National Resource Efficient and Cleaner Production (RECP) Programme Indonesia. Kementerian Lingkungan. Hidup dan Kehutanan

Transcription

1 Resource Efficient and Cleaner Production Centre for Assessment & Development of Green Industry & Environment Sector Applications Bekasi, 7 National Resource Efficient and Cleaner Production (RECP) Programme Indonesia Funded by Implemented by In partnership with Kementerian Lingkungan RECP Introductory Training 1 Hidup dan Kehutanan Root Source Analysis Root Cause Diagnosis WHERE? Option Generation Quantification of WHY? the different usages HOW? and sources Factors contributing to usage and sources Alternative ways to avoid the identified causes Literature, checklists + In House Innovation RECP Introductory Training 2 RECP applications in manufacturing sector 1

2 RECP for green industry Glass Industry Metal Products Industry Efisiensi Sumber Daya dan Produksi Bersih Ceramic Industry RECP Introductory Training 3 Glass industry is energy and resource intensive sector. Diverse set of measures available to improve productivity and energy efficiency, and reduce waste and emissions (GHG, NOx). RECP Introductory Training 4 RECP applications in manufacturing sector 2

3 Glass Industry in Gujarat (India) 1. Optimize combustion efficiency of furnace Target 2-6% O 2, 8-11% CO 2, <400ppm CO and minimum excess air Measure O 2 and regulate air flow (VFD on fan) Investments typically 30-45,000 USD (up to 100 tpd) Payback period typically 3-8 months GCPC (2016), February Cleaner 2017Production in Glass Sector RECP Introductory Training 5 Glass Industry in Gujarat (India) 2. Electricity savings Variable Speed Drives on large motors (blowers) Investment USD1-4,000 Pay back 2-9 months Optimize compressed air usage Eliminate unnecessary use and leaks Reduce pressure variations Efficient compressors Reduce air inlet temperature (3 o C decrease saves 1% energy) RECP Introductory Training 6 GCPC (2016), Cleaner Production in Glass Sector RECP applications in manufacturing sector 3

4 Glass Industry in Gujarat (India) 3. Oxygen Enhanced Combustion Better glass quality, lower emissions (NO x and PM), higher throughput, energy savings (10-50%) and no air-preheating Investments ,000 USD Pay back months 4. Batch and Cullet Preheating Direct or indirect 10-20% reduction of specific energy consumption 10-15% increase in throughput Investments ,000 USD Pay back months RECP Introductory Training 7 GCPC (2016), Cleaner Production in Glass Sector Energy Use in Glass Industry Over the past twenty years, glass demand has grown more quickly than GDP and is still growing at nearly 4% per year. About EJ of energy is used for glass production worldwide, and the energy used in the production of container and flat glass results in emissions of about Mt CO 2 per year. With the adoption of best available technologies, energy efficiency of the sector can be improved by as much as 40% in developing countries and up to 35% in industrialized ones. RECP Introductory Training 8 RECP applications in manufacturing sector 4

5 Sector Energy Benchmarks Furnace Type/Capacity Furnace Energy Consumption (GJ/tonne melted glass) Overall Energy Consumption (GJ/tonne finished product) Container Glass <100 t/d Bottles & Jars >100 t/d <7.7 Electric furnaces Flacconage <100 t/d 7 9 >100 t/d <16 Flat Glass All capacities 5 7 <8 Continous filament glass fibre All capacities 7 14 <20 Domestic glass Conventional furnaces <100 t/d a < 24 for capacities < 100 t/d a >100 t/d 5 6 < 18 for capacities > 100 t/d Electric furnaces b Special glass All products Electric furnaces b Soda-lime glas < Conventional furnaces Borosilicate glass RECP Introductory Training 9 Best Available Techniques RECP Introductory Training 10 RECP applications in manufacturing sector 5

