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Dr Zahiruddin KhanIESE NUST

CLEANER PRODUCTION

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What is

Cleaner Production ?

A pro-active approach of reviewing all

processes and business activities to identify

environmental improvement and cost

reduction opportunities

It is digging well before the fire

breaks out

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What is

Cleaner Production ?

Better planning in operations & wastedisposal

Reduce /eliminate need for end-of-pipe

technologies More efficientless polluting technologies

Reduced energy, water and raw material

consumption Cost reduction & marketing advantages

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OBJECTIVES OF CP

Maximize resource conservation

Minimize waste generation at source

Improve environmental and economicperformance

Develop Environmental Policy

Improve social image Comply with legislation & Industry Stds.

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Environmental Audit

Policy & procedures

Compliance issues

Conformance with statedvalues/standards

Chemicals / oils storage

Potential for stormwater

pollution

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Cleaner Production The Big Picture

Environmental audits Review of costs at each

step

Mass and energy balances

Cost reduction strategies Materials and energy

reduction strategies

Waste minimization andmanagement plans

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Cleaner Production Audits -Methodology-General

ImproveHousekeeping

Material Substitution

Change Process orTechnology

Reformulate orRedesign Products-LCA

Reuse & Recycle

Materials on-site

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Cleaner Production Audits -Methodology-General

Improve Housekeeping

Reduce raw material and product loss due toleaks & spills etc.

Improve monitoring of operations & maintenance Schedule production to reduce equipment cleaning

Train employees in cleaner production-

Ownership

Improve management inventory of raw materialsand products

Waste heat recovery

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Cleaner Production Audits -

Methodology-General

Material SubstitutionReplace toxic solvent-based coatings withless toxic, water-based coating

Eliminate hazardous materials

Change Process or Technology

Use mechanical cleaning devicesReduce high pressure lines to reduce fugitiveemissions of air toxins

Cl P d ti A dit

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Methodology-General

Reformulate or Redesign ProductsFormulate paint without lead

Analyze impact created by products over theirlife cycle

LCA Cradle to grave assessment

Reuse & Recycle Material On-siteUtilize wastewater & energy

Reuse product rejectsSeparate waste streams

Reuse of storm water

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Methodology-Technical

Develop a pareto chart of costs

Qualitative analysis of opportunities / risks

Select key investigations

Develop strategies via:

Gaining commitment from Top Management

Consultation with in-house experts- Engineering design

- Long time workers

Cost benefit analysis

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Cleaner Production - Comparing Options

0

50,000

100,000

150,000

200,000

250,000

Energ

y

Wate

r

RawMaterials

Maintenance

Fuel/Oils

Stationar

y

PPE

Waste

Management

TradeWaste

Packagin

g

Cleaner Production Variables

AnnualCosts($)

Series1

Series2

Series3

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Cost Saving Opportunities-1

RAW MATERIALS

Try bulk purchase

Refill containers

Use flexible packaging

Buy concentrated solutions

Shop around & prefer local suppliers

Use recycled raw material where possible

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CONSUMABLES Keep record

Use both sides of the paper

Use recycled toner cartridges Decentralize purchasing

Monthly review of PPE

Shop around for petrol and other fuels

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ENERGY & TELEPHONE CHARGES Paint walls as white

Use clear panels in the ceiling

Increase number & size of windows

Keep a gap between start of heavy machinery Recover heat loss

Develop a culture of turning light & machine offwhen not in use.

Check pressure lines on regular basis

Replace high power light fixture with low powerones

Revisit electricity & telephone contracts

Revisit power correction factor

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MAINTENANCE COST Keep all machinery well lubricated.

Keep maintenance record of each

equipment Never use sole supplier for equipment &

spares.

Keep in touch with modern developments

& budget for replacement of equipment Switch to long life chemicals eg. Coolants

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SOLID WASTE MANAGEMENT

Think through operations and minimize rawmaterial consumption.

Segregate effluent streams with reuse focus Segregate solid waste streams with recycling

focus.

Ask your supplier to take back waste chemicals

Shop around for most economical waste collector.

