Cleaner Production &

Waste Minimization
KKKR4873 POLLUTION CONTROL AND CLEANER PRODUCTION

Lecturers:
Dr. Rosiah Rohani (Set 1)
Assoc. Prof. Dr. Hassimi Abu Hasan (Set 2)
Topic outcomes
• Students are able to characterize
wastewater/solids waste to be minimized
through reuse and recycling – zero discharge

• Students understand the concept of waste

management and minimization

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Cleaner Production (CP)
“ Cleaner Production is the continuous
application of an integrated, preventive
environmental strategy towards processes,
products and services in order to increase
overall efficiency and reduce damage and
risks for humans and the environment.”
- United Nation Environments Program

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Cleaner Production (CP)

Continuous Processes Humans

Preventive ENVIRONMENTAL Products RISK

STRATEGY REDUCTION

Integrated Services Environment

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CP Key Elements
1) CP adds value to the EMS: it places emphasis on pollution
prevention rather than control, with clear improvement
in environmental performance.
2) CP does not deny or impede growth but insists that
growth can be ecologically sustainable.
3) CP is not limited only to manufacturing industries of a
certain type or size, it can be applied towards the
provision of services also.
4) CP includes safety and protection of health.
5) CP emphasizes risk reduction.
6) CP improves immediate efficiency as well as long-term
effectiveness/ success.
7) CP is Win-Win-Win factor: it benefits the environment,
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communities and businesses.
Waste Minimization
• Waste minimisation is one area where developing
economies can learn from, and avoid repeating, the
mistakes of the developed world, where it was not
addressed at an early stage in their hazardous waste
management programmes.

• The benefits are not just environmental, but also reduced

costs, improved efficiency and often a more positive public
image for the company.

• A number of countries/companies have demonstrated the

value of undertaking waste minimisation measures
• i.e. Zero Waste Technology by Sime Darby 6
• http://wte.kpkt.gov.my/
What is waste minimization?
• Waste minimization:
• refers to the use of source reduction and/or
environmentally sound recycling methods prior to
energy recovery, treatment, or disposal of wastes

• Source reduction
• commonly known as pollution prevention, reduces
or eliminates the generation of waste at the
source and refers to any practice that reduces the
use of hazardous materials in production 7
processes
• Recycling:
• reclaiming value from production by-products
• recycling includes the reuse or recovery of in-
process materials or materials generated as
by-products that can be processed further on-
site or sent offsite to reclaim value
• Example:
• processing the waste to recover or regenerate
a usable product
• such as collecting vapor from dry cleaning
operations, turning it back into liquid, and
reusing the liquid to clean more clothes. 8
 Importance of waste minimization
waste No waste
Source disposal minimization

treatment
With waste
Source waste minimization,
disposal
recycling and
treatment

Off-site recycling
On-site recycling 9
Waste minimization incentives
• Reduced costs:
• raw materials, energy, water
• storage and handling
• waste disposal
• health and safety

• Regulatory compliance
• Improved efficiency
• Improved corporate image
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 Preventive Measures:
Cleaner Production and Waste Minimisation
Benefits to a manufacturing process
Reduced costs: Risk reduction:
 Lower capital spending on end-of-  Reduce inventory of
pipe treatment facilities: eg. potentially hazardous waste
reactor and pump sizes. streams.
 Lower production costs, eg. for  Reduce amount of waste
utilities. handling.
 Changes in fixed costs.  Reduce risk associated with
 Improvement in process process.
availability, eg. for different  Reduce operator exposure
coloured paints, different drink
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flavours, etc.
Waste Management (WM) Hierarchy

Source Elimination

Source reduction
Recycling

Treatment

Disposal
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Example of WM Hierarchy
Liability Processes for Electroplating

Greatest Solidify and Landfill

Medium Recycle-Recover Metals out of Plant

Low Recycle – Recover Metals in Plant

Least Eliminate Sludge Production

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WM in a Biodiesel Plant
Recovery of
methanol for in
plant reuse.

