.000
117.925.000
Amount (t)
2013
15,75
165.000
2.598.750
2014
16,8
165.000
2.772.000
2015
17,1
165.000
2.821.500
2016
17,33
165.000
2.859.450
2017
18,3
165.000
3.019.500
14.071.200
Company cost for treatment of waste condensate in given period is 117,925,000 dinara, and
for waste PVC paste is 14,071,200. Total company cost is 131,996,200 dinars. Waste PVC
materials are being exported to the company owned by Tarkett, so there is no significant cost
for the company for this type of waste.
7. Conclusion
MFA has enabled process grouping using certain characteristics and similarities, as well as
discovering points in process that requires attention. In this study, processes for raw material
preparation, incinerations, and different coating were grouped. This grouping allows better
control of the production, sensitivity of one group to changes, also the need for and
profitability of improvement.
It is determined that currently the biggest problem is hazardous waste, mostly waste
condensate, than waste PVC paste.
Tarkett DOO as a generator of hazardous waste is in obligation to provide suitable storage of
hazardous waste in the company until it has been treated or submitted for permanent landfill
or treatment.
The proposition for improvement is, first, to build suitable temporarily storage for all
hazardous waste in the company. In this way, better and more efficient hazardous waste
management can be achieved. This storage can provide easier control over handling,
packaging and storing procedures in the whole company.
Second step is installation of an incinerator for waste gas and waste condensate. Results
have showed that investment would be justified for a period of eight years.
The MFA results obtained in this work may help company management to define different
priorities in managing this kind of waste, but also to enable early recognition of a potential
resource or threat to the environment and to establishing a sustainable system for the
hazardous waste management. It should be noted that process of incineration requires
special license from the government. Application for the license requires some time and
additional cost for the company.
Acknowledgements
I am obliged to staff members of Tarkett DOO, for the valuable information provided by them
in their respective fields, especially to Mrs Sunica Vjetica, Environmental Manager. I am
grateful for their cooperation during the period of my work.
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