RE Options
Strategies for Waste Minimization Reduction at the Source Process Modification Good Housekeeping Level 1: GOOD HOUSEKEEPING
Case Study: Reduced water consumption electroplating SME in Gurgaon Improvement actions: Conductivity profile of rinse tanks monitored over 3 months Based on this, optimum water flow rate implemented Operators trained to measure conductivity as a basis for flow rate Result: 25% saving, pay back: 0,1
Case Study: Reduced energy consumption auto parts SME in Manesar After Process: 36 pieces of mirror are placed on a standard brick for convex process in an oven. Measure: Number of pieces increased from 36 to 39 per slot. Size of brick altered within the possible regime to occupy more pieces thus saving energy on one hand and enhancing productivity on the other. Savings/a: Cost: Pay back 207,000 INR 33,120 INR 0,16
Case Study: Shopping mall: aircon optimisation Reduced operating hour of some Aircon equipment from total 78 hours to total 72 hours to reduce operating cost Savings per day: Savings per year: 124 kwh 1.125 INR 22.372 kwh 202.466 INR (180 days/ year)
Case Study: water reduction - anodising company Electroplating (Aluminium), 20 employees, ISO 14000 Use of spray rinses, longer drain time, daily control of chemicals, reduction of the water consumption of 46 % (14.000 m³)
Specific water consumption [m³/m²] 1,2 1 0,8 Environmental management Ecoprofit Zero emission research project 0,6 0,4 0,2 0 1996 1997 1998 1999 2000 Year CP Options in general 2001 2002 2003
Case Study: Water savings - Caterer Daily monitoring of water meters for early detection and repair of leaks. Use of last wash of laundry to soaking dirty laundry. Conscious effort of all involved in conserving water. NO Investment M3/ Month INR/m3 Per Month Per Year Before 536.60 40.50/m3 21732.30 260,787.60 After 324.64 40.50/m3 13,147.92 157,775.04 Savings 211.96 8,584.38 103,012.56
Case Study: reduction packaging material - Fan producer Packing of Card Board Carton with a plastic strip was reduced from 2 strips to 1 strip INR ~210,000/ year
Additional Good housekeeping options Dosage of Chemicals Proper storage of Chemicals Proper handling and usage of compressed air.
Proper Storage of Chemicals
Problem: Compressed Air
Air leak costs Hole diameter mm at 6 bar l/s Air loss Energy loss Costs at 12 bar l/s at 6 bar kw at 12 bar kw at 6 bar INR* at 12 bar INR* 1 1.2 1.8 0.3 1 20,400 68,000 3 11.1 20.8 3.1 12.7 2,10,800 8,63,600 5 30.9 58.5 8.3 33.7 5,64,400 22,91,600 10 123.8 235.2 33 132 22,44,000 89,76,000 *kw x 8.5 INR x 8,000 h/y
Strategies for Waste Minimization Reduction at the Source Process Modification Select New Materials Level 1: Change of Raw Materials
Strategies for Waste Minimization Reduction at the Source Process Modification Select New Technology Level 1: Change in Technology
Case Study: energy saving - Metal finishing Precision Machine Components: Pneumatic gauges were used to measure the dimensions of the components services which continuously blow compressed air during measurement and idle time. A micro switch base was made on which these pneumatic gauges can be rested which switches off the coupled solenoid valve for compressed air.
Case Study: Reduced waste auto parts SME in Gurgaon Before After Problem: Losses of brass chips in turning process Measure: Guard provided on machine to avoid coolant & chips on floor. This results in proper brass chips collection. Savings/a: Cost: Pay back: 27,600 INR 27,600 INR 1,0
Case Study: Reduced energy and water consumption auto parts SME in Bhiwadi Improvement actions: Insulated top surface of tanks Result: 80% energy and water saving; Pay back: 0,2 Saved 43,200 kwh/yr (Approx. Rs. 2 lakhs/yr) Fresh water saved 67,000 liter/yr
Case Study: Reduced energy consumption sweets production in Manesar Result: >90% saving; Improvement actions: Compressed air was used to blow away empty pouches from thepay back: 0.01 packing line. A simple low voltage micro-blower was installed to do the job TECHNO-ECONOMICS BEFORE AFTER Orifice size 3 NA Pressure 5 NA 40 40 7,200 7,200 Compressed air (cfm/year) 4,059,102 NA Energy needed (kwh/year) 608,865 7,200 Energy saved (kwh/year) 0 601,665 Equipment cost 0 40,000 Savings 0 4,738,112 NA 2.5 d No. of orifices Operation hours Payback period
Case Study: Reduced water consumption car repair shop Installation of a ultrafiltration unit, modified cleaning equipment saving of washing agent by 76 %, water by 80 %
Case Study: Reduced energy consumption Textil producer Replacement of Air-conditioning Units (ACU) in several buildings with other ventilation means which are stationed strategically for improved ventilation. Investment cost: ~ 2.5 Mio PHP Actual savings: ~ 1,7 Mio kwh or 8,3 Mio INR
Case Study: Reduced water consumption power plant Water Pumps: Conversion of Packing Seal To Mechanical Seal Lessen Power Consumption Prolong Motor Life Prolong Pump Shaft Life and Bearings Totally Eliminates Leak Cost of leak/pump/year Jacket Water Pump Nozzle Cooling Water Pump 64,633.00 49,849.00 Price of Mechanical Seal Conversion Kit Pay back Expected Savings/ pump/year 41,670.00 7.74 months 64,633.00 38,920.00 9.37 months 49,849.00
Strategies for Waste Minimization Internal Recycling Level 2: Internal Recycling
Strategies for Waste Minimization External Recycling Level 3: External recycling