1. INTRODUCTION TO CLEANER PRODUCTION (CP) CONCEPTS AND PRACTICE

2. 2 Contents 1. How did environmental strategies evolve? 2. What is CP? 3. How CP is applied in practice: CP practices Benefits and barriers Procedures 4. What is CP contribution to main stakeholders? Industries Governments Financial institutions

3. 3 Course Objective At the completion of this course the participants will have understanding of : -Evolution of environmental strategies, concept of sustainable development -Basic concepts of preventive environmental approaches -Methodology of CP implementation in industrial enterprises -How to develop and implement CP project

4. 4 Passive environmental strategies Ignored or non recognized Environmental problem. Industrialist thought less apparent & less harmful Dilute & disperse

5. 5 Re-active environmental strategies End-of-pipe treatment Control of pollution & Waste Emergence of regulations & laws

6. 6 Constructive environmental strategies On - site recycling & Recovery Development of environmental technology to loop back waste as process input Waste considered in product design & process Engineering

7. 7 Pro-active environmental strategies: Cleaner Production - Good housekeeping - Input substitution - Better process control - Equipment modification - Technology change - On-site recovery/reuse - Production of a useful by- product - Product modifi cation Prevention of Pollution & Waste generation

8. 8 CP versus End-of-Pipe approach Cleaner Production Continuous improvement Progress towards use of closed loop or continuous cycle processes Everyone in the community has a role to play; partnerships are essential Active anticipation and avoidance of pollution and waste Elimination of environmental problems at their source Involves new practices, attitudes and management techniques and stimulates technical advances Pollution Control and Waste Management One-off solutions to individual problems Processes result in waste materials for disposal ain pipeline with resources in and wastes out Solutions are developed by experts often in isolation Reactive responses to pollution and waste after they are created Pollutants are controlled by waste treatment equipment and methods Relies mainly on technical improvements to existing technologies

9. 9 What is waste? There are literally hundreds words for different types of waste: greenhouse loss hidden losses leakage non-conforming material overfill packaging process loss rework second quality stock loss washings and etc. allowance BOD broke contaminated solids core loss customer returns damage draining dust effluent evaporation furnace loss

10. 10 Waste is unwanted what ever name you call it : take the opportunity to cut waste and increase profits! Wailing Waste!!! Key Waste Types WaterEnergyMaterial

11. 11 Waste Hierarchy

12. 12 Its Our Future

13. 13 Cleaner Production Financing The “Cost of Waste” Iceberg THE HIDDEN COST OF WASTE Company Image Liability Regulatory Compliance Treatment & Disposal Lost Raw Materials, Energy, Labor Enormous cost underneath

14. 14 Where are you now? Only a change in technology would eliminate waste completely We are optimising our processes and achieving big cost reductions Waste is coming down as we change the way we work We have identified our waste and monitoring it We plan to reduce waste Waste is cost and regulatory issue Waste is only disposal issue Waste is not an issue

15. 15 Cleaner Production Definition “The continuous application of an integrated preventive environmental strategy applied to processes, products, and services to increase overall efficiency and reduce risks to humans and the environment.” (United Nations Environment Programme)

16. 16 Continuous Preventive Integrated STRATEGY for ProductsProcesses Services Risk Reduction Humans Environment Cleaner Production Definition

17. 17 always reduces long-term liabilities which companies can face many years after pollution has been generated or disposed at a given site Properly implemented CP :

18. 18 Properly implemented CP : usually  increases profitability  lowers production costs  enhances productivity  provides a rapid return on any capital or operating investments required  increases product yield  leads to the more efficient use of energy and raw materials

19. 19 usually (continuation)  results in improved product quality  increases staff motivation  relies on active worker participation in idea generation and implementation  reduces consumer risks  reduces the risk of environmental accidents  is supported by employees, local communities, customers and the public Properly implemented CP :

20. 20 Cleaner Production principles precaution principle preventive principle integration principle

21. Are you Energy Efficient? 21 1.Reduce energy and production costs 2.Improve environmental performance and reduce greenhouse gas emissions 3.Reduce exposure to rising energy prices and energy shortages 4.Win new customers who consider environment as an important selection criteria

22. 22 What is not CP? Off-site recycling Transferring hazardous wastes Waste treatment Concentrating hazardous or toxic constituents to reduce volume Diluting constituents to reduce hazard or toxicity

23. 23 What are the benefits of Cleaner Production? Improving environmental situation Increasing economical benefits Increasing productivity Gaining competitive advantage Continuous environmental improvement

24. 24 How CP could be applied in practice?

