Environmental Assessment of an Innovative Plant for … · Environmental Assessment of an...

Environmental Assessment of an Innovative Plant for

the Wastewater Purification in the Beverage Industry

Marco Bortolini,

Lucia Botti, Mauro Gamberi, Riccardo Manzini,

Cristina Mora, Alberto Regattieri

Alma Mater Studiorum – Bologna University

Department of Industrial Engineering

Poznan, Poland, August 2nd 2017

Aim & Research Direction

Environmental Assessment of an Innovative Plant for the Wastewater Purification in the Beverage Industry

24th International Conference on Production Research (ICPR2017), Poznan, Poland Marco Bortolini

Focus

To reduce the water intensity in the FOOD & BEVERAGE INDUSTRY

(F&B) proposing a technology integrated to a ready-to-use plant to locally

recover and reuse the process wastewater (up to 25,000 recovered

litres/hour);

To evaluate the environmental impact of the plant manufacturing and

assembly phases from a Design for Environment perspective.

Final mission

To outline the components, materials and processes having critic

environmental impact to adopt, in the future, alternative technologies and

materials.

Presentation Agenda

1. Background and overview on European and Italian

regulations of water use within F&B;

2. Functional description of the plant;

3. Review of Life Cycle Assessment (LCA) methodology and assessment

methods;

4. Environmental assessment of the plant manufacturing and assembly: Life

Cycle Inventory (LCI), Assessment (LCA) and interpretation keys;

5. Conclusions and future developments.





Background

Water is known as the ‘blue gold’, the key of life, and its availability is crucial for the equal

growth of communities (UN Millennium Development Goal Report, 2011).

Focusing on the European Union (EU) area, the highest amount

of water consumption is from industry.

Furthermore, among all industrial activities, Food & Beverage

industry is known as a very water intensive sector (~100.000

liters/hour of raw water generating thousands of litres of

wastewater per day).

Wastewater recovery is a MUST at the EU

level:

To save the environment – water footprint

of processes;

To comply with the EU regulations;

To match high technical/economic target

in product/market.

Global investments in

wastewater treatments: $150

billion/year;

$12 billion/year for

equipment;

Trend until 2020: +6%.

http://3.bp.blogspot.com/-7Wofh5H4nm0/T5hzpoRSbGI/AAAAAAAAANU/ibFL6kt6SL4/s1600/goccia+d'acqua.jpg

http://3.bp.blogspot.com/-7Wofh5H4nm0/T5hzpoRSbGI/AAAAAAAAANU/ibFL6kt6SL4/s1600/goccia+d'acqua.jpg



Reference regulation framework

EU LEVELEc No. 178/2002, Council Directive 98/83/EC

1. Increase efficiency standards for water

using products, +16% by 2030;

2. European Food Safety Authority to

promote, apply and control the procedures

in matters of food safety;

3. Obligation of protecting human health

from the adverse effects of any

contamination of water intended for

human consumption;

4. Sets quality standards to achieve and

forces the member states to follow the

principles of planning, regulating,

monitoring, informing and reporting

toward the F&B stakeholders about the

quality level of water.

ITALYNational regulations

1. Legge 36/94 setting the concepts of water

saving, recovery and reuse;

2. D.Lgs. 152/99 (Testo unico sulle acque)

transfering to regions the responsibility of

setting rules for water saving, control and

reuse;

3. GAB/DEC/93/06 prohibiting the use of

recovered and purified wastewater within

F&B and pharmaceutical industries except

in the case of a local recover;

4. D.Lgs. 31/2001 actuating the EU Council

Directive 98/83/EC and regulating the

water quality control and responsibilities

of industry and the control Authority.

Research Context:

The ‘Less Water Bev.Tech.’ EU Project

Official Project Web-Site for

detailed info & docs:

http://www.lesswaterbevtech

.com/en/en-home

Headquarter in Fornovo di Taro, Parma, Italy;

Active in the F&B process business since 1967;

57 employees (23 in R&D) × ~20M€/y

turnover;

Businesses in EU, Africa, Mid/South America,

Middle East;

High customization solutions.

