Eye opener.. Do you Know.. HOW LONG DOES IT TAKE TO DECOMPOSE? Just think of the list below before you throw something on to the soil.

Transcription

1 Cleaner Production

2 Eye opener.. Do you Know.. HOW LONG DOES IT TAKE TO DECOMPOSE? Just think of the list below before you throw something on to the soil. Paper Towel weeks Banana Peel weeks Paper Bag - 1 month Newspaper months Apple Core - 2 months Cardboard - 2 months Cotton Glove - 3 months Orange peels - 6 months Plywood years

3 Wool Sock years Milk Cartons - 5 years Cigarette Butts years Leather shoes years Tinned Steel Can - 50 years Foamed Plastic Cups - 50 years Rubber-Boot Sole years Plastic containers years Aluminum Can years Plastic Bottles years Disposable Diapers years Monofilament Fishing Line years Plastic Bags years Glass million years

4 What is the Problem? The major cause of the continued deterioration of the global environment is the unsustainable patterns of consumption and production, particularly in industrialized countries, which is a matter of grave concern, aggravating poverty and imbalances. Agenda 21 (Chap. 4.3), Earth Summit, Rio 1992

5 What is the Magnitude? It is simply impossible for the world as a whole to sustain a Western level of consumption for all. In fact, if 7 billion people were to consume as much energy and resources as they do in the West today we will need more than one planet to satisfy all our needs. Gro Harlem Brundtland, 1994

6 Sustainable Development: a long-term issue If we go on with current production and consumption patterns, Two planets are needed by

7 Traditional Sri Lankan Approach What can we do?? Steam & Water leakage A traditional DC mill at Wennapuwa

8 Cleaner Production Content Driving forces for implementing CP. What is CP? CP Benefits. Steps of CP Audit & implementation. Examples of CP applications.

9 Driving forces for implementing CP Standards Customers Cost reduction Laws and regulations Employees Envt. organizations Increased efficiency Environmental quality Financial sector

10 Definition What is CP? Cleaner Production is the continuous application of an integrated preventive environmental strategy to processes, products, and services to increase overall efficiency, and reduce risks to humans and the environment. Cleaner Production can be applied to the processes used in any industry, to products themselves and to various services provided in society.

11 What is CP? CP refers to a mentality of how goods and services are produced with the minimum environmental impact under present technological and economic limits. Cleaner Production is a 'win-win' strategy. It protects the environment, the consumer and the worker while improving industrial efficiency, profitability, and competitiveness.

12 What is CP? The key difference between pollution control and Cleaner Production is one of timing. Pollution control is an afterthe-event, 'react and treat' approach. Cleaner Production is a forward-looking, 'anticipate and prevent' philosophy.

13 CP at a glance! High consumption of raw materials and resources, generating much waste Use only necessary raw materials and other inputs, apply strategic process changes, reduce waste while increasing productivity

14 Environmental Management Hierarchy Minimizing waste Before Pollution Prevention or CP Re-use (in the process)/ Recycling Treatment and disposal After

15 Benefits of CP Reducing cost of production. Reducing environmental impacts at source. Reduce waste treatment cost. Improved product/service quality. Optimal consumption of raw materials and Improved production efficiency. Higher profits.

16 cont. CP Benefits Enhancing good relations among workers and between industries and the local community. Promoting health and safety. Reducing the load of public inspection. Creating business advantages. Better image of your business.

17 CP philosophy 1. Prepare inventory of sources Where is waste generated? 2. Reasons why waste is generated Why waste is generated? 4. Select most suitable suggestions & implement Stop waste 3. What are the solutions- Propose How to stop waste generation?

18 Steps of CP implementation Interest in CP 1. Planning and setting up a CP Team 2. CP Audit 6. Implement and sustain 5. Asses Technical & Economic feasibility 3. Data analysis 4. Develop & Select CP options

19 Proven Economic and Environmental benefits from CP on Wastewater Mgt. A leading food company, located in Kandy, the company does a profitable business. However, it was facing grave wastewater treatment and disposal problem. The out-put quality of wastewater did not meet the environmental regulations. The company was very keen to reduce their overall production costs & build the image by reducing wastage of water and treating wastewater.

20 Cont A CP assessment was carried out in the plant in order to identify the wastewater streams. The audit team studied wasteful outflows. Many opportunities for implementing CP options were recommended immediately. The company is in the process of minimizing their water use from 125 m 3 /day to less than 25 m 3 /day. This will save 80% of their water bill. This saving is more than enough to treat remaining wastewater.

21 Cont A profit making food and beverage company in the Kelani River basin has a proper water treatment plant. Quality of treated water is up to the standards. They were keen on CP!! After doing CP, they are planning to reduce water and energy consumption by at least 15%. A coconut based product factory, generating 15m 3 of wastewater a day is facing a huge problem of waste water. They are very keen on environmental conservation in their business. A CP option was proposed to convert 5 m 3 of wastewater into a value added product. An additional income of Rs. 300, could be generated per day.

