Clean Techn Environ Policy (2011) 13:195–206
DOI 10.1007/s10098-010-0288-2
ORIGINAL PAPER
Evaluation of cleaner production audit in pharmaceutical
production industry: case study of the pharmaceutical plant
in Dalian, P. R. China
Li Zhi-dong • Zhang Shu-shen • Zhang Yun •
Zhang Yong • Wei Li
Received: 9 October 2009 / Accepted: 10 March 2010 / Published online: 1 April 2010
 Springer-Verlag 2010
Abstract The pharmaceutical industry in China makes an
important contribution to the national economy. However,
the associated pollution problems cause gradual deteriora-
tion of the environment and impact adversely on the local
community. Cleaner production (CP) technology, an effec-
tive way to reduce waste emission and save resources, has
been widely employed in the pharmaceutical industry in the
developed countries. Such technologies have been applied
in a number of factories in China, although there is no
integrated assessment and implementation procedure for
implementing CP technologies in pharmaceutical plants. To
solve such problems, a series of CP options are proposed and
assessed here. CP is a powerful tool for decreasing waste
production, limiting environmental pollution and natural
resource depletion. Moreover, the return on investment
in CP is quick, so it would seem that CP activities should
be very much in demand by enterprises. Reality is less
L. Zhi-dong
Z. Shu-shen
Z. Yun (&)
Key Laboratory of Industrial Ecology and Environmental
Engineering (MOE), School of Environmental Science
and Technology, Dalian University of Technology,
Linggong Road 2, 116024 Dalian, People’s Republic of China
e-mail: lzd_xx@163.com
L. Zhi-dong
Z. Yong
W. Li
Dalian Cleaner Production Centre, 116023 Dalian, Liaoning,
People’s Republic of China
L. Zhi-dong
Z. Yong
W. Li
Dalian Municipal Design and Research Institute
of Environmental Science, 116023 Dalian, Liaoning,
People’s Republic of China
optimistic: frequently only limited interest is expressed,
even after an explanation; business people hesitate to
become actively involved. The processes in the pharma-
ceutical production industry produce a vast amount of
waste, including wastewater with high concentrations of
organic substances (the principal component), solid waste,
and organic off-gas. To solve such problems, a series of CP
options are proposed and assessed in this study. Having
consideration to environmental impacts and economic effi-
ciency, four groups of medium/high cost CP options were
screened in an integrated assessment. To verify the proposed
options, a case study was conducted in Degussa Luyuan,
Northeast China. The characteristics of resource consump-
tion and waste emission during the production process were
identified. The proposed options were evaluated according
to different aspects. An integrated CP system based on the
proposed options was designed and then implemented in the
factory. In three years of practical use, the productivity and
quality of alcohol product were improved, with a reduction
in waste and pollution and a marked increase in water/
energy savings. This study provides theoretical and practical
support for the extensive application of CP technologies and
sustainable development in China’s pharmaceutical indus-
try. These methods include ways to clean up production that
are incorporated in the process design, reforming present
production technologies, updating the equipment, exploit-
ing new producing flowcharts, using cleaner energy, build-
ing recycling into the manufacturing process, recycling
waste, enhancing management, developing environmental
protection technology, and ensuring satisfactory end-of-
pipe disposal.
Keywords Pharmaceutical industry

