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Resource Efficient and Cleaner Production
Concept, Practices & Applications
Medan, 23 February 2017
February 2017 RECP Introductory Training 1
National Resource Efficient and Cleaner Production (RECP) Programme Indonesia
Funded by Implemented by In partnership with
Kementerian Lingkungan Hidup dan Kehutanan
Centre for Assessment & Development of Green Industry & Environment
February 2017 RECP Introductory Training 2
Efisiensi Sumber Daya dan Produksi
Bersih
Concept
PracticesApplications
RECP for green industry
February 2017 RECP Introductory Training 3
Resource Efficient and Cleaner Productionemerged as a business response to worsening(industrial) pollution and escalating use ofnatural resources
February 2017 RECP Introductory Training 4
disperse
control
recycle
Resource Efficient and
Cleaner Productionprevent
pollution
replace
protect
recover
reduce
scarcity
natu
ral reso
urces
enviro
nm
en
t
Efisiensi Sumber Daya dan Produksi Bersih
Efisiensi Sumber Daya dan Produksi Bersih
• Finding and implementing ways to– Improve productive use of materials,
water and energy;• Thereby
– Reduce the generation of waste, effluent and emissions;• Thereby
– Improve well being of employees, consumers and community; • Thereby• …….• ……..
February 2017 RECP Introductory Training 5
February 2017 RECP Introductory Training 6
Productive output per unitof resource consumption
Pollution intensity per unitof productive output
RECP Issues
February 2017 RECP Introductory Training 7
Produktivitas Bahan Baku
Pemilihan dan efisiensi bahan baku
Intensitas Sampah
Penurunan dan buangan yg aman dari limbah
Produktivitas
Air
Pemilihan dan efisiensi air
Intensitas
Limbah Cair
Penurunan dan Pengolahan air limbah
Produktivitas
Energi
Pemilihan dan efisiensi energy
Intensitas
Emisi
Penurunan dan Pengendalian gas buang
February 2017 RECP Introductory Training 8
Resource Efficient and Cleaner Production canbe implemented through – combinations of –different prevention practices
February 2017 RECP Introductory Training 9
Tata KelolaArea Kerja
Substitusi Bahan
Peningkatan Pengenda-lian Proses
Modifikasi Peralatan
Penggan-tian
Teknologi
Guna Ulang Dan Daur Ulang di
Lokasi Sendiri
Pemanfaatan Produk
Samping
Modifikasi Produk
• Maintain a clean, organized andproductive workplace to eliminateavoidable ‘wastage’
• Typical solutions– Switch off what is not in use
– Repair what needs reparation
– Keep workplace organized and clean
– Minimize and manage inventory
– Confirm right way for all tasks
– Keep staff motivated
10February 2017 RECP Introductory Training
• Choose inputs that are efficient, effective and/or pose minimum harm to the environment and health
• Typical solutions– Use renewable energy
– Use sustainably-sourced renewable materials
– Use of recycled materials, water and energy
– Use fit for purpose materials
– Use less harmful substances
– Source locally
11February 2017 RECP Introductory Training
• Monitor and control processes andequipment so that they always run athighest efficiency and with lowestwastage
• Typical solutions
– Standard operating procedures and process monitoring
– Sub-metering water, energy and materials
– Preventive maintenance
12February 2017 RECP Introductory Training
• Make existing equipment more efficient and less wasteful
• Typical solutions– Insulation– Proper alignment of
production line– Improve process
temperature, pressure, speed, mixing
– Automatic switch off & level controls
– Combine process steps in same equipment
13February 2017 RECP Introductory Training
• Change over to new technologythat is more efficient or producesless waste
• Typical solutions– Efficient boilers, motors, fans,
compressors etc.
