2. Cleaner Technology - CT for Factories Cleaner Technology Unit Bureau of Industrial Environment Technology Department of Industrial Works Copyrights of Department of Industrial Works

3. 2Content  Driving force for implementing CT  What is CT?  CT Benefits  Steps of CT implementation  Samples of CT Options

4. 3Driving forces for implementing CT Cost reduction Increased efficiency Financial sector Private organizations Customers Laws and regulations Standards Employees Environmental quality

5. 4CT Definition pollution reduction at source Cleaner Technology is defined as a measure to improve or adjust production processes or products, so that consumption of raw materials, energy and natural resources is accomplished efficiently, with minimum waste or none at all. It is pollution reduction at source, including substitution of raw materials, recycling and re-using, which will help conserve the environment and simultaneously reduce production costs.

6. 5Before and after CT implementation Before After High consumption of raw materials and resources, generating much waste Using only necessary raw materials and resources, thereby reducing waste while increasing products

7. 6Environmental Management Hierarchy Minimizing waste Pollution Preventi on or CT Bef ore Afte r Re-use (in the process)/ Recycling Treatment and disposal

8. 7 CT Benefits  Reducing production cost  Reducing environmental impacts at source  Improved production efficiency  Optimal consumption of raw materials and increased products

9. 8CT Benefits  Enhancing good relations among workers and between industries and the local community  Promoting health and safety  Reducing the load of public inspection  Creating business advantages

10. 9CT Concept How much is generated? How to prevent it? How? Why? What is generated? When?

11. 1010 Steps of CT implementation 1. Planning and setting up a CT Team 2. Audit 3. Data analysis and feasibility study 4. Setting procedure and implementatio n 5. Assessment

12. 1 1. Planning and setting up a CT Team Objectives  To establish a policy to use as a guideline for implementation  To have a CT team working as a core group

13. 1212A good CT policy  Is approved by the factory’s top management  Stresses waste reduction at source  Has definite target for waste reduction per production unit  Has a timeframe  Is related to legal regulations

14. 1313Samples of a good CT policy  Our factory is aiming to reduce water consumption per production unit by 10% per year.  Our factory aims to reduce acid consumption in skim crepe production down to 0.45 kg./kg. skim crepe by the end of year 2001.

15. 1414 Responsibilities of the CT team  Gather data from various sources, construct production flowchart and decide scope of unit operations  Prepare mass balance of production processes and unit operations of interest  Collect additional data required for a mass balance  Present CT options  Study feasibility of various options  Set up steps for implementing selected options  Assess and monitor

16. 1515Typical members of a CT team CT team managerFactory Manager CT team members1. Production Head 2. Utility Head 3. Purchasing Head 4. Accounting Head 5. Pollution Prevention Officer (Team Head) 6. Other interested employees

17. 1616Qualification of CT team members  Responsible  A good team player  Observant  Eager to learn  Is creative  Respects others’ opinion  Working for the common cause  High academic degrees  Extensive work experience

18. 1717 2. Audit Comprises:  Pre-assessment  Detailed audit

19. 1818 Pre-assessment Objectives  To construct production flowchart and gather basic information  To set scope of unit operations within the production process  Survey and look for areas of loss, both quantitative (how much?) and qualitative (what are the characteristics? )  To set more appropriate CT targets

20. 1919 Sample of production flowchart 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 carton Filling Spoilt milk Cold room Cleaning water/ acid/alkaline

21. 2020Caution:  Production flowchart must be verified as correct before proceeding further.  Unit operations must be approved by those involved, as correct and appropriate for conducting detailed audits.

22. 2121 Detailed audits Objectives  To prepare mass balance and/or energy balance for each unit operation  Collect data necessary for proposing CT options

23. 2How to prepare a mass balance  Decide on scope of unit operations  Study input entering unit operations  Are there chemical reactions in the unit operations?  Study output from unit operations  Is recycling practiced? Total input = total output

24. 2323Sample of input-output of a unit operation Catalyst Waste/chemicals to be disposed of Unit operation Raw materials Water/a ir Energy Re-use Recycling in other processes Air emission Products By-products (includes waste to be recycled/rec overed) Effluent Excess materials Source: Audit and Reduction Manual for Industrial Emission and Wastes, UNIDO

25. 2424 Precautions in preparing mass balance and collecting data  Set clear scope for each unit operation  Set scope and measures involving energy (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 data was obtained  Is data obtained representative of the factory?

26. 2525Possible areas for waste reduction  Types and characteristics of raw materials  Raw material reception; quality and amount check  Use and storage of raw materials  Transportation of raw materials and products (in solid, liquid and gas forms) in the production process  Control of production processes  Use of water in cleaning and cooling  Product storage

27. 2626 3. Data analysis and feasibility study Objectives  To propose CT options  To find CT options suitable for the factory (both technically and economically)

28. 2727 CT options can be found from:  Machine operators  Comments from other factory employees  CT team  Case studies from similar industries  Case studies adapted from other industries  Experts  Suppliers of raw materials and equipment  Clients/markets

29. 2828 Feasibility study Technical  Is it scientifically feasible?  Is there available technology?  Are there available implementers? Economic  Is investment required?  How much is the expected savings?  What is the payback period?

