Resource Efficient and Cleaner Production Concept ...recpindonesia.org/sites/default/files/Presentation Materials/Nd266... · Resource Efficient and Cleaner Production Concept, Practices

Resource Efficient and Cleaner Production

Concept, Practices & Applications

Medan, 23 February 2017

February 2017 RECP Introductory Training 1

National Resource Efficient and Cleaner Production (RECP) Programme Indonesia

Funded by Implemented by In partnership with

Kementerian Lingkungan Hidup dan Kehutanan

Centre for Assessment & Development of Green Industry & Environment


Efisiensi Sumber Daya dan Produksi

Bersih

Concept

PracticesApplications

RECP for green industry


Resource Efficient and Cleaner Productionemerged as a business response to worsening(industrial) pollution and escalating use ofnatural resources


disperse

control

recycle

Resource Efficient and

Cleaner Productionprevent

pollution

replace

protect

recover

reduce

scarcity

natu

ral reso

urces

enviro

nm

en

t

Efisiensi Sumber Daya dan Produksi Bersih

Efisiensi Sumber Daya dan Produksi Bersih

• Finding and implementing ways to– Improve productive use of materials,

water and energy;• Thereby

– Reduce the generation of waste, effluent and emissions;• Thereby

– Improve well being of employees, consumers and community; • Thereby• …….• ……..



Productive output per unitof resource consumption

Pollution intensity per unitof productive output

RECP Issues


Produktivitas Bahan Baku

Pemilihan dan efisiensi bahan baku

Intensitas Sampah

Penurunan dan buangan yg aman dari limbah

Produktivitas

Air

Pemilihan dan efisiensi air

Intensitas

Limbah Cair

Penurunan dan Pengolahan air limbah

Produktivitas

Energi

Pemilihan dan efisiensi energy

Intensitas

Emisi

Penurunan dan Pengendalian gas buang


Resource Efficient and Cleaner Production canbe implemented through – combinations of –different prevention practices


Tata KelolaArea Kerja

Substitusi Bahan

Peningkatan Pengenda-lian Proses

Modifikasi Peralatan

Penggan-tian

Teknologi

Guna Ulang Dan Daur Ulang di

Lokasi Sendiri

Pemanfaatan Produk

Samping

Modifikasi Produk

• Maintain a clean, organized andproductive workplace to eliminateavoidable ‘wastage’

• Typical solutions– Switch off what is not in use

– Repair what needs reparation

– Keep workplace organized and clean

– Minimize and manage inventory

– Confirm right way for all tasks

– Keep staff motivated

10February 2017 RECP Introductory Training

• Choose inputs that are efficient, effective and/or pose minimum harm to the environment and health

• Typical solutions– Use renewable energy

– Use sustainably-sourced renewable materials

– Use of recycled materials, water and energy

– Use fit for purpose materials

– Use less harmful substances

– Source locally


• Monitor and control processes andequipment so that they always run athighest efficiency and with lowestwastage

• Typical solutions

– Standard operating procedures and process monitoring

– Sub-metering water, energy and materials

– Preventive maintenance


• Make existing equipment more efficient and less wasteful

• Typical solutions– Insulation– Proper alignment of

production line– Improve process

temperature, pressure, speed, mixing

– Automatic switch off & level controls

– Combine process steps in same equipment


• Change over to new technologythat is more efficient or producesless waste

• Typical solutions– Efficient boilers, motors, fans,

compressors etc.

– Change of core process, e.g. chemical to mechanical cleaning

– Equipment with integrated recovery loops

– Advanced separation processes

– Solar dryers, heaters and lighting


• Use previously ‘wasted’ material, energy and/or water for similar or alternative purpose in company

Typical solutions

• Countercurrent or cascaded use of water and energy

• Condensate and heat recovery

• Reuse of incoming packaging for outgoing products

Practices


• Convert a previous ’waste’ for a useful use elsewhere

Typical solutions

• Provision of used cooling water for external heating or cooling purposes

• Segregate recyclables for external recycling and resource recovery, such as composting

• Symbiosis - use waste material for new product development


• Redesign product to reduce its environmental impact during production, use and/or disposal

• Typical solutions– Design for optimal product

lifetime– Design for lower material

use– Design for low-waste

manufacturing– Design for refurbishment,

recycling etc.


RECP Method

Source

Cause

Option


Root Source Analysis

WHERE?

Quantification of the different usages and sources

Root Cause Diagnosis

WHY?

Factors contributing to resource usage and pollution sources

Option Generation

HOW?

