cp gp day02 session 6 - data collection, quantification of waste streams
TRANSCRIPT
Quantification of resource
flows –
Data collection and Material
Balance in CP assessments
Samantha Kumarasena
Deputy Director
National Cleaner Production Centre, Sri
Lanka
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Quantification of Resource Flows
Collection of data
- Collection of available data
- Introducing new data sheets and data collection in daily basis
- On-site measurements
Making a balance and verifying
Sample material balance
Establish the baseline and CP Potential
Presenting the Quantified data
Information to be established in
CP assessments Baseline information – absolute
consumption and waste generation
data and specific consumption and
specific waste generation data
CP Potential
Collection of available data
Monthly utility consumption (electricity,
water etc.
Input resource consumption – raw
materials, diesel, furnace oil etc.
Products output inventory
Solid wastes collected
Waste water treated and discharged
Monthly Resource Flow:
(From ......... To ………) Item Unit
Period
Inputs
Raw materials
Main Raw Materials
Other Raw Materials
Water
From national supply m3
From own source m3
From contractors m3
Energy
Electricity from grid kWh
Electricity from generator kWh
Electricity (Max. demand) kVA
Fuel (furnace) oil litre
Diesel / kerosene/LPG litre
Firewood
Other renewable sources TOE
Products
Main product output
By Products
Wastes
Solid waste Ton/ kg
Liquid waste m3
Air Emissions
Data sources
Purchase & sales records
Stock control data
Production records
Utility bills etc.
Data collection
Work Sheets
◦ Simple
◦ Fill In
◦ Add Instructions
Preparation of Work SheetsWS 1 General data
WS 2 Procurement Data on Inputs
WS 3 Water Usage
WS 4 Steam Usage
WS 5 Electrical Consumption
WS 6 Layout Plan
WS 7 Production Data
WS 8 Maintenance Records/Downtime
WS 9 Solid Waste Records
WS10 Boiler Performance
WS11 Material Flow Sheet
WS12 Packaging Material Data
WS13 Sales Data
WS14 Waste Water Analysis
WS 2 a Procurement Records for Sugar
Month Quantity
Purchased
Quantity
Used
Balance
Stock
Remarks
Work Sheet 3a Water Usage for Operation
Bottle Washing
Qty of Water Quality/Day Quantity Temperature Steam Input
1st Wash
2nd Wash
3rd
Wash/Steaming
4th Wash
Work Sheet 4 Steam Usage for Operation
Operation Steam
Pressure
Steam
Quantity
Consumption
Mode
Heat Content
Jacketed Pan
Bottle Washing
Hot Water
Steaming
Sterilizing
Daily Resource Flow (during the period
of assessment) (From: … To: …)Item Unit
Period (Day)
Inputs
Raw material
Main Raw Materials
Other Raw Materials
Hazardous Materials
Water (Supply)
From national supply m3
From own source m3
From contractors m3
Water (Consumption)
Process Consumption m3
Human Consumption m3
Other (Maintenance /Landscaping etc.) m3
Energy
Electricity from grid kWh
Electricity from generator kWh
Electricity kVA
Fuel (furnace) oil litre
Diesel / Kerosene / LPG litre
Firewood
Other renewable sources TOE
Products
Main product output
By Products
Waste
Solid waste Ton
Liquid waste m3
Air emissions/Evaporations
Hazardous waste
Measurement
Sampling
Population Measuring/Full Screening
When Data not available
When accuracy of data is doubtful
As a cross check
Energy Measurement
Electrical EnergyMotors/Lighting/Heaters/Controllers
Thermal Energy
Fuel/Radiant Losses/Flue Losses/Blow Down
Steam Flow/Steam Leaks/Compressed Air Leaks
Measure Ambient Conditions
Obtain the assistance of an expert in the energy balance
Data should be,
Accurate
Reliable and
Representative
Issues in data Collection
Different departments may have different figures
Many enterprises have so much figures but makes no sense.
