Cp gp day04 cp report-cp report format 20110802

Acknowledgement

Table of Content

Content Page

Acknowledgement

Table of Content

Executive Summary

1.0 Introduction

2.0 Scope, Focus and Objectives

2.1 Scope

2.2 Focus

2.3 Objective

3.0 Cleaner Production Assessment

3.1 Process Description

3.2 Quantification of Resource Flow

3.2.1 Monthly Resource Flow

3.2.2 Daily Resource Flow

3.2.3 Sample Material Balance

3.2.4 Energy Balance

3.2.5 Baseline and Performance Indicators

3.2.6 Cost of Waste

3.2.7 Cleaner Production Potential

3.3 Waste Cause Analysis and Option Generation

3.4 Selection of CP Solutions

3.5 Achievable Savings Through Implementation of Cleaner Production Solutions

4.0 Cleaner Production Implementation

4.1 Short Term Implementation

4.2 Medium Term Implementation

4.3 Long Term Implementation

5.0 Conclusion

Executive Summary

1.0 INTRODUCTION

Name and Address

of Company

Telephone

Fax

E-mail

Website

Year of

Establishment

Ownership Sole

Proprietor

Joint

Venture

Multi-

national

Limited

Liability

Company

Other

(Please

Specify)

Physical Location

Manufacturing Service Other (Please Specify) Type of Activity

Sector

Size of the Facility Small Medium Large

Industrial Process

Used

Production / Service

Capacity Current Full Capacity

Market Export Local Mix Export %

Local %

Total No. of

Employees

Direct

(Permanent)

Direct

(Casual)

Direct

(Contract) Outsourced Others

Company Highlights

Contact Person

(Name &

Designation)

CP Team members

Name Designation Section

Leader:

2.0 SCOPE, FOCUS AND OBJECTIVES

2.1 Scope

2.2 Focus

2.3 Objectives

3.0 CLEANER PRODUCTION ASSESSMENT

3.1 Process Description

Detailed Process Flow Diagram(s) is given in Annex ……

3.2 Quantification of Resource Flow

3.2.1 Monthly Resource Flow: (From ........................... To ……………………)

Item Unit Period

Inputs

Raw materials

Main Raw Materials

Other Raw Materials

Water

From national supply m3

From own source m3

From contractors m3

Energy

Electricity from grid kWh

Electricity from generator kWh

Electricity (Max. demand) kVA

Fuel (furnace) oil Litre

Diesel / kerosene Litre

LPG Kg

Firewood

Other renewable sources TOE

Products

Main product output

By Products

Wastes

Solid waste Ton/kg

Liquid waste m3

Air Emission (GHG) tCO2e

3.2.2 Daily Resource Flow (during the period of assessment) (From: …………… To: ……………..)

Item Unit Period (Day)

Inputs

Raw material

Main Raw Materials

Other Raw Materials

Hazardous Materials

Water (Supply)

From national supply m3

From own source m3

From contractors m3

Water (Consumption)

Process Consumption m3

Human Consumption m3

Other (Maintenance /Landscaping etc.) m3

Energy

Electricity from grid kWh

Electricity from generator kWh

Electricity kVA

Fuel (furnace) oil litre

Diesel / Kerosene litre

LPG kg

Firewood

Other renewable sources TOE

Products

Main product output

By Products

Waste

Solid waste Ton

Liquid waste m3

Air Emission (GHG) - tCO2e

3.2.3 Sample Material Balance (Outcome) at ……………….

Process

Step Input (Materials / Water) Unit Quantity Output (Products/ Waste) Unit Quantity

A

Main raw materials

100 Main Output of Process (A)- As

Main Input to next step (B) 104

Other inputs

10 Waste stream 1 2

Waste stream 2 2

Unaccounted losses 1 2

Total 110 Total 110

B

Main Output of Process(A)

{Main Input to step (B)} 104

Main Output of Process (B)- As

Main Input to next step (C) 103

Other inputs- (eg.: water)

100 Waste water 90

Waste Stream 3 5

Waste Stream 4

4

Unaccounted losses 2 2

Total 204 Total 204

C

Main Output of Process (B)

{Main Input to step (C)} 103

Main Output of Process (C)- As

Main Input to next step (D) ……

………………. ….. Waste stream 5 …….

………………. ….. Waste stream 6 …….

………………. ……..

Unaccounted losses 3

……..

Total ……..

…..

………………. ……………

………………. ……………

Total Total

Y

Main Output of Process (X)

{Main Input to step (Y)}

Main Output of Process (Y) -

Main Input to Final Process (Z)

……………… ….. ……………. …..

……………… ….. ……………. …..

Total Total

Z

Main Output of Process (Y) -

Main Input to Final Process Main Product Output

Other inputs By Product Output

…………. Waste streams

Waste streams

Unaccounted losses

Total Input Quantity Total Output Quantity

Note: Relevant data and calculations are given in Annex …..