25. 25 Cleaner Production practices 1. Good housekeeping take appropriate managerial and operational actions to prevent: - leaks - spills - to enforce existing operational instructions

26. 26 Cleaner Production practices 2. Input substitution substitute input materials - by less toxic - or by renewable materials - or by adjunct materials which have a longer service life-time in production

27. 27 Cleaner Production practices 3. Better process control modify: - operational procedures - equipment instructions and process record keeping in order to run the processes more efficiently and at lower waste and emission generation rates

28. 28 Cleaner Production practices 4. Equipment modification modify the existing production equipment and utilities in order: - run the processes at higher efficiency - lower waste and emission generation rates

29. 29 Cleaner Production practices 5. Technology change replacement of: - the technology - processing sequence - synthesis pathway in order to minimise waste and emission generation during production

30. 30 Cleaner Production practices 6. On-site recovery/reuse - reuse of the wasted materials in the same process for another useful application within the company

31. 31 Cleaner Production practices 7. Production of a useful by- product consider transforming waste into a useful by-product, to be sold as input for companies in different business sectors.

32. 32 Cleaner Production practices 8. Product modification modify the product characteristics in order: -to minimise the environmental impacts of the product during or after its use (disposal) -to minimise the environmental impacts of its production

33. 33 Cleaner Production procedures The recognized need to minimise waste Planning and Organization Assessment Phase Feasibility Analysis Phase Implementation Successfully implemented CP projects The first step The second step The third step The fourth step

34. 34 1. Planning & Organization Obtain management commitment Identify potential barriers and solutions Set plant-wide goals Organize a project team

35. 35 Team for CP success Appoint CP Project Team:-Top Manager(MD), Vice Leader(Chief Engineer), Member (responsible Manager). Particular those responsible for business strategy, product development, plant operations and finance Appoint Assessment team:-, Both departmental and supporting divisions, who play an important role in promoting CP Appoint Facilitator:- who play an important role in disseminating information on good environmental practice

36. 36 LeadingTeam Role Role Initiate & support CP assessment Nominate assessment team Set goal for assessment plan Budget allocation for CP improvements Manage CP option implementation Reviewing CP progress Team Characteristics Motivated to improve efficiency Knowledgeable on waste prevention & energy efficiency Familiar on EP laws & regulations Understand on assessment process

37. 37 Assessment Team Role Role Establish CP goals Develop a working plan Performing assessment Selecting suitable options Monitor project implementation Communicate feed back of CP implementation Ensure continuous CP Team Characteristics Thorough on process, technology & procedures Familiar on waste generation, treatment & management Knowledgeable on EP laws & regulations Creative in problem solving

38. 38 CP barriers Internal to the companies: -Lack of information and expertise -Low environmental awareness -Competing business priorities, in particular, the pressure for a short term profits -Financial obstacles -Lack of communication in firms -Middle management inertia -Labour force obstacles

39. 39 -Difficulty in accessing cleaner technologies -Difficulty in accessing external finance CP barriers External to the companies: The failure of existing regulatory approaches

40. 40 CP motivators and drivers Internal to the companies: - Improvements in productivity and competitiveness -Environmental management systems and continuous improvement -Environmental leadership -Corporate environmental reports - Environmental accounting

41. 41 CP motivators and drivers External to the companies: -Innovative regulation -Economic incentives -Education and training -Buyer – supplier relations - Soft loans from Financial institutions -Community involvement -International trade incentives