Industrial Mechanical Plant Engineering group

& lab;

Design, field-test and support in industrial

process & advanced manufacturing

technologies;

Strong connection with industry to «transfer

techs.».

Design of project/machinery software solutions

and commissioning, training to the final user;

Fully conversant in manufacturing automation

platforms including Siemens, Allen Bradley and

Omron, alongside the SCADA/HMI solutions.



http://www.lesswaterbevtech.com/en/en-home



Local Water Recovery Plant (1)

Target: mid-size F&B Italian company producing soft drinks, non-carbonated beverages,

juices and vegetable sauces. Annual water intensity: 2.4 billion liters/year actually supplied

from five wells and managed in open-loop.

Water streams:

Fillers: 3 lines, 30000 l/h, continuous;

Osmosis retentate: 15000 l/h, continuous;

CIP: 4000 l/h, discontinuous & highly polluted;

Cooling towers: 2,000 l/h, continuous;

Syrup room: 1000 l/h discontinuous.

Focus 45000 l/h (plant capacity)



Local Water Recovery Plant (2)

Acid neutralization

(e.g. PPA)

Ultrafiltration membranes

(suspended solids)

Reverse Osmosis membranes

(dissolved solids)

UV

(microbiological charge)



LCA Methodology (1)

LCA is an useful standard technique to evaluate the environmental impacts of a product

throughout its whole life (from a “cradle to grave/cradle” perspective)

LCA spreads around the world since the development of standards by ISO (International

Standards Organization) in

Environmental Product Declaration

Re-design of product and services

The LCA framework includes four steps (ISO 14040:2006):

1. Goal and scope definition

2. Inventory Analysis (LCI)

3. Impact assessment (LCIA)

4. Interpretation

LCA Methodology (2)

Life cycle impact assessment (LCIA) is carried out using SimaPro 7.3.3 by Pré

Consultants with the use of three methods:

1. Eco-indicator 99 Hierarchical version (EI99H)

2. ReCiPe H/A

3. IPCC 2007 Global Warming Potential (GWP)

GLOBAL WARMING

POTENTIALis defined as “the climatic

warming potential of a

greenhouse gas relative to

that of carbon dioxide.” The

GWP of a gas is measured in

mass of equivalent carbon

dioxide CO2eq.

RECIPE H/AFocuses on the evaluation of three

endpoint categories:

• damage to human health

(HH), measured in “DALY”;

• damage to ecosystem

diversity (ED), measured in

Ecosystem species*yr;

• damage to resource

availability (RA), measured in

Resources Surplus Cost.

ECO-INDICATOR 99Focuses on the evaluation of

midpoint indices:

• damage on human health,

measured in “DALY”

(Disability Adjusted Life

Years);

• ecosystem quality, quantified

in PAFm2year (Potentially

Affected Fraction);

• resource preservation,

evaluated in “MJ surplus”



Plant LCA (1)

ATMOSFERIC

EMISSIONS

Energy

Raw material Acquisition

Assembly

Manufacturing

Transportation

System

boundary

INPUTS PROCESSES OUTPUTS

Raw material

WATERBORNE

WASTE

SOLID

WASTE

The environmental impact evaluation of the manufacturing and

assembly phases of the industrial system;

Functional Unit: the construction of an innovative plant for water

treatment and wastewater recovery and purification in the F&B

industry.

The boundaries of the system are

from “the cradle to the gate of

the industry”, considering:

• raw material extraction

processes;

• manufacturing and assembly

of components; transports;

• energy.The USE of the plant and

its DISPOSAL are not

considering in this study

GOAL AND SCOPE

DEFINITION

INVENTORY



Plant LCA (2)

INVENTORY:

The plant is subdivided in the following functional parts:

• Cleaning In Place (CIP)

• Carbon Filter

• Pump for water recovery

• Reverse Osmosis

• Tank 8000 l

• Tank 3000 l

• Ultrafiltration

• Ultra Violet Treatment (UV)

• Electrical system

The ELETRICAL

SYSTEM is not considering

in this study

For the key functional parts, all the

constitutive components and

materials are considered within the

analysis.

