modules 5&6 june 3, 2013 malolos city · pdf fileprocess units – production, ......
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Improving SME Profitability
and Environmental
Performance Through Cleaner
Production
Prof. Nonita T Yap SEDRD,
University of Guelph Canada
Modules 5&6
June 3, 2013
Malolos City
How to do a
Cleaner Production
Audit
CP
Key requirement for
initiating a program for
Commitment from
Management
Reducing production cost and
therefore reduction of waste.
Providing incentives to workers
who reduce waste – rewards,
recognition.
Providing the necessary training
to workers
The owner and manager must
be serious about …
TRAINING OF
WORKERS
Training the workers in Identifying and managing wastes.
Recognising that there is a cost associated with producing wastes
Different ways of reducing wastes.
At the very least – training in good housekeeping practices
GOOD HOUSEKEEPING
PRACTICES - examples Minimise spills and leaks Improve operating practices Adequate and proper storage of materials
Keeping containers closed and
in a secure place.
Ensuring that all containers are
properly labeled (content, date,
etc.)
Having different containers for,
i.e., not mixing, different wastes
Why does the following constitute
good business practice?
1. CP Advisor signs the agreement with management
2. Form and train the CP team
3. Develop the flow diagrams for different processes
4. Determine the critical points
5. Prioritise the environmental impacts
6. Determine the real causes - using fishbone diagram
7. Develop measures /options for improvement
8. Feasibility study : prioritise, evaluate, rank
9. Review, finetune the options
10. Develop the action plan
11. Monitor and evaluate
12. Change if necessary to meet market demands
1. Planning &
organisation
2. In-plant evaluation
/ On-site audit
/CP assessment
3. Select CP
options
4. Implement
Monitor,
Evaluate & adjust
Days 1 &2
Day 3 & 4
Obtain management
commitment
Organize a CP team
Set SMART goals
• Identify the main processes and the most wasteful
process units – production, material handling &
storage, uitilies, etc
• Identify inputs and outputs – collect necessary data
• Prepare flow charts
• Establish material, water and energy balances
• Identify critical points in terms of financial
viability, environmental impacts and quality control.
• Raw materials usage and costs
• Production quantities and sales revenue
• Quantities of wastes generated in each unit
operation if possible
• Labour costs
• Utilities consumption and costs
• Environmental and labour compliance costs
This baseline is important for evaluating and.
selecting the best CP options
STANDARDS for developing flow charts
Integrity – all revelant environmmental impacts of the operations should be listed. Transparency /objectivity – All the flow of materials and energy should be registered objectively Continuity – time period should be equal for all the areas (e.g., 1 yr) Practicality/efficiency – to utilise all resources (time personnel, expenditures) register only the material and energy that are ecologically relevant Confidence – the data collected should lead to plausible results Clarity – The results are unequivocal and useful from the perspective of decision making.
Consistent units of measurement Consistent form of measurement Unit price of inputs and products – for costing purposes
Basic points to remember
1 ) u s e yo u r e y e s , e a r s , n o s e - l o o k , l i s t e n a n d s n i f f
2 ) R e v i e w w h at c o m e s i n – r aw m at e r i a l i n p u t s ,
e n e rg y, wat e r - c o m pa r e t h e m w i t h w h at l e av e s
i n t e r m s o f t h e p ro d u c t t o d e t e r m i n e t h e wa s t e
o r l o s s – e n v i ro n m e n ta l i n d i c at o r s f o r t h e
c o m pa n y.