Environmental protection
Cleaner production

Water saving
Pollution reduction
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Introduction
Cleaner production (CP) has spread to almost every
industrial sector and many researchers have devoted
themselves to the development of clean technologies in the
pharmaceutical industry. CP, which has been developed in
recent years as a tool for environmental protection and for
higher efficiency, has shown its ability to decrease envi-
ronmental pollution, preserve natural resources from
excessive depletion and generally to limit the adverse
environmental impact of economic activities. Moreover,
the return on investment in CP is quick, so would be easy
to conclude that CP activities should be in great demand
and that most enterprises should invest in the effort to
introduce the CP approach as widely as possible in their
operations.
Internationally, the application of CP systems in the
pharmaceutical industry has resulted in significant reduc-
tions in the demand for natural resources, including water,
energy and raw materials. CP applications have also
resulted in significant reductions in the release of toxic
waste into the environment. The successful application of
CP usually starts with a CP audit. Such an audit depends
significantly on the availability of the necessary skills, the
availability of precise data, and it is time intensive. These
factors imply that companies seeking CP evaluations must
engage in significant financial outlays (Stasiskiene 2000;
Staniskis and Stasiskiene 2003; Staniskis and Kliopova
2001; Kliopova 2000; Kliopova and Bagdonas 2003;
Tarozaite and Giliene 2002).
CP in pharmaceutical industry in China
In China the promotion and implementation of CP started in
the 1990s, and its first CP project began in 1993 with support
from the World Bank and the UNEP. Since then, more than
15 other bilateral and multilateral, comprehensive coopera-
tion projects have been conducted, with a focus on CP,
resulting in numerous pilot projects in industries and enter-
prises [China Council for International Cooperation on
Environment and Development (CCICED)]. A legislative
network of national and local CP policies and an institutional
network of promotional centers have also been formed. The
State Environmental Protection Administration (SEPA) and
the UNIDO/UNEP CP Program established a National
Cleaner Production Center (NCPC) in 1993, which is now
linked with 20 more local and industry-based CP centers;
furthermore, up to May 2000, 550 CP training sessions had
been conducted in China, reaching more than 16,000 par-
ticipants (NCPC). Moreover, a database of environmental
solutions is available to researchers and practitioners. In May
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L. Zhi-dong et al.
1999, China also launched a national CP demonstration
program; it selected ten cities (Beijing, Shanghai, Tianjin,
Chongqing, Shenyang, Taiyuan, Jinan, Kunming, and
Lanzhou and Fuyang) and five industrial sectors (petro-
chemical, metallurgical, chemical, light industry, and ship-
building) to conduct pilot CP projects. According to Zhu and
Zhao, by the end of 2001, some 700 CP demonstration pro-
jects had been implemented in 24 provinces around the
country (Hicks and Dietmar 2007).
The Pharmaceutical industry is an important factor in
the national economy. It is also the basic industry that is
related to the people’ life and the nation’s development.
The pharmaceutical industry has the capacity to the natural
environment, even as it stimulates the national economy to
develop rapidly, as it can consume vast quantities of
resources and energy, while releasing a vast pollutant
burden. The current focus of the industry is on ecology
which achieving the simultaneous development of the
economy and the environment. CP is achieved by com-
bining economic development with environmental protec-
tion. It is also the necessary road leading to sustainable
development.
Since the foundation of The New China, the pharmaceu-
tical industry has been exploring routes to CP. Enterprise
management is grasping technological innovation and
technological revolution, seeking to reduce material con-
sumption and energy, improve product quality. Neverthe-
less, management has still not warmed to the concept of
‘‘clean production’’. Under the planned economy system, the
relevant government departments do a lot of work. The
China chemical industry association was established in
1998, simultaneously with 15 associations of professional
institutions devoted to environmental protection, antibiotics,
amino acids, tablets, transfusions, etc. The associations did a
great deal of work on rejuvenating the pharmaceutical
industry, leading it into sustainable development, with
coordination between the divisions and promotion of tech-
nological progress. The Association is the earliest academic
organizations to support CP technologies in the pharma-
ceutical industry in China. For nearly a decade, the phar-
maceutical industry has been conscientiously implementing
a coordinated economic and environmental development pol-
icy, to control pollution and optimize industrial production.
This paper summarizes the problems that exist with CP
in the pharmaceutical plant. The problems are that little is
known in the pharmaceutical plants about CP, they have
little interest in implementing CP, and the measures needed
are not practicable. This paper also analyses the main
reasons for these problems, which include the fact that
government action remains imperfect, the plants’ profit has
no direct relation to CP, and it is just not sufficient to
receive support from other people.
Evaluation of Cleaner production audit 197

CP audit procedures seven stages and 35 steps. Each CP implementation step

has specific targets, as shown in Fig. 1.
The CP audit is an important part of CP: it is an effective The CP audit methodology ensures that subsequent fol-
program for the scientific and systematic assessment of the low-up and integration into the company’s Environmental
plant’s operability. The program consists of three layers, Management System is developed afterwards. This allows

Fig. 1 Working diagram of Behavior

cleaner production scheme Output
Designed and organization
1. Obtain leadership support 1. Leader-Participation
2. An audit group formation 2. Audit group
3. Formulate plans for the work 3. Overcome the block
4. Conduct propaganda education

Pre-evaluation
1. Current research Current research conclusion
2. On-site investigation 1. Audit emphasis
3. The evaluation of pollutants creation and emission 2. CP Target
4. Determine the audit emphasis 3. Explore implementation of non/low cost CP
5. Set CP Target Options on-site
6. Put forward and implementation of non/low cost CP
Options

Evaluation
1. Prepare audit materials Material balance
2. Measure input and output of matter 1. Causes of pollutants creation
3. Build material balance 2. Implementation non/low cost
3. Analysis of causes of waste 3. CP Options of audit emphasis

Producing and screening Schemes

1. Produce programs 1. Collect all CP schemes
2. Classify collection schemes 2. Analyze recommended Feasibility schemes
3. Screen schemes 3. Verify and collect Implementation Non/Low
4. Triturate Schemes Cost Cleaner Production Option effects before
5. Implementation persistent Non/Low Cost Cleaner intermediate report
Production Option
6. Verification and collect implementation non/low
Cost CP option effects
7. Compile the audit mid-report

Feasibility analysis
1. Market research 1. Feasibility analysis results
2. Technology assessment 2. Recommended enforceable schemes
3. Environmental assessment
4. Economic assessment
5. Recommending the enforceable schemes

Implementing schemes
1. Implement schemes
2. Collect implemented no/low cost CP options 1. Recommend enforceable schemes
3. Verify implemented medium / high cost CP options 2. Results and conclusions of implemented
4. Analyze and summarize the effect of schemes
implementation program in company

