Cleaner Production Cleaner Production AssessmentAssessment

(Chapter 4)(Chapter 4)

Siarhei Darozhka,Siarhei Darozhka, Belarusan National Technical University, MinskBelarusan National Technical University, Minsk

Borki-Molo, BUP EM Course Teachers Conference, Borki-Molo, BUP EM Course Teachers Conference, 30.06.200630.06.2006

Cleaner Production Cleaner Production DefinitionDefinition

Cleaner Production meansCleaner Production means the continuous application of an integrated the continuous application of an integratedpreventative environmental strategy to processes, products and services to preventative environmental strategy to processes, products and services to enhance efficiency. enhance efficiency. This leads to improved environmental performance, cost savings, and the This leads to improved environmental performance, cost savings, and the reduction of risks to humans and the environment.reduction of risks to humans and the environment.

For production processesFor production processes: cleaner production includes conserving raw : cleaner production includes conserving raw materials and energy, eliminating toxic raw materials, and reducing the materials and energy, eliminating toxic raw materials, and reducing the quantity and toxicity of all emissions and waste quantity and toxicity of all emissions and waste beforebefore they leave the they leave the processprocess

For productsFor products: the strategy focuses on reducing impacts along the entire : the strategy focuses on reducing impacts along the entire life cyclelife cycle of the product, from raw material extraction to the ultimate of the product, from raw material extraction to the ultimate disposal of the productdisposal of the product

For servicesFor services: using a preventative approach involves : using a preventative approach involves designdesign issues, issues, housekeeping improvements and the better selection of material inputs (in housekeeping improvements and the better selection of material inputs (in the form of products). The selection of what kind of service is to be the form of products). The selection of what kind of service is to be provided and in what way it leads to varying kinds of environmental provided and in what way it leads to varying kinds of environmental impacts impacts

Main Reasons to Main Reasons to Implement Cleaner Implement Cleaner

Production ProgrammesProduction Programmes

Economical benefit and top-management Economical benefit and top-management commitmentcommitment

Legislative pressureLegislative pressure EMS ProgrammesEMS Programmes

Cleaner ProductionAssessment Methodology

Planning and Organizing Cleaner Production Phase

Obtain management commitment Establish a project team Develop environmental policy objectives

and targets Plan the Cleaner Production assessment

Pre - Assessment Pre - Assessment PhasePhase

Company description and flow chart - What does the company produce? - What is the history of the company? - How is the company organized? - What are the main processes? - What are the most important inputs and outputs?

Walk - through inspection

Establish a focus Pay attention to processes that - Generate a large quantity of waste and emissions - Use or produce hazardous chemicals and materials - Entail a high financial loss - Have numerous obvious Cleaner Production benefits - Are considered to be a problem by everyone involved

Walk - through Inspection

Questions to be answered during a walk-through inspection:

Assessment PhaseAssessment Phase Collection of quantitative data

Material balance Total material in = material out (product) + material out (wastes) + material out (emissions) + material accumulated

Sources of material balance information

- Samples, analyses, and flow measurements of feed stocks, products, and waste streams - Raw material purchase records - Material inventories - Emission inventories - Equipment cleaning and validation procedures - Batch make-up records - Product specifications - Design material balance - Production records - Operating logs - Standard operating procedures and operating manuals - Waste manifests

Flows Sankey DiagramFlows Sankey Diagram

Example: Tips for Reducing Cooling Water

Avoid the need of cooling, use in-process available cool and hot sources, or prevent overheating so that cooling requirements are reduced or eliminated

Eliminate water use in cooling. If ambient temperatures are low enough, possibilities for cooling with air may be beneficial. In some cases, it may require a forced draft (blowing air with fan) for cooling

Reuse cooling water. In most cases the once through water-cooling can be converted to a closed loop system by installing a cooling tower. In the cooling tower, the water is sprayed against a forced draft of air. This cools the water- but, in turn, a portion of water is vaporised. A constant bleed (purge) is needed to keep the contaminants in the loop within acceptable levels. Cooling towers (closed loop system) can result in up to 95 % water conservation as compared to the once-through process, but will of course require investments and energy for operation

Recycle cooling water. Reuse of cooling water for cleaning, washing, boiler make-up (softened), and other in plant uses does not only saves water but also provides (at least marginally) heated water and increases thereby its usability

Do not use higher quality than necessary. Quality requirements are generally lower than for other uses of water

Identifying Cleaner Production Opportunities

Identification of Cleaner Production options: - Literature - Personal knowledge - Discussions with suppliers - Examples in other companies - Specialized databases - Further research and development Generating options: - Input materials - Technology - Execution of the process - Product - Waste and emissions

Improving the environmental performance of processes: - Input material changes or input substitution - Technology changes or technology modifications - Good housekeeping or good operating practices - Product changes or product modifications - Recycling

Record and Sort Options

Example of information recorded for identified options

Evaluation and Feasibility Study Phase

Preliminary evaluation Is the Cleaner Production option available? Can a supplier be found to provide the necessary

equipment or input material? Are consultants available to help develop an

alternative? Has this Cleaner Production opportunity been applied

elsewhere? If so, what have been the results and experience?

Does the option fit in with the way the company is run?

Evaluation and Feasibility Study

Technical evaluation Will the option compromise the company’s product? What are the consequences for internal logistics,

processing time and production planning? Will adjustments need to be made in other parts of

the company? Does the change require additional training of staff

and employees?

Example of Technical Evaluation

Insulation manufacture

Evaluation and Feasibility Study

Economical evaluation What are the expected costs and benefits? Can an estimate of required capital investment

be made? Can an estimate of the financial savings be

made, such as reductions in environmental costs, waste treatment costs, material costs or improvements to the quality of the product?

Economical Evaluation

Payback period Net present value (NPV) Internal rate of return (IRR).

Evaluation and Feasibility Study

Environmental evaluation What is the expected environmental effect of

the option? How significant is the estimated reduction in

wastes or emissions? Will the option affect public or operator health

(positive or negative)? If so, what is the magnitude of these effects in terms of toxicity and exposure?

EnvironmentalEvaluation

For a good environmental evaluation, the following information is needed:

Changes in amount and toxicity of wastes or emissions Changes in energy consumption Changes in material consumption Changes in degradability of the wastes or emissions Changes in the extent to which renewable raw materials are

used Changes in the reusability of waste streams and emissions Changes in the environmental impacts of the product

Implementation and Implementation and Continuation Phase Continuation Phase

Preparing an implementation plan (finance, responsibility, documentation, training, etc.)

Implementation selected options (technology, good housekeeping measures, product, services)

Monitoring of performance (monitoring, records, internal audits, management review)

Making Cleaner Production activities sustain (commitment, internal policy, voluntary agreements, regular reports to the

interested parties, etc.)

Thank you very much for Thank you very much for your attention!your attention!