3 ) I n f o r m at i o n o n t h e f l o w o f e n e rg y & m at e r i a l s
h e l p t o s p e c i f y t h e m e a s u r e s f o r r e d u c i n g r aw
m at e r i a l c o n s u m p t i o n , e m i s s i o n s & t h e r i s k s ,
d e t e r m i n e t h e c o n t ro l & d i r e c t i o n o f t h e
p ro c e s s e s a s w e l l a s a n a ly s e t h e c o s t o f
e n v i ro n m e n ta l p ro t e c t i o n
Other important points Chronological comparison (this
way it is possible to detect changes
and trends over time)
Evaluation in terms of regulatory
compliance
Comparison between enterprises
(with which it is possible to
establish benchmarking)
Gathering and preparing
information – complement
and triangulate 1. Interviews
2. Visual Inspection
3. Document review (e.g., notice of
permit, registers, activities for
inventory and measurements,
etc.)
• Identify sources of wastes
based on flow charts
• Identify opportunities for
reducing/ eliminating wastes
using Fishbone diagram
• Screen & rank CP option
1. Good housekeeping
2. Process optimization
3. Raw material substitution
4. On-site recovery/reuse
5. Product modification
6. Offsite recovery and reuse
7. Equipment modification/ Technology change
1) What are the main environmental and
economical benefits to be obtained by
implementing the identified CP options?
2) Can these options be done within a reasonable
timeframe without disrupting production?
3) What are the related costs to the
implementation of these CP options?
4) No and low costs options should be
implemented before medium and high cost
options
• Secure funding
• Implement feasible CP options
• Monitor and evaluate CP progress
• Compare the situation before and
after the implementation
MODULE 6
1. Case study: meat
processing plant – highlights
2. Greening the economy from CP to industrial ecology
25
1. Delivery & holding of livestock
2. Stunning & slaughter
3. Hide removal,
dehairing/ defeathering
4. Evisceration
5. Trimming & carcass washing
6. Boning 7. Chilling
8. Packaging
9. Cold Storage
28
1 - Transport
• Animals delivered in
trucks;
• Trucks are washed
2 - Holding &
Inspection
• Animals are held in pens
& inspected.
• Condemned animals are
separated and killed.
fuel
Animals
dead on
arrival
Faeces, urine,
contaminated
water
Condemned
animals
water
Live
animals
Live
animals
Faeces, urine,
contaminated
water
water
Incineration
Wastewater treatment
29
4 - Evisceration & Splitting • Abdomen cut open & viscera removed
• Breastbone split
• Heart/liver/lungs removed;
• Head removed
• Carcass cut into two along the spine
• Hide removed
Energy (to sterilize
equipment)
Wastewater
Water
Intestines,
edible organs
Hides
Inedible offal & Parts
3 - Stunning &
Bleeding
Animals are first
stunned or killed,
and then bled
Carcass
blood
Faeces, urine,
contaminated
water
Water Disinfectant
Wastewater treatment
Carcass
Disinfectant
Condemned parts
Incineration
30
5 - Chilling
Carcasses
refrigerated
overnight
water
wastewater
Energy (for
refrigeration)
6 - Cutting &
boning
Carcasses are cut
into pieces for
retail, some bones
removed
7 - Packaging
Energy (to sterilize
equipment &
refrigeration)
water
Bones
fat
Meat Carcass
Energy (to sterilize
equipment &
refrigeration) water
Leaks of refrigerant fluids (Ammonia, CFCs
Wastewater treatment
31
Incineration
Condemned animals
and parts
Rendering
Parts and scraps
are rendered for
tallow
?
Waste treatment
processes
Secondary production
processes
And what other processes?
?
? ?
? ? ?
? ?
There may be some secondary
production processes
OPTION
1
OPN 2 OPN 3 OPN 4 OPN 5 OPN 6 OPN 7
DOAs (Dead on
arrival)
Who are the suppliers?
Water consumption
BOD level in
Wastewater
Fat and grease
Energy (steam)
consumption
Waste (DOAs) disposal
Meat losses in packing
Opportunities through Cleaner
Production and Ecology
1. Green Economy
2. Intl Environmental
Governance
3. Sustainable Consumption
and Production
35
36
• A low-carbon economy
• Green growth
• An economic system that is compatible
with the natural environment.