Sustain Cleaner Production 1. CP organization

1. Establish and perfect CP organization 2. CP managerial system
2. Establish and perfect CP managerial system 3. Sustain CP plan
3. Formulate sustain CP plans 4. CPA report
4. Compile CPA report

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the evaluation of the economic and environmental efficiency
of implementation of various CP programs (Stasiskiene
2000). This in turn requires the systematization of all
existing information about the evaluation of CP innova-
tions in optimizing production processes and increasing the
entire company’s environmental and economic efficiency
(Staniskis and Kliopova 2001). To that end, a database
of solutions to environmental problems has been devel-
oped, which could be a good engineering instrument for
researchers and practitioners.
Overview of the study factory
Basic status of company
The Degussa Luyuan (Dalian) Co., LTD was founded in
July 1995. It is one of the better, new pharmaceutical
production companies in China. The plant is located in the
Dalian Economic Development Zone of Liaoning Prov-
ince, Northeast China, and occupies a large land area of
54.5 km2 (Building area is 6.4 km2). In total, 924 workers
including 260 technicians are employed by Degussa Luy-
uan. The fixed assets are approximately 3.5 billion yuan
and the sales income was 1.7 billion yuan in 2006. Degussa
is a high-tech company, and the business includes phar-
macy, study of pharmaceutical intermediates and speciality
chemical sales. The company has seven production work-
shops and six auxiliary workshops, more than 2,000 sets of
production equipment, producing 91 products. The factory
produces 308.4 t of pharmaceutical and medical products
per annum. The principal products include TFMS, TCA,
FQA, 5-ASA, RAK-1, m-TFMME, NaHP, EMCA, etc.
Deciding on the main units of CP audit
Deciding on the main units of the CP audit principle means
looking at the following aspects:
• Waste generation
• Environmental costs
• Toxic waste
• CP potential
• Others
The equipment and technical requirements are higher in
NaHP and TCA manufacture than in other projects,
according to the global analysis. Energy and material
consumption per unit of product are significantly higher
than other products in production. NaHP is the main
product of the company, and produce a corresponding
amount of waste. The total phosphorus content in the TCA
wastewater is higher than for other products. NaHP and
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L. Zhi-dong et al.
Technology and Equipment Process Monitoring
Product
Raw Material
Course of Production By-products
Energy
Wastes
Recycling Wastes
Fig. 2 All aspects of the production of wastes in the production
process
TCA have a great deal of potential for CP, so NaHP and
TCA are confirmed as the key aspects of the CP audits.
Analysis of the links producing pollution
Material balance and process analyses identified the con-
ditions of water consumption and waste discharge, as
shown in Fig. 2.
Analysis of the amounts of pollutant emitted
by the plant
Analysis of wastewater
Considered in terms of wastewater produced in solids pro-
duction, water consumption is approximately 11888.08 m3/
a; water consumption mainly comes from running water.
Approximately 5023.945 m3/a wastewater treated by the
second biochemical method are discharged to the Dengsha
River annually. Wastewater solids incinerated in the incin-
erator amount to 3106.468 m3/a. Inorganics emitted in
wastewater amount to 61.667 m3/a. Although such waste-
water is classified as a low-concentration wastewater
according to the national standards, it may potentially impact
the water quality in the river. From the environmental pro-
tection point of view, the high-concentration organic matter
is the main waste generated from pharmaceutical produc-
tion. This high-concentration organic wastewater has COD,
ammonia and TP concentration of 1000, 30000, 12032 mg/l,
respectively. COD, ammonia and TP concentration of
wastewater treated by the second biochemical method are
5456.48, 30000, 62000 mg/l, respectively. Currently, over
90 t of such wastewater is continuously drained to ambient
water bodies every day after biochemical treatment, with
COD, ammonia and TP concentration of respectively 146,
75, and 2.26 mg/l.
Analysis of solid wastes
About 1975 t of solid wastes are generated each year.
Some are recycled for reuse, while and the others are sold
Evaluation of Cleaner production audit 199

directly. A total of 350 t of household garbage and 173 t of The recognized need to minimize waste for CP options
sludge generated in the production process are disposed of
by authorized and certified cleansing companies. In addi-
tion, another 1452 t of waste are incinerated in the Available CP Technologies and Opinions
incinerator.

Decision-makers& Experts
Opinions assessment
Analysis of waste gases

Feasibility Analysis
Of the solid wastes gas, about 252.124 t of waste gas is
Opinions Ranking
generated each year. The waste gas consists of HCl, Cl2,
HF, methylene dichloride, methanol, SO2, toluene, naph-
thyridine, sulfureted hydrogen, HBr, ethanol, etc. The
Integration and System Design
volume of Waste Gas entering the wastewater stream is
200.753 t/a. Approximately 17.915 t of waste gas is dis-
charged directly to the atmosphere annually, containing Implementation
CO, CH2Cl2, CH3OH, N2, etc.