Alternative ways to avoid the identified causes


Resource Efficient and Cleaner Production hasbeen beneficially applied in many industrysectors, including pulp and paper, rubber andfood processing sectors

Viet Tri Paper (Viet Nam)• Options implemented

– VSD on main paper machine motors

– Condensate recovery from paper machines

– Insulation and repair of steam pipes and valves

– Install economizer on boiler

– Dry storage of coal

• Economics– Investment USD113,000

– Annual savings USD 123,000


Energy Efficiency Guide for Industry in Asia–www.energyefficiencyasia.org

Anhui Tiandu Paper (China)• Options implemented

– Heat recovery from blow down of pulp digesters

– Insulation and leak repair of steam pipes

– Increase pulping capacity by better feeding of straw

– Segmentation in steam supply system

– Cogeneration of heat and power

• Economics

– Investment USD 2.1 M

– Annual savings USD 650,000

• Environment

– Coal savings 15,000 tpa

– GHG reduction 5.2%



Energy Opportunities in Pulp & Paper Mills


11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)

Water Opportunities in Pulp & Paper Mills


11 pulp and paper mills in PakistanSustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)

Energy Benchmarks


http://www.iipnetwork.org/

Energy Benchmarks



Energy Benchmarks



Best Available Technologies

February 2017 RECP Introductory Training 27February 2017


Best Available Technologies (examples)



Best Available Technologies (examples)



AMC Tyres (Sri Lanka)• Implemented options

included:– New efficient compressor

– Leak survey and repair compressed air system

– Leak repair and insulation for boiler and steam system

– Condensate recovery

• Economics– Invested USD49,000

– Savings USD84,000/yr

• Environment– Electricity saved 521

MWh/yr

– Furnace oil saved 173 kl

– GHG reduction ~600 ton

June 2016 Module 1: RECP Concept and Business Case 30


Medigloves (Thailand)

• Producer of surgical and cleanroom latex gloves– Reduced air intake temperature and fixed leaks in compressed air

system

– Recovery and reuse of water and chemicals from latex dipping process

– Recovery and reuse of water from wash and chlorination process

• Annual cost savings of USD19,200 for investment of USD8,000 (payback <5 months)

• Annual resource conservation of 166,000 kWhr, 17 kl oil and 14,300 m3

• GHG reduction ~150 ton CO2-eq

June 2016 Module 1: RECP Concept and Business Case 31


Concentrated Latex Production

• Gate to Gate Life Cycle assessment – Total environmental impact dominated by

• 1. electricity use for centrifugation• 2. ammonia use for preservation• 3. DAP use

– Total environmental impact can be reduced by:• 1. energy efficiency for centrifuge (inverter, VSD): 12%• 2. improved ammonia handling and storage: 8%• 3. extending coagulation time (reduced DAP use): 3%• 4. fuel switch from diesel to LPG: 5%


Jawjit et al, Evaluating the Environmental Performance of Concentrated Latex Production in Thailand, 2012

Veraval• Fish processor in Gujarat, India

– Total investment <44,000 USD, with payback of 14 months

5 April 2016 RECP (seafood sector) 33

Cleaner Production Opportunities Investment (USD)

Pay Back

(month)

Use belt conveyor for transferring baskets filled with fish from

weighing section to processing hall1,725 10

Use of sprays instead of using running hoses for cleaning & rinsing

of fish.100 5

Reuse chlorinated wash water after filtration from 0.2 mm mesh

screen in non-critical applications like preliminary washing of R/M,

cleaning floors.

400 15

Improve insulation of cooling systems & pipe work (required 6" and

3" is used)1,600 10

Use SS made /aluminum allied trays instead of plastic trays for

efficient cooling.16,000 14

Installation of R.O. plant & reusing of treated water in the process

areas.23,500 15

Installation of water level controllers in overhead tanks 500 7

www.gcpcgujarat.org.inlast accessed 9 August 2015

http://www.gcpcgujarat.org.in/

Rathkerewwa Desiccated Coconut Industry

22 September 2016 RECP Introductory Training 34

National Cleaner Production Centre Sri Lanka

Sri Lanka

RECP@ Chea Hap Rice Mill


Sustainable Food Systems


Food Safety

Provenance (traceability)

Sustainable Source

Energy Use(& air

emissions)

Water Use & Effluents

Food Waste (Losses)

Waste & Byproducts

+source processing

RECP Starters


Water Use & Effluents

WATER AND WASTE WATER

Measure and monitor water consumption

Increase staff awareness and motivation

Use efficient spray nozzles

Optimize rate of water flows

Install automatic controls and valves

Repair leaks, eliminate spill areas

Select water efficient processing routes

Dry-clean before facility wash down

Optimize pipe cleaning, e.g. with pigging systems

Optimize use of and controls over high pressure cleaners

Trigger operated controls and valves for hoses and spray guns

Design and install equipment with a view to ease of cleaning

Optimize Clean In Place systems (conductivity controls etc.)