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Cost Saving Opportunities-Water

Identify consumers/major machines in factory

Find a practical division of the plant

machines

departments buildings

Distribute consumption

over these parts

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WATER CONSUMPTION Conduct an internal water use & quality

survey

Identify wastewater streams that can be

diverted to reuse Explore storm water harvesting

opportunities

Use AAA rates low flow water savingshowers

Apply high temperature, high pressurewater to clean large vessels

Fix leaky taps.

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PACKAGING Quarterly review most popular & unpopular

packaging

Design packing as to maximize reuse andrecovery of products

Convince suppliers to take their packagingback

Shred and reuse waste packaging for shockabsorbing materials.

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Lighting in Commercial Buildings and Offices

Lighting Accounts for up to 40% of energy bills

Requirements recommended = 8 11 watts/m2

Florescent Tubes- T8, 36 Watt Halophospher

- 36 watt + std. Magnetic Ballest (9w)

- Life = 6000 hrs

-T8, 36 Watt Triphospher

- 20% more light than Halophospher

- Lesser Lamps, Low energy consumption. Low Capital Cost- Life => 13000 hrs ( mag ballast), 16000 hrs ( Elect. Ballast)

- Low Loss mag. ballast 6W

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T5, Triphospher 28 watt23% more efficient than T8 Triphosper & 38% more than

T8 Halophospher

Life = 16000 hrs

With electronic ballast (4w)

Fewer Lamps

Low Cap cost

Low energy Cost

Lower maintenance

Lower raw material consumption

Compare 100 T8 + mg Bal l with 100 T5 Tri

phosphor with ref lecto r + elect . Bal last

Li hti i C i l B ildi d Offi

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Incandescent Light (IL)Most common,

Most in-efficient- Only 5% of the energy

is converted to light

Compact Fluo rescent Lamps (CFLs)

75% more efficient than

IL, i-eAn 11 W CFL = 60 Watt IL & 18 Watt CFL= 100Watt IL

Life 10 13 times that of IL

Light in Lateral direction so reflectors help


Compare Energy saved when 1000 CFLsreplace 1000 IL of 100 Watts Ea. For 1000 hrs.

Calculate CO2saved if each power unit produces

0.92 Kg of CO2

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Improved Use- Timer Controlled

- Occupancy sensor controlled- Day-Light-Linked dimming system

- Building Design-White Light paint

- Sky-Lights

- Reflectors


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-Lighting accounts for up to 7% of Energy lamps

-High Intensity Discharge (HID)

Difficult to access

Expensive to replace

Costly maintenance

Industrial Sites

Mercu ry Vapo r Lamps (MV)

Std = 400 Watt + Magnetic Ballast

Low CostLong Li fe

L ife 1600 2400 hrs

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Metal Hal ide (MH) Lamps 60% more l igh t than MV

Excellent when color in an issue

Life 10000 20000 hr

Good for flood light matches

High Pressu re Sodium (HPS) Lamps.Twice the light by MV

Yellow Light

Good for outdoor car-park, Storage & supporting

fields, street lighting life = 2400 hrs.

Carbon filters reduce particulate entry during cooling oflight after turn-off

Indus tr ial Sites

Addit ion al Techniq ues

(1) Timer Con tro l; (2) Day-Lig ht-Lin ker Senso r (3) Whit e & Lig ht Paint

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20 % of energy bill in the commercial sectorUsing energy efficient office equipment can reduce

energy consumption of individual products by 50%

Off ice Equipment

Off ice Consum ables Include:Paper

Computers

Printer Cartr idges

Stat ionary

PhotocopiersTelephone

Vehicles

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Office Equipment

PaperCommunicate electronically as far as possible

Do not print until final draft is ready

Use both sides of the paper while printing or hand writing

Use low grade paper for draft prints

Buy paper in bulkKeep records of paper consumption per officer per week

PrinterUse centrally located photocopy machine for printing ratherthan printer on each desk

Print in draft quality until final copy

Toner CartridgeUse recycled toner cartridges

Ensure 95% of toner consumption before replacement

Offi

E i t

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Computers Average PC draws 110 150 Watts. Monitors accounts for 2/3 or more of the energy

consumed by computers. To save energy: Buy Energy Star labeled equipment

Enable Energy Star function This reduces consumption up to 30 watt

Switch off Computers when leaving for more than hr.

