1. Evaluation Methodologies in a Cleaner Production Plant
Presenter: Ms. Julia Brown
Manager,
Process Development
Scientific Research Council

2. Contents Cleaner production–PRISM methodology
Planning and organization
Pre-evaluation
Plant evaluation
Feasibility Studies
Implementation
Generation of options of Cleaner product-ion

3. Evaluation for Cleaner Production
It´s a systematic and planned procedure done with the objective of identifying the raw material, water and energy wastes sources.
Facilitates the corporative efforts to obtain uninterrupted environmental improvement in the plant operations.

4. Evaluation Tools Information and evaluation compilation. Records
Worksheets,
Procedures
Raw material, water, energy consumption indicators, residues generation
Generation options of Cleaner production
National and international bibliographic information
Manage techniques of: storm of ideas, team work

5. Success Elements Support and participation of Higher Management
Evaluation equipment formed by staff of different departments
Methodology applied continually and in an ordered way.

6. Planning and organization Implementation and continuity
Cleaner production methodology
Cleaner production interest
Planning and organization
Pre-evaluation
Evaluation
Feasibility Studies
Implementation and continuity
Evaluation

7. Project Methodology Phase 3.C: Implementation Phase 3.B: Feasibility
Preparation
Phase 2:
Pre-evaluation
Phase 3.C:
Implementation
Phase 3.B:
Feasibility
studies
Phase 3.A:
Evaluation
Cleaner production
necessity recognition
New priority
areas
System
changes
Contaminant
minor charges
Phase 4:
Continuation
Resources earnings

8. Recognized Necessity of Cleaner Production
Phase 1:
Planning and Organization
Recognized Necessity of Cleaner Production
Activity 1: Obtain commitment of Management
Activity 2: Organize project equipment from Cleaner production project
Activity 3: Define goals of Cleaner Production in plant
Activity 4: Identify barrier and solutions
Established Evaluation Organization

9. Activity 1: Obtain the commitment of the Administration
Emphasize economical benefits! (e.g. reduction in the costs because of the efficient use of water, energy and residue reduction)
Illustrate environmental benefits! (e.g. emission reduction, residual water contaminant charge and toxic substances)
Other external benefits! (e.g. improvement in the public image of the enterprise and comply with the standing environmental laws)
Promote responsible inquiries !

10. Activity 2: Organize the Team of Cleaner production (1)
Team has to be able of identify solution opportunities, develop them and implement them. (Characteristics: knowledge, creativity and authority)
Size and integration of the team has to be according to the enterprise organization (5 a 8)
Team has to coordinate the Cleaner product-ion activities and the responsibility over the established goals success

11. Activity 2: Organize the Team of Cleaner production (2)
Suggested members of the team
Management representation.
Production Manager
Environmental area
Motivated Supervisor
Motivated Operator or technician
External Supervisor or Advisor

12. Activity 2: Organize the Team of Cleaner production (3)
To instruct the project team
To assure the comprehension of the Cleaner production concept between the members of the team.
To reinforce the systematic evaluation importance and records of each process stage that may give an environmental or economical impact. To enable the project team.
Create conditions for success (time, information access, etc..).
Assure the implementation of the options without any cost and low price.
To create incentives (recognitions).

13. Activity 3: Establish Cleaner Pro-duction Goals in the Plant
Considerations
Goals have to be appropriate and measurable.
Have to give significant environmental and/or economical improvement.
Short term goals have to be realistic.
Long term goals have to be a threat.
Indicators
Internal productivity standards.
Water consumption, energy, generation of residues.
Innovative technology.
Environmental legislation.

14. Activity 4: Identify Barriers (1)
Concepts and attitudes between employees and the Management.
Organizational structure of the enterprise.
Actual situation of the equipment technology in the plant.
Available and accessible information.
Financial functioning of the enterprise.
Absence of communication between the different areas of the plant.

15. Activity 4: Identify Barriers (2)
Diffuse the cleaner production concept between the enterprise staff to facilitate:
To obtain fluid information.
Employees participation in the generation of options and its evaluation.
Effective implementation of the feasible options.
Continuity in the cleaner production activities.

16. Planning and organization
Phase 2: Pre-evaluation
Planning and organization
Evaluation of the organization
Activity 5: Flow diagram development
Activity 6: Input and Output of materials evaluation
Activity 7: Define the focus of the diagnostic.
Evaluation

17. Activity 5: Diagram flow develop-ment
Identify all the unit operations or process stages.
Check Input and Output.
Relate process stages and material´s flow (incomes, forms water consumption, energy, amount of solid wastes, liquids, gaseous emissions, etc..)