42. CP Management Cycle 42

43. 43 Pre-Assessment Identify sources of waste Draw process flow chart Identify water, energy, material flow survey on pollution & resource consumption Select focus areas Implement obvious options Make assessment plan

44. 44 Material and energy balances The Industrial Process HeatPower The Energy Balance Cooling Raw Materials Products & Waste The Mass Balance

45. 45 Why are material and energy balances so important? The material and energy balances are not only used to identify the inputs and outputs of mass and energy but their economic significance is related to costs, such as: cost of raw material in waste cost of final product in waste cost of energy losses cost of handling waste cost of transporting waste cost of solid wastes disposal cost of pollution charges and penalties

46. 46 Possible causes for waste generation Process Management Planning & Information Systems Personnel Skills & Motivation Wastes & Emissions Choice & Quality of Input Materials Technical Status of Equipment Choice of Production Technology Process Efficiency Product Specifications

47. 47 CP assessment practices Process On-site Recovery/ Reuse Production of Useful By-Product Product Modification Equipment Modification Input Substitution Good Housekeeping Technology Change Better Process Control

48. 48 Pre assessment work through Investigate present status: -Historical data -Base Line data -Performance indicators -Process flow charts Performing on site investigation: -Sequential approach (RM store-FG warehouse) -Actual operation & Process control look at -Supportive services too investigate -Material handling methods & procedures considered -Process monitoring points investigate Compile input-output flow chart: -Details of flows & quantities considered Selection of assessment focus:- - Consider high potential for CP, high production cost, high waste generation & high material and energy consumption

49. 49 Pre assessment work through Setting CP Targets: -SMART targets -Challenging targets -More on short term targets -Few long term targets Attend obvious options first Like -Unnecessary lights -Spills & Leaks -Unmotivated personnel -Inadequate storage conditions -Inappropriate tools -Cross contaminations Develop assessment plan:- Include -Specify targets -Monitoring method -Majour activities -Responsibility of area -Expected output

50. 50 Setting Objectives Compliance Improve Housekeeping Improve Maintenance Better Performance Short TermLong Term Phase out toxic components Introduce new product

51. 51 Marketing Top management commitment Pre-assessment CP policy declaration The continuous CP loop Assessment Start CP project Project organization CP options Feasibility analysis Assessment report Project implementation Measure progress Final report Top Management reviews CP management system

52. 52 What are the benefits of Cleaner Production? Financial advantages: Usually a short Payback Period of only months Many low-cost options Quick to implement Improved cash flows Greater shareholder value Better access to capital and appeal to financial institutions Inherent preventive approach leads to insurance savings

53. 53 Overall Risk ProfileRISKS ENVIRONMENTAL ACCIDENTS WORKERS’HEALTH CONSUMERS’HEALTH NEW REGULATIONS REPUTATION BUSINESS VALUE INSURANCE CLAIMS CLAIMS LIABILITYCLEAN-UP PRODUCT SALES

54. 54 !!! CP is a journey not a destination

55. 55 Broader Application of CP CP is closely linked to: Environmental Management Systems ISO 14001 Total Quality Management ISO 9001 Health and Safety Management OSHAS 18001 Food Safety Management System 22001 Energy Management System ISO 50001

56. 56 What have we learned?  The CP approach reduces pollutant generation at every stage of the production process  CP can be achieved through: - good operating practices - process modification - technology changes - raw material substitution - redesign and/or reformulation of product  The economic advantages of CP are: - cost effectiveness - increased process efficiency - improved product quality and enterprise competitiveness - cost of final treatment and disposal is minimised  Effluent treatment, incineration, and waste recycling outside the production process are not regarded as CP

57. 57 Cleaner Production and Sustainable Development Responsible Entrepreneurship Eco-efficiency Cleaner Production Compliance Government Agenda Business Agenda ICC Charter EMS EHS Auditing Sustainable development Agenda 21 Factor X Environmental space Time Sustainability Economic Instruments Co-regulatory agreements Command & control