Portable computers use less energy Enable sleep mode for the monitor when not used for more than three

minutes

Photocopiers

- Use energy efficient photocopiers

- Locate centrally so that it can be used as printer too.- Use machine that would turn to stand-bye mode if not used for more thantwo-minutes

- Attach use Instructions at the top to facilitate use and reduce wastageof paper

- Enable 2-sided copy mode unless required otherwise

Office Equipment

Offi C bl

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Office Consumables

StationaryBuy in bulk

Conduct market survey before every purchase

Keep records of use per person per week

Get officers signature while issuing new lot of stationary

Energy - GeneralMaximize the use of natural light

Use energy saver lighting. Use reflectors behind F-tubes

Install lighting where required

Open doors and windows in the morning for a flush by the fresh winds

Turn A/C and Heaters off hr before closing time

Use mobility driven light sensors in toilets and store rooms

Use thermostats to control temperature at 26 oC in Summer and 24 oC in

Winter.

Office Cons mables

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Office Consumables

TelephoneUse centrally controlled telephone system

Use inter-com or e-mail for internal communication

Review the available line vs required lines.

Keep track of bills and instruct to minimize calling time.

VehiclesCarpool wherever possible

Ban the use of office vehicle for private use especiallyafter office hours.

Review Contracts with the fuel suppliers and the repair &maintenance workshops

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Equipment Specific CP Options Compressed Air Systems

Reduce the temperature inair intake

Reduce operating pressure Repair air leaks

Remove unusedcompressed air lines

Investigate alternatives tocompressed air

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Cost of Compressed Air Leaks (24/7 Basis)

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

0 1 2 3 4 5 6

Hole Diameter (mm)

CostofAirLeak$/yra

t$0.1

0kWh

100 kPa

300 kPa

500 kPa

700 kPa

B il

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Boilers

Use gas in preference to oilor coal

Match capacity and supplyto demand

Minimize demand by otherenergy efficiency measures

Use efficient combustionequipment

Maintain regularly

STEAM SYSTEMS

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STEAM SYSTEMS

Repair leaking steamtraps

Insulate steam andcondensate lines

Check size of thesteam traps

Optimize operatingpressure

Install condensatereturn lines

H t W t S t

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Hot Water Systems

Install AAA ratedshower heads

Repair leaky taps &

pipes Insulate hot water

lines

Re-set thermostat to

60oC

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Heat loss from steam pipes (24/7 Basis)

0

50

100

150

200

250

300

350

400

450

500

0 200 400 600 800 1000 1200

Steam Pressure (kPa)

Co($ym)

50 mm uninsulated pipe

50 mm insulated pipe

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Electric Motors Install variable speed drive

Install time switch to turn off motorwhen not in use

Check, if oversized

Check all piping & valves to minimize

pressure loss. Minimize rewinds

Reduce Ts and elbows whereverpossible

50 % of worlds energy goes through

electric motors Capital: Operating Cost = 5:1

2.4 KW saved at Motors save 8 KW at

Power plant

W t f E

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Wastage of Energy

0

200

400

600

800

1000

1200

0 1 2 3 4 5 6 7 8 9 10

Motor kW

$/yrat$0.1

0/kW

h5 hrs/wk

10 hrs/wk

15 hrs/wk

20 hrs/wk

P d F

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Pumps and Fans

Ensure pipes & ducts or notundersized-15% rise in pipe diareduces pressure drop by 50 %

Trim impellers below design flow

rate Alter the angle of the blades in fans

Install timers to stop when not inuse.

Install variable speed drives to

reduce power consumption Regularly maintain.

Cleaner Production

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Cleaner Production

General Outcomes

- Improved efficiency

- Improved productivity

- Reduced operating costs

- Enhanced public image and marketingadvantages

- Reduced environmental risks

- Regulatory compliance

Cleaner Production

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Cleaner Production

Specific Outcomes

Raw materialsMore environment friendly inputs& productsReduced raw material consumption

Dangerous goods/hazardous wastereduction

Water savings

Reduced fresh water useReduced cost of wastewater management

Cleaner Production

Specific Outcomes

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Specific Outcomes

Electrical EnergyReduced consumption

Reduced tariff

Solid/Liquid WasteReduced waste

Enhanced on-site re-use

Improved segregation & recycle

Improved communication & Training

Savings for ever

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Cost/Benefit Analysis

Average payback period for

identified projects = 4 months.