• Investing in sectors producing
environmentally friendly or enhancing
products, contributing to economic
growth and jobs.
• “A green economy is... • an economic system that ensures social equity,
protects the ecological balance and creates economic sufficiency.”
• the replacement of the current economic order of inequity, destruction and greed that has kept half of the global people in poverty and created a potential climate catastrophe.”
• The core idea of a GE should be to enforce Sustainability as in wellbeing of all people and biodiversity.
• only be about the market opportunities for green technology
• make the mistake of a Green Revolution that promoted mass-scale industrialized food production
• evolve around just a smart grid business platform based on public-private partnerships.
• be a Green Washing of the consumerist society seeking increased consumption of quality products. “
“A Green Economy can be defined as one that results in improved human well-being and social equity, while significantly reducing environmental risks and ecological scarcities.”
Green Economy : civil society groups
UNEP – GREEN ECONOMY INITIATIVE
• Agriculture,
•Fisheries,
•Manufacturing,
•Tourism,
•Energy
•Transport,
•Buildings,
• Cities,
•Forests,
•Water and
•Waste
• decoupling of production and environmental degradation
• Environmental degradation = fcn (Pollution or waste per GDP x GDP/capita x Population)
This decoupling is possible ONLY through industrial ecology and cleaner production
Prof. Nonita T. Yap, DOST Balik Scientist
DENR presentation – May 20 2011
42
• The percentage of goods going directly from
production to disposal (i.e., single-use products)
is reaching 30% in some sectors
• For many products, the number of goods thrown
away is comparable to the number of goods
sold, indicating a substitution, rather than an
increase in wealth
• Technological progress is still focused on
production not on utilisation 43
44
“Doing Nothing” (Dilute & Disperse)
End-of-Pipe Technology
Pollution Prevention/
Cleaner Production
(21st century?)
Industrial Ecology/
circular economy
45
1. It is a systematic, comprehensive, integrated view of all the components of the industrial economy and their relationship with the biosphere
2. Emphasizes the complex patterns of material flows both within and outside of the industrial system RATHER than in terms of abstract monetary units or energy flows
3. Technological dynamics and development is a crucial, but not exclusive, element to achieve viable and sustainable industrial economic systems
IT IS BASED WITH CLOSING THE LOOPS
AMONG FIRMS
CLEANER PRODUCTION CLOSES THE LOOPS WITHIN.
Prof. Nonita T. Yap, DOST Balik Scientist
DENR presentation – May 20 2011
46
The Natural Ecosystem
Abiotic
Substances
Producers (e.g. plants)
Consumers (e.g. animals)
Decomposers (e.g. bacteria)
Ind
ustr
ial E
co
log
y . M
imic
bio
log
ical
syste
ms (
UN
EP
n.d
.)
47
The Natural Ecosystem
The Industrial Ecosystem
Raw Materials
Supplier Manufacturer Consumer
Waste
Processor
Abiotic
Substances
Producers (e.g. plants)
Consumers (e.g. animals)
Decomposers (e.g. bacteria)
WASTE RESOURCES
RESOURCES
from the
Lithosphere
Ind
us
tria
l E
co
log
y.
Ide
nti
fy p
ote
nti
al i
nd
us
tria
l
‘me
tab
oli
c’ p
ath
ways
(U
NE
P n
.d.)
48
The Natural Ecosystem
The Industrial Ecosystem
Resources
Raw Materials
Supplier Manufacturer Consumer
Waste
Processor
Secondary
RESOURCES
‘Producers’ (manufacturers)
‘Consumers’
‘Decomposers’
WASTE
RESOURCES
from the
Lithosphere
Ind
us
tria
l E
co
log
y –
es
tab
lis
h in
du
str
ial
me
tab
olic
p
ath
wa
ys
.
