Resource Efficient and Cleaner Production Concept, Practices & Applications Medan, 23 February 2017 RECP Introductory Training National Resource Efficient and Cleaner Production (RECP) Programme Indonesia Funded by Implemented by In partnership with Kementerian Lingkungan Hidup dan Kehutanan Centre for Assessment & Development of Green Industry & Environment
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Resource Efficient and Cleaner Production
Concept, Practices & Applications
Medan, 23 February 2017
February 2017 RECP Introductory Training 1
National Resource Efficient and Cleaner Production (RECP) Programme Indonesia
Funded by Implemented by In partnership with
Kementerian Lingkungan Hidup dan Kehutanan
Centre for Assessment & Development of Green Industry & Environment
February 2017 RECP Introductory Training 2
Efisiensi Sumber Daya dan Produksi
Bersih
Concept
PracticesApplications
RECP for green industry
February 2017 RECP Introductory Training 3
Resource Efficient and Cleaner Productionemerged as a business response to worsening(industrial) pollution and escalating use ofnatural resources
February 2017 RECP Introductory Training 4
disperse
control
recycle
Resource Efficient and
Cleaner Productionprevent
pollution
replace
protect
recover
reduce
scarcity
natu
ral reso
urces
enviro
nm
en
t
Efisiensi Sumber Daya dan Produksi Bersih
Efisiensi Sumber Daya dan Produksi Bersih
• Finding and implementing ways to– Improve productive use of materials,
water and energy;• Thereby
– Reduce the generation of waste, effluent and emissions;• Thereby
– Improve well being of employees, consumers and community; • Thereby• …….• ……..
February 2017 RECP Introductory Training 5
February 2017 RECP Introductory Training 6
Productive output per unitof resource consumption
Pollution intensity per unitof productive output
RECP Issues
February 2017 RECP Introductory Training 7
Produktivitas Bahan Baku
Pemilihan dan efisiensi bahan baku
Intensitas Sampah
Penurunan dan buangan yg aman dari limbah
Produktivitas
Air
Pemilihan dan efisiensi air
Intensitas
Limbah Cair
Penurunan dan Pengolahan air limbah
Produktivitas
Energi
Pemilihan dan efisiensi energy
Intensitas
Emisi
Penurunan dan Pengendalian gas buang
February 2017 RECP Introductory Training 8
Resource Efficient and Cleaner Production canbe implemented through – combinations of –different prevention practices
February 2017 RECP Introductory Training 9
Tata KelolaArea Kerja
Substitusi Bahan
Peningkatan Pengenda-lian Proses
Modifikasi Peralatan
Penggan-tian
Teknologi
Guna Ulang Dan Daur Ulang di
Lokasi Sendiri
Pemanfaatan Produk
Samping
Modifikasi Produk
• Maintain a clean, organized andproductive workplace to eliminateavoidable ‘wastage’
• Typical solutions– Switch off what is not in use
– Repair what needs reparation
– Keep workplace organized and clean
– Minimize and manage inventory
– Confirm right way for all tasks
– Keep staff motivated
10February 2017 RECP Introductory Training
• Choose inputs that are efficient, effective and/or pose minimum harm to the environment and health
• Typical solutions– Use renewable energy
– Use sustainably-sourced renewable materials
– Use of recycled materials, water and energy
– Use fit for purpose materials
– Use less harmful substances
– Source locally
11February 2017 RECP Introductory Training
• Monitor and control processes andequipment so that they always run athighest efficiency and with lowestwastage
• Typical solutions
– Standard operating procedures and process monitoring
– Sub-metering water, energy and materials
– Preventive maintenance
12February 2017 RECP Introductory Training
• Make existing equipment more efficient and less wasteful
• Typical solutions– Insulation– Proper alignment of
production line– Improve process
temperature, pressure, speed, mixing
– Automatic switch off & level controls
– Combine process steps in same equipment
13February 2017 RECP Introductory Training
• Change over to new technologythat is more efficient or producesless waste
– Change of core process, e.g. chemical to mechanical cleaning
– Equipment with integrated recovery loops
– Advanced separation processes
– Solar dryers, heaters and lighting
14February 2017 RECP Introductory Training
• Use previously ‘wasted’ material, energy and/or water for similar or alternative purpose in company
Typical solutions
• Countercurrent or cascaded use of water and energy
• Condensate and heat recovery
• Reuse of incoming packaging for outgoing products
Practices
15February 2017 RECP Introductory Training
• Convert a previous ’waste’ for a useful use elsewhere
Typical solutions
• Provision of used cooling water for external heating or cooling purposes
• Segregate recyclables for external recycling and resource recovery, such as composting
• Symbiosis - use waste material for new product development
16February 2017 RECP Introductory Training
• Redesign product to reduce its environmental impact during production, use and/or disposal
• Typical solutions– Design for optimal product
lifetime– Design for lower material
use– Design for low-waste
manufacturing– Design for refurbishment,
recycling etc.
