Cleaner Technology Cleaner Technology - CT- CT

for Factories for Factories

Cleaner Technology Unit Cleaner Technology Unit Bureau of Industrial Env Bureau of Industrial Env

ironment Technology ironment Technology Department of Department of

Industrial Works Industrial Works Copyrights of Department of Industrial Work

s

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ContentContent Driving force for implementing

CT What is CT? CT Benefits Steps of CT implementation Samples of CT Options

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Driving forces for Driving forces forimplementingimplementing CTCT

Cost reduction

I ncreasedeffi ci ency

Fi nanci al sector

Private organizations

Customers

Laws andregulations

Standards

Employees

Environmental quality

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CT DefinitionCT Definition Cleaner Technology is defined as a measure

to improve or adjust production processes o r products, so that consumption of raw mate

rials, energy and natural resources is accom plished efficiently, with minimum waste or n

one at all. It is pollution reduction at source

, including substitution of raw materials, rec - ycling and re using, which will help conserve

the environment and simultaneously reduce production costs .

5 Before and after Before and after CT CT implementationimplementation

Befo

reA

fter

High consumption of raw mat erials and resources, generati

ng much waste

Using only necessary raw mate rials and resources, thereby re

ducing waste while increasingproducts

6Environmental Environmental Management Management

HierarchyHierarchy Minimizing waste

Pollutio n

Prevention or CT

Before

After

- Re use (in the process)/Recycling

Treatment and disposal

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CT BenefitsCT Benefits Reducing production cost Reducing environmental impact

s at source Improved production efficiency Optimal consumption of raw ma

terials and increased products

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CT BenefitsCT Benefits Enhancing good relations amon

g workers and between industri es and the local community

Promoting health and safety Reducing the load of public insp

ection Creating business advantages

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CT ConceptCT Concept

How much is generated?

How to prevent it?How?

Why?

What is generated?

When?

10 Steps of Steps of CT CT

implementationimplementation1. Planning and setting up a CT Team

2 . Audit

3 . Data analysis and feasibility study

4 . Setting procedure an

d implementation

5 . Assessment

11 1. Planning and

setting up a CT TeamObjectives To establish a policy to use as a

guideline for implementation To have a CT team working as a

core group

12 A good A good CT CT policypolicy

Is approved by the factory’s topmanagement

Stresses waste reduction at source

Has definite target for waste re duction per production unit

Has a timeframe Is related to legal regulations

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Samples of a good Samples of a good CTCT p policyolicy Our factory is aiming to reduce

water consumption per product ion unit by 10% per year.

Our factory aims to reduce acid consumption in skim crepe prod

uction down to 0.45 kg./kg. ski m crepe by the end of year 2001

.

14 Responsibilities of the Responsibilities of the

CT teamCT team Gather data from various sources, con

struct production flowchart and decide scope of unit operations

Prepare mass balance of production pr ocesses and unit operations of interest

Collect additional data required for a m ass balance

Present CT options Study feasibility of various options Set up steps for implementing selecte

d options Assess and monitor

15 Typical members of a Typical members of a

CT teamCT team CT team manager Factory Manager CT team members 1. Production Head

2. Utility Head 3. Purchasing Head

. ......... . ...4 .

......... .......... . ...... 5 . ....( )

. .... .......... .. ....... 6.

16Qualification of CT Qualification of CT

team membersteam members Responsible A good team

player Observant ..... .. ..... Is creative Respects others’

....... Working for the

common cause

High academicdegrees

Extensive workexperience

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2. AuditComprises: -Pre assessment Detailed audit

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-Pre assessmentObjectives To construct production flowchart and g

ather basic information To set scope of unit operations within t

he production process Survey and look for areas of loss, both q

uantitative (how much?) and qualitativ e (what are the characteristics? )

To set more appropriate CT targets

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Sample of production fl Sample of production flowchartowchart

Raw

milk

Ready to

drink milk

Cleaning water/acid/alkaline

Lost milk/ Effluent from cleaning

Raw milk reception

Milk left in pipes/ Effluent from cleaning

Pasteurization

Film/carton Lost milk/

Film/defective cartonFilling

Spoiltmilk Cold room

Cleaning water/acid/alkaline

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Caution:Caution:

Production flowchart must be v erified as correct before procee

ding further. Unit operations must be approv

ed by those involved, as correct and appropriate for conducting

detailed audits.