Some data can lead to wrong interpretations
Process Personnel can be secretive or misleading
Some data can be confidential and proprietary
When in doubt cross check or measure
Monthly Water Intake
0
500
1000
1500
2000
2500
3000
3500
Jan-0
8
Mar-0
8
May-
08
Jul-0
8
Sep-08
Nov-
08
Jan-0
9
Mar-0
9
May-
09
Month
Un
its
(m
3)
Units (m3)
Assessment in Hospital ‘A’
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Water consumption pattern
in daily basis
Water Consumption - Units (m3)
0
5
10
15
20
25
30
5/15/2
009
5/16/2
009
5/17/2
009
5/18/2
009
5/19/2
009
5/20/2
009
5/21/2
009
5/22/2
009
5/23/2
009
5/24/2
009
5/25/2
009
5/26/2
009
5/27/2
009
Date
Un
its (m
3)
Office hours Non office hours
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Daily Water Intake
0
10
20
30
40
50
60
70
80
7/12
/200
9
7/13
/200
9
7/14
/200
9
7/15
/200
9
7/16
/200
9
7/17
/200
9
7/18
/200
9
7/19
/200
9
7/20
/200
9
7/21
/200
9
7/22
/200
9
Date
Un
its
(m3)
Water Intake m3
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Material, water and energy
balance
Balance principle based on law of
conservation of mass
Incoming material
+
Generated material=
Outgoing material
+
Consumed material
Simplified Mass Balance
Input=Output+ Losses
Losses: Discharges & emissions,
degraded materials, low value outputs,
allowances, rejects/defects,
Material, Water and Energy
Balance Balance with available data (1 year)
and
Data collected with data sheets
designed (1 month)
Supported with data of In-situ
measurements
Undertake a Sample balance
Sample Material Balance
(Outcome)Process Step
Input (Materials / Water) Unit Quantity Output (Products/ Waste) Unit Quantity
A
Main raw materials 100Main Output of Process (A)- As
Main Input to next step (B) 104
Other inputs 10 Waste stream 1 2
Waste stream 2 2
Unaccounted losses 1 2
Total 110 Total 110
B
Main Output of Process(A)
{Main Input to step (B)}104
Main Output of Process (B)- As
Main Input to next step (C)103
Other inputs- (eg.: water) 100 Waste water 90
Waste Stream 3 5
Waste Stream 4 4
Unaccounted losses 2 2
Total 204 Total 204
C
Main Output of Process (B)
{Main Input to step (C)} 103
Main Output of Process (C)- As
Main Input to next step (D) ……
………………. ….. Waste stream 5 …….
………………. ….. Waste stream 6 …….
………………. ……..
Unaccounted losses 3 ……..
Total ……..
…..………………. ……………
………………. ……………
Total Total
Y
Main Output of Process (X)
{Main Input to step (Y)}
Main Output of Process (Y) -
Main Input to Final Process (Z)
……………… ….. ……………. …..
……………… ….. ……………. …..
Total Total
Z
Main Output of Process (Y) -
Main Input to Final Process
Main Product Output
Other inputs By Product Output
…………. Waste streams
Waste streams
Unaccounted losses
Total Input Quantity Total Output Quantity
Derive material balance
Assemble information
Derive preliminary balance
Evaluate and refine balance
In the balance
Maintain consistency of units
Degree of Preciseness of balance to
be depend on hazardousness/toxicity
and cost of resource flow
Each constituent material to be
balanced separately, as much as
possible
Cross check to reveal inconsistencies
Eg. Water Balance of office ‘A ‘
Description (per month) m3 %
Total water intake
( Avg. value 2008 Jan - 2009 Feb)915 100
Water User Points (15 – 31 May 2009)
Employees (during office hours) 148.72 16.25
Visitors on public day 4.18 0.46
Washroom cleaning 18.20 1.99
Gardening 116.55 12.74
Glass cleaning 0.86 0.09
Ponds cleaning and refilling 16.80 1.84
Vehicle washing (exact value can be high) 123.65 13.51
Water leaks from user points 103.00 11.26
Accounted Quantity 531.97 58.14
Unaccounted Quantity 383.32 41.89
(Drivers' and security quarters, canteen, etc)
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Water Balance
Water Consumption - Units (m3) / month
16%
11% 14%
2%
0%
13%
2%
0%
42%
Employees (during office hours) Visiters on public day
Washroom cleaning Gardening
Glass cleaning Ponds cleaning and refilling
Vehicle washing (exact value can be high) Water leaks from user points