17February 2017 RECP Introductory Training
RECP Method
Source
Cause
Option
February 2017 RECP Introductory Training 18
Root Source Analysis
WHERE?
Quantification of the different usages and sources
Root Cause Diagnosis
WHY?
Factors contributing to resource usage and pollution sources
Option Generation
HOW?
Alternative ways to avoid the identified causes
February 2017 RECP Introductory Training 19
Resource Efficient and Cleaner Production hasbeen beneficially applied in many industrysectors, including pulp and paper, rubber andfood processing sectors
Viet Tri Paper (Viet Nam)• Options implemented
– VSD on main paper machine motors
– Condensate recovery from paper machines
– Insulation and repair of steam pipes and valves
– Install economizer on boiler
– Dry storage of coal
• Economics– Investment USD113,000
– Annual savings USD 123,000
February 2017 RECP Introductory Training 20
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Anhui Tiandu Paper (China)• Options implemented
– Heat recovery from blow down of pulp digesters
– Insulation and leak repair of steam pipes
– Increase pulping capacity by better feeding of straw
– Segmentation in steam supply system
– Cogeneration of heat and power
• Economics
– Investment USD 2.1 M
– Annual savings USD 650,000
• Environment
– Coal savings 15,000 tpa
– GHG reduction 5.2%
February 2017 RECP Introductory Training 21
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Energy Opportunities in Pulp & Paper Mills
February 2017 RECP Introductory Training 22
11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
Water Opportunities in Pulp & Paper Mills
February 2017 RECP Introductory Training 23
11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
Energy Benchmarks
February 2017 RECP Introductory Training 24
http://www.iipnetwork.org/
Energy Benchmarks
February 2017 RECP Introductory Training 25
http://www.iipnetwork.org/
Energy Benchmarks
February 2017 RECP Introductory Training 26
http://www.iipnetwork.org/
Best Available Technologies
February 2017 RECP Introductory Training 27February 2017
http://www.iipnetwork.org/
Best Available Technologies (examples)
February 2017 RECP Introductory Training 28February 2017
http://www.iipnetwork.org/
Best Available Technologies (examples)
February 2017 RECP Introductory Training 29February 2017
http://www.iipnetwork.org/
AMC Tyres (Sri Lanka)• Implemented options
included:– New efficient compressor
– Leak survey and repair compressed air system
– Leak repair and insulation for boiler and steam system
– Condensate recovery
• Economics– Invested USD49,000
– Savings USD84,000/yr
• Environment– Electricity saved 521
MWh/yr
– Furnace oil saved 173 kl
– GHG reduction ~600 ton
June 2016 Module 1: RECP Concept and Business Case 30
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Medigloves (Thailand)
• Producer of surgical and cleanroom latex gloves– Reduced air intake temperature and fixed leaks in compressed air
system
– Recovery and reuse of water and chemicals from latex dipping process
– Recovery and reuse of water from wash and chlorination process
• Annual cost savings of USD19,200 for investment of USD8,000 (payback <5 months)
• Annual resource conservation of 166,000 kWhr, 17 kl oil and 14,300 m3
• GHG reduction ~150 ton CO2-eq
June 2016 Module 1: RECP Concept and Business Case 31
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Concentrated Latex Production
• Gate to Gate Life Cycle assessment – Total environmental impact dominated by
• 1. electricity use for centrifugation• 2. ammonia use for preservation• 3. DAP use
– Total environmental impact can be reduced by:• 1. energy efficiency for centrifuge (inverter, VSD): 12%• 2. improved ammonia handling and storage: 8%• 3. extending coagulation time (reduced DAP use): 3%• 4. fuel switch from diesel to LPG: 5%
February 2017 RECP Introductory Training 32
Jawjit et al, Evaluating the Environmental Performance of Concentrated Latex Production in Thailand, 2012
Veraval• Fish processor in Gujarat, India
– Total investment <44,000 USD, with payback of 14 months
5 April 2016 RECP (seafood sector) 33
Cleaner Production Opportunities Investment (USD)
Pay Back
(month)
Use belt conveyor for transferring baskets filled with fish from
weighing section to processing hall1,725 10
Use of sprays instead of using running hoses for cleaning & rinsing
of fish.100 5
Reuse chlorinated wash water after filtration from 0.2 mm mesh
screen in non-critical applications like preliminary washing of R/M,
cleaning floors.
400 15
Improve insulation of cooling systems & pipe work (required 6" and
3" is used)1,600 10
Use SS made /aluminum allied trays instead of plastic trays for
efficient cooling.16,000 14
Installation of R.O. plant & reusing of treated water in the process
areas.23,500 15
Installation of water level controllers in overhead tanks 500 7