CLEANER PRODUCTION

AND ENERGY MANAGEMENT IN

SMES

Joy Clancy
Department of Governance and Technology for
Sustainability (CSTM)
University of Twente
TOPICS

4 December 2017
 Part 1: Industry and Pollution
 Part 2: Introduction to Cleaner Production

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 Part 3: What are the benefits of Cleaner
Production to Industry?
 Case studies

 Tools to identify opportunities for implementing

Cleaner Production
 An exercise

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 4 December 2017
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INDUSTRY AND
POLLUTION
3
Part 1: Introduction to Cleaner
Production
INDUSTRY

4 December 2017
AND POLLUTION

 Industry is major contributor to environmental

impacts

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 Main sources of concern: manufacturing, mining,
utilities and construction

 From the energy side: major energy consuming

industries (2/3 of global total!) which are often
the most polluting:
chemicals
iron and steel
pulp and paper
4
cement
 Selected Pollutants Associated with
Industry

4 December 2017
Industrial Subsector Potential Pollutants*
Chemicals Sulphuric and nitric acids, ammonia, fluorocarbons

Pesticides Organohalogens, organophosphates, other toxic

organics, arsenic

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Textiles Hydrochloric, sulphuric acids, high BOD (organic
content), dye, various organic chemicals and
detergents
Pharmaceuticals Ammonia, acids, zinc

Leather tanning Heavy metals (chromium, cadmium, etc.), various

organic chemicals, acids, high BOD
Food processing Ammonia, sulphur dioxide

Cement Alkalines, limestone dust

Electrical/electronics Fluorocarbons, heavy metals (including cadmium,

nickel, selenium)
Glass/ceramics Arsenic, fluorine

Petroleum refining Phenols, sulphides, oily residues, ammonia

Pulp and paperboard Mercaptans (organic sulphides) high BOD and organic
solids, mercury

* Quantities and characteristics dependent on type of manufacturing process and whether waste treatment exists
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ENVIRONMENTAL IMPACTS OR
POLLUTION?

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Impacts are more than pollution

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 Global Climate Change
 Ozone Depletion
 Acidification
 Atmospheric Pollution
 Water Pollution
 Land Degradation
 Toxic Chemicals/Hazardous Wastes

 All have an energy linkage 6

All have an industrial linkage
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CHANGE IN APPROACH TO DEALING
WITH POLLUTION
7 Part 2: Introduction to Cleaner Production
 4 December 2017
CLEANER PRODUCTION

Defined as:

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Continuous application of an integrated preventative
environmental strategy to processes and products to reduce
risks to people and the environment

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HISTORICAL APPROACHES

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TO POLLUTION CONTROL

 Dilution
 Treatment
Avoidance / Cleaner Production

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

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DILUTION

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 Direct discharge into environment
 Relies on capacity of environment to

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assimilate or neutralize impacts

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TREATMENT

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 “End-of-pipe” solution
 Collect pollutants for treatment or

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storage

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CLEANER PRODUCTION

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 Neither dilution nor treatment is long term
 End-of-pipe is expensive and industry feels no

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direct benefit
 Wastes are becoming more difficult to treat

 More stringent regulations are being

introduced

 Cleaner Production provides a more effective

way to avoid or minimize problems by
treating the causes rather than symptoms
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FOCUS OF CLEANER PRODUCTION

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 Production Processes:
conserving raw materials (including energy)
eliminating toxic processing materials

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reducing quantity and toxicity of all emissions
and wastes

 Products
Reducing environmental impacts during entire
life cycle of product through product design

 Does not always require new technologies and

equipment 13
ENERGY AND CLEANER PRODUCTION

4 December 2017
 Energy consumption per million $ of GDP for
developing countries is 440 toe and industrialised
countries it is 290 toe

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 Options for reducing energy consumption include:
- speed control of fans, pumps, agitators
- enhanced heat recovery
- computer aided control of temperature, flow and
load control
- cogeneration of heat and power

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ENERGY EFFICIENCY COMBINED WITH
CLEANER PRODUCTION

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 Initially CP concept focused on waste reduction
 Now increased interest in energy efficiency

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(climate change, SEforALL, SDGs)

 Saving energy reduces pollution

Reducing pollution can save energy

 Are CP & EE always compatible?

