1. PRESENTER:Julia Brown Waste Research Management & Training Centre Scientific Research Council CLEANER PRODUCTION TECHNOLOGIES

2. Objective To provide industries with an awareness of becoming efficient in an effort to reduce the cost of production and thus earning more. CLEANER PRODUCTION TECHNOLOGIES

3. Contents i.What is Cleaner Production as it relates to product, processes and services ii.Benefits of Cleaner Production Technologies iii.Execution of Cleaner Production iv. Case study CLEANER PRODUCTION TECHNOLOGIES

4. Cleaner production  This is an integrated preventive strategy applied to processes, products and services as a way to increase the efficiency and to reduce risks for human beings and the environment.

5.  For processes - this is the efficient use of raw material, water and energy, the elimination of toxic or dangerous products and the reduction of emission and wastes at the source. Cleaner production

6.  In the case of the products, the strategy is centered around lowering their environmental impact and promoting friendly designs. Cleaner production

7.  In the case of the services, the strategy is focused on lowering the environmental impact and promoting friendly procedures during its management. Cleaner production

8. Internal RecyclingSource reduction Process Change Product Change Raw material Substitution Technological modification Good Practices Cleaner production strategies

9. Prism Methodology Enterprise data and its processes. Materials flow of wastes and emissions. Work groups creation. Generate options in Cleaner production. Evaluate Technology. Evaluate economy. Evaluate environment, Evaluate organization, Select options. Obtain funding Equipment installation. Advise evaluation of results. Project adaptation Planning of new projects To obtain a commitment with the Management. Establish the evaluating organization To propose general objectives. Overcoming barriers. Begin a preliminary study Be reminded of the increasing competitivity with Cleaner Production Planning and Organization Plant evaluation Feasibility Study Implementation

10. Legislation - environmental legislation is increasing world-wide. This can reduce the risk of penalties and provide competitive advantages. Cost Savings - This identify opportunities for cost savings via energy efficiency and waste minimization measures. Customer requirements - increasing businesses will not want to risk reputation or inherit liabilities as a result of poor performance by suppliers. Benefits:EMS/Cleaner Production

11. Market Opportunities - this can be a likely factor in market profiling and provide a competitive edge. Corporate Image - a good environmental record can improve corporate image and better relations with stakeholders. Adverse publicity on environmental performance can be very damaging. Benefits cont.:EMS/Cleaner Technologies

12. What are the economic benefits? –Energy, water and raw material –Wastes disposition –Compliments and procedures –Financing –Product responsibility Economic Value Added Environmental System Management Reduction of costs : Flexibility in prices Relationship with clients Competitive and strategic positioning Access to the maket Increase in services Increase of income :

13. Reduction of costs to develop value added The cost of a failure in Environmental Quality  Trainning  Manteinance  Better process  Design of products  External communication Prevention x $1  Inpsection and monitoring  Reports  Calibration Discovery x $10  Waste of materials  Treatment and control  Productive space  Time Internal error x $100  Consultancy fees  Remediation  Loss of clients  Relation with the community External error x $1000 System Approach

14. Competitivity Support Products improvement Processes efficiency increase Production costs decrease Elimination costs decrease Profit increase Market opening

15. Advices: Raw Material determination Consider the following questions: –Is the size of the raw materials inventory appropriate so their losses may be minimized? –Could it be possible to reduce the transference distances between storage and processing or between operation units? –Is there any mutual contamination risk in reservoirs that may store two or more raw materials? –Are the material sacks completely emptied?

16. Consider the following questions : –Is the raw material storage area secure? –Is there solar light incidence in the storage place? –Does the material pumping system receives maintenance? –Are there leaks? –Can the drainage be by gravity? Advices: Raw Material determination

17. Consider the following points: –From where is the water extracted and where is this stored? –Water storage capacity in plant? –How is the water transported in the plant? –Does there exist considerable precipi- tation in that place? Advises: Water consumption

18. What is the water used for in each operation? With what frequency do each action take place? How much water is used in each action? Advices: Water consumption for each unit operation

19. Strict control of water consumption. Concentrations increase - Less raw material Good manufacturing practices options. Waste water storage options for a possible reuse. Countercurrent soaks and recycling of soak water. Advices: Reduction in water consumption

20. ALL discharge points location. (frequently there is more than one) Identify where do the flows of multiple operation units or process areas join. Define a program for the volumes of water used for each unit operation. Define maximum production conditions, opening, closing and washing to obtain the water generation characterization of the enterprise. Advices: Effluent contamination

21. Determine if there exit a combination of pluvial and residual waters. Use volumetric measurement for small and intermittent flows. Advices: Effluent contamination

22. Include in the analysis pH, DO, BOD, suspended solids, FOG. Use up to it may be possible a compound sampling for continuous flows. Advices: Effluent concentration de- termination

23. The following questions have to be asked: –Are there odour associated with any unit operation? –Is there a moment where emissions may be marked? –Is there any contamination control equipment? –Are emissions directed to the outside of the confined spaces? –Are gases washed in the enterprise? Advices: Gaseous emissions contamination

24. The following questions have to be asked: –Where is the origin of the residue? –Can it be optimized by any process so there may be less residue generation? –Can alternative raw materials be used to generate less residue or may facilitate its management? –Is there any component that may cause all the residue to be harmful? Advices:Outside residues disposal contamination

25. Sugar Factory Rum Distillery Agro - Processing facilities Areas of work involving Cleaner Technologies

26. Wastewater production –6000 m 3 /hr at peak –3200 m 3 /hr reduce by approx. 50 % through separation of drains (clean water and polluted water), avoiding/reducing spillage and repairing leaking taps. –3000 m 3 /hr at peak –1600 m 3 /hr CASE STUDY - A SUGAR FACTORY

27. COST FOR TREATMENT –Approx. US$200/m 3 (cost effective system) –Initial cost for treatment was approx. US$1.2 million –After reduction approx. US$600,000 CASE STUDY - A SUGAR FACTORY