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Detailed audits

Objectives To prepare mass balance and/or

energy balance for each unit op eration

Collect data necessary for prop osing CT options

22 How to prepare a mass How to prepare a mass

balancebalance

Decide on scope of unit operations Study input entering unit operations Are there chemical reactions in the u

nit operations? Study output from unit operations Is recycling practiced?

Total input = total output

23 - Sample of input output - Sample of input output

of a unit operation of a unit operation

Catalyst

Waste/chemicals to be disposed of

Unit operation

Raw materials

Water/

air Energy

-Re use

Recycling in other processes

Air emission

Products

-Byproducts

(includes waste to b

e recycled/recovered)Effluent

Excess materials Source: Audit and Reduction Manual for Industrial Emission and Wastes, UNIDO

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Precautions in preparing Precautions in preparing mass balance mass balance

and collecting data and collecting data Set clear scope for each unit operation Set scope and measures involving energ

y (normally only lost energy is recorded) -Beware of repeated counts in case of re

use/internal recycling Collect only necessary data, using what

is available, correct and easy to obtain - Consider the on going activities when d

ata was obtained Is data obtained representative of the fa

ctory?

25 Possible areas for waste Possible areas for waste

reductionreduction Types and characteristics of raw materi

als Raw material reception; quality and am

ount check Use and storage of raw materials Transportation of raw materials and pro

ducts (in solid, liquid and gas forms) in t he production process

Control of production processes Use of water in cleaning and cooling Product storage

26 3 . Data analysis and f

easibility studyObjectives To propose CT options

To find CT options suitable for t he factory (both technically and

economically)

27 CT options can be fou CT options can be fou

nd from: nd from: Machine operators Comments from other factory employ

ees CT team Case studies from similar industries Case studies adapted from other indu

stries Experts Suppliers of raw materials and equipm

ent Clients/markets

28........... ................ .....

Technical Is it scientifically feasible? Is there available technology? Are there available implemente

rs?

Economic Is investment required? How much is the expected savin

gs? What is the payback period?

29........ ..... .. .... ........ ..... .. ....

and safety and safety Is inefficient consumption of raw

materials and energy reduced? Is amount of waste incurring trea

tment costs reduced? Is amount of waste discharged to

the environment reduced? Is working condition improved? Are accidents and illnesses reduc

ed?

30 4. Setting procedure a

nd implementationObjectives To have steps in implementing

selected CT options To proceed within a timeframe

31 Sample of Sample of CT CT

implementation implementation procedureprocedure

Activity Month…

Month…

Month…

Month…

Responsible party

1. Request approval ___ CT team

2. Approve project __ Management

3. Provideequipment/manpower

____ Utility Department

4. Implement ____ __ Production/ UtilityDepartments

5. Monitor progress ____ CT team

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5. Assessment

Objective To summarize results and start

- new options or re start the cycle

33 Sample of progress mo Sample of progress mo

nitoringnitoring

CT option Date Result Recommendation

Option 1

Option 2

Option 3

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...... ..... ... ......... ..... ... ... Defective raw materials/poor storage sy

stem Outdated technology/equipment not in

good working condition Poor work practices/management High amount of undesirable products pr

oduced - Expired/off speculation products Reprocess/rework

35 Reasons why losses ar Reasons why losses ar

e neglected: e neglected: Management misunderstanding and la

ck of interest Poor working habits Unawareness of damages incurred by c

ertain activities Unawareness of benefits of preventive

measures Unawareness of proper work practice Lack of incentives

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Types of CT optionsTypes of CT options Adjustment of operations and managemen

t

Reuse and internal recycling

External recycling

Partial adjustment

Total change

New product improvement

Product chain system improvement

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Sample of insulation for Sample of insulation for heating butter oil heating butter oil

Before

After