The evaluation of Cleaner Production performance in Lithuanian industries

Journal of Cleaner Production 14 (2006) 1561e1575

www.elsevier.com/locate/jclepro

The evaluation of Cleaner Production performance inLithuanian industries

Irina Kliopova, Jurgis Kazimieras Staniskis*

Kaunas University of Technology, Institute of Environmental Engineering, Lithuania

Received 18 March 2004; accepted 22 April 2005

Available online 5 July 2005

Abstract

The analysis of the Cleaner Production (CP)/pollution prevention concept application in Lithuanian companies demonstratesa number of opportunities in waste minimization and pollution prevention areas aimed at sustainable development.

To compare the efficiency of various CP methods and to identify the preventive methods with the highest energy saving

possibilities in different Lithuanian sectors of the economy the database ‘‘The implementation of Cleaner Production in Lithuania’’was used. This database was developed in line with CP implementation methodology and contains technical, environmental,economic and financial information on implemented CP innovations in Lithuanian companies during the last decade. In addition,

several applicable CP innovations are described in case studies.� 2005 Elsevier Ltd. All rights reserved.

Keywords: Cleaner Production; Database; Environmental performance; Process control; CP efficiency

1. Introduction

The implementation of the Cleaner Production (CP)concept in Lithuania started in 1993, when WorldEnvironmental Center (WEC) implemented Waste Min-imization Program in the Baltic States’ Industry, whichwas financed by the United States Agency for In-ternational Development (USAID). Seven Lithuanianchemical industrial companies took part in this program.Fifteen CP innovations have been implemented withtotal investments in amount of 194,000 EUR. Theseinnovations enabled to save 548,000 EUR/year [1].

Since 1993, the Institute of Environmental Engineer-ing (APINI), in collaboration with international partners,organized several Cleaner Production, CP financing and

* Corresponding author. Tel.: C370 37 300760; fax: C370 37

209372.

E-mail address: [email protected] (J.K. Staniskis).

0959-6526/$ - see front matter � 2005 Elsevier Ltd. All rights reserved.

doi:10.1016/j.jclepro.2005.04.017

Environmental Management System’s implementationprograms with different targets and objectives. Special-ists from more than 100 Lithuanian companies took partand successfully completed these programs [2].

In 1995, Norwegian CP methodology was adaptedand developed in Lithuania by APINI experts. This method-ology consists of five logical steps of CP assessment andimplementation (Fig. 1) [3,4].

Each CP implementation step has specific targets:

Targets of planning and organization:B To get approval from the company’s manage-

ment;B To establish a proper project organization;B To identify CP objectives.Targets of pre-assessment:B To make processes flow chart;B To assess inputs and outputs;B To select one or a several assessment focuses.

mailto:[email protected]

http://www.elsevier.com/locate/jclepro

1562 I. Kliopova, J.K. Staniskis / Journal of Cleaner Production 14 (2006) 1561e1575

Targets of assessment:B To create material and energy balances;B To identify the main reasons of waste and losses

generation;B To generate the alternative CP options;B To select CP options for next analysis.Targets of feasibility studies:B To make the first selection;B To carry out technical evaluation;B To carry out environmental evaluation;B To carry out economic evaluation;B To carry out financial evaluation of options that

require external financing;B To make the final selection.Targets of implementation and continuation:B To create time schedules for implementation of

selected CP options;B To implement these options;B To evaluate CP progress: monitoring and evalu-

ation of the achieved results;B To initiate new CP activities.

CP implementation methodology ensuring the follow-up and integration to the company’s EnvironmentalManagement System was developed afterwards. Itallowed the evaluation of the economic and environmen-tal efficiency of implementation of various CP programs[2,4]. This required systematization of all existing in-formation about evaluation of CP innovations to

The recognized need to minimize waste

Planning, organization

Assessment Phase

Feasibility Analysis Phase

Successfully implemented CP projects

Created organizational structure

Comprehensive list of CP options

Selected object for evaluation

Pre-assessment

Implementation andcontinuation

List of selected CP options forimplementation

Fig. 1. Cleaner Production procedure.

optimize production processes and to increase processor whole company environmental and economic effi-ciency [5]. Therefore, a database of solutions to envi-ronmental problems which could be a good engineeringinstrument for researches and for practitioners wasdeveloped.

2. Data systematization and database development

According to the monitoring results of implementedCP innovations, the database ‘‘Implementation ofCleaner Production in Lithuania’’ was created onMicrosoft Assess 2000 platform in 2002 (Fig. 2). Thisdatabase provides the information on 168 CP innova-tions in 74 companies implemented during the lastdecade in different Lithuanian sectors of economy. Thisinformation is presented in line with the main fiveprocedures of the CP implementation methodology(Fig. 1). The following types of information wereincluded in the database:

� information about the company (name, address,economy sector, number of employees, year ofestablishment, participation in different CP pro-grams, main areas of activity, production volume);� information about the company’s economic situation(authorized capital, annual turnover, total profit,costs of activities, net profit);� information about CP development in the company(the title and duration of CP program, the number ofgenerated CP proposals, the number of implementedCP innovations during CP program, the title of themain CP project, project investments and savings(including environmental savings), payback period,applicable CP method, the type of process optimiza-tion method, the date of project implementation);� technical information about CP innovation (projecttitle, company name, short project description:existing environmental problem and suggested tech-nical solution, functional scheme);� project environmental benefits (company name, pro-ject title, energy, raw and additional materialconsumption before and after CP implementation(units/year and EUR/year), environmental effect(unit/year, EUR/year and percent from the totalcompany consumption), savings due to minimizationof environmental fees (EUR/year), informationabout the real yearly consumption of energy, rawand additional materials and real savings during thepayback period);� information about CP projects, financed by externalfinancial institutions (financial evaluation and in-vestment analysis);� environmental impact of all implemented CP projectsin each company during each CP program.