Results Evaluation

Design and contents of CP options programs

The CP system is an integrated group of technologies, made
up of a series of individual techniques. The design and
contents of CP options programs that ensure follow-up and
integration into the company’s Environmental Management
System was developed subsequently. This allowed the
evaluation of the economic and environmental efficiency of
the various CP programs implemented. This required sys-
tematization of all existing information on the evaluation of
CP innovations to optimize the production processes and to
increase both process and whole-company environmental
and economic efficiency. The principle screening processes
are illustrated in Fig. 3. CP processes are explained in terms
of the recognized need to minimize waste by the CP options
and to evaluate results. These processes mainly include: raw
material and energy, technology modification, equipment,
operating practices/housekeeping, product change, reuse/
recycling, management, etc.
Raw material and energy
Raw materials are mainly materials and auxiliary materials,
including ammonia, benzene, xylene, DMSO, methanol,
methylene dichloride etc. Energy is electricity, coal, steam,
oil etc. ‘Raw materials improvement’ refers to reduction or
elimination of hazardous materials that enter into the pro-
duction process. For example, purification or substitution
can help to eliminate the generation of hazardous waste
within the production process.
The wastes generated mainly include the following
aspects:
• Materials and auxiliary materials are impure or unpurified.
Fig. 3 Screening procedure for CP options
• Materials and auxiliary materials are run-offs in the
process of storage, provision, and transport.
• Materials and auxiliary materials consumption are over
standard.
• Materials and auxiliary materials are hazardous and
noxious substances.
• Products manufacture leading to manufactured products
do not use clean energy and secondary resources.
Technical matters
‘Technology modification’ refers to changes in the process
and/or equipment to increase productivity and reduce waste
and emissions. These modifications can range from small,
low-cost options to the replacement of processes involving
large capital investments. For example, the process con-
ditions, such as flow rates and/or temperature, could be
optimized to save resources (raw materials and water) and
energy consumption.
The wastes generated due to technical matters, mainly
including the following aspects:
• There are problems with low technology, low percent-
age conversion of materials.
• Equipment layout is not reasonable, and some trans-
mission lines are too long.
• Reactions and transformation process take too long.
• Continuous manufacturing ability is very poor.
• Technological conditions are severe in operation.
• Production confirmation is poor.

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• Technical process needs materials that can be harmful Wastes

to the environment.
‘Reuse/recycling’ refers to the return of a waste material
either to the originating process as a substitute for an input
Equipment
material, or to another process as an input material.
‘Wastes generated because waste is not recycled’ mainly
‘Wastes generated due to equipment’ mainly include the
includes the following aspects:
following aspects:
• Utility wastes are not recycled.
• Outdated equipment.
• Physicochemical properties of wastes are not suitable
• Equipment automation is poor.
for further treatment and disposal.
• Equipment configuration is not optimised.
• Per unit produced, the volume of waste generated is
• Main items of equipment and utilities are mismatched.
higher than is commonly found in advanced plant at
• Lack of effective equipment maintenance and general
home and abroad.
maintenance.
• Equipment function does not meet technological
requirements. Management

• Effective CP regulations for administration and job

Operating practices/housekeeping
operation rules are not effectively implemented.
• Current management system is a long way from
‘Good operating practices/housekeeping’ refers to effi-
meeting CP demands.
ciency improvements and good management practices that
can be employed to minimize wastes and emissions, and
which can be implemented in most areas of a company at Staff
relatively low cost. For example, improvements in han-
dling and inventory practices can reduce the loss of input ‘Wastes generated due to staff’ mainly includes the fol-
materials. lowing aspects:
‘Wastes generated due to process monitoring’ mainly
• Staff skills are inadequate to satisfy production
includes the following aspects:
requirements.
• Detection thresholds of measurement analyzers are not • No measures to encourage active participation in CP.
good.
A series of possible CP solutions will help create a more
• Some technological parameters cannot meet effective
integrated, effective CP system. After the screening pro-
control requirements.
cedure based on consideration of environmental impacts
• Process monitoring level cannot meet the technical
and economic efficiency, 22 integrated CP options were
specifications requirement.
suggested to improve pharmaceutical production, save
water/energy resources, and reduce pollutant emissions are
Product suggested (Table 1).

‘Product changes’ refers to changes in quality/quantity/

variety of final products through modifying quality stan-
dards, product composition, and durability and/or substi-
tuting all or part of the product range to increase profits and
reduce wastes. For example, using waste lees to produce
methane as an extra final product can give benefits from
market sale and waste disposal.
‘Wastes generated due to product’ mainly includes the
following aspects:
• Product spillage and leakage in storage and carriage.
• Conversion rate of product less than is commonly
found in advanced plant at home and abroad.
• Product standard and packaging is not beneficial to the
environment.
Screening CP options
The CP options are analyzed and discussed by the audit
group from the technical, environment, economic feasi-
bility and difficulty of implementation perspectives.
Screening results are shown in Table 2.
The screening results showed three schemes ripe for
implementation: methanol recycle (in the TCA), pretreat-
ment of wastewater (in the TCA), wastewater recycling (in
the NaHP). The reason for these three schemes lies in the
fact that the technical aspects of CP are not yet up to
requirement; the cleaner has been listed in future sched-
ules, though, and improvements will be implemented step-
by-step.