Slim fluorescent tubes EE – but what about
mercury coating?
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HOW IS PROGRESS GOING?

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 Energy efficiency measured by energy intensity
 Primary EI has been falling since records started

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in 1990
 Global average (2014) - 5.5 MJ/2011 PPP $

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10 MINUTE BREAKOUT

4 December 2017
 How well is your country doing in reaching the
SEforAll target for energy efficiency?

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 You need to look for the Global Tracking
Framework report.

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SPEED OF PROGRESS – 2012-14

4 December 2017
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Not good enough to meet 2030 target 18
EXAMPLES OF CLEANER PRODUCTION
TECHNIQUES (1)

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 Good housekeeping
tighten valves and reduce leaks
improve materials handling to reduce spillage

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 Material substitution
replace acid pickling of steel with peroxide
treatment

 Technology changes
automatic instead of manual chemical feed

 On-site recycling
steam condensate recovery and recycling 19
EXAMPLES OF CLEANER PRODUCTION
TECHNIQUES (2)

4 December 2017
 Product redesign
concentrate product to reduce packaging
use materials that can be recycled

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 In Netherlands analysis of 10 most efficient
companies in “dirty industries” showed 164
possibilities for CP

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 4 December 2017
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WHAT ARE THE BENEFITS
OF CLEANER PRODUCTION TO
INDUSTRY?
21 Part 3 Introduction to Cleaner Production
 4 December 2017
We begin with a case study

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from Tunisia

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POLLUTION PREVENTION AUDITS IN VARIOUS
INDUSTRIES IN TUNISIA (BY TECHNIQUE)
Industry No Material Process Energy Water Gen Product In-Process Total
subst Mod Cons Cons House- Mod Recycling
keeping
Battery man 1 0 15 6 3 7 0 4 35
Olive Oil extract 1 2 14 5 4 2 1 3 31
Veg Oil refining 2 1 4 0 2 1 0 0 8
Soap 2 0 2 0 0 0 0 0 2
Leather tanning 2 1 4 2 4 5 0 5 21
Electroplating 2 4 11 3 4 6 0 5 23
Textile 2 2 8 11 5 13 0 2 41
Total 12 10 48 27 22 34 1 19 161

4 December 2017 EMSI 23

POLLUTION PREVENTION AUDITS IN VARIOUS
INDUSTRIES IN TUNISIA
(BY ENVIRONMENTAL BENEFIT)

Industry Energy Water Material Toxic Waste Air

conservation Conservation Conservation Substitution minimisation Minimisation
Battery man 6 3 7 0 13 4
Olive Oil extract 5 4 9 1 7 9
Veg oil refining 0 2 2 0 2 0
Soap 0 0 0 0 2 0
Leather tanning 2 4 5 1 6 2
Metal Finishing 3 4 7 6 8 4
Textile 11 5 6 0 12 2
Total 27 22 36 8 50 21

4 December 2017 EMSI 24

POLLUTION PREVENTION AUDITS IN VARIOUS
INDUSTRIES IN TUNISIA
(BY LENGTH OF PAYBACK PERIOD)

Industry immediate < 6 months 6 to 12 1 to 2 > 2 years Unknown

months years
Battery man 9 2 1 3 0 4

Olive Oil extract 0 4 4 0 3 2

Veg Oil Refining 1 1 2 0 2 1

Soap 2 0 0 0 0 0

Leather tanning 1 4 1 1 4 9

Metal Finishing 9 3 4 2 0 9

Textile 7 6 5 1 3 10

Total 29 20 17 7 12 35

4 December 2017 EMSI 25

FINANCIAL IMPACT OF POLLUTION PREVENTION
INNOVATIONS IN A NUMBER OF TUNISIAN
INDUSTRIES
Industry No Initial investment Financial benefit
US$ US$/year
Battery man 1 first yr: 8,000 first yr: 746,730
sec yr: 400,000 thereafter: 2,257,416