Transportation: is considered for all the components and materials.

The vehicles considered for the transportations are lorry >16t, fleet average and lorry 3.5-

7.5t, EURO4.

Energy: Medium voltage Italian electricity with importation.

Database: data bank of SimaPro 7.3.3; data collected from direct observation, literature and

other data banks; simplifying hypotheses concerning material or processes.Environmental Assessment of an Innovative Plant for the Wastewater Purification in the Beverage Industry




Plant LCA (3)

IMPACT ASSESSMENT

EcoIndicator 99

Reverse Osmosis has the

major impact in Resp.

Inorganics, Carcinogens

and Fossil Fuels.

Carbon Filter introduces

significant damages in

Resp. Inorganics and in

Land Use.

Ultrafiltration generates

significant damage in

Fossil Fuels and in Resp.

Inorganics.

Reverse Osmosis, Ultrafiltration and Carbon Filter are

the units with the highest environmental burden.

4321.17 Pt



Plant LCA (4)

IMPACT ASSESSMENT

ReCiPe Reverse Osmosis have

the major impact in

Climate Change and

Fossil Depletion.

Ultrafiltration

generates significant

damage in Fossil

Depletion and in

Climate Change.

Carbon Filter

introduces significant

damages in Agricultural

land occupation and in

Particulate matter

formation.

Reverse Osmosis, Ultrafiltration and Carbon Filter are

the components with the highest environmental burden.

3206.60 Pt



Plant LCA (5)

Impact Category Unit Total

Carbon Filter CIP

N.4 Pump for Water Recovery

Reverse Osmosis

Tank 30k

Tank 8k Ultrafiltration UV

IPCC GWP 100a

kg CO2 eq 60872,6 3696,9 2165,9 1430,2 32400,5 525,84 3711,5 16782,78 158,78

GWP 100a

Reverse Osmosis is the group with

the major impact.

The manufacturing of this component

produces 32,400 kg CO2eq that

represent the 53.2% of the total kg

CO2eq.

The ultrafiltration group is the second

in term of GWP emissions.

Plant LCA (6)

Since Reverse Osmosis, Ultrafiltration and Carbon Filter are the parts with the greatest

impact, the manufacturing and assembly phases of these components are considered in order

to find the processes or the sub-components generating the majority of the damage.

The major damaging

contribution is due to the

pressure vessel and pump

components.

Future change in

manufacturing of this

component is desirable for a

more sustainable design.

REVERSE OSMOSIS



Conclusions

The three methods considered lead to common results:

In manufacturing and assembly phase of the water recovery plant Reverse

Osmosis, Ultrafiltration and Carbon Filter are the components with the highest

environmental burden;

The major damaging contribution is due to the pressure vessel and pump

components;

Reverse Osmosis is responsible of the 53.2% of the total kg CO2 eq. emitted, of the

44.85% of damage Pt in Ecoindicator99 and of 45.78% of damage Pt in ReCiPe

H/A;

The impact categories of Eco-indicator 99 method, characterised by major damage,

are Resp.Inorganics (38.69%), Carcinogens (26.35%) and Fossil Fuels (14.95%).

As regards ReCiPe H/A the impact categories mainly interested are Fossil Deplation

(25.65%), Climate Change Human Health (24.14%) and Climate change

Ecosystem (15.79%).Environmental Assessment of an Innovative Plant for the Wastewater Purification in the Beverage Industry




Future Developments

Analysis of the whole life cycle of the plant with particular attention to the

use phase, in which the water recovery could have a positive effect on the

environmental impact for the ground water’s consumption avoided;

Comparison between a traditional system without water recovery and the

system with the prototype object of this study is desirable;

Changes to the prototype design, toward an eco-design perspective, with

equal performance;

Sensitive analysis, with the aim of defining the better configuration in an

environmental point of view.

Eng. Marco Bortolini, Ph.D.

Department of Industrial Engineering (DIN)

Alma Mater Studiorum – Bologna University

[email protected]

Thank You

mailto:[email protected]

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