Cleaner Production Technologies (KULIAH 26 SEPT 2011)

PRESENTER: Julia BrownWaste Research Management & Training CentreScientific Research Council

CLEANER PRODUCTION TECHNOLOGIES

Objective

To provide industries with an awareness of becoming efficient in an effort to reduce the cost of production and thus earning more.

CLEANER PRODUCTION TECHNOLOGIES

Contents

i. What is Cleaner Production as it relates to product, processes and services

ii. Benefits of Cleaner Production Technologies

iii. Execution of Cleaner Production

iv. Case study

CLEANER PRODUCTION TECHNOLOGIES

Cleaner production

This is an integrated preventive strategy applied to processes, products and services as a way to increase the efficiency and to reduce risks for human beings and the environment.

For processes - this is the efficient use of raw material, water and energy, the elimination of toxic or dangerous products and the reduction of emission and wastes at the source.

Cleaner production

In the case of the products, the strategy is centered around lowering their environmental impact and promoting friendly designs.

Cleaner production

In the case of the services, the strategy is focused on lowering the environmental impact and promoting friendly procedures during its management.

Cleaner production

Cleaner production

Internal RecyclingSource reduction

Process ChangeProduct Change

Raw materialSubstitution

Technological modification

Good Practices

Cleaner production strategies

Prism Methodology

Enterprise data and its processes.Materials flow of wastes and emissions.Work groups creation.Generate options in Cleaner production.

Evaluate Technology.Evaluate economy.Evaluate environment,Evaluate organization,Select options.

Obtain fundingEquipment installation.Advise evaluation of results.Project adaptation Planning of new projects

To obtain a commitment with theManagement.Establish the evaluating organization To propose general objectives.Overcoming barriers.Begin a preliminary study

Be reminded of theincreasing competitivity with Cleaner Production

Planning and Organization

Plant evaluation

FeasibilityStudy

Implementation

• Legislation - environmental legislation is increasing world-wide. This can reduce the risk of penalties and provide competitive advantages.

• Cost Savings - This identify opportunities for cost savings via energy efficiency and waste minimization measures.

• Customer requirements - increasing businesses will not want to risk reputation or inherit liabilities as a result of poor performance by suppliers.

Benefits; Cleaner Production

• Market Opportunities - this can be a likely factor in market profiling and provide a competitive edge.

• Corporate Image - a good environmental record can improve corporate image and better relations with stakeholders. Adverse publicity on environmental performance can be very damaging.

Benefits cont.:Cleaner Technologies

What are the economic benefits?

– Energy, water and raw material

– Wastes disposition

– Compliments and procedures

– Financing

– Product responsibility

Economic Value Added

Environmental System Management

Reduction of costs :

Flexibility in prices Relationship with clients Competitive and strategic

positioning Access to the maket Increase in services

Increase of income :

Reduction of costs to develop value added

The cost of a failure in Environmental Quality

Trainning Manteinance Better process Design of products External

communication

Prevention

x $1

Inpsection and monitoring

Reports Calibration

Discovery

x $10

Waste of materials

Treatment and control

Productive space

Time

Internal error

x $100

Consultancy fees Remediation Loss of clients Relation with the

community

External error

x $1000

System Approach

Competitivity Support

•Products improvement•Processes efficiency increase•Production costs decrease•Elimination costs decrease•Profit increase•Market opening

Advices: Raw Material determination

• Consider the following questions:– Is the size of the raw materials inventory

appropriate so their losses may be minimized?

– Could it be possible to reduce the transference distances between storage and processing or between operation units?

– Is there any mutual contamination risk in reservoirs that may store two or more raw materials?

– Are the material sacks completely emptied?

• Consider the following questions :– Is the raw material storage area secure?– Is there solar light incidence in the

storage place?– Does the material pumping system

receives maintenance?– Are there leaks?– Can the drainage be by gravity?

Advices: Raw Material determination

• Consider the following points:– From where is the water extracted

and where is this stored?– Water storage capacity in plant?– How is the water transported in the

plant?– Does there exist considerable

precipi-tation in that place?

Advises: Water consumption

• What is the water used for in each operation?

• With what frequency do each action take place?

• How much water is used in each action?

Advices: Water consumption for each unit operation

• Strict control of water consumption.• Concentrations increase - Less raw

material• Good manufacturing practices options.• Waste water storage options for a

possible reuse.• Countercurrent soaks and recycling of

soak water.

Advices: Reduction in water consumption

• ALL discharge points location. (frequently there is more than one)

• Identify where do the flows of multiple operation units or process areas join.

• Define a program for the volumes of water used for each unit operation.

• Define maximum production conditions, opening, closing and washing to obtain the water generation characterization of the enterprise.

Advices: Effluent contamination

• Determine if there exit a combination of

pluvial and residual waters.

• Use volumetric measurement for small

and intermittent flows.

Advices: Effluent contamination

• Include in the analysis pH, DO, BOD, suspended solids, FOG.

• Use up to it may be possible a compound sampling for continuous flows.

Advices: Effluent concentration de-termination

• The following questions have to be asked:– Are there odour associated with any unit operation?

– Is there a moment where emissions may be marked?

– Is there any contamination control equipment?

– Are emissions directed to the outside of the confined spaces?

– Are gases washed in the enterprise?

Advices: Gaseous emissions contamination

• The following questions have to be asked:– Where is the origin of the residue?

– Can it be optimized by any process so there may be less residue generation?

– Can alternative raw materials be used to generate less residue or may facilitate its management?

– Is there any component that may cause all the residue to be harmful?

Advices: Outside residues disposal contamination

• Sugar Factory

• Rum Distillery

• Agro - Processing facilities

Areas of work involving Cleaner Technologies

• Wastewater production– 6000 m3/hr at peak

– 3200 m3/hr

• reduce by approx. 50 % through separation of drains (clean water and polluted water), avoiding/reducing spillage and repairing leaking taps.– 3000 m3/hr at peak

– 1600 m3/hr

CASE STUDY - A SUGAR FACTORY

• COST FOR TREATMENT

– Approx. US$200/m3 (cost effective system)

– Initial cost for treatment was• approx. US$1.2 million

– After reduction • approx. US$600,000

CASE STUDY - A SUGAR FACTORY