ECO-EFFICIENCY AND HOW

INDUSTRY 4.0 IMPROVES IT

AGORADA+2017

Industry 4.0 for Eco-efficiency

28th September 2017

İzmir

Ferda Ulutaş İşevi

Senior Executive of Macro Environment

ÖTE Ltd.

Content

What is eco-efficiency?

How is it applied?

How is it measured?

How does Industry 4.0 support eco-

efficiency?

An example

What is eco-efficiency? A strategy for creating an increased

value while reducing environmental

impacts and consumptions

Achievement of both economic and

environmental efficiency simultaneously

Picture: http://www.corporate-engagement.com/research/27

What is eco-efficiency? Decoupling resource use and pollutant

release from economic development and

welfare

Time

Future

(Source: WBCSD)

What is eco-efficiency?

HP in California reduced its waste by 95%

and saved $870,000.

STMicroelectronics saved £38 million in

energy and $8 million in water costs, with

a total saving over a decade predicted

at $900 million.

In 5 years, SC Johnson increased

production by 50% while waste emissions

were cut by half and $125 million was

saved annually. (Source: WBCSD)

What is eco-efficiency?

(Source: TTGV & İZKA)

Raw material saving: 100 tons/year

Energy saving: 7,800,000 kWh/year

Steam saving: 5,000 tons/year

Waste reduction: 100 tons/year

Water saving: 63,000 m3/year

Wastewater reduction: 19,000 m3/year

Chemicals saving: 81 tons/year

Investment: 1,121,818 TL.

Pay-back period: ~ 1.4 years

İzmir Eco-efficiency Program

Eco-efficiency practices in 4 four companies

How is it applied?

PROCESS

INPUTS

PRODUCTS

WASTES

Reduced environmental impact and

consumption

Increased value

How is it applied?

Analysis of inputs, processes, products and

wastes, within the context of eco-

efficiency criteria, with a life cycle

approach

Identification of potential areas and

improvement opportunities

Improvement of eco-efficiency

performance continuously and

systematically through the implementation

of eco-efficiency opportunities

audit

Measure, calculate, search, decide, act

How is it applied? Eco-efficiency Process/Program

For:

Audits

Implementation

Sustainability

T

O

O

L

S

How is it applied? Eco-efficiency Tools

Mass-energy balances

Life cycle analyses

Energy audits

Cleaner production audits

Benchmarking

Carbon and water footprints

Performance indicators

Green procurement

Eco-design

Process control, automation

Eco-labels

Sustainability reports

Environ. supply chain man.

How is it applied? Eco-efficiency Tools

Measure,

calculate,

search, decide,

act

Eco-efficiency indicators

Value of the product or service (V)

Environmental impact (E)

V: mass, volume, money, function, quality, etc.

E: energy cons., raw material cons., waste

amount, wastewater amount, GHG emission,

etc.

I =

How is it measured?

Example indicators:

Production per unit energy consumed

(ton product/ kilojoule)

Fabric washed per unit wastewater

generated (m2 fabric/ m3 wastewater)

Heat produced per carbon emission

caused (kcal/ ton CO2)

How is it measured?

How is it measured?

The most appropriate indicators should be

identified.

May be generic or industry/plant specific

Should be easily measurable, reportable,

not too many

The data related to the

indicators should be

analyzed, assessed and

compared with standards

and other companies

(benchmarking).

Inputs, outputs, processes

Process parameters

Production plans

Costs and gains

Quality

Automation

Customers, suppliers

Other plants, standards

Legislation, limits

Measurements, calculations, data,

reports, decisions

And the interrelations thereof

Eco-efficiency is about…

What does Industry 4.0

involve?

A digital world

Merging of internet and production

Intellegent communication of industrial

systems and equipment

Continuous flow

and analysis/

processing of real

time and historical

data from different

sources (internal,

external) Picture: https://www.attunity.com/blog/big-data-

needs-a-fast-secure-connection-to-the-cloud/

What does Industry 4.0

involve?

Smart machines, smart factories

Digitalization of production processes

Decisions based on facts

Manufacture at the best performance

and most efficient level

Warnings and

measures taken in

advance/ on time

Optimization and

efficiency

Picture: http://www.wieland-electric.com/en/news/industry-40

What does Industry 4.0

contribute to eco-efficiency?

Industry 4.0 is a never ending «audit

process»

It has the power and capacity to

provide the access to and analysis of

historical data

relate different dimensions of eco-

efficiency to eachother

conduct benchmarking with different

sources

pick up on inefficiencies and problems

What does Industry 4.0

contribute to eco-efficiency?

Industry 4.0 helps

identify high potential areas

identify critical performance indicators

identify best performance cases for

replication

Picture: http://www.machinedesign.com/motion-control/tale-two-

iot-initiatives-industry-40-vs-rest-iot

What does Industry 4.0

contribute to eco-efficiency?

Industry 4.0 provides several means for

implementation:

Smart sensors, smart control and monitoring

High efficiency and consistent production

systems

Simulations

Eco-design

process and

efficient

products

Picture: http://www.iitdsamarthudyog.com/index.php/technologies

What does Industry 4.0

contribute to eco-efficiency?

Industry 4.0 helps managing:

environmental supply chain

symbiotic networks

life cycle impacts

legislative

compliance

internal and

external

cooperations and

communiactions

Picture: http://greensupplychainnews.blogspot.com.tr/

An example

Oji Papers - Japan

Used Industry 4.0 tools for optimizing and

stabilizing chemical consumption.

Source: Connected Factory #1 – Manufacturing

Intellegence International magazine – Braincube

An example

Oji Papers - Japan

First Phase:

They created process control groups with

28 consumption variables

They monitored these variables by means

of a real time process follow up interface

Picture: https://www.automationworld.com

The real time reports

led to a 10%

reduction in

consumption and a

greater stability in the

product.

An example

Oji Papers - Japan

Second Phase:

They focused on optimizing these settings.

The team analyzed the 8 months

historical data.

Within the 2450 variables Oji found a

combination of 4 parameters that made

it possible to stay within the target.

Then this best practice was systemized.

This led to an additional 5% reduction in

chemicals consumption.

Ferda Ulutaş İşevi

Senior Executive of Macro Environment

ÖTE Ltd.

Thank you for listening…