ECOProfit Novi Sad

Succes stories

denkstatt GmbH

Hietzinger Hauptstraße 28 � A-1130 Vienna � Austria

T (+43)1 786 89 00 F (+43)1 786 89 00-15

E office@denkstatt.at W www.denkstatt.at

Aida Szilagyi

References: Prof Rene Van Berkel,

Chief of Cleaner Production Unit, UNIDO

International success stories

Types of benefits connected to Cleaner Production:

� Cost savings - improved resource productivity (materials, water, energy) - reduced pollution (treatment/disposal of waste, reduction of and emissions)

� Improved environmental performance

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� Improved environmental performance� Compliance to regulation, certification� Increased productivity� Improved work safety� Enhanced product quality� Reduced risks of accidents (reduced liability,

remediation costs, insurance costs)

Usually options range from no-cost to low-cost requiring investments. Payback periods are typically short.

Diverse sectors

� Food industry sector

� Dairy

� Meat Processing

� Fish Processing

� Breweries, wineries and distilleries

� Grains processing

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� Grains processing

� Chemical and petrochemical industry

� Tourism industry, etc

� Common issues

� Energy Water

� Effluents Waste/by-products

Dairy Processing

Energy saving ideas

� Implement switch off programs and sensors to turn off equipments and lights when not in use

� Improve insulation on heating and cooling systems and pipes

� Favor more energy efficient equipments

slide 4UNEP, Cleaner Production Assessment for Diary Processing, 2000

� Favor more energy efficient equipments

� Improve maintenance to optimize energy efficiency equipments

� Eliminate steam leaks

� Heat recovery and capture low grade energy for use elsewhere in the operations

� Installation of variable frequency on funs, pumps and other motors (AC drive)

Dairy boiler feed water pump - AC drive instead of throttling

Heat recovery from compressors

Serbia – dairy/IMLEK

Results of RECP assessment:

• 16 key options identified

• investment costs ranging from EUR 0 to EUR 2,500,000

• savings per year ranging from EUR 8,200– EUR 537,000

• payback periods from 0 months to 5 years

Core business: dairy, 80 different products

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• payback periods from 0 months to 5 years

Implementation of all options (investment of EUR 2,840,406) would lead to annual cost savings of EUR 853,853 (payback period of 3.5 years), reduced CO2

emissions by 1,475 tons/year

No cost option:

Option: Tank cleaning 3 washing stages instead of 5

Benefits: savings of EUR 11,100/year, reduction of water consumption by 10,000 m3, reduction of energy, chemicals and waste-water load

Serbia – dairy/IMLEK

Low cost option: Regular maintenance of pipes, valves, loss and leak prevention

Cost: EUR 2,000

Benefits: savings of EUR 12.400/year (payback 2 months), reduction of water consumption and waste-water by 11,000 m3/year

Option: Reconstruction of steam distribution and substations (incl. new distributors, valves and insulation)

Cost: EUR 17,022

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Cost: EUR 17,022

Benefits: savings of EUR 80,738/year (payback 2.5 months), reduction of

waste heat, saving around 13,000 m3 gas/year, reducing CO2 emissions by

271 tons/year

Option: Installation of 2 smaller ammonia compressors

Cost: EUR 20,000

Benefits: savings of EUR 51,000/year (payback 5 months), reduced electricity consumption by 777,600 kWh/year and CO2 emissions by 778 tons/year

Meat Processing

Water Saving ideas

� Undertaking dry cleaning of trucks, areas and floors prior to washing with water� Using dry dumping techniques for the processing of cattle paunches and pig stomachs that avoid or minimize the use of water� Reusing the final rinse from cleaning

slide 7UNEP, Cleaner Production Assessment for Meat Processing, 2000

� Reusing the final rinse from cleaning operations for the washing of inedible products� Using high pressure rather then high volume for cleaning surfaces� Using automatic control systems to operate the flow of water in hand-wash stations and knife sterilizers