– Change of core process, e.g. chemical to mechanical cleaning
– Equipment with integrated recovery loops
– Advanced separation processes
– Solar dryers, heaters and lighting
14February 2017 RECP Introductory Training
• Use previously ‘wasted’ material, energy and/or water for similar or alternative purpose in company
Typical solutions
• Countercurrent or cascaded use of water and energy
• Condensate and heat recovery
• Reuse of incoming packaging for outgoing products
Practices
15February 2017 RECP Introductory Training
• Convert a previous ’waste’ for a useful use elsewhere
Typical solutions
• Provision of used cooling water for external heating or cooling purposes
• Segregate recyclables for external recycling and resource recovery, such as composting
• Symbiosis - use waste material for new product development
16February 2017 RECP Introductory Training
• Redesign product to reduce its environmental impact during production, use and/or disposal
• Typical solutions– Design for optimal product
lifetime– Design for lower material
use– Design for low-waste
manufacturing– Design for refurbishment,
recycling etc.
17February 2017 RECP Introductory Training
RECP Method
Source
Cause
Option
February 2017 RECP Introductory Training 18
Root Source Analysis
WHERE?
Quantification of the different usages and sources
Root Cause Diagnosis
WHY?
Factors contributing to resource usage and pollution sources
Option Generation
HOW?
Alternative ways to avoid the identified causes
February 2017 RECP Introductory Training 19
Resource Efficient and Cleaner Production hasbeen beneficially applied in many industrysectors, including pulp and paper, rubber andfood processing sectors
Viet Tri Paper (Viet Nam)• Options implemented
– VSD on main paper machine motors
– Condensate recovery from paper machines
– Insulation and repair of steam pipes and valves
– Install economizer on boiler
– Dry storage of coal
• Economics– Investment USD113,000
– Annual savings USD 123,000
February 2017 RECP Introductory Training 20
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Anhui Tiandu Paper (China)• Options implemented
– Heat recovery from blow down of pulp digesters
– Insulation and leak repair of steam pipes
– Increase pulping capacity by better feeding of straw
– Segmentation in steam supply system
– Cogeneration of heat and power
• Economics
– Investment USD 2.1 M
– Annual savings USD 650,000
• Environment
– Coal savings 15,000 tpa
– GHG reduction 5.2%
February 2017 RECP Introductory Training 21
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Energy Opportunities in Pulp & Paper Mills
February 2017 RECP Introductory Training 22
11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
Water Opportunities in Pulp & Paper Mills
February 2017 RECP Introductory Training 23
11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
Energy Benchmarks
February 2017 RECP Introductory Training 24
http://www.iipnetwork.org/
Energy Benchmarks
February 2017 RECP Introductory Training 25
http://www.iipnetwork.org/
Energy Benchmarks
February 2017 RECP Introductory Training 26
http://www.iipnetwork.org/
Best Available Technologies
February 2017 RECP Introductory Training 27February 2017
http://www.iipnetwork.org/
Best Available Technologies (examples)
February 2017 RECP Introductory Training 28February 2017
http://www.iipnetwork.org/
Best Available Technologies (examples)
February 2017 RECP Introductory Training 29February 2017
http://www.iipnetwork.org/
AMC Tyres (Sri Lanka)• Implemented options
included:– New efficient compressor
– Leak survey and repair compressed air system
– Leak repair and insulation for boiler and steam system
– Condensate recovery
• Economics– Invested USD49,000
– Savings USD84,000/yr
• Environment– Electricity saved 521
MWh/yr
– Furnace oil saved 173 kl
– GHG reduction ~600 ton
June 2016 Module 1: RECP Concept and Business Case 30
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Medigloves (Thailand)
• Producer of surgical and cleanroom latex gloves– Reduced air intake temperature and fixed leaks in compressed air
system
– Recovery and reuse of water and chemicals from latex dipping process
– Recovery and reuse of water from wash and chlorination process
• Annual cost savings of USD19,200 for investment of USD8,000 (payback <5 months)
• Annual resource conservation of 166,000 kWhr, 17 kl oil and 14,300 m3
• GHG reduction ~150 ton CO2-eq
June 2016 Module 1: RECP Concept and Business Case 31
Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org
Concentrated Latex Production
• Gate to Gate Life Cycle assessment – Total environmental impact dominated by
• 1. electricity use for centrifugation• 2. ammonia use for preservation• 3. DAP use
– Total environmental impact can be reduced by:• 1. energy efficiency for centrifuge (inverter, VSD): 12%• 2. improved ammonia handling and storage: 8%• 3. extending coagulation time (reduced DAP use): 3%• 4. fuel switch from diesel to LPG: 5%
February 2017 RECP Introductory Training 32
Jawjit et al, Evaluating the Environmental Performance of Concentrated Latex Production in Thailand, 2012
Veraval• Fish processor in Gujarat, India
– Total investment <44,000 USD, with payback of 14 months
5 April 2016 RECP (seafood sector) 33
Cleaner Production Opportunities Investment (USD)
Pay Back
(month)
Use belt conveyor for transferring baskets filled with fish from
weighing section to processing hall1,725 10
Use of sprays instead of using running hoses for cleaning & rinsing
of fish.100 5
Reuse chlorinated wash water after filtration from 0.2 mm mesh
screen in non-critical applications like preliminary washing of R/M,
cleaning floors.