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Evaluation of Cleaner production audit 201

Table 1 Introduction of CP options

CP options Work Description of the Process introduction Environmental benefits
section process

Raw material NaHP NaHP solvent recovery To recycle DMSO, toluene, xylene solvent To reduce waste production and
and energy after distillation reduce consumption
TCA Methylene chloride To recycle methylene chloride by distillation To reduce waste production and
recycling reduce consumption
Technology NaHP Absorb ammonia in the DAPRO cooling tower use glycol as Odor control
modification exhaust refrigerant in place of water, so as to
increase the ammonia saturation in the
water and the recovery rate of ammonia
Wastewater Facilities innovation Wastewater treatment can be renovation Improve COD and ammonia nitrogen
treatment technique, at the same time, COD and treatment load, reduce emissions,
facilities ammonia nitrogen treatment ability is also reduce costs
increased
NaHP Recovery of waste Recovery of waste liquor to make valeric Reduce waste production and reduce
liquor to make valeric acid by adding secondary extraction consumption
acid
TCA Add phosphorous Build a set of phosphorous removal Meet demands for biochemical index
removal equipment in equipment wastewater treatment plant of wastewater by removing the
the process of phosphorus wastewater
wastewater treatment
Equipment TCA off-gases treatment Off-gases in process of production are Reduce exhaust emissions and control
maintenance system treated by exhaust system environment odor
and update m-TFMME Batch charging Feed material inlet change into funnel type Prevent dust
transformation in process of m-TFMME production
Vaporization Clean burned exhaust Build a set of new scrubbers in order to Reduce exhaust emissions
further wash acid gases and smoke
Process NaHP Overtemperature alarm System will alarm when temperature in the Puts an end to product polymer
monitoring dehydration kettle exceeds a specific because of over temperature
numerical value
TCA Phosphorus wastewater Phosphorus wastewater classified storage It was suggested that phosphorus
classified storage wastewater classified storage be de-
phosphorized which controls
phosphorus emissions
NaHP Wastewater classified Wastewater classified storage and discharge Reduce wastewater treatment cost
storage
To improve the NaHP Training Staff need be trained in production, Strengthen the environmental
competence techniques, safety, environmental protection consciousness and
and skill of its protection, so as to enhance the improve operation skills
employees supervision, examination and management
of the process of production.
TCA Training Staff need be trained in production, Strengthen the environmental
techniques, safety, environmental protection consciousness and
protection, so as to enhance the improve operation skills
supervision, examination and management
of the process of production.
Waste recovery NaHP Ammonia concentration Ammonia is distilled from ammonia- Reduce the emission amount of
and utilization recycle containing wastewater, and the ammonia- ammonia nitrogen
containing wastewater is decrease from 3–
5% to 500 ppm. The distilled from
wastewater is recovery.
FQA TGTU Tail gas Isopropanol is recycled by the scrubber Reduce exhaust emissions
treatment unit
TCA Pd/C Catalyst recycle Pd/C Catalyst is recycled Reduce exhaust emissions
TCA Methanol recycle Recycled methanol can be used in the TCA, Reduce cost
but it can be used in other procedures

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Table 1 continued
CP options Work Description of the process Process introduction Environmental benefits
section

Reinforce TCA Strengthen management of the 1. Put together shift hand-over Reduce the unit product
Management period of shift hand- over and 2. Summarize, comment and appraise at regular intervals, in wastes discharge
roll-on run order to make staff aware of work flow and material
conditions
3. Prevent kinds of social phenomena of abnormal operation
and spillage by strengthening management
TCA Strengthen management of Staff needs be strict in management in accordance with Reduce manmade
material dispense requirements of production after training, which can pollution and created
reduce and avoid inorganic emissions pollution
Product TCA Pretreatment of wastewater Burned wastewater needs be sample pretreated, which will Reduce cost and energy
development add to its good biodegradability consumption
NaHP Wastewater recycling Acidulated wastewater will be recycled after distilling Reduce water
consumption and
wastewater
production