22 OGM Rice flour Mill at Mawanella Investigation According to the baseline data Rs (0.07 Kwh) value of electricity and Rs (0.260 Kg) value of coconut shell is needed for producing 1 kg of roasted rice flour. The annual wastage of rice flour is kg with the value of Rs The highest wasting steps were manual roasting (30%) and shifting or grading (27%). Average annual coconut shell wastage is about 2460 kg equivalent to Rs The calculated annual electricity wastage was Kwh, equivalent to Rs

23 Myths About CP Good only for large companies Requires huge amount of money Requires modern technology Requires qualified professionals Automation is a must One time activity Limited potential

24 CP Mental Blocks Fear of being seen as fool Fear of disturbing tradition Fear of being alone Fear of being criticized Fear of being misused Fear of resistance to change Fear of making mistakes Fear of being a guinea pig

25 CP FIRST TREATMENT SECOND Thank you For Your Interest in Saving The Earth MINIMUM WASTE MAXIMUM PROFIT

26 1. Planning and setting up a CP Team Objectives To establish a policy to be used as a guideline for implementation To have a CP team working as a core group

27 A good CP policy Is approved by the top management of the factory. Stresses waste reduction at source. Has definite target for waste reduction per production unit. Has a timeframe. Is related to legal regulations.

28 Examples of good CP policies Our factory is aiming to reduce water consumption down to 2L per 1L of Processed milk at the end of Our factory aims to reduce milk waste in yogurt production by 50% at the end of year 2015.

29 Responsibilities of the CP team Gather data from various sources, construct production flowchart and decide scope of unit operations Prepare mass balance of production processes and unit operations of interest Collect additional data required for a mass balance Present CP options Study feasibility of various options Set up steps for implementing selected options Assess and monitor

30 Members of a CP team CP team manager CP team members Factory Manager 1. Production Head 2. Utility Head 3. Purchasing Head 4. Accounting Head 5. Pollution Prevention Officer (Team Head) 6. Other interested employees

31 Qualifications of a CP team member Responsible High academic Qualification A good team player Extensive work experience Observant Eager to learn creative Respects opinions of other people Working for the common cause

32 2. CP Audit Comprises: Pre-assessment Detailed audit

33 Pre-assessment Objectives To construct production flowchart and gather basic information To set the scope of unit operations within the production process Survey and look for areas of loss, both quantitative (how much?) and qualitative (what are the characteristics? ) To set more appropriate CP targets

34 Sample of a production flowchart Raw milk Cleaning water/ acid/alkaline Cleaning water, acid/alkaline Film/carton Raw milk reception Pasteurization Filling Cold room Ready to drink milk Lost milk/ Effluent from cleaning Milk left in pipes/ Effluent from cleaning Lost milk/ Film/defective carton Spoilt milk

35 Detailed audits Objectives To prepare mass balance and/or energy balance for each unit operation Collect data necessary for proposing CP options

36 How to prepare a mass balance Total input = total output Decide the scope of unit operations Study inputs entering unit operations Are there chemical reactions in the unit operations? Study output from unit operations Is recycling practiced?

37 Sample of input-output of a unit operation Raw materials Air emission Catalyst Water/air Unit Products Energy Re-use operation By-products (includes waste to be recycled/recovered) Effluent Recycling in other processes Waste/chemicals to be disposed of Excess materials Source: Audit and Reduction Manual for Industrial Emission and Wastes, UNIDO

38 Possible areas for waste reduction Types and characteristics of raw materials Raw material reception; quality and amount check Use and storage of raw materials Transportation of raw materials and products (in solid, liquid and gas forms) in the production process Control of production processes Use of water in cleaning and cooling Product storage

39 3. Data analysis and feasibility study Objectives To propose CP options To find CP options suitable for the factory (both technically and economically)

40 CP options can be found from: Machine operators. Comments from other factory employees. CP team. Case studies from similar industries. Case studies adapted from other industries. Experts. Suppliers of raw materials and equipment. Clients/markets.

41 Few examples for different CP options for saving water When cleaning factory floors, sweep off dirt and scraps before hosing down with water. Check for leaks in various connections, e.g., pipes for raw, soft and cold water, and repair immediately if leaks are found. Plan production process so that minimal washing is required.

42 Feasibility study Technical Is it scientifically feasible? Is there available technology? Are there available implementers? Economic Is investment required? How much is the expected savings? What is the payback period?

43 Environmental impact and safety Is inefficient consumption of raw materials and energy reduced? Is amount of waste incurring treatment costs reduced? Is amount of waste discharged to the environment reduced? Is working condition improved? Are accidents and illnesses reduced?

44 4. Setting procedure and implementation Objectives To have steps in implementing selected CP options To proceed within a timeframe

45 Sample of CP implementation procedure Activity Month Month Month Month Responsible party 1. Request approval _ CT team 2. Approve project Management 3. Provide equipment/manpower Utility Department 4. Implement Production/ Utility Departments 5. Monitor progress CT team

46 5. Assessment Objective To summarize results and start new options or re-start the cycle

47 Sample of progress monitoring CT option Date Result Recommendation Option 1 Option 2 Option 3

48 Types of CP options Adjustment of operations and management Reuse and internal recycling External recycling Partial adjustment Total change New product improvement Product chain system improvement

49 More examples for different CP options for saving water Ensure that float valves are properly functioning. Where possible, use high-pressure nozzle on water hoses. Avoid cleaning by overflow system; counter-flow system is preferable. Check quality of water used and use appropriate type of water. Consider returning condensate. Water used to cool machines should be reused. Install water meters at key points so that loss and production efficiency will be known.