3.2.4 Energy Balance

Energy Share (based on historical data)

Source of Energy Common unit of

supply Consumption/year MJ

Percentage

(%)

Electricity (Grid) kWh

Electricity (Self generation) kWh

Diesel liters

Furnace oil litres

Kerosene litres

LPG kg

Firewood m3

Solar Energy kWh

Other (if available)

Electrical Energy Balance (based on measurements)

Process/Section Electricity consumption

(kWh / day) Percentage (%)

Thermal Energy balance (based on measurements)

Energy Supply (MJ/day) Usage / Water (MJ/day)

Boiler

Usage

Flue gas losses

Insulation losses

Leaks

Radiation losses

Process losses

condensate losses

Furnace

Usage

losses

Energy Consumption by Utilities

Activity /Utility Electricity consumption (kWh

/ day) Percentage (%)

Lighting

Heating

Air Conditioning

Ventilation

Compressed air

Cooling Towers Pumping

Others


3.2.5 Baseline and Performance Indicators

Product(s) / Service: (Please specify)

(a) Total Absolute Consumption/Generation (per year)

Product / Resource / Waste Unit Absolute Quantity

Production Output

Raw Material

Energy

Water

Solid waste

Liquid Waste

Air Emissions (GHG)


(b) For Resource Consumptions

Resource Unit Actual Specific

Consumption

National

Benchmark

(if available)

International

Benchmark

(if available)

Reference

Main Raw Materials

(Please specify)

1.

2.

3.

Process Water

Energy


(c) Resource Productivity Indicators

Indicator Unit Value

National

Benchmark

(if available)

International

Benchmark

(if available)

Reference

Material Productivity

Water Productivity

Energy Productivity


(d) Pollution Intensity

Indicator Unit Pollution Intensity

National

Benchmark

(if available)

International

Benchmark

(if available)

Reference

Solid Wastes

Liquid Waste

Air Emissions (GHG) Note: Relevant data and calculations are given in Annex …..

3.2.6 Cost of Resources and Wastes

(a) Cost of Energy Share

Source of Energy Cost Percentage (%)

Electricity

Diesel

Furnace oil

Kerosene

LPG

Fire wood

Others

(b) Material and Process Water

Process Step Materials / Process Water Quantity of

Waste /Year

Value of Waste

(Rs/Year)

Reference

for

Calculations

A

B

C

Total


(b) Wastewater

Process Step Quantity of Waste / Year Value of Waste

(Rs/Year)

Reference for

Calculations

Total


(c) Energy

Process Step Energy

Consumption / Year

Quantity of Waste /

Year

Value of Waste

(Rs/ Year)

Reference for

Calculations

Total


3.2.7 Cleaner Production Potential

3.3 Waste Cause Analysis and Option Generation

Process Step Waste Stream Waste Cause Sub Waste Cause CP Option Screening

R DI NFA

A

Waste Stream 1

(Please specify)

Waste Cause 1.1

(Please specify)

Sub Waste Cause 1.1.1

(Please specify)

CP Option 1.1.1.1 (Please specify)


CP Option 1.1….(Please specify)


(Please specify)



CP Option 1.1.2…..

Sub Waste Cause 1….

CP Option 1…….

CP Option …….

Waste Cause 1.2

(Please specify)


(Please specify)



CP Option 1.2.1…….


(Please specify)


CP Option 1.2.2……

Sub Waste Cause 1.2….

CP Option 1.2..…….

………

Waste Cause …..

Sub Waste Cause …. CP Option …..

…….. ……..

…….. ……..

Waste Stream 2

(Please specify)

Waste Cause 2.1

(Please specify)


(Please specify)


CP Option 2.1.1….

Waste Cause 2.2

(Please specify)


(Please specify)


CP Option 2.1.2 ….

Waste Cause 2… Sub Waste Cause 2.1….

CP Option 2.1……

………..

Note: (i) R – Rejected; DI- Direct Implementation; NFA- Need Further Analysis ((Technical / Economic / Environment Aspects)

(ii) Please continue the table for all the process steps

3.4 Selection of CP Solutions

Options Needing Further Analysis Feasibility

Technical Environment Economic Total Prioritization


3.5 Achievable Savings Through Implementation of Cleaner Production Solutions

Waste Stream Selected CP option to be implemented Resource Saving

Potential

Monetary

Value

(Rs./Year)

Directly Implementable Solutions

Short Term Solutions

Medium Term Solution

Long Term Solutions

Total


4.0 CLEANER PRODUCTION IMPLEMENTATION

4.1 Short Term Implementation

Proposed solution Process Step(s) Waste Stream Cost saving Potential Investment required (Rs) Payback period Expected Environment

Benefits

Expected Social Benefits

4.2 Medium Term Implementation


Benefits


4.3 Long Term Implementation


Benefits


5.0 CONCLUSION