Reduce change overs and optimize change over cleaning regimes

Custom design automatic container washing systems

Minimize cooling tower blow down

Optimize cooling tower operation for maximum water recovery

Use alternatives to water for cooling operations

Collect and reuse seal water from vacuum pumps

Eco-Efficiency Toolkit for Queensland Food Processing Industry, Govof Queensland, Brisbane, 2004

RECP Starters


Waste & Byproducts

WASTE AND BY-PRODUCTS

Improve material flow and plant layout to reduce materials wastage

Improve plant operations to reduce wastage

Develop options for recovery and reuse of waste, as animal feed,

byproduct or alternative fuel

(Vermi)compost organic waste

Segregate recyclables for third party recycling


RECP Starters


Energy Use(& air

emissions)Boilers and Production of Steam and Hot Water

Improve boiler efficiency

Match steam supply with steam demand

Steam distribution

Condensate return

Maintenance of steam traps and condensate lines

Rationalization of boiler use and steam lines

Insulation of pipes

High efficiency boilers

Reducing hot and warm water use

Consider co-generation

Consider solar (pre-)heating

Motors

Select high efficiency motor, sized to your needs

Install variable speed drive on fixed speed motors (e.g. compressors, fans, pumps, etc.)

Lighting

Minimize lighting requirements (e.g. daylight, light colors, task level)

Use light efficient lighting fixtures

Use appropriate and decentralized lighting controls and switches

Use energy-efficient lights


RECP Starters


Energy Use(& air

emissions)

Refrigeration Systems

Select right compressor size

Improve load distribution between compressors

Minimize temperature differences

Install hot gas bypass defrost

Reduce load on refrigeration system

Reduce heat ingress on refrigerated areas

Optimize selection and use of refrigerants

Consider alternative refrigeration, e.g. absorptive refrigeration

Consider solar cooling

Compressed Air Systems

Use energy-efficient compressor, sized to your needs

Install sequence controller to manage staggered operation of multiple compressor

Install variable speed drive to meet varying compressor load demands

Minimize compressed air leaks

Substitute use of compressed air wherever feasible alternatives exist

Optimize compressed air pressure to demands

Reduce compressor air inlet temperature

Optimize compressed air distribution system


Business Case


Cost savings

Productivity enhancements

Quality improvements

Organizational efficiency

License-to-operate

Indonesia RECP Programme• Networked initiative to foster

RECP implementation at scaleand at speed in Indonesia

1. RECP Capacity & Network

2. RECP Implementation & Replication

3. RECP Policy & Strategy

4. RECP Technology & Innovation

5. RECP Finance & Investment

Sectors

(food processing,

textile & garment

Industrial Zones

(Makassar & Batam)

Micro-Industries

(rice milling)

Tourism Destinations

(Sleman/ Magelang & Lake Toba)


RECP Network

Programme activities in North Sumatra



Food Processing

Training of Experts and Enterprises

Assessor Assessments

Self Assessments

RECP Assessors Training• Aim

– Equip trainee assessors with necessary methods and skills to undertake RECP assessments in enterprises

• Modality – Class room training (twice, three days each)– Practical assignment (RECP assessments in two

demonstration enterprises)– Expert coaching and guidance

• UNIDO RECP Award


6 experts from North Sumatra trained and being coached to execute RECP assessments

Assessor Assessments• Enterprises

– Obtain a catalogue of RECP options that will improve resource efficiency and reduce pollution with recommendations for implementation

– Improve awareness, understanding and capacity to manage and minimize resource consumption and pollution generation

• Associate RECP Assessors– Gain practical experience

in conducting RECP assessments in sector, under guidance of RECP expert team

– Complete basic RECP assessment training and obtain recognition as RECP expert


First assessments undertaken in six palm oil mills under PTPN II, PTPN III and PTPNIV

RECP Clubs


• Facilitate RECP uptake in groups of food processing enterprises– Self assessment

• Utilize internal resources for RECP option identification, evaluation and implementation

– Combined with enterprise training and coaching

Self Assess

1. Baseline

2. Materials & Waste

3. Water & Effluents

4. Energy

5. Chemicals & Emissions

6. Action plan

Expressions of interest sought

12 October 2016 RECP Introductory Training 48

Lake Toba

Tourism

Assessor Assessments

Community of Practice

Tourism planning and advocacy

Other Elements (TBD)

Expert PoolAlliance/

Partnership

RECP NetworkIndonesia

Bandung Declaration8 Nov 2016

Vibrant network of Indonesian RECP professionals that work together to expand and improve the awareness, knowledge and

application of RECP in Indonesia

An action partnership of organizations that commit to promote RECP and implement

RECP within their activities and/or sphere of influence

Local Practitioners Forums


Terima kasih banyak!


National Resource Efficient and Cleaner Production (RECP) Programme Indonesia

Funded by Implemented by In partnership with

Kementerian Lingkungan Hidup dan Kehutanan

www.recpindonesia.orgwww.recpnet.org

Centre for Assessment & Development of Green Industry & Environment

http://www.unido.org/cp

http://www.recpnet.org/

Documents

Resource Efficient and Cleaner Production Concept ...recpindonesia.org/sites/default/files/Presentation Materials/Nd266... · Resource Efficient and Cleaner Production Concept, Practices