30. 2929Environmental impact and safety  Is inefficient consumption of raw materials and energy reduced?  Is amount of waste incurring treatment costs reduced?  Is amount of waste discharged to the environment reduced?  Is working condition improved?  Are accidents and illnesses reduced?

31. 3030 4. Setting procedure and implementation Objectives  To have steps in implementing selected CT options  To proceed within a timeframe

32. 3131 Sample of CT implementation procedure

33. 3232 5. Assessment Objective  To summarize results and start new options or re-start the cycle

34. 3Sample of progress monitoring

35. 3434Losses occur due to:  Defective raw materials/poor storage system  Outdated technology/equipment not in good working condition  Poor work practices/management  High amount of undesirable products produced  Expired/off-speculation products  Reprocess/rework

36. 3535 Reasons why losses are neglected:  Management misunderstanding and lack of interest  Poor working habits  Unawareness of damages incurred by certain activities  Unawareness of benefits of preventive measures  Unawareness of proper work practice  Lack of incentives

37. 3636 Types of CT options  Adjustment of operations and management  Reuse and internal recycling  External recycling  Partial adjustment  Total change  New product improvement  Product chain system improvement

38. 3737 Sample of insulation for heating butter oil Before After

39. Case sample of a CT option Control of sulfuric acid use in concentrated latex industry

40. 3939Working conditions found during audit  In latex sedimentation, workers add sulfuric acid to the latex to promote coagulation. They do this by depending on long experience - without measuring. Then they use a stick to stir and mix the acid with latex, and later scoop the coagula floating on the surface. The water remaining is drained into the rubber trap.

41. 4040Suggested CT option  Ensure appropriate consumption of acid used in coagulation, by plotting titration curve of skimmed latex at various amount of ammonia, and add only required amount of acid each time.

42. 4141 Technical feasibility study  It is an operational control measure in use.  The factory is capable of implementing.  There are no other technical limitations.

43. 4242Economic feasibility study  Investment cost 7,000 baht (handheld pH meter and cost for plotting skim latex titration)  Service cost 50baht (sampling skimmed latex for ammonia check)  Savings 360 baht (Acid costs saved per sedimentation)  Investment payback after sedimentation 23times (calculated from 7,000/(360-50) times)

44. 4343Implementation steps

45. Case sample of a CT option Proper use of a water softener

46. 4545 Working conditions found during assessment  Resin is rinsed off the water softener by using 100 kg. of salt in each regenerating cycle.  Regeneration takes 15 minutes  The softener is used for eight hours before the next regeneration

47. 4646Suggested CT options  Use salt with 10% concentration for cleaning, or about 125 kg. per regenerating cycle.  Increase regeneration time to 30 minutes  Operational time is increased to 24 hours

48. 4747 Technical feasibility study  It is a proper resin washing method, lasting no less than 30 minutes.  The factory is capable of implementing such adjustments.  There are no other technical limitations.

49. 4848Economic feasibility study  Investment costNone  Savings385 baht/24 hours (salt cost 175 kg./day x 2.2 baht/kg., excluding cost for water, labor and time saved)  Payback period Immediate

50. 4949Work procedure

51. Samples of different CT options

52. 5151  When cleaning factory floors, sweep off dirt and scraps before hosing down with water  Check for leaks in various connections, e.g., pipes for raw, soft and cold water, and repair immediately if leaks are found  Ensure that float valves are properly functioning  Where possible, use high- pressure nozzle on water hoses

53. 5252  Avoid cleaning by overflow system; counter-flow system is preferable  Plan production process so that minimal washing is required  Product change should not take place too often  Check quality of water used and use appropriate type of water

54. 5353  Insulate hot and cold water pipes and repair the insulation if damaged  Consider returning condensate  Avoid using steam directly by using indirect heat transfer where applicable  Water used to cool machines should be reused

55. 5454  Acid and alkaline should not be dumped after only one use; try to re-use by adding acid or alkaline to obtain required concentration  For light, fluffy materials, trap systems should be utilized to prevent loss  Install water meter at key points so that loss and production efficiency will be known  Avoid using hazardous chemicals

56. 5  Prepare work manuals and have them available for use  Maintain machines in good working condition  Check condition of boilers regularly  If production is much lower than production capacity, production process should be revised to minimize loss

57. 5656  Air conditioner should be set at an appropriate temperature  Lights should be turned off when not in use; use spot lighting where possible  Light switches should be positioned throughout different work areas. Replace spent bulbs with energy saving bulbs.  Clean light bulbs and reflectors regularly

58. 5757Summary CT benefits  Increased production efficiency  Reduced production cost  Reduced environmental problems at source  Good image  Good relations with local community

59. 5858SummaryFactors crucial for sustaining CT  Management support  Team work  Determination  Communication  Training  Incentives

60. 5959SummaryManagement role in CT implementation  Continuous support for CT activities  Involve everyone in the organization in CT activities  Incorporate CT into management plan (marketing, production, finance, accounting, personnel and information system

61. For additional information, contact: Cleaner Technology Unit Tel. 281-2010 Fax 281-7287 e-mail : ctu@diw.go.th