Refining of
glycerin for
high quality
product,
otherwise
glycerin would
become very
high COD waste
water.

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WASTE MINIMIZATION PROCESS
Begin the Waste Minimization
Assessment Program

PLANNING AND ORGANIZATION

 Get management commitment
 Set overall assessment program goals
 Organize assessment program task force

Assessment organization and

commitment to proceed
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 ASSESSMENT PHASE
Select new • Compile process and facility data
assessment • Prioritize and select assessment target
• Select people for assessment teams
targets and • Review data and inspect site
evaluate • General options
previous • Screen and selection options for further study
options
Assessment report of selected options

FEASIBILITY ANALYSIS PHASE

• Technical evaluation
• Economic evaluation
• Selection options for implementation
Final report, incl. recommended options

IMPLEMENTATION
• Justify projects and obtain funding
Repeat the process • Installation (equipment)
• Implementation (procedure)
• Evaluate performance

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Successfully operating waste
minimization projects
 Guidelines for site Inspection- for
WM Process
 Interview operators, shift supervisors, and foremen in the
assessed area to assess their awareness of waste generation
aspects of the operation.
 Photograph the area of interest
 Observe housekeeping: Check for spills or leaks.
 Assess overall cleanliness of site, detect odours and fumes.
 Assess organizational structure and coordination of
environmental activities between various departments.
 Assess administrative controls, eg procedures for cost-
accounting, materials purchasing, waste collection, etc.
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WM Options
• Input material change examples:
• Replacement of chlorinated solvents
• Substitution of chemical biocides
• Replacement of solvent-based paints, inks and adhesives
• Replacement of organo-lead compounds
• Avoidance of mercury as electrode material
• Replacement of PCBs
Priority for replacement: Toxic Materials
• Changes to product composition:
• A change in a product’s specification to reduce the quantity of
chemicals used.
• A modification of the composition or the final form of the
products to make it more environmentally acceptable.
• Changes to reduce or modify packaging.
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LCA based ecolabelling: Would change in composition significantly
alter LCIA score?
Process Modifications
Waste production in Reducing waste – single
reactors due to: reaction
• Low conversion in the • Avoid formation of waste
reactor by-product by using a
• Primary reaction by- different reaction path.
products • Low conversion can be
• Secondary reaction forced to higher
by-products conversion, in
• Impurities in the feed irreversible reaction, by
materials using:
• Catalyst degradation • Longer residence time
or loss • Higher temperature,
or 20

• Higher pressure
Process Modifications
• Process wastewater minimization may be via various
means, if process mechanisms are thoroughly
understood, i.e.
• Increasing number of absorption or scrubbing stages
• Increasing number of extraction stages (counter-
current)
• Using indirect contact, eg for condensation
• Removing water use if possible

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 Water Conservation
• Cooling water systems tend to be major water users thus major sources of
wastewater.
• Reduce water demand and wastewater volume (& treatment costs) by treating
side-stream or segregated stream:
• Via coagulation followed by filtration
• Via RO or electro-dialysis and recycle
• By introducing air cooling thus reducing cooling water demand
• Cleaning operations are often major water users and wastewater generators in
many industries, e.g. food, paint, packaging, textile, rubber product etc.
• Minimise cleaning wastewater, thus water demand by:
• Using spray balls for effective internal vessel washing
• Using mechanical cleaning (esp. for viscous materials) before washing
• Using mechanical agitation by shaking particle
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• Agitating wash-water, mechanically or by aeration
• Using cleaning-in-place (CIP) instead of dismantling and manual cleaning
Water Conservation (Cont.)
• Rinsing operations are often the highest water users (i.e. in textile industries,
boiler supplying hot water)
• Minimise water requirement by:
• Using counter current rinsing
• Scheduling operations to minimize product changeovers (schedule)
• Fixing triggers to hose to prevent unattended running
• Fixing solenoid valve so water flow can be conveniently cut when
washing operation is halted
• Installing water quality control meters eg turbidity meter, to control
flow to washing process
• Reuse wastewater: many operations do not require potable water quality
• Recycle water for reuse in-plant at those points
• From waste audit date, identify points not requiring water of potable quality,
ideally through Pinch analysis
• Collect used water: treat and recycle or reuse thus saving water and treatment 23
for disposal costs.
Housekeeping: Spills, leaks and
contamination management
(IChemE. 1995)
• Minimise spills and leaks by identifying possible sources,
such as:
• Leaking valves, hoses, pipes and pumps
• Leaking tanks and punctured containers
• Overheating of tanks and drums
• Overfilling of tanks
• Avoiding inadequate, poorly maintained or
malfunctioning high level protection systems
• Avoiding gas generation in drums
• Inventory to avoid spoilt from shelf life
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• Schedule improvement
Recovery from wastes
• Recovery requires Segregation of wastes
• Segregation plan:
• Separation of streams
• Storage before reuse unit
• If only one storage to serve different points
in plant:
• Plan or program use of storage
• List operating condition for each waste
component 25
 Bottle drink plant
Caustic H2O Treated