Introduction of CP medium/high cost CP options
CP option 1: biochemical alterations to wastewater
treatment system
The company designated Shanghai Combined Environ-
mental Engineering Company (SSCEEC) to design its
wastewater treatment system according to Degussa (Ger-
man) standards. The company offers the technique as
routine. In order to improve COD and NH3–N treatment
effect, to achieve biochemical automatic control, to save
energy, and to ensure stable operation and reduce emis-
sions, SSCEEC designed a second stage, technical upgrade
proposal for the biochemical treatment system. Techno-
logical innovations include more aeration equipment and
nitrification technology to increase the COD and NH3–N
treatment loading, and an on-line control system for pH
and DO.
CP option 2: phosphorus removal equipment
Total phosphorus in the wastewater exceeds the national
standard. High concentrations of phosphorus in wastewater
are difficult to treat by biological methods, but if this kind
of wastewater is pretreated with phosphorus removal
equipment it can be delivered directly into the wastewater
treatment system. Obviously, this would lessen the burden
on the wastewater treatment plant, while simultaneously
meeting national standard for effluent discharge.
To investigate this question, the engineering department
designed equipment to remove phosphorus before the
wastewater enters the wastewater treatment system. The
equipment works on the following principles:
(1) pH value is raised to 8.5 by neutralization of
phosphorus with limewater;
(2) Calcium phosphate precipitates simultaneously and is
separated in the process of neutralization, to remove
the phosphorus from the wastewater. Numerous
experimental results show that this system can satisfy
the company’s requirements. The principal items of
equipment, are a neutralization tank, settling tank,
plate and frame filter etc.
CP option 3: ammonia concentration recycle
In order to solve the problem of high ammonia nitrogen
content in the wastewater and reduce the cost of ammonia
nitrogen wastewater treatment, the engineering department
designed an ammonia thickening reuse device.
The equipment works according to the following principles:
(1) Ammonia is distilled from the water by steam heating
the low boiling point liquor. Distilled ammonia enters
the ammonia water tank, from where it is reused in
the NaHP production;
(2) Part of the ammonia in the water enters directly into the
wastewater treatment system. The principal items of
equipment are: a flash film concentrator (10 m2 SS),
ammonia tank (30 m3 CS). The environmental effect is
achieved as follows: the equipment increases ammonia
reuse and reduces the ammonia nitrogen content of the
liquid entering the wastewater treatment.

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Evaluation of Cleaner production audit 203

Table 2 Screening CP options

Work Description of the process Abbreviated analysis Conclusion
section
Technical Environmental Economic Degree of Impact on both
feasibility feasibility feasibility difficulty of production and
implementation product quality

NaHP NaHP solvent recovery Feasible Feasible Feasible Easy No influence Preliminary
feasible
TCA Methylene chloride recycling Feasible Feasible Feasible Easy Influence Preliminary
feasible
NaHP Absorb ammonia in the exhaust Feasible Feasible Feasible Easy No influence Preliminary
feasible
Wastewater Facilities Feasible Feasible High cost Complex No influence Preliminary
treatment innovation(biochemical feasible
facilities alterations)a
NaHP Recovery of waste liquor is made Feasible Feasible Feasible Easy Influence Preliminary
valeric acid feasible
TCA To add phosphorous removal Feasible Feasible High cost Complex No influence Preliminary
equipment in the process of feasible
wastewater treatmenta
TCA Off-gases treatment systema Feasible Feasible High cost Complex No influence Preliminary
feasible
m-TFMME Batch charging transformation Feasible Feasible Feasible Easy No influence Preliminary
feasible
Vaporization To clean burned exhausta Feasible Feasible High cost Complex No influence Preliminary
feasible
NaHP Over temperature alarm Feasible Feasible Feasible Easy No influence Preliminary
feasible
TCA Phosphorus wastewater classified Feasible Feasible Feasible Easy No influence Preliminary
storage feasible
NaHP Wastewater classified storage Feasible Feasible Feasible Easy No influence Preliminary
feasible
NaHP Training Feasible Feasible Feasible Easy No influence Preliminary
feasible
TCA Training Feasible Feasible Feasible Easy No influence Preliminary
feasible
NaHP Ammonia concentration recycle Feasible Feasible High cost Easy Influence Preliminary
feasible
FQA TGTU Tail gas treating unit Feasible Feasible Feasible Easy No influence Preliminary
feasible
TCA Pd/C catalyst recycle Feasible Feasible Feasible Easy Influence Preliminary
feasible
TCA Methanol recycle Feasible Feasible Feasible Complex Influence Temporarily
out of
feasible
TCA Strengthen management of shift Feasible Feasible Feasible Easy No influence Preliminary
hand-over and roll-on run feasible
TCA Strengthen management of Feasible Feasible No Easy No influence Preliminary
dispensing material economic feasible
benefit
TCA Pretreatment of wastewater Feasible Feasible Feasible Complex No influence Temporarily
not feasible
NaHP Wastewater recycling Feasible Feasible Feasible Complex Influence Temporarily
not feasible
a
Suitable for medium/high cost cleaner production options, others are no/low cost cleaner production options

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204
CP option 4: off-gas treatment system
(fluid bed incinerator)
Smoke and carbon monoxide in the incinerator tail gas
exceeds the national standard. To resolve this problem, the
engineering department designed an off-gas treatment
system. The principal components are: the Company pur-
chased a scrubber to absorb off-gas in three incinerators.
Absorbed off-gas is fed into a secondary combustion
chamber and all of off-gas is completely incinerated, which
removes CO in the off-gas. Finally, off-gas enter the
atmosphere through 100 m tall stacks after the off-gas is
washed in a three-stage countercurrent alkali absorber.
Treated and purified off-gas meets the national environ-
mental pollution standards.
Feasibility analysis of CP options
To identify the optimum CP system for the company, a
comprehensive feasibility analysis of the proposed CP
options was conducted. The ultimate option should be the
one containing advanced CP techniques which is friendly to
the environment, as well as bringing attractive economic
benefits. In this study, the four proposed options were eval-
uated in terms of technology, economy and environment as
follows.
Technical aspects
(1) Biochemical alterations
The Degussa biochemical experts optimized the bio-
chemical treatment plant: the new biochemical pro-
cess uses nitrification–denitrification biochemistry.
Batch experiments supplied data allowing small-sized
continuous experiments to be conducted. The exper-
imental results showed that the removal rate of COD
and ammonia nitrogen increased significantly: the
ammonia nitrogen concentration in the effluent will
drop to 15 ppm, while the COD loading will double.
(2) Phosphorus removal equipment
Batch experiments supplied data to allow small-sized
continuous experiments to be carried out. The exper-
imental results show that the equipment is technically
feasible. The specific experimental procedure is as
Table 3 Phosphorus removal in small-sized continuous experiments
Filtration fabric Extractive Area Weight of filter
time (min) (cm2) mass (g)
Non-woven fabrics 4 69.4 108
woven fabrics 4107 4 69.4 78
woven fabrics 663 4 69.4 109
123
L. Zhi-dong et al.
follows: an amount of 90 g of finely powdered Ca
(OH)2 was weighed out and dissolved in 360 g water,
which was then made up into 20% Ca (OH)2 solution.
Aliquots of this solution were then poured into three
similar beakers and 200 ml wastewater was added (in
the TCA). Finally, extractive distillation was done for
one hour. The experimental results are shown in
Table 3.
As the phosphorus removal effects and filter cake
show, the phosphorus removal techniques are tech-
nologically feasible. The tables show that non-woven
filter gives better removal. Filtering equipment can be
a centrifuge or filter press.
(3) Ammonia concentration recycle
Wastewater with 10% ammonia is pumped into the raw
material tank, with simultaneous opening of the flash
film concentrator, for which the jacket test pressure will
be approximately 0.2 Mpa. Wastewater with 10%
ammonia enters uniformly into the flash film concen-
trator via the feed transfer pump. Wastewater is
separated in the flash film concentrator. Evaporated
ammonia enters into the front distillate tank, which will
be reused in the system. Wastewater containing less
than 500 ppm ammonia enters the wastewater treat-
ment plant. This fraction of the treated wastewater has
an ammonia concentration less than 25 ppm.
(4) Off-gas treatment system
The solid phase in the smoke is increased by adopting
new type of high-efficiency Venturi mixer. Acid gas
is thoroughly mixed with alkali scrub liquor, the scrub
solution is allowed to settle and is filtered in the
sedimentation tank, which removed the acidic gas
from the off-gas. The cleaned off-gas enters a
secondary combustion chamber, where is it com-
busted sufficiently achieve CO removal. Treated and
purified off-gas meets the national atmospheric pol-
lution emission standard.
Environmental impacts
After wastewater is treated in the new treatment facility,
the removal rate of COD, ammonia nitrogen and total
phosphorus has increased significantly; the ammonia
nitrogen in the effluent drops to 15 ppm, and COD loading
Thickness of Pressure Effluent
filter mass (cm) drop (Mpa) TP (mg/l)
1 0.035 15
0.8 0.035 21
1.1 0.035 25
Evaluation of Cleaner production audit 205

doubles; total phosphorus in the effluent is less than
40 ppm. The effluent quality index meets the national
atmospheric pollution emission.
After off-gas is treated in the new treatment facility, the
removal rate of smoke and dust, acid gas and carbon
monoxide exceed 95, 99 and 98.5%, respectively, which
meets the national standard for atmospheric pollutant
emission. All the CP options together produce the envi-
ronment impacts shown in Table 4.
Economic benefits
The evaluation indices include a set of economic parame-
ters, such as gross investment, operational cost saving,
increased cash flow, internal rate of return, and net present
value. Among these, the gross investment and the rate of
return are the most critical factors, which strongly affect
the decision of stakeholders and managers when selecting
the CP option for the plant. Although each option has its
own advantages, their disadvantages can also be disclosed
through integrated evaluation. (Guoa et al. 2006)
All the four CP options are compared in Table 5.
In this study, the operation cost saving per year and net
present value of option 1 are the greatest, but the gross
investment is the highest and the internal rate of return on
investment is the lowest. This means that this option is the
most attractive one since the associated reduction in
operational costs is higher than the sum of the other three
options, but its disadvantages lie in the high investment
with a low rate of return. If reviewed according to the
economic return and option cost reduction aspects, option 2
is better than options 3 and 1. Option 1 presents the dis-
advantage of relatively high capital investment since it
requires the purchase of new equipment and worker
training. Option 4 has no economic benefit, but it resolves
the problem that smoke and CO exceed the national
atmospheric pollutant emission standard, so its environ-
mental benefit is immense.