6 Process-Related Energy Efficiency Worell e.a February (2008), Energy 2017 Efficiency Improvement RECP Introductory Training 11 and Cost Savings Opportunities in Glass Industry Process-Related Energy Efficiency Worell e.a February (2008), Energy 2017 Efficiency Improvement RECP Introductory Training 12 and Cost Savings Opportunities in Glass Industry RECP applications in manufacturing sector 6

7 Process-Related Energy Efficiency Worell e.a February (2008), Energy 2017 Efficiency Improvement RECP Introductory Training 13 and Cost Savings Opportunities in Glass Industry Cross Cutting Energy Efficiency Energy Management Systems (ISO 50001) Compressed Air Systems Motor Systems Lighting Heat and Steam Systems Building Management, including HVAC Worell e.a February (2008), Energy 2017 Efficiency Improvement RECP Introductory Training 14 and Cost Savings Opportunities in Glass Industry RECP applications in manufacturing sector 7

8 Ceramics sector produces variety of products (bricks, tableware, sanitary ware, tiles etc.). Energy and resource use are high, as are air emissions and waste generation. RECP Introductory Training 15 Nguon Sam Ath Brick Company (Cambodia) RECP Introductory Training 16 RECP applications in manufacturing sector 8

9 Angkor Brick Kiln (Cambodia) RECP Introductory Training 17 Ceramics Industry in Gujarat (India) 1. Optimize combustion efficiency of furnace Target 2-6% O 2, 8-11% CO 2, <400ppm CO and minimum excess air Measure O 2 and regulate air flow (VFD on fan) Investments typically < 1,000USD Annual cost savings up to ~USD65,000 RECP Introductory Training 18 GCPC (2016), Cleaner Production in Ceramic Sector RECP applications in manufacturing sector 9

10 Ceramics Industry in Gujarat (India) 2. Optimize combustion efficiency of spray dryer furnace Installation of O 2 analyzers for 3 spray dryers» Invested ~USD110,000, pay back in 4 months Solar greenhouse drying of coal» Reduce moisture from 30 to 5%» Investment of ~USD40,000 with pay back in 5 months GCPC (2016), February Cleaner 2017Production in Ceramic Sector RECP Introductory Training 19 Ceramics Industry in Gujarat (India) 3. Modifying kiln cars for efficient transfer of heat (reduction of mass) Replace solid shelves with extruded shelves Invested USD8-20,000, payback < 5 months Use light weight filling materials Invested ~USD4,500, payback < 5 months Redesign spacers/holding racks Invested ~USD3,600, with payback < 1 month RECP Introductory Training 20 GCPC (2016), Cleaner Production in Ceramic Sector RECP applications in manufacturing sector 10

11 Ceramics Industry in Gujarat (India) % reuse of water and sludge in process (zero effluent discharge) Material recovery and water conservation at very low cost 5. Electricity conservation Power factor improvement with capacitators Variable speed drive on ball mill motors On-off timers and other controls Reduce and optimize use of compressed air Improvement in kiln wall insulation GCPC (2016), February Cleaner 2017Production in Ceramic Sector RECP Introductory Training 21 Metal products industries employ comparable processes to produce wide variety of components and products. Energy consumption is high in most processes, whilst chemicals use, generation of waste and effluents vary. Multiple common RECP approaches are well known and proven. RECP Introductory Training 22 RECP applications in manufacturing sector 11

12 Shining Engineers & Founders Grey iron foundry, using cupola furnaces Replaced cupola and change to Divided Blast Cupola (DBC) operation Reduced reject from 7 to 5% Coal use reduced by 30% Eliminated need for alloying ferro-nickel and ferromanganese Cost savings ~USD13/ton product Investment of ~USD15,000 recovered within 1 year RECP Introductory Training 23 Ceylon Heavy Industries & Construction Company Steel rolling mill Improved fuel oil quality control Replacement of fuel nozzles and recuperation tubes Installed flue gas analyzer to optimize fuel-air ratio Installed high tension transformer Invested USD58,000 to achieve annual cost savings of USD75,000 Enabled production capacity increase by 25% Achieved GHG emission reduction of 444 ton Energy Efficiency Guide for Industry in Asia RECP Introductory Training 24 RECP applications in manufacturing sector 12