•
•
49
“... involves designing industrial infrastructures as
if they were a series of interlocking man-made
ecosystems interfacing with the natural global
ecosystem.” (H. Tibbs, Industrial Ecology - An Environmental
Agenda for Industry, 1993)
These interlocking ecosystems can be
defined/bounded at three levels – material, sector,
spatial (region/estate)
50
The Industrial Symbiosis
in Kalundborg, Denmark
Asnæs Power Station [photo: Indigo Development]
51
Th
e L
oc
ati
on
of
Ka
lun
db
org
…
ASNÆS - the largest coal-fired power station producing electricity in Denmark.
STATOIL - an oil refinery belonging to the Norwegian State Oil company
NOVO NORDISK - a multi-national biotechnology company producing insulin and industrial enzymes.
GYPROC - a Swedish company producing plasterboard for the building industry.
City of KALUNDBORG - receives excess heat from Asnaes for its residential district heating system.
BIOTEKNISK JORDRENS - a soil remediation company.
52
53
Statoil
Novo
Nordisk
Gyproc
Asnæs
Municipality
Photos: Symbiosis Institute, Novo Nordisk, Statoil
54
55
Asnæs
Power
Station
Statoil
Refinery
Gyproc
Municipality
of
Kalundborg
Novo
Nordisk
Bioteknis
k
Jordrens
Fertiliser
Industry (NH4)2S2O3
Cement
Industry
Farms
Sulphur- and
Ammonia-rich
Effluents Gas
Fly Ash Gypsum Waste
Water
Biomass
& Yeast
Slurry
Sludge
Used Water
Nickel &
Vanadiu
m
56
Asnæs
Power Station
Statoil
Refinery
Municipality
of Kalundborg
Novo
Nordisk
Lake
Tissø
Waste
Water
Steam
Steam
Water Water
Water
Used Water
Water
Artificial
Lake
57
Asnæs
Power Station
Statoil
Refinery
Gyproc
Municipality
of Kalundborg
Novo
Nordisk
Fish
Farms
Gas
Residual
Heat
Residual
Heat
Steam
Steam
58
Asnæs
Power
Station
Statoil
Refinery
Gyproc
Municipality
of
Kalundborg
Novo
Nordisk
Bioteknis
Jordrens
Lake
Tissø
Fertiliser
Industry (NH4)2S2O3
Cement
Industry
Farms
Fish
Farms
Sulphur- and
Ammonia-rich
Effluents Gas
Fly Ash Gypsum
Residual
Heat
Residual
Heat
Waste
Water
Steam
Steam
Water Water
Water Biomass
& Yeast
Slurry
Sludge
Used Water
Water
Artificial
Lake
Nickel &
Vanadium
• Reduction in consumption of resources:
• oil - 45,000 tons/year
• coal - 15,000 tons/year
• water - 600,000 m3/year
• Reduction in emissions:
• carbon dioxide - 175,000 tons/year
• sulfur dioxide - 10,200 tons/year
• Valorisation of “wastes”:
• fly ash (for cement etc.) - 130,000 tons/year
• sulfur - 4,500 tons/year
• calcium sulfate (gypsum) - 90,000 tons/year
59
With 18 projects -
Investments: $ 75 million
Total Revenues: $ 160 million
60
A co-operative approach can result in significant reductions in
environmental impacts … and save money.
The Symbiosis essentially « organised itself » over a long period of
time using sound financial criteria to decide on projects BUT
INITIALLY TRIGGERED (and sustained) BY POLICY.
Confidence was built between partners, resulting in long-term
contracts to supply « wastes » to each other.
The close proximity of partners has helped to reduce investment
costs for infrastructure (e.g. pipelines etc.)
The proximity and the social relations among the human partners -
crucial in developing co-operation (socio-cultural factors) and reducing
transaction costs.
Creation of a working group to follow the development of projects is
very important (e.g. Symbiosis Institute, 1996)
OTHERS HAVE FOLLOWED - AUSTRALIA, CHINA, FINLAND, SWEDEN