Table 4 Environmental benefits after implementing cleaner production options

Waste and consumption Prior to Standard After implementing this program (reduced quantity)
implementation
Absolute Relative Whether all requirements
quantity quantity (%) of the standard are
satisfied or not

COD (mg/l) 146 150 51 34.9 Meets the discharge standard

NH3–N (mg/l) 75 25 54 72 Meets the discharge standard
TP (mg/l) 2.26 1 1.72 76.1 Meets the discharge standard
Wastes gas (t/a) 17.915 – 1.7915 99 –
Solid waste (tons per ten thousand 0.32 – 0.01 3.1 –
yuan output value)
Consumption of coal (tons per ten 0.93 – 0.02 2.2 –
thousand yuan output value)
Consumption of water (tons per ten 45.88 – 0.7 1.53 –
thousand yuan output value)

Table 5 Comparison of economic benefits of alternative options

Economic evaluation index CP option 1 CP option 2 CP option 3 CP option 4

Total investment expense (million Yuan) 1204 137 49.5 270

Operational cost saving (million Yuan) 260 85 18.85 0
Annual depreciation of new equipment(million Yuan) 60.2 17.13 6.19 33.75
Taxable profit (million Yuan) 199.8 67.87 12.66 -33.75
Retained profits (million Yuan) 167.83 49.54 10.96 -33.75
Increase of annual cash low (million Yuan) 228.03 66.67 17.15 0
Discount rate (%) 7 7 7 7
Pay-back period of investment (N) 5.28 2.05 2.89 –
Net present value (NPV) 1211.75 261.11 52.91 –
Net present value rate (NPVR) (%) 100.64 190.6 106.9 –
Internal rate of return (IRR) (%) 18.29 [40 30.54 –

123
206
To sum up, Option 3 does not figure in five options, but
it has higher environmental benefits. Provided conditions
allow, our recommendation in practice is for Option 3.
Options 1, 2 and 4 provide considerable economic and
environmental benefits.
Effects of implementation
This CP analysis has allowed the company to make great
achievements. In practice, the implementation of non/low
and medium/high cost options is feasible. In each scheme,
in normal operation conditions, thanks to the efforts of all
staff, the implementation of CP schemes has coincided
with the company’s goals. At the time of writing, all CP
schemes have been implemented; moreover, some of the
indexes are superior to the expected goals.
In terms of economic benefit, by the end of 2009, all 9 no/
low cost CP schemes have been implemented, bringing
direct economic benefits of 44.8 million Yuan to the com-
pany. Biochemical alterations and phosphorus removal
schemes in the high middle/high cost range have been
completed, bringing 345 million Yuan in economic benefits.
In terms of environmental impacts, COD concentrations
have been reduced by 34.9%, annual emission reduced by
465 t; ammonia nitrogen concentrations reduced by 72%,
annual emission reduced by 83.95 t; phosphorus concen-
trations reduced 76.1%, annual emission reduced by 2.44 t.
After all wastewater treatment CP options had been imple-
mented, all contamination in the wastewater now meets the
national wastewater pollutant emission standard. According
to the planned implementation, after the liquid incinerator is
introduced in December 2009, smoke and carbon monoxide
emissions can meet the nation atmospheric pollutant emis-
sion standards. In terms of energy, the expenditure of coal
and water per ten thousand yuan output are reduced by 2.2
and 1.53%, respectively. At the same time, the generation of
solid waste per ten thousand Yuan of output is reduced by
3.1%.
In conclusion, the implementation of the CP system not
only created high economic efficiency for the company but
also reduced energy and material consumption.
Conclusions
In this study we sought to improve pollution reduction and
save water in China’s Pharmaceutical Production indus-
tries, so we proposed an integrated system combined with a
series of advanced CP technologies. Based on the proposals
of related experts outside the company and technical staff
123
L. Zhi-dong et al.
within the company, a number of technologies were
grouped and screened. After consideration of the environ-
mental impacts and economic efficiency, four CP options
were proposed, integrated with various advanced technol-
ogies. The effects of four options were then evaluated from
the technical, environmental, and economic aspects.
Throughout three years of practice, significant results were
obtained. The productivity and quality of pharmaceutical
manufacture were improved, while the efficiency of
wastewater reduction and water savings were markedly
increased. The goals of increasing economic benefits and
improving environmental quality were achieved by means
of the integrated CP system. This study has analyzed the
current situation of CP technology implementation within
the pharmaceutical industry in China.
Implementation of various CP techniques in Degussa
Luyuan (Dalian) enabled it to save 2.2 and 1.53% expen-
diture of coal and water per ten thousand yuan output. At
the same time, the generation of solid waste per ten thou-
sand Yuan output reduced by 3.1%, COD annual emission
reduced by 465 t, ammonia nitrogen annual emission
reduced by 83.95 t, total phosphorus, and annual emission
reduced by 2.44 t, all of the contamination in the waste-
water meets the national wastewater pollutant standard. By
the end of 2009, all the CP is bringing direct economic
benefits of 44.8 million Yuan to the company.
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