Olive Oil extract 1 343,000 >407,165

Veg Oil refining 2 65,000 41,000

Soap 2 incorporated in above

Leather tanning 2 47,000 >103,000

Metal Finishing 2 39,000 >82,000

Textile 2 160,000 127,300

Total 12 1,062,000 >3,765,000

4 December 2017 EMSI 26

AN ASSIGNMENT

4 December 2017
 What are the benefits of CP to industry (in
general)?

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 What are the barriers to SMEs adopting CP?

 How would you overcome these barriers?

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WHAT ARE THE BENEFITS TO COMPANIES?

4 December 2017
(1)

 Cost-saving through reduced wastage of raw materials

and energy

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 Improved operating efficiency of plant

 Better product quality (high price for goods?)

 Recovery of some wasted materials

 PPP = Pollution Prevention Pays

Short payback times: few months to three years
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WHAT ARE THE BENEFITS TO
COMPANIES? (2)

4 December 2017
Savings from:
- reduced raw materials and labour costs
- lower energy consumption

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- less expensive maintenance costs
- reduced waste management costs
- improved worker safety
- lower product liability

 Remember end-of-pipe treatment is an add-

on cost and gives no payback

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 BARRIERS TO INTRODUCING CLEANER
PRODUCTION

4 December 2017
 Lack of awareness of approach

Lack of finance

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

 Lack of expertise, skills, access to existing

knowledge

 Lack of appropriate government policies to

stimulate introduction

 Fear of being put at competitive disadvantage due to

incorrect perceptions about costs
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 CLEANER PRODUCTION INCENTIVES

4 December 2017
Internal to Company External to Company

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1. Leadership and management Commitment 1. Environmental Regulations
2. Employee Involvement and Initiatives 2. Market Pressure
3. Cost Awareness 3. Public Pressure
4. Occupational Health & Safety Programs 4. New Technological Opportunities
5. Internal Research and Development

Overview of factors which encourage firms to take up

Cleaner Production
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 4 December 2017
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TOOLS FOR CLEANER
PRODUCTION
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The Cleaner Production Cycle

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ANALYTICAL TOOLS FOR CLEANER
PRODUCTION

4 December 2017
 Waste reduction audits
- examines materials flows through plant or process

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 Environmental compliance audits
- assess compliance with environmental standards both
present and anticipated future

 Product life-cycle analysis

- estimates environmental impacts of product from raw
materials extraction through to final disposal and
identifies cost-effective options for minimising waste

 Environmental impact assessment

- identifies most significant impacts of a project and
opportunities for avoiding adverse impacts
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WASTE REDUCTION AUDIT

4 December 2017
 Assess inputs into and outputs from a plant to identify opportunities
for more efficient use of resources and reduction or elimination of
wastes

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 Activities
- Prepare audit procedures
- Determine process inputs
- Determine process outputs
- Derive a material balance
- Identify waste reduction options
- Evaluate waste reduction options
- Prepare a waste reduction action plan
- Implement action plan

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WASTE REDUCTION AUDIT - STEPS

4 December 2017
0 – Get management interested

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1. Create process flow diagram
2. Quantify material flows and composition
• Product specifications
• Input materials
• Technological factors
• Operating principles
• Waste handling procedures

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WASTE FLOW DIAGRAM

4 December 2017
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WASTE REDUCTION AUDIT – STEPS

4 December 2017
(CONT)
3. What are options for eliminating or controlling waste?

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• Product modification
• Input substitution
• Technology modifications
• Housekeeping
• Recycling
4. Identify barriers and solutions
5. Set up project team (knowledge, creativity, authority)
6. Develop Cleaner Production Plan, Implement, Monitor