Maximum payback period for

identified projects = 5.5 years.

A $ saved at the shop-floor appears

as $ 4-10 on your balance sheet.

Examples from Leather

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Industry

Objectives

Reduction in chemical consumption

Reduction in water use

Reduction in solid/liquid waste production

Reduction in treatment cost

Quality Split Suppliers(P t ) Ltd

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(Pvt.) LtdCP Opportunities

Water consumption, and Chemical consumption

Changes IntroducedInstalled a water heater to use hot water for fat removal from hidesIntroduced personal protection equipment

BenefitsEnvironmental

1134 Kg of fat removed from going to drain per yearBOD, COD and TDS of effluent reducedImproved dyestuff uptake by hides (saving of 54 Kg/year)

Energy consumption reduced as drum rotation time reducedFinancial

Rs. 157,000 per year (payback period less than a month)Social

Many other tanneries followed QSSs example

A B Leather (Pvt ) Ltd

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A. B. Leather (Pvt.) LtdCP Opportunities

Review of Re-chroming and drying Processes

ChangesIntroducedStopped adding excess salt during re-chromingInstalled a drying chamber to accelerate hide drying process

BenefitsEnvironmental

Saved 500 Kg of salt that was otherwise going into theeffluent

Reduced use of fat liquor

Reduced consumption of dyestuffFinancial

Rs. 56,000 per year (payback period less than a month)Social

Many other tanneries followed ABLs example

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UNIVERSAL ANODISERS Pty LtdSaved 163 K p.a. Replace / repair of Rectifier Clean wires and

cables to Rectifier #3.

Replace fine bubblers with circulating liquidjets. This reduces 20 % of the power required

for agitation In-efficient heat transfer change pipe size

between chillers and heat exchangers

Install heat exchanger to recover heat that is

being lost. Recycle alumina sludge.

SICPA Australia Pty Ltd

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Saved $50 K p.a Improved Non-compliance Report System (NCR)

Eliminated wastage of press-base and finished goods.

Efficient local delivery system

Eliminated non-popular packaging

Enhanced waste segregation & recycling, reduced waste

by crushing drums, reduced no. of waste pick-ups Adjusted power factor to near 1.0, effects of demand chan

and cool room temperature to 20 oC,

explored changes in lighting tubes, improve ventilation inflammable storage rooms

Telephone charges explore which line and service

contracts can be eliminated

Johnson Diversey Pty LtdSaved 23 K p a

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Saved 23 K p.a.

Decentralized purchasing and limiting inventory in each dept Improved production scheduling to reduce

raw material consumption

Collected and segregated chemical dust for reuse

Segregated and recycled waste. Used most economical

waste collector.

Replace disposable drinking cups with reusable ones.

Remove all fluorescent tubes and 1000 Watt high bays that

are not contributing to light.

Power savings- Adjust power factor to near 1.0, check effects

of demand changes and eliminate compressor leaks.

Use high pressure cleaners for tank cleaning

Replace phosphoric acid with sulphuric acid

Rmax Pty Ltd

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Saved 78 K p.a. House Keeping Improve storage of machine

moulds, storage of recyclable material, layout ofcutting & shape moulding areas, rationalise palletstorage, relocate maintenance workshop, remove

inefficient granulators and silos, Raw Materials- re-visit manufacturing targets vs

raw material consumption,

Energy - use-rectify air & steam leaks, repairleaky steam chests, review machine cycle time,

Waste Handling Install low temperature meltingmachine and remove 3 granulators,

PRAIRIEWOOD LEISURE CENTRE

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SAVED 63 K p.a.

Power Savings Install sensors/timers, turn-off when not in use,fix door seals, potential for pool solar heating.

Reduce water consumption by changing shower head, harvest

storm-water for lawn watering, fix any leaks, re-use backwash water.

Chemical re-agents savings- Compare O3-NaOCl system

with UV-Ca(OCl)2

system.

Gas Savings- Assess Potential for gas supplemented Solar

Heating vs electric heating

Building maintenance ensure building maintenance is cost

effective, future building management system consistent to

CP objectives.