400 15
Improve insulation of cooling systems & pipe work (required 6" and
3" is used)1,600 10
Use SS made /aluminum allied trays instead of plastic trays for
efficient cooling.16,000 14
Installation of R.O. plant & reusing of treated water in the process
areas.23,500 15
Installation of water level controllers in overhead tanks 500 7
www.gcpcgujarat.org.inlast accessed 9 August 2015
Rathkerewwa Desiccated Coconut Industry
22 September 2016 RECP Introductory Training 34
National Cleaner Production Centre Sri Lanka
Sri Lanka
RECP@ Chea Hap Rice Mill
22 September 2016 RECP Introductory Training 35
Sustainable Food Systems
22 September 2016 RECP Introductory Training 36
Food Safety
Provenance (traceability)
Sustainable Source
Energy Use(& air
emissions)
Water Use & Effluents
Food Waste (Losses)
Waste & Byproducts
+source processing
RECP Starters
22 September 2016 RECP Introductory Training 37
Water Use & Effluents
WATER AND WASTE WATER
Measure and monitor water consumption
Increase staff awareness and motivation
Use efficient spray nozzles
Optimize rate of water flows
Install automatic controls and valves
Repair leaks, eliminate spill areas
Select water efficient processing routes
Dry-clean before facility wash down
Optimize pipe cleaning, e.g. with pigging systems
Optimize use of and controls over high pressure cleaners
Trigger operated controls and valves for hoses and spray guns
Design and install equipment with a view to ease of cleaning
Optimize Clean In Place systems (conductivity controls etc.)
Reduce change overs and optimize change over cleaning regimes
Custom design automatic container washing systems
Minimize cooling tower blow down
Optimize cooling tower operation for maximum water recovery
Use alternatives to water for cooling operations
Collect and reuse seal water from vacuum pumps
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Govof Queensland, Brisbane, 2004
RECP Starters
22 September 2016 RECP Introductory Training 38
Waste & Byproducts
WASTE AND BY-PRODUCTS
Improve material flow and plant layout to reduce materials wastage
Improve plant operations to reduce wastage
Develop options for recovery and reuse of waste, as animal feed,
byproduct or alternative fuel
(Vermi)compost organic waste
Segregate recyclables for third party recycling
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Govof Queensland, Brisbane, 2004
RECP Starters
22 September 2016 RECP Introductory Training 39
Energy Use(& air
emissions)Boilers and Production of Steam and Hot Water
Improve boiler efficiency
Match steam supply with steam demand
Steam distribution
Condensate return
Maintenance of steam traps and condensate lines
Rationalization of boiler use and steam lines
Insulation of pipes
High efficiency boilers
Reducing hot and warm water use
Consider co-generation
Consider solar (pre-)heating
Motors
Select high efficiency motor, sized to your needs
Install variable speed drive on fixed speed motors (e.g. compressors, fans, pumps, etc.)