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WASTE REDUCTION AUDIT

4 December 2017
 Material balance quantities resource use and gives
opportunities for reducing use
- water

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- chemicals
- raw materials
- energy

 Central for introducing Cleaner Production

 Identifies immediate cost savings and opportunities for

increased competitiveness, therefore cost effective

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ENVIRONMENTAL COMPLIANCE AUDIT

4 December 2017
 Involves a systematic review of management, production,
marketing, product development and organisation to assess
how well performing with regard to environmental standards

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and practices

 Annual activity - external conducted

 Advantages
- safeguards the environment
- assure compliance with law and company policy
- identifies matters needing correction
- reduces litigation and enforcement
- raises awareness in company of need for
environmental protection 40
PRODUCT LIFE-CYCLE ANALYSIS

4 December 2017
 Cradle-to-grave environmental management

Reasons include:

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
- mitigating environmental impact of product
- eco-labelling
- assist in marketing
- education for management and consumers

 Activities
- inventory analysis of impacts
- impact analysis of effects pm environment and health
- improvement analysis

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ENVIRONMENTAL IMPACT ASSESSMENT
(EIA)

4 December 2017
 Usually only for large scale projects (legal
requirement)
 Activities

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- Planning assessment, including screening similar
projects
- conducting EIA
identify impacts
estimate extent
evaluate significance
identify mitigation measures
reporting
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ENVIRONMENTAL IMPACT ASSESSMENT
(EIA) (CONT)

4 December 2017
 Using EIA
prepare plan for reducing impacts
allocate responsibilities

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implement plan
evaluate results

 EIA’s frequently not followed up to check with

compliance

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 4 December 2017
Energy Saving in Soap Production

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A Case study of Cleaner Production
from Tanzania

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ENERGY SAVING IN SOAP PRODUCTION
A CASE STUDY OF CLEANER PRODUCTION FROM

4 December 2017
TANZANIA
 Background
Shivji and Sons Ltd. Manufactures soap

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Process:
Fat is treated with caustic soda
Solid separated, crushed mixed with colour,
perfume, etc.
Flashed cooled, then extruded for cutting, etc.
Main energy input: steam used throughout
Combustion of industrial diesel oil

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ENERGY SAVING IN SOAP PRODUCTION
A CASE STUDY OF CLEANER PRODUCTION FROM

4 December 2017
TANZANIA (2)

 Cleaner Production Assessment

Leakages of steam from valves

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Inefficient use of steam
3,000 kg of fat spilled during
unloading
Absorbed by soil

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 4 December 2017
ENERGY SAVING IN SOAP PRODUCTION
A CASE STUDY OF CLEANER PRODUCTION FROM
TANZANIA (CONT’D)

Cleaner Production Solutions

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
Replace leaking steam valves and traps
Reduce time required for heating fat from 6 to 7
hours down to 3
Control water quantities added to first stage -
reduces steam consumption
Recover spilled fat

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ENERGY SAVING IN SOAP PRODUCTION
A CASE STUDY OF CLEANER PRODUCTION FROM

4 December 2017
TANZANIA (CONT’D)

 Environmental Benefits
Diesel oil consumption reduced to 30 L per tonne
of soap (54% saving)

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Reduced COx, SO2, NOx
Fat spillage prevention reduced soil pollution

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 4 December 2017
ENERGY SAVING IN SOAP PRODUCTION
A CASE STUDY OF CLEANER PRODUCTION FROM
TANZANIA (CONT’D)

Financial Benefits

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
Investment for valves US$ 830
Steam saving US$ 185,700 per year!
Pay-back time - 2 DAYS!!!!

Recovery of spilled fat saved US$ 2,400 per year

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CONCLUSIONS

4 December 2017
 Cleaner Production presents win-win opportunities

Benefits end-user, environment and society

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

 Needs policy changes, including improvement in skills,

energy pricing and access to finance to enable investments
in improvements

ENFORCEMENT OF LEGISLATION

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 4 December 2017
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ASSIGNMENT
51 Peanut Factory