Cleaner Production

Submitted By: Me
ENVIRONMENTAL ENGINEERING
SEMINAR REPORT
 ❖-Introduction
According to UNEP (1996) Cleaner Production is “The continuous
application of an integrated preventative environmental strategy
applied to processes, products, and services to increase overall
efficiency and reduce risks to humans and the environment.“
Production processes:
Conserving raw materials and energy. eliminating toxic raw materials,
and reducing the quantity and toxicity of all emissions and wastes.
- Products:
reducing negative impacts along the life cycle of a product,
from raw materials extraction to ultimate disposal.
-Services:
incorporating environmental concerns into designing and delivering
services.
CONTINUE….

➢Cleaner Production is one of the key ways to ensure sustainable

development—there is or should be a close link between Cleaner
Production and sustainable development.
➢- Cleaner Production aims to increase production and corporate
productivity through the more efficient use of raw materials, water and
energy in order to reduce wastes and emissions of any kind at source
rather than simply to deal with them afterwards, and to contribute to
improved product designs for products which will be more environment-
friendly and cost effective over the whole of their life-cycles.
➢-Cleaner Production of cleaner products and sustainable production
and consumption are key elements of sustainable societies
BASIC PRINCIPLES OF CLEANER
PRODUCTION
Four basic guiding principles are implied in the conception of cleaner
production
a) The precaution & preventative principle.
❖Precaution is not simply a matter of avoiding breaking the law, it is also
about ensuring that workers are protected from irreversible ill-health and
that the plant is protected from irreversible damage.
❖The preventative principle is to look to upstream changes in the causal
network of the system of production and consumption. The preventative
nature of cleaner production calls for the new approach to reconsider
product design, consumer demand, patterns of material consumption,
and indeed the entire material basis of economic activity.
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b) The integration Principle
➢Integration involves adopting a holistic view of the production cycle.
➢By reducing the need for emission into the environment of such
substances, these measures thereby provide for an integrated protection
of all environmental media.
c) The comprehensive or democratic principle
➢The comprehensive or democratic principle involves people, workers
and local residents, in the way where production and consumption are
organized.
d) The continuity principle
➢Cleaner production is a no-end process. Its implementation calls for the
ever-lasting efforts of governments, industries and consumers.
PHASES OF CLEANER PRODUCTION

Planning & Organization

Preliminary Assessment

Detailed Assessment

Implementation &
Monitoring Progress

Successfully implemented
CP projects
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1) Planning and Organization Phase.
➢ In this phase a project team are establish, and assessment goal are set. At
this phase, the participation and commitment of the owners and workers
were confirmed because they determine the success of CP implementation.
2) Preliminary Assessment Phase
➢The purpose of the preliminary assessment phase is to gain an
understanding of the processes at each site, to identify the major inputs and
outputs, and to quantify and then to compare the wastes.
➢This phase is carried out to know basic information about the enterprise.
This phase is conducted to acquire qualitative review including a description
of the company and identification of all stages of the production process.
CONTINUE….
3) Detailed Assessment Phase
➢During the detailed assessment phase CP ideas were generated to
reduce, either directly or indirectly, the quantity and toxicity of the focus
waste streams. More detailed knowledge of the processes that generate
the focus wastes was required.
➢it include assessment of various waste and collection of quantitative
data.
4) Feasibility Assessment Phases
➢The identified Cleaner Production options were then subjected to a
feasibility analysis in the feasibility assessment phase. Options that were
deemed feasible may then be implemented and monitored.
 Recognize need to prevent
pollution by clearer production

Planning and organization

Implementation
•Get managerial commitment
• Obtain find
•Select cleaner production team
• Implement solution
•Set overall assessment goals
• Monitor and evaluate results
•Overcome barriers
• Plan new project •Start preliminary study

Continual improvement
Feasibility analysis
• Collect data
•Technical evaluation
• Set priorities
•Economic evaluation
• Select assessment team
•Environmental analysis
•Generate cleaner
•Select option for
production opinion
Implementation
•Start preliminary study
CLEANER PRODUCTION PRACTICES