Lighting
Minimize lighting requirements (e.g. daylight, light colors, task level)
Use light efficient lighting fixtures
Use appropriate and decentralized lighting controls and switches
Use energy-efficient lights
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Govof Queensland, Brisbane, 2004
RECP Starters
22 September 2016 RECP Introductory Training 40
Energy Use(& air
emissions)
Refrigeration Systems
Select right compressor size
Improve load distribution between compressors
Minimize temperature differences
Install hot gas bypass defrost
Reduce load on refrigeration system
Reduce heat ingress on refrigerated areas
Optimize selection and use of refrigerants
Consider alternative refrigeration, e.g. absorptive refrigeration
Consider solar cooling
Compressed Air Systems
Use energy-efficient compressor, sized to your needs
Install sequence controller to manage staggered operation of multiple compressor
Install variable speed drive to meet varying compressor load demands
Minimize compressed air leaks
Substitute use of compressed air wherever feasible alternatives exist
Optimize compressed air pressure to demands
Reduce compressor air inlet temperature
Optimize compressed air distribution system
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Govof Queensland, Brisbane, 2004
Business Case
February 2017 RECP Introductory Training 41
Cost savings
Productivity enhancements
Quality improvements
Organizational efficiency
License-to-operate
Indonesia RECP Programme• Networked initiative to foster
RECP implementation at scaleand at speed in Indonesia
1. RECP Capacity & Network
2. RECP Implementation & Replication
3. RECP Policy & Strategy
4. RECP Technology & Innovation
5. RECP Finance & Investment
Sectors
(food processing,
textile & garment
Industrial Zones
(Makassar & Batam)
Micro-Industries
(rice milling)
Tourism Destinations
(Sleman/ Magelang & Lake Toba)
February 2017 RECP Introductory Training 42
RECP Network
Programme activities in North Sumatra
February 2017 RECP Introductory Training 43
February 2017 RECP Introductory Training 44
Food Processing
Training of Experts and Enterprises
Assessor Assessments
Self Assessments
RECP Assessors Training• Aim
– Equip trainee assessors with necessary methods and skills to undertake RECP assessments in enterprises
• Modality – Class room training (twice, three days each)– Practical assignment (RECP assessments in two
demonstration enterprises)– Expert coaching and guidance
• UNIDO RECP Award
February 2017 RECP Introductory Training 45
6 experts from North Sumatra trained and being coached to execute RECP assessments
Assessor Assessments• Enterprises
– Obtain a catalogue of RECP options that will improve resource efficiency and reduce pollution with recommendations for implementation
– Improve awareness, understanding and capacity to manage and minimize resource consumption and pollution generation
• Associate RECP Assessors– Gain practical experience
in conducting RECP assessments in sector, under guidance of RECP expert team
– Complete basic RECP assessment training and obtain recognition as RECP expert
February 2017 RECP Introductory Training 46
First assessments undertaken in six palm oil mills under PTPN II, PTPN III and PTPNIV
RECP Clubs
February 2017 RECP Introductory Training 47
• Facilitate RECP uptake in groups of food processing enterprises– Self assessment
• Utilize internal resources for RECP option identification, evaluation and implementation
– Combined with enterprise training and coaching
Self Assess
1. Baseline
2. Materials & Waste
3. Water & Effluents
4. Energy
5. Chemicals & Emissions
6. Action plan
Expressions of interest sought
12 October 2016 RECP Introductory Training 48
Lake Toba
Tourism
Assessor Assessments
Community of Practice
Tourism planning and advocacy
Other Elements (TBD)
Expert PoolAlliance/
Partnership
RECP NetworkIndonesia
Bandung Declaration8 Nov 2016
Vibrant network of Indonesian RECP professionals that work together to expand and improve the awareness, knowledge and
application of RECP in Indonesia
An action partnership of organizations that commit to promote RECP and implement
RECP within their activities and/or sphere of influence
Local Practitioners Forums
February 2017 RECP Introductory Training 49
Terima kasih banyak!
February 2017 RECP Introductory Training 50
National Resource Efficient and Cleaner Production (RECP) Programme Indonesia
Funded by Implemented by In partnership with
Kementerian Lingkungan Hidup dan Kehutanan
www.recpindonesia.orgwww.recpnet.org
Centre for Assessment & Development of Green Industry & Environment
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