Slides 1 CP Basics Cleaner production Considers your
Slides 1 – CP Basics Cleaner production Considers your Ø Technologies Ø Employees Ø Raw materials Ø Processes Ø Emissions Ø Partners and Ø Products
Slides 1 – CP Basics Elements of a CP-project ØData collection Mass flow Energy flow Costs and safety ØReflection: Where and why do we generate waste? ØOption generation ØFeasibility ØImplementation ØControlling, continuation, EMS
Slides 1 – CP Basics Common waste treatment: Waste is generated! What’s that got to do with me? Cleaner production: Waste is generated! Where does it come from?
Slides MATERIAL Raw material, process material, other material ENERGY CARRIERS Fuels, e. g. gas, oil, coal ENERGY Mass free, e. g. electricity or district heating OBSERVED SYSTEM 1 – CP Basics PRODUCTS Primary and secondary MATERIAL EMISSIONS Solid waste, gases, wastewater ENERGETIC EMISSIONS Waste heat, noise
Slides No Waste or liquid or gaseous emissions 1 Waste water 2 Spent grain (wet) Annual quantity 1 – CP Basics Unit 180, 000 m³ 5, 000 t Purchasing cost Disposal cost Total cost 6 10 2, 880, 000 around 800 -350 -1, 750, 000 (2, 250, 000) 3 Malt dust 447 t 4, 000 ? 1, 788, 000 4 Waste barley 220 t 4, 000 ? 880, 000 5 Bottoms 30 t - 250 7, 500 6 Glass/broken glass 92 t 2, 400 350 253, 000 7 Plastic containers 18 t 10, 000 216, 000 8 Labels (wet) 50 t 30/1000 pcs 600 3, 600, 000 30, 000 9 Cardboard / paper 35 t 5, 000 - 175, 000 10 Wood pallets 24 t 6, 000 40 144, 960 11 Plastic film 1. 5 t 22, 000 4, 500 39, 750 12 Industrial waste 104 t ? 800 83, 200 13 Diatomaceous earth 45 t 8, 000 930 401, 850 14 Waste from maintenance, 200 kg ? 11 2, 200 greasy 15 Contents of oil separator 3, 200 kg ? 2. 8 8, 960 16 Waste oil 1, 000 kg 50 2 52, 000 17 Waste paints 50 kg 100 15 5, 750 18 Fluorescent lamps 20 kg 120 12 2, 640 19 Accumulators 25 kg 70 2. 8 1, 820 20 Waste gas, steam boiler 1, 000 m³ - - -
Slides 1 – CP Basics Reasons for an environmental team Ø Because there are many different departments/machines in a company, it is difficult to get the necessary overview and the detailed technological knowledge. Ø Because there are motivated and competent employees in a company. Ø Because as a TEAM – with a common goal – it is possible to work more efficiently than a lone ranger. Gather people from differnet departments: production, maintenance, technology, purchasing, management, quality, accounting, research and development, environment, health and safety, legal branch, etc.
Slides 1 – CP Basics Material flow analysis Sankey-diagram: www. sankeyeditor. net
Slides 1 – CP Basics Material flow analysis Detailed description of the material and energy use Ø Which waste and emission streams are generated? Ø Which raw materials are lost? Ø Where and why does this happen? Ø Where are the weak points? Ø Where are potentials for improvement? Ø Which materials can be reused?
Slides Ø Within the production process, there are many points where materials and energy are lost. Ø These points are also environmental and economic weak points. Ø A material flow analysis identifies the points where materials are lost and their amount. 1 – CP Basics
Slides Ø A comparison with the best available technology shows process weaknesses. Ø The material flow analysis facilitates the evaluation of the "production costs" of waste and emissions. Ø Eco-efficiency: the best use of materials reduces emissions. 1 – CP Basics
Slides 1 – CP Basics Strategies for cleaner production
Slides 1 – CP Basics Product change ØSubstitute the product ØIncrease the product life-time ØChange the materials ØChange the product design ØUse recycled materials ØAvoid critical components
Slides 1 – CP Basics Good housekeeping Ø Improve information Ø Change dosage/concentration Ø Increase the utilization of process capacities Ø Check cleaning and maintenance period Ø Foster standardization/automation Ø Improve purchasing, storage and distribution Ø Carry out a material flow analysis
Slides 1 – CP Basics Waste logistics Separation of waste and wastewater to Ø Set up closed cycles Ø Facilitate recovery and re-utilization Ø Minimize quantities of hazardous waste Ø Minimize disposal costs Ø Minimize cleaning expenses (wastewater, exhaust gases, etc. )
Slides 1 – CP Basics Technological modification Ø Substitute thermo-chemical processes by mechanical alternatives Ø Use countercurrent cascades instead of single-static rinse techniques Ø Manage separate waste and wastewater streams Ø Improve process conditions Ø Foster recovery and reuse of materials Ø Increase life time of chemicals/materials Ø Reduce the infiltration of impurities Ø Ensure airtight sealing of equipment
Slides 1 – CP Basics Energy efficiency Typical areas of improvement Ø Cooling/refrigeration Ø Heating Ø Compressed air Ø Insulation Ø Heat recovery Ø Separation processes Ø Lighting Ø. . .
Slides 1 – CP Basics Internal recycling Ø Reuse materials (solvents, etc. ) Ø Reuse materials for different purposes (paper, solvents for lower-quality use, e. g. pre-cleaning, etc. ) Ø Close internal loops (water) Ø Use returnable systems (packaging materials) Ø Reclaim materials with high value
Slides 1 – CP Basics ECOPROFIT Graz 2000 Realized and planned options In total 594 options, thereof: 60 %; 355 = realized options 2000 40 %; 240 = planned options 2001
Slides Anodizing company Ø Use of spray rinses Ø Reconstruction of water pipes Ø Longer drag-out time Ø Daily check Ø Reduction in water consumption by 46% (14, 000 m³) 1 – CP Basics
Slides 1 – CP Basics
Slides 1 – CP Basics Car repair shop Ø Installation of an ultrafiltration unit Ø Modified cleaning equipment Ø Saving of washing agent by 76 %, of water by 80 %
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