Week 6

Introduction on our Product 

After implementing Material for Design using CWOS Matrix Method in Week 4, the idea with the highest score is decided to be made into product. As such, we are making Air-to-Water machine which make use of hydrogel to capture water from atmosphere. In Week 5, we learnt that not only do we considered material, but also the design of the product to enjoy the attributes of the machine in an environmentally friendly way. To do this, we have to look at the product life cycle to understand the manufacturing process of the product. As such, we can use more sustainable material to manufacture our product. This can be implemented in extraction stage, manufacturing and production stage, packaging stage, distribution stage, use stage and disposal stage of the product life cycle. Moreover, Cradle-TO-Cradle Design is used to ensure sustainable ad potential infinite use of materials in cycle. 

Activity 2

Main Chemical Product: Hydrogel

     1.     Construct a product life cycle of your chemical product.

2.     Provide an explanation for each life cycle stage on the completed diagram.

      Stage 1: Raw Materials or Extraction

Raw Materials

-        Acrylonitrile

-        2-acrylamido-2-methylpropanesulfonic acid (AMPS)

-        Water

-        Starch

-        manganese pyrophosphate

Extraction

• Acrylonitrile: 

  Acrylonitrile is manufactured by combining propylene, ammonia, and air in a process called ammoxidation. During this process, propylene, ammonia and air are fed through a catalyst at a high temperature.

• 2-acrylamido-2-methylpropanesulfonic acid (AMPS): The preparation of AMPS requires a reaction of acrylonitrile, isobutene and oleum under the action of sulfur-containing organic acid. Sulfur-containing organic acid is used in the process of the reaction and can form mixed anhydride with oleum. HO₃S⁺ will then be separated from the mixed anhydride, it has electrophilic activity and will react with isobutene to form carbocation with a sulfo group. The carbocation with the sulfo group reacts with acrylonitrile under the action of sulfuric acid. AMPS will be formed.
• Manganese pyrophosphate: Manganese pyrophosphate can be prepared by dissolving manganese (II) nitrate in  phosphoric acid. It will then be oxidised by using concentrated HNO₃, allow it to evaporate to dryness. The product is in a powdery form.

          Stage 2: Manufacturing and Production

• The hydrogel that we will be using is superabsorbent hydrogel. Superabsorbent hydrogels compromise of graft polymer of acrylonitrile and 2-acrylamido-2-methylpropanesulfonic acid (AMPS) added onto starch. It is prepared using a manganese pyrophosphate redox initiating system. The addition of AMPS results in a gradual decrease in saponification time for the graft polymer. The total duration of the superabsorbent hydrogel production also decreases.

• The maximum response at the optimal saponification conditions can be obtained. The water absorbency was 1345 g/g dry superabsorbent, using the following saponification conditions: KOH volume 203.7 ml, KOH concentration 0.51 mol/L, and saponification temperature 92.6°C. The shortest saponification time is 17 min, and the total synthesis time of superabsorbent hydrogel is 2.5 h.

• The biodegradable superabsorbent polymers were prepared by the graft copolymerization between the gelatinized starch and acrylamide/itaconic acid via foamed solution polymerization using ammonium persulphate (APS) and tetramethylethylene diamine (TEMED) as an oxidation-reduction initiator and co-initiator, respectively, while methylene bisacrylamide (MBA) as a cross-linking agent.

            

            Stage 3: Packaging 

• The superabsorbent hydrogel will be packed into containers for sale. 
• The hydrogels will be transported to dealers/distributors to be shipped to consumers.

            Stage 4: Distribution

• The hydrogels will be transported to dealers/distributors to be shipped to consumers.

            Stage 5: Use

• For our idea of Air-to-Water machine, the hydrogel is used to capture water from air because of its water absorbent ability. It will be assembled with other parts of the machine, and it will be tested for its safety and efficiency. Then, it can be used to capture water from the atmosphere.

            Stage 6: Disposal

• Recycling: There are a wide range of synthetic hydrogels that may potentially have suitable physical and chemical properties for tissue engineering applications, thus recycled hydrogels can be used for tissue engineering applications.

• Reuse: The hydrogel can be dried, and it will turn into a rigid and transparent material with a smooth surface. It will return to its original shape after a day-long immersion in water.

• Disposal: The hydrogel can be disposed to landfills. Another way is to dissolve it with weak acids such as citric or acetic acid.

Main Chemical Product: Centrifugal Stainless-steel Fan

1.     Construct a product life cycle of your chemical product.

2.     Provide an explanation for each life cycle stage on the completed diagram.

 

Stage 1: Raw Materials or Extraction (Focusing on nickel & iron ore)

-    Stainless steel metal is formed when the raw materials of nickel, iron ore, chromium, silicon, molybdenum, and others, are melted together. 

Nickel

-    For nickel mined from lateritic ore is mined from various depths beneath the surface using large earth-moving equipment.

-    Nickel from lateritic ore is extracted trough extractive metallurgy. It is extracted from its ores trough a conventional roasting method which removes the moisture from the ore. Next the nickel oxide is removed by reduction furnace which also greatly reduces the chemical bound water. Resulting in a 75% pure form of nickel.

-   After the mining and processing of either the lateritic ore or sulfidic ore there remains nickel matte. Through further refining a 95% pure nickel can be obtained by using the fluid bed roasting technique.

 

Iron

-    Iron ore is mined out of the ground.

-    The process of smelting involves heating up the ore until the metal becomes spongy and the chemical compounds in the ore begin to break down.

-  Heating and hammering this mass forces impurities out and mixes the glassy silicates into the iron metal to create wrought iron.

Stage 2: Manufacturing and Production

-    Nickel, iron and other metals are melted to form stainless steel.

-   After which, the melted stainless steel is used to make components of the fan such as housing, impeller, shaft, etc using the mould.

-   Then, various parts of the components are joined together to form the fan.

 

Stage 3: Packaging

-  End-Product of the centrifugal fan is packed in boxes for selling

 

Stage 4: Distribution

- The prepared boxes of product will be delivered to various part of the world such as the supplier, retail shops, etc.

 

Stage 5: Use

-    The fan is a component of our Air-to-Water machine, so it is joined with other parts of the machine for usage. The fan is used to suck air from atmosphere into the machine to capture water.

Stage 6: Disposal

-   Recycle: The metal of the pump can be melted again to make into other product.

-  Reuse: Some of the working part of the fan can be used reused to make other product.

-   Litter/Landfill: The product is disposed in landfill

Activity 3

3.    Integrate any two C2C design strategies into your chemical product and update the product life cycle diagram.

 

Nutrients become nutrients again: Instead of using stainless steel centrifugal fan, use fan that is made of wood. Wood is a biodegradable material; hence it can be decomposed and break down into simpler substances which can be act as fertilizer for the soil, a nutrient that is provided by other living organisms such as plants or fungi. This contributes to the health of the whole ecosystem. This ‘waste’ of the product is food for another living organisms.

 

         Use of renewable energies: Renewable energy such as solar energy can be used to extract the water absorbed by hydrogel. This is because temperature affects hydrogel absorption performance. At higher temperature, it tends to desorb, so water is released. Not only that, but solar energy can also be converted to electrical energy for fan to rotate. This will make the product environmentally friendly as no fossil fuel is burned to generate electricity.