Empty
Decrate Bottle
Bottle Depelletizer Bottle Bottle Rinser
Inspector
Transfer
WW1
Caustic
Caustic
H2O Treated
Carbon
Filling & Washing
Crate Washer Crate Coder Cooler
Station
CO2 System

Beverage WW2 WW3 Syrup

Pet Wrap-around
Product To Packetizer Buffer
Packer
Consumer H2O Treated
WW4

Sugar H2O
Cartridge Vacuum Simple Treated
Blender Syrup Tank
Water Filter Tank Tank Syrup Tank
Coke

Water H2O Treated H2O Treated H2O Treated

(JBA)
Storage Semi Treated Sand Filter Carbon Filter Cartridge 26
Clarifier
Tank Water Tank Tank Tank Filter Tank

WW Treatment
Plant WW5 WW6 WW7 WW8
 Bottle drink plant wastewater
characteristics
Waste Source Flow Characteristics
water rate COD pH T
stream (kg/day) mg/L oC

WW1 Bottle rinser 479.0 1480 12.8 85

WW2 Crate washer 486.5 45 7.9 28
WW3 Filling & washing station 60.0 20 7.8 18
WW4 Syrup buffer tank cleaning 2477.5 33 4.5 28

WW5 Clarifier backwashing 684.0 10 9.6 28

WW6 Sand filter backwashing 670.0 6 7.0 28

WW7 Carbon filter backwashing 657.0 5 7.0 28

WW8 Cartridge filter tank 644.0 2 7.0 28 27

backwashing
Process for production of
crystalized fruit
Water + Water + Water +
Sodium bisulphate Sodium bisulphate Sodium bisulphate

Raw materials/
fruit
DESEEDER CUTTER BLANCHER

WW1 WW2 WW3

Water + citric acid+sugar

DRYER DOUSER EVAPORATOR

WW5 WW4

FLOURING PACKING Crystallized fruit

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Crystallized fruit processing

Waste Source Flow rate Characteristics

stream (kg/day) COD BOD SS pH T
mg/L mg/L mg/L oC

WW1 Deseeder 1000 532 107 1000 4.25 25

WW2 Cutter 800 528 106 750 4.10 25
WW3 Blancher 255 500 110 1000 3.96 95
WW4 Evaporator 100 547 113 1250 3.78 25
WW5 Douser 1500 2800 560 1050 3.5 25

Critical stream
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 Waste Treatment & Minimization
Sago Log Biogas to dryer & Recycle to front
Boiler end of mill

Debarking Bark
Anaerobic Aerobic /
Polishing
Digestion Algae
discharge

Pulping Sludge Algae

biomass
Sago Animal
Drier
Hampas Feed
Starch
Extraction
sugar
Starch Effluent
Pretreatment Fermentation
Drying &
Packaging Solid residue Bioethanol
(Biofuel)

composting biofertilizer 30

Sago Industry