Meat Processing - CP options

Energy Use

� Improving insulation on heating and cooling equipment and pipework� Recovering wasted heat from effluent streams, vents, exhausts and compressors� Maintaining a leak-free compressed air system

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UNEP, Cleaner Production Assessment for Meat Processing, 2000

system� Selecting more efficient equipment� Improving maintenance to optimize energy efficiency of equipment� Maintaining optimal combustion efficiencies on steam and hot water boilers, eliminating steam leaks� Optimize production processes

Meat Processing Plant Cuts Energy Consumption by 43% by using the recovered heat and advanced dehumidifiyers in the cooling system

Check Republic – Zlín Slaughterhouse

Results of CP assessment:

1. Installation of water counters on specified places of water distribution and monitor the water consumption

2. Reconstruction of bleeding process in order to avoid release of blood in the water

Core business: medium size enterprise, meat products

Goals of the project: I. Reduction of water consumption approx. by 10 % in the entire facility

II. Reduction of water pollution to level close to the limits set by the regulations on sewerage operation

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in the water3. Adaptation of carcass shower tunnels 4. Replacement of water taps by spherical valves with lever control5. Mechanical removal of blood clot, meat and fat waste from the shop

floors6. Addition of automatic presser washers in all of the company shops 7. End-of-pipe improvement - building of pressure flotation cleaning in

the existing mechanical wastewater treatment plant 8. End-of-pipe improvement - adding of chemical purification to the

flotation 9. Pressing of waste paper and plastic covers

UNEP, Cleaner Production Assessment for Meat Processing, 1995

Check Republic – Zlín Slaughterhouse

Group A - measures without investments:

The goals were achieved through implementation of measures 1, 2, 3, 4, 5 from group A. Economic savings resulted mainly from savings of water, reduced fees for water pollution and increased amount of blood for sale (this blood was lost in wastewater before). These savings amounted to US$ 28,850 per year

Group B - medium investment requirements

� Measure 6. Installation of automatic washer for washing of vessels used in the shops - Investment of US$ 15,460.

slide 10UNEP, Cleaner Production Assessment for Meat Processing, 1995

the shops - Investment of US$ 15,460.

� Carrying out this measure resulted in reduction of water consumption by 1,660 m3 / year among other effects. Savings were together US$ 7,690 per year due to a decrease of water consumption, costs on weasels, decrease of use of chemicals for cleaning and elimination of one workforce. The payback was 1 year and 8 months.

Group C - higher investment requirements

� Measures 7 – 8 Building of pressure flotation and chemical purification to the existing mechanical wastewater treatment plant. The total investments were approximately USD 38,500, costs of installation US$ 3,850 - 5,780

Chemical industry

� A fin fan cooler is a special type of fan which normally lies in the vertical plane, drawing air from outside and blowing it downwards into a manufacturing process.

� Variable speed control gives enormous energy savings. The case is calculated for a 100 kW fan

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Chemical industry fin fan cooler - AC drive instead of damper

is calculated for a 100 kW fan motor.

� Energy saving ~ 438,000 kWh/year Reduction in CO2 emissions 219,000 kg/year Other

� Benefits:Production running stableReduced maintenance costReduced reactive power

Tourism industry Romania –

Hotel Howard Johnson Grand Plaza****

Example of identified options:

� Replace the existing light bulbs with low consumption light bulbs in the rooms and public spaces

� Installation of speed drivers on the water pump’s electric engine

� Periodical cleaning of the condensers from frigorific systems

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� Isolation of the warm water reservoir

� Selective collection and recycling of waste

� Electricity: 198 223 kWh/yr (10%)

� Gas: 70 202 m3/yr (7,3%)

� Waste: 314 m3/yr ( 18% )

� Investments: 40592 Euro

� Financial benefits: 32 000 Euro/yr

Thank you

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Thank you