Maintenance of HVAC system

KOMATSU AUSTRALIA PTY LTD

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Saved 10.5 K p.a. Segregate waste and hire a single general

waste collector

Examine power tariff structure & power

consumption Reduce stationary consumption-Double

side print

Reduce Trade waste cost by recycling

wash-water.

CONPLANT HIRE PTY LTD

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Saved 15 K p.a. Reduce compressed air leaks

Improve segregation of wastes (rags etc)

Switch to long life coolant

Reduce raw materials wastage nut-bolts and PPE

Use sky lights and painting walls forsaving energy.

Improve design of new buildings.

Results of Previous CleanerProduction Audits/Case Studies

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Production Audits/Case Studies

11%

37%

12%

0%

27%

5%7%

1%

Water

Waste Water

Power

Power Tariff

Raw Materials

Solid Waste

Risk Reduction

Maintenance

CLEANER PRODUCTION DEMONSTRAITON PROJECTCASE STUDIES -1

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Company Projects Implementation

Costs

Economic Benefits

(approximate)

NowraChemicals

Modification ofeffluent streams

$25,000 $27,800year in sludgedisposal, water andproductivity

ACI GlassPackaging

Solid wasteminimisation

Improved cullet

water qualityBatch house dustcollection

Operatingprocedures/training

$5,040/year

Minimal

$43,000

Minimal

$25,800/year in reducedwastes

Reduction in wastewater

pollution$25,100year in reduced rawmaterial wastes

Higher staff morale andawareness

Australia MeatHoldings

Boilerimprovements

Minimal $65,000/year in reducedcoal consumption

HotelKurrajong

Solid wasteminimisation

Minimisation ofwater usage

Minimal

Minimal

$4,500/year in reduced solidwaste disposal

Unknown, but at least$2,250/year at laundry

CLEANER PRODUCTION DEMONSTRAITON PROJECTCASE STUDIES -2

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Costs

Economic Benefits

(approximate)

CSR Wood

Panels

Reduced boarddefects

Improved paintapplication

Board thickness

Solid waste recycling

Brick strips recycling

Reduce wastewater

Increased pack sizes

$100,000

$50,000

Minimal

Minimal

Minimal$5,000

Minimal

$750,000/year in reducedrejects

$310,000/year in reduced paintusage

$35,000/year in reduced rawmaterials, plus employment

$50,000/year in reuse of

material, plus employment9.5ML of wastewater estimatedat $14,250/year

$28,000/year in reducedmaterial usage

Moore

BusinessSystems

Process optimisation

Dryer temperaturesetting

Minimal

Minimal

$200,000/year in productivity

and reduced wastage$162,000/year and betterworking conditions

CLEANER PRODUCTION DEMONSTRAITON PROJECTCASE STUDIES - 3

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Costs

Economic Benefits

(approximate)

Austcast Sandreclamation*

$1,100,000* $270,000/year* in rawmaterials and reduceddisposal

Holdens

EnginesCompany

Improvedcoolantmanagement

Coolantexchange

Better coolant

Minimal

Minimal

Minimal

$52,000/year in reducedoil/sludge disposal

$16,000/year in reduced

coolant usage$30,000/year in reducedcoolant usage

Bonlac Foods Chemicalschangeover

Effluent

diversionSolidsscreening

Minimal

Minimal

$30,500

$97,000/year lesschemicals, improvedproductivity

30% reduction in effluentdischarges

$100,000/year increasedproductivity

CLEANER PRODUCTION DEMONSTRAITON PROJECTCASE STUDIES - 4

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Company Projects ImplementationCosts

Economic Benefits(approximate)

PaybackPeriod

Schweppes

Cottees

Backwash

waterutilisation

Replacementof spraynozzles

Wash waterrecycling

$3,500

$3,390

$1,500

$8,280/year in reduced

water consumption$15,400/year inreduced water usage &wastewater

$5,300/year in reducedwater consumption

5 months

10 weeks

4 months

Cleaner Production

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Cleaner Production

Key Issues for Perspective Candidates

- Openness to change

- Commitment for continuous

improvement- Long term objectives

- Constant Review of operations

- Strict maintenance schedule Asking

the right questions

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Thank you folks

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