INTRODUCTION TO CLEANER PRODUCTION CP CONCEPTS AND PRACTICE

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INTRODUCTION TO CLEANER PRODUCTION (CP) CONCEPTS AND PRACTICE

INTRODUCTION TO CLEANER PRODUCTION (CP) CONCEPTS AND PRACTICE

Contents 1. How did environmental strategies evolve? 2. What is CP? 3. How CP

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 2

Course Objective At the completion of this course the participants will have understanding of

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 3

Passive environmental strategies Ignored or non recognized Environmental problem. Dilute & disperse Industrialist thought

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

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

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

Constructive environmental strategies Development of environmental technology to loop back waste as process input

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

Pro-active environmental strategies: Cleaner Production - Good housekeeping - Input substitution - Better process

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 byproduct - Product modification 7 Prevention of Pollution & Waste generation

CP versus End-of-Pipe approach Cleaner Production Pollution Control and Waste Management Continuous improvement One-off

CP versus End-of-Pipe approach Cleaner Production Pollution Control and Waste Management Continuous improvement One-off solutions to individual problems Progress towards use of closed loop or continuous cycle processes Processes result in waste materials for disposal ain pipeline with resources in and wastes out Everyone in the community has a role to play; partnerships are essential Solutions are developed by experts often in isolation 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 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 8

What is waste? There are literally hundreds words for different types of waste: •

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

Wailing Waste!!! Waste is unwanted what ever name you call it : take the

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

Waste Hierarchy 11

Waste Hierarchy 11

Its Our Future 12

Its Our Future 12

Cleaner Production Financing The “Cost of Waste” Iceberg t& n e tm osal a

Cleaner Production Financing The “Cost of Waste” Iceberg t& n e tm osal a e Tr Disp Reg Co ulato mp r lian y ce THE HIDDEN COST OF WASTE , bil Lia ge ma y. I an mp Co aw , E R t s ls Lo teria Ma or b La ity gy ner 13 Enormous cost underneath

Where are you now? • Only a change in technology would eliminate waste completely

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 14

Cleaner Production Definition “The continuous application of an integrated preventive environmental strategy applied to

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) 15

Cleaner Production Definition Continuous Products Preventive Integrated Processes STRATEGY for Services Humans Risk Reduction

Cleaner Production Definition Continuous Products Preventive Integrated Processes STRATEGY for Services Humans Risk Reduction Environment 16

Properly implemented CP : always • reduces long-term liabilities which companies can face many

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

Properly implemented CP : usually · · increases profitability lowers production costs enhances productivity

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 18

Properly implemented CP : usually (continuation) · results in improved product quality · increases

Properly implemented CP : 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 19

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

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

Are you Energy Efficient? 1. Reduce energy and production costs 2. Improve environmental performance

Are you Energy Efficient? 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 21

What is not CP? • Off-site recycling • Transferring hazardous wastes • Waste treatment

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 22

What are the benefits of Cleaner Production? Improving environmental situation Increasing economical benefits Increasing

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

How CP could be applied in practice? 24

How CP could be applied in practice? 24

Cleaner Production practices 1. Good housekeeping take appropriate managerial and operational actions to prevent:

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

Cleaner Production practices 2. Input substitution substitute input materials - by less toxic -

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 26

Cleaner Production practices 3. Better process control modify: - operational procedures - equipment instructions

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 27

Cleaner Production practices 4. Equipment modification modify the existing production equipment and utilities in

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 28

Cleaner Production practices 5. Technology change replacement of: - the technology - processing sequence

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

Cleaner Production practices 6. On-site recovery/reuse - reuse of the wasted materials in the

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

Cleaner Production practices 7. Production of a useful by- product consider transforming waste into

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. 31

Cleaner Production practices 8. Product modification modify the product characteristics in order: - to

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 32

Cleaner Production procedures The recognized need to minimise waste The first step The second

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

1. Planning & Organization • Obtain management commitment • Identify potential barriers and solutions

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

Team for CP success • Appoint CP Project Team: -Top Manager(MD), Vice Leader(Chief Engineer),

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 35

Leading. Team Role • Initiate & support CP assessment • Nominate assessment team •

Leading. Team 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 36

Assessment Team Role • Establish CP goals • Develop a working plan • Performing

Assessment Team 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 37

CP barriers Internal to the companies: - - Lack of information and expertise Low

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 38

CP barriers External to the companies: -Difficulty in The failure of existing regulatory approaches

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

CP motivators and drivers Internal to the companies: - Improvements in productivity and competitiveness

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 40

CP motivators and drivers External to the companies: - Innovative regulation - Economic incentives

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 41

CP Management Cycle 42

CP Management Cycle 42

Pre-Assessment • Identify sources of waste • Draw process flow chart • Identify water,

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 43

Material and energy balances Heat Raw Materials Power The Industrial Process Cooling The Energy

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

Why are material and energy balances so important? The material and energy balances are

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 45

Possible causes for waste generation Choice of Production Technology Choice & Quality of Input

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

CP assessment practices Good Housekeeping Equipment Modification On-site Recovery/ Reuse Input Substitution Process Production

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

Pre assessment work through • Investigate present status: - Historical data Base Line data

Pre assessment work through • Investigate present status: - Historical data Base Line data Performance indicators Process flow charts • Performing on site investigation: • Compile input-output flow chart: • Selection of assessment focus: - Consider high potential for CP, high production cost, high waste - - 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 Details of flows & quantities considered generation & high material and energy consumption 48

Pre assessment work through • Setting CP Targets: - SMART targets Challenging targets More

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

Setting Objectives Short Term • Compliance • Improve Housekeeping • Improve Maintenance • Better

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

CP management system Marketing Top management commitment Pre-assessment CP policy declaration Start CP project

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

What are the benefits of Cleaner Production? Financial advantages: Usually a short Payback Period

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 • • • 52

Overall Risk Profile CONSUMERS’ WORKERS’ HEALTH NEW REGULATIONS ENVIRONMENTAL ACCIDENTS HEALTH RISKS REPUTATION LIABILITY

Overall Risk Profile CONSUMERS’ WORKERS’ HEALTH NEW REGULATIONS ENVIRONMENTAL ACCIDENTS HEALTH RISKS REPUTATION LIABILITY CLEAN-UP BUSINESS VALUE INSURANCE PRODUCT SALES CLAIMS 53

!!! CP is a journey not a destination 54

!!! CP is a journey not a destination 54

Broader Application of CP CP is closely linked to: • Environmental Management Systems ISO

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 55

What have we learned? · The CP approach reduces pollutant generation at every stage

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 56

Cleaner Production and Sustainable Development Sustainability Environmental space Economic Instruments Factor X Co-regulatory agreements

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