Unaccounted Quantity
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Water Balance (m3/Month)
Operation
Theatre, 74.74,
3%
Blood Bank,
10.04, 0%
Laboratory, 3.31,
0%
Ward 9, 45.97,
2%
Ward 8, 226.47,
9%
Ward 7, 329.76,
13%
Laundry, 165.00,
6% SCBU, 4.95, 0%
Kitchen, 26.31,
1%
Minor Staff,
267.15, 10%
Water boiling for
drinking, 24.12,
1%
Water for
Gardening,
15.00, 1%
Identified water
leaks, 252.56,
10%
Ward 5, 142.68,
6%
Ward 4, 115.12,
5%Ward 2, 191.81,
8%
Ward 1, 144.00,
6%Unaccounted
water quantity,
511.51, 20%
Ward 1 Ward 2
Ward 4 Ward 5
Ward 7 Ward 8
Ward 9 Laboratory
Blood Bank Operation Theatre
SCBU Laundry
Kitchen Minor Staff
Water boiling for drinking Water for Gardening
Identified water leaks Unaccounted water quantity
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Material Balance
Input Output Deficit Waste paper 10 ton/day
Fibres 8,500 kg/day
Fillers 900 kg/day
Water 600 kg/day
Back water
Water 400 ton/day
Decker filtrate
Fibre 350 kg/day
Fillers 450 kg/day
Water 200 ton/day
Pulp
Fibre 8,075 kg/day
Fillers 400 kg/day
Water 190 ton/day
Total input
Fibres 8,500 kg/day
Fillers 900 kg/day
Water 400.6 ton/day
Total output
Fibres 8,425 kg/day
Fillers 850 kg/day
Water 390 ton/day
Not accounted
75 kg/day (1%)
50 kg/day (6%)
10.6 ton/day (3%)
Energy Balances
Example: heat balance in a dryer of
fish meal production process
Heat Balance Heat in Heat out
kW kW
Steam 2062 484
Air 786 2027
Product 291 456
Total 3139 2967
=> Losses 172 5.5%
Case of Coffee Powder
factory Expected yield where costs are
calculated was 79%
According to the material balance
based on available data of 2008 the
yield was 71%
According to the sample material
balance conducted the yield was 75%
How to move forward now?
Presentation of Quantified
data Process Flow Diagram
Data Flow diagram/Tree Diagram
Table
Sankey Diagram
Cutting & peeling
Blending
Mixing
Cooking
Bottling
Pine Apples
PiecesJuice
suga
r
water
Fibe
r
Spill
s
Bottled drink
Data Flow diagram
Heat Loss in a Furnace
Sankey Diagram
Work Sheet 12 Material Flow for Pine Apples
Process step Input Total Waste Outp
ut
Remarks
Storing/Sorting 850 850 17 833
Peeling 833 264.6 568.4 Partly
RecoverableCutting 568.4 76.44 491.9
6
Recoverable
Water Addition 200 691.96 - 691.9
6Blending
Filtering
Re Blending 100 791.96 32 759.9
6
Recoverable
Filtering 759.96 332 427.9
6
17% Recoverable
Sugar Addition 60 487.96 467.9
6Mixing 467.9
6Cooking/Cooling 487.96 97.59 390.3
7Bottling 390.57 14.43 375.0
0
Recoverable
Baseline and Performance
Indicators
Total Absolute Consumption (per year)
Specific Resource Consumptions
Resource Productivity Indicators
Pollution Intensity
Total Absolute Consumption
(per year)
Product / Resource / waste Unit Absolute Quantity
Production Output
Raw Material
Energy
Water
Solid waste
Waste water
Emissions (GHG)
Specific resource
consumptions Material consumption per unit of
Product output
Energy Consumption per Unit of
Product output
Water Consumption per unit of
product out put
Specific resource
consumptions
Resource Unit
Actual Specific
Consumption National Bench Mark
(if available)
International Bench
Mark (if available)Reference
Main Raw Materials 1.
(Please specify)
2.
3.
Process Water
Energy
Resource Productivity
Indicators
Unit
Value
National Bench Mark
(if available)
International Bench
Mark (if available)Reference
Materials Productivity
Water Productivity
Energy Productivity
Pollution Intensity
Unit
Pollution Intensity
National Bench
Mark (if available)
International Bench
Mark
(if available)
Reference
Solid Wastes
1.(Please specify)
2.
3.
Effluents
Air Emissions
Costing of wastes –
helps to
Comprehend,
Communicate &
Convince !!!
Recognize the CP Potential
Total cost of wastes
Total cost of wastes
Process Step Materials / Process WaterQuantity of Waste
/Year
Value of Waste
(Rs/Year)Reference for
Calculations
A
B
C
Total
Your
Questions
12/16/2015 Samantha Kumarasena 45
?
Thank
you!
12/16/2015 Samantha Kumarasena 46