18. Process Flow Example Returned Bottles Washed bottles First soak
by aspersion
Caustic soda
bath
Soak by immersion
Final soak
Water
Detergent
Vapor
Soak water containing:
- Caustic soda residues
- detergent residues
- organic and inorganic matter
Labels + caustic solution absorbed by
labels
Residual bath
Mud (organic or inorganic matter)
Condensates (discharged)
Returned Bottles
Washed bottles

19. Diagram Flow Example Batey Mills Clarification Evaporation
Cristalization
Centrifugation
Drying
Water
Sugar cane
Sanitary disposal
Bagasse
Fat and cooling water
Chemicals
Chemical excess
Water vapor
Displacing water
First froth on cane
juice when bolied
Molasses
Sugar to Refinery
Standard Sugar

20. Activity 6: Evaluation of Entrances and Exits of Materials (1)
In each stage of the process: enlist inputand output (raw materials, energetic and wastes)
Assign costs to input and output by raw material, water consumption, energy, residues manage, etc.
Check operation and maintenance practices.
Materials selection practices.
Used criteria for the selection of the products and incomes.
Number of products used for each stage of the process.

21. Activity 6: Evaluation of Entrances Exits of Materials (2)
Inventory manage practices: inventory movements of first input, first output, package conditions and storage.
Internal costs: Manage and recollection of residues, value of the incomes. Treatment facilities operation, raw material losses and intermedium products.
External costs: Discharge fares, taxes, license costs, etc..

22. Activity 6: Evaluation of Entrances Exits of Materials (3)
Operation and maintenance practices:
Obvious fails in the process control in the work procedures.
Spills and leaks.
Obvious lacking in equipment maintenance.
Begin to improve order and cleanliness:
Obtain the support of the administration to solve obvious problems.
Communicate with the workers involved.

23. Example: evaluation of Inputand Output
Annual costs $
Annual Quantities
(kg, m3)
Raw Materials
Unit operation
Secondary
Products
Annual
costs $
(kg, m3
Bottle Washing
Water
Soda
Detergent
Vapor
Soak water
Caustic soda
Detergent residues
Organic and inorganic matter
Labels
Condensates
Process: bottles washing

24. Activity 7: Select the Cleaner production Diagnosis Focus (1)
Economical considerations
Economical losses related to residues
Elevated energetic consumption, tap water treated.
Technical considerations
Expected improvement potential.
Possibility to apply cleaner production standards in the operative activities.
Environmental considerations
Volume and composition of the residues.
Actual situation in the environmental management program.

25. Cleaner Production Example
First soak
By aspersion
Caustic soda
bath
60°C, 2.0% NaOH
70°C, 2.5% NaOH
Soak by
immersion
50°C
Final soak
30°C
Reposition soft water
Detergent
Vapor
Soft water(15°C)
Soak water(45ºC) containing:
- caustic soda residues
- detergent residues
- organic and inorganic matter
Labels + caustic solution absorbed by labels
Residual bath (discharge of 8 m³each 3 months)
Mud (organic and inorganic matter)
Condensates
Returned bottles
Washed bottles
Soak water
Residual bath (discharge of 8 m³each 3 months) Baño residual (descarga de 8 m3 cada 3 meses)

26. Activity 7: Select the Cleaner production Diagnosis Focus (2)
Process unit
Economical
priority
Environmen-
tal priority
Technical
potential
Other
considerations
Residues
generation 1 2
Dangerous waste
EIA - SETENA 3
Fuel change 2 3 1
Other fuels costs
Water
recovering 3 2 1
Treatment costs
Operative report
3. High Medium Low

27. Cleaner Production complete options package
Phase 3: Evaluation
Pre - Evaluation
Selected evaluation focus
Activity 8: Make material balance
Activity 9: Evaluate the causes of the residues
generation, energetic inefficiency or excessive
water consumption.
Activity 10: Generate Cleaner production options.
Activity 11: Select Cleaner production options.
Cleaner Production complete options package
Feasibily studies

28. Make Material Balance (1)
Activity 8:
Make Material Balance (1)
Process Input
Raw materials,
water, energy and
others records
Process Output
Products,sub products,
Residues and emissions
records.
Make Material Balance
1.- To collect information
2.- Make preliminary balance
3.- Evaluate and accurate the balance

29. Make Material Balance (2)
Activity 8:
Make Material Balance (2)
Divide procedures in process stages.
Information sources:
Measures in place over normal conditions of line service operations (e.g., time, temperature, pressure, flow, chemicals, water consumption, etc.)
Raw materials purchase and products sales records.
Production records

30. Make Material Balance (3)
Activity 8:
Make Material Balance (3)
Quality evaluation of data
Reliability
Precision
Representatively

31. Activity 9: Evaluation of Inefficiency Causes (1)
Equipment
design and
its plant
distribution
Process
Technology
Product
specifications
Raw materials
discharges of raw
material intermedium
products and end
products
Process
Type and
Quality of
Raw materials
Equipment,
operation and
maintenance
Process
capacity
Materials
losses

