presenter:julia brown waste research management & training centre scientific research council...
TRANSCRIPT
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: EMS/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.: EMS/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