13 Greening Thai Automotive Supply Chain 74 SMEs achieved Annual monetary savings of 7.9M EUR Waste reduced by 2,161 ton/yr, average of 49% Waste water reduced by 118,230 m3/yr, average of 51% Energy reduced by 27%, contributing to 16,431 ton reduction of GHG emissions Improved rankings in GreenMark Certification Improved access to financing RECP Introductory Training 25 EAF Steel Sector (Vietnam) Viet Nam EAF steel sector 2 are within good practice range ( GJ/t) Energy intensity (GJ/t) L O M G K Q F N D I J H A P B E C R 9 use 20-80% more energy then good practice Energy intensity significantly higher then international good practice Low scrap quality Insufficient process monitoring Lacking slag analysis compounded by limited basic furnace and metallurgical knowledge UNIDO (2012): Towards Green Growth though Green Industry Development in Vietnam RECP Introductory Training 26 RECP applications in manufacturing sector 13

14 EAF Steel Sector (Vietnam) 10.00% 5.00% 0.00% -5.00% % Energy Reductions G K F D J A P B E C 10% 5% 0% -5% -10% -15% -20% GHG Reductions K D A G J F C P B E % -25% % -30% % -35% 7 improved, 4 thereof reduced energy by 6-21% 8 improved, 6 thereof reduced GHG emissions by 10-30% UNIDO February (2012): Towards 2017 Green Growth though RECP Introductory Training 27 Green Industry Development in Vietnam Key Concerns Large variety of processes each with their own environment and resource use footprint Foundry & casting (Fugitive) Emissions Scrap Energy Use Cutting, forming & welding Parts cleaning Metal Products Parts finishing Assembly (Hazardous) Waste Water and Waste Water Chemicals Use RECP Introductory Training 28 RECP applications in manufacturing sector 14

15 RECP Starters Foundry/casting Reduce fixed scrap from risers, re-work, etc. Energy efficiency in melting and holding of hot, liquid metals Improve feed and melting regimes Use appropriate binder systems molds and cores Increase recycling rates in sand systems Cutting/forming/welding Reduce fixed scrap through optimization of nesting Energy efficient equipment Use appropriate welding techniques and aids RECP Introductory Training 29 RECP Starters Machining Reduce fixed scrap by matching inputs with final parts specification Management and maintenance of machining tools Fit for purpose machining coolants Treatment and continuous reuse of coolants Scrap drainage Parts Cleaning Reduce cleaning need by avoiding contamination and over-cleaning Select appropriate cleaning method, mechanical, waterbased, chemical, etc. Design appropriate cleaning process Minimize and manage resulting cleaning wastes RECP Introductory Training 30 RECP applications in manufacturing sector 15

16 RECP Starters Metal Finishing (electroplating) Optimize process sequence and conditions Minimize and/or eliminate processes depending on hazardous chemicals (Cr VI, Cd, CN, etc.) Energy efficiency rectifiers, heaters, blowers, etc. Water efficiency counter-current use, efficient nozzles, carry-over reduction etc. Metal recovery and treatment of waste water Metal Coating (Painting) Select paint system that matches parts specifications Select appropriate application process spray, roll, water-based, electrostatic etc. Optimize application process Good operating practices Minimize change overs Minimize and manage paint waste, waste water and fugitive emissions RECP Introductory Training 31 RECP for green industry Glass Industry Metal Products Industry Efisiensi Sumber Daya dan Produksi Bersih Ceramic Industry RECP Introductory Training 32 RECP applications in manufacturing sector 16

17 Terima kasih banyak! Centre for Assessment & Development of Green Industry & Environment National Resource Efficient and Cleaner Production (RECP) Programme Indonesia Funded by Implemented by In partnership with Kementerian Lingkungan RECP Introductory Training 33 Hidup dan Kehutanan RECP applications in manufacturing sector 17