32. To implement obvious options:
Activity 9: Evaluation of Inefficiency Causes (2)
To implement obvious options:
Raw material and energy management
Production technologies and plant design
Actual situation of the maintenance operation
Optimum process conditions control
Potential water reuse and recycling
Abilities and employees motivation

33. Production of usable sub products
Activity 10:
Generation of Cleaner production options
PROCEDURE
Production of usable sub products
Improvement
in the process
control
“Clean house”
practices
Raw
materials
substitution
Recovering
& materials reuse in plant
Technological
change
Equipment modification
Products
formulation
modification

34. Cleaner production generation options (1)
Activity 10:
Cleaner production generation options (1)
Information sources
Storm of ideas developed in the working team.
Ask for ideas out of the working team.
Check options of cleaner pro-duction examples.
Check technology.

35. Select Cleaner production options
Activity 11:
Select Cleaner production options
Organize options for operation unit.
Evaluate obvious mutual interferences.
Implement measures obviously possible.
Eliminate those not feasible.

36. Implementation and Continuity
Phase 4: Feasibility studies
Activity 12: Preliminary evaluation.
Activity 13: Technical evaluation.
Activity 14: Economical evaluation.
Activity 15: Environmental evaluation.
Activity 16: Feasible selection of options.
Evaluation
Implementation and Continuity
Complete options pack
Feasible options list

37. Preliminary evaluation
Activity 12:
Preliminary evaluation
Options are based on persons or in teams?
Are they simple or complex?
Are they cheap or expensive?

38. Technical Evaluation (1)
Activity 13:
Technical Evaluation (1)
Verification List
Team availability and reliability.
Effect over the product quality and its productivity.
Maintenance and services requirements.
Operators and supervisors abilities.

39. Technical Evaluation (2)
Activity 13:
Technical Evaluation (2)
Input
Raw materials
Energy, Water
Hand work
Consumption
Output
Solid Residues
Residual Waters
Gaseous emissions
Before
Implementation
After

40. Investment Costs and operation benefits
Activity 14:
Economical evaluation (1)
Evaluate the economical impact of the cleaner production recommendation
Investment Costs and operation benefits
Realize economical calculations, (e.g., Investment recovering period)
Investment Investment
recovering =
Earnings
Rapid method for small projects.
It´s an approximate indicator for high risk projects.

41. Economical evaluation (2)
Activity 14:
Economical evaluation (2)
Time of investment recovering:
1 year (simple project)
< 3-4 years (medium cost project)
> 4 years (high cost project)

42. Combine results of technical, economical and environmental evaluations
Activity 16:
Selection of the Cleaner production measurements
Combine results of technical, economical and environmental evaluations

43. Phase 5: Implementation and Continuation
Feasibility
Feasible options list
Activity 17: Prepare a Cleaner production plan.
Activity 18: Implement Cleaner production options.
Activity 19: Progress advisement.
Activity 20: Cleaner production sustainability.
Cleaner production pursuit

44. Activity 17: Cleaner production Plan
Option
Responsible
Person
Implantation
End date
Key
factors

45. To Implant Cleaner Production Options
Activity 18:
To Implant Cleaner Production Options
Details Preparation
Detailed technical specifications.
Appropriate planning to reduce the installation time.
Financing.
Installation.
Appropriate control of installation.
Preparation for the beginning of operation.

46. Activity 19: Cleaner production Progress program Advisement.
Selection of measurement method:
Changes in the amount of residues.
Changes in the resources consumption (water and energy).
Profit change.
Productivity change.
Labor conditions changes.

47. Cleaner Production Sustainability
Activity 20:
Cleaner Production Sustainability
Quantify wastes generation, water and energy consumption.
Incorporate Cleaner production in the technical development, training.
To assure that employees may get involved.
Establish a preventive maintenance program.
Verify the environmental impact of new equipments.
Cleaner production in Research and Development.
Spread the results.

48. Cleaner production strategies
Internal Recycling
Reduction in source
Process Change
Product Change
Entrances Substitution
Technological Modification
Good Practices

49. Prism Methodology Recognize the necessity of
increasing competitivity with
Cleaner Production
Obtain commitment from Management.
Establish the evaluation organization.
Propose general objectives.
Overtake barriers.
Begin a preliminary study.
Planning and
Organization
Fund obtention.
Equipment installation.
Advisement and evaluation of results.
Project adaptation.
Planning of new
projects
Enterprise data and its processes.
Flow of materials,
wastes and emissions.
Create work groups.
Generate Cleaner production options.
Implementation
Plant
Evaluation
Feasibility
Study
Technical evaluation.
Economical evaluation.
Environmental evaluation.
Organizational evaluation.
Selection of options.