Cleaner Production offers several complementary techniques or practices,

ranging from no cost or low cost solutions to advanced clean technologies
that demand high investment levels.
Good Housekeeping
➢Good housekeeping involves every phase of industrial operations and
should apply throughout the entire premises, indoors and out.
➢Take appropriate managerial and operational actions to prevent: Leaks,
Spills, to enforce existing Operational instructions
Input Substitution
➢It involves Replacement of input materials by less toxic or renewable
materials or by adjunct materials which have a longer service lifetime in
production.
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Better Process Control
➢Better process Control includes modification in Operational
procedures, Equipment instructions and Process record keeping in order
to run the processes more efficiently and at lower waste and emission
generation rates.
Equipment modification
➢ it Modify the existing production equipment and utilities in order to
run the processes at higher efficiency, lower waste and emission
generation rates.
➢Design change refers to modifications or changes made to the
equipment
used for processes and activities. It may bring about significant results if
implemented properly.
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Technology change
➢Technology change involves replacement of; the technology, Processing
sequence, Synthesis pathway in order to minimize waste and emission
generation during production.
On-site recovery/reuse
➢There are many materials that can be reuse or recycle in the industry. It
may be from the process, offices and from any part of the premise. It
includes Reuse of the wasted materials in the same process for another
useful application within the company.
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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. It is the process of
Modification in the waste generation process in order to transform the
wasted material into a material that can be reused or recycled for
another application within or outside the company.
Product modification
It is achieved by modify the product characteristics in order to Minimize
the environmental impacts of the product during or after its use
(disposal) and Minimize the environmental impacts of its production
BARRIERS TO CLEANER
PRODUCTION
✓Resistance to change
✓Lack of information, expertise and adequate training
✓Lack of communication within enterprises
✓Competing business priorities - in particular, the pressure for short-term
profits
✓Perception of risk
✓Difficulty in accessing cleaner technology
✓Accounting systems which fail to capture environmental costs and
✓benefits
✓Difficulty in accessing external finance
✓The failure of existing regulatory approaches
✓Perverse economic incentives
 POLICY MECHANISMS
To overcome the identified barriers, a number of policy options to promote
Cleaner Production were researched through the informal
discussions/seminars and questionnaires with representatives from
enterprises and the departments of the central as well as local governments.
➢ According to policy functions, the mechanisms of the policy options were
divided into four categories:
(1) Regulatory mechanisms;
(2) Supportive mechanisms;
(3) Economic incentive mechanisms; and
(4) Social pressure mechanisms.
CASE STUDY
➢Cleaner Production studies were conducted in the Textile Mill (Luthra
Dyeing and Printing Mills, Surat, INDIA).
➢They Produces Printed and dyed fabric of polyester cotton, rayon.
➢The Cleaner Production Team was formed and The Boiler House
was taken as focus area.
➢ A Textile Processor has to be Lean, Efficient and Innovative
✓Lean - Good housekeeping, Conservation,
✓Control Efficient - "Right in First Time" Approach,
Mechanical/Chemical/Water/ Energy/Audits, optimization/Rationalization.
✓ Innovative - Reuse, Recovery, and Recycle Initiative Process Change,
"Informed" Equipment Selection.
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Operation Sources of Nature Probable Causes of waste generated
waste of
waste
Fuel -Air fuel is not maintained
Steam Boiler Gasses -No monitoring of relevant parameters (O2 or CO2)
Generation - No device/method for heat recovery
-Air ingress through various portion
- Air quantity and pressure is not sufficient
- Distribution of primary air through grate
Un-burnts - Sizing of coal not proper
in Ash - Design of grate not appropriate
-Firing rate is not uniform
- Manual ash removal
- Poor fuel quality and combustion is not proper

Blow-down Back Boiler feed water quality

Condensate is not recovered
Boiler drum TDS is not maintained as required

Radiation -Un-insulted portion of boiler

Loss -Openings
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These are the Cleaner Production technique used in Luthra Dyeing and
Printing Mills, Surat, INDIA:
✓Good House Keeping
✓Operational Practices
✓Process Optimization
✓Raw Material Substitution
✓New Technology
✓New Product Design
✓Onsite Recycle & Reuse
✓Equipment Modification
 Table 2: Cleaner Production Options in Various
Waste Stream
Waste Stream CP Options
Heat Loss due to ▪ Install air healer for recovery of waste heat.
flue gas ▪ Plug all the air leakages into boiler fumace
Un-burnt in Ash ▪ Conversion of existing boiler to the FBC boiler
▪ Replacing existing boiler to FBC Boiler
▪ Optimize the coal sizing by proper crushing & sieving
▪ Modify the existing grate by reducing the gaps between
the rods .
▪ Optimize the firing rate by use of stoker firing
Blow down loss ▪ Install water treatment System (RO) plant
▪ Change the water used in the boiler from tanker water
to Municipal - Supply Water
▪ Install conductivity meter to check boiler drum water
quality and therefore optimize the blow down rate
▪ Recover flash steam from boiler blow down
▪ Re-circulate condensate from steam separator and
wherever possible

Radiation Loss ▪Insulate all the bare and damaged portions

▪Insulate the flanges (125 Flanges)
▪Installation of Steam Traps (Thermo Dynamic Traps)
Table 3: Results of the Cleaner Production Option Implementation[16]

INVESTMENT 204.000 US$

NET ANNUAL SAVINGS 196.300 US$
PAYBACK PERIOD 11 MONTHS
REDUCTION IN GHG EMISSIONS 1300 TONS PER YEAR
 OVERALL BENEFITS OF CLEANER
PRODUCTION

➢Cleaner Production improves products and services a Cleaner Production

lowers down the risks (liability)
➢Cleaner Production improves company image Cleaner Production
improves worker's health and safety conditions
➢Cleaner Production reduces waste treatment and disposal costs
➢Cleaner Production can be integrated with the business Environmental
Management Systems.
➢Cleaner Production saves costs on raw material, energy and water.
➢Cleaner Production makes companies more profitable and competitive.
➢Cleaner Production can help implementing MEAS
 DISCUSSION

✓Cleaner production is an approach to reduces pollutant generation at

every stage of the production process Cleaner production can be achieved
through, good operating practices, process modification, technology
changes, raw material substitution, redesign and/or reformulation of
product.
✓It also observed that Cleaner production technologies exercises are not
only desirable from the environmental point of view as a preemptive
strategy, but also make good economic sense.
✓It is encouraging to note that in most cases where cleaner production
technologies were implemented, the cost benefit is large, both
quantitatively and qualitatively.