1563I. Kliopova, J.K. Staniskis / Journal of Cleaner Production 14 (2006) 1561e1575

Additional forms have been created in order toestablish links between the main forms:

1) the list of environmental sectors: air, water, waste-water, waste, energy, physical pollution, work safety;

2) the list of usable CP methods: product modification,input substitution, technology modification, processoptimization, onsite recycling, energy recovery &new products, good housekeeping;

3) the list of usable process optimization methods:implementation of monitoring or measurementsystems, open-loop control systems, automaticcontrol systems (feedback or feed-forward controlsystems), optimization of existing control system;

4) the list of the usable recycling methods during processoptimization: wastewater recycling, heat energy re-covery, condensate recycling, waste reuse, coolingwater recycling;

5) the list of all possible environmental effects;6) the list of the industrial sectors in Lithuania.

The main advantage of the database is the possibilityto analyze the data effectively. Use of queries ensuresselection of information and analysis of data: to enterformulas, graphics, to develop the reports, etc.

The environmental areas, where database has beenused are presented in Fig. 3.

3. Results of practical application of the database

The database was used for the evaluation of CPpossibilities, which consist of the following main stages:

1) The comparison of the efficiency of different CPmethods:U the comparison of economic efficiency of CP

methods;

Fig. 2. The switchboard of the database.

U the comparison of environmental efficiency of CPmethods;

U the analysis of the innovation’s implementationperiod;

2) The development of CP methods for energy saving;3) The implementation of various CP methods in

different sectors of economy (evaluations of CPefficiency by sectors).

The results of the comparison of the efficiency ofdifferent CP methods are presented in the followingsections.

3.1. Comparison of the economic efficiency ofCP methods

The results of the economic evaluation of theimplemented CP methods using the database arepresented in Fig. 4.

It is not possible to evaluate the economic efficiencyof particular CP methods in a proper way by analyzingthis diagram only, because about 55% of all imple-mented innovations are from process optimization area,22% e technology modification, 10% e onsite recyclingmethod. The advantage of good housekeeping methodsmust be stressed, as it allowed companies to save about0.5 million EUR/year after the implementation of

Fig. 3. Possible application of the CP database.


Processoptimization

Technologymodification

Energyrecovery &

new products

Onsiterecycling

Goodhousekeeping

Inputsubstitution

Productmodification

CP methods

0.6

of total number of CP innovations

of total saving

of total investments

1.20.1

8.6

4.2

10.411,0

12.213.214.3

21.521.5

25.6

54.650,0

47,9

3.1

60,0

50,0

40,0

30,0

20,0

10,0

0,0

Fig. 4. The distribution of CP investments and savings for different CP methods (1993e2003).

innovations, which did not require investments. There-fore, in order to compare the economic efficiency ofdifferent CP methods, it is necessary to carry out thefollowing analysis of implemented innovations: thedistribution according to the payback period (Table 1),to the investments volume (Table 2) and to the savings(Table 3) [7].

The results of the economic efficiency evaluation ofthe implemented innovations proved the advantage ofthe process optimization methods and revealed the mainreason why this CP method is widely used in Lithuanianindustrial companies: good economic effects areachieved with relatively small investments. Fifty-eightpercent of the investments in process optimizationinnovations did not exceed 15,000 EUR. These invest-ments resulted in savings from 60,000 to 300,000 EUR(Table 2). Therefore, the payback period of suchinnovations was short, with approximately 52% of theCP investments in process optimization paid back inseveral months (Table 1).

The investments in technology modifications wereoften higher, with payback periods for 51% of suchinnovations in 2e3 years and for 8.5%,more than 3 years.

The investments in 40% of innovations in energyrecovery & new products were up to 300,000 EUR ormore. Implementation of such projects gave the best

economic effects; the yearly savings of 40% of the wasterecycling innovations varied from 150,000 to 300,000EUR. However, the main part of the return was receivedfrom selling new products. For example, a wood andwood products manufacturing company, annually pro-duced about 15,000 m3 of dressed boards and 1500 m3

of other wood products, during the modernization ofthe heat production department, they installed a newboiler house with a capacity of 14 MWh in which alltypes of wood wastes are burned for heat energyproduction. The implementation of this project allowedthe company to save 724,000 EUR/year. Ninety percentof this sum was from selling excess heat energy to themunicipal heat supply system [6].

Another example is the production of dry whey andmilk substitute products from whey in a cheese company.Approximately 100 t of whey was produced per day inthis company. The savings from this CP innovation were220,000 EUR/year. Forty-five percent of these savingscame from the minimization of environmental costs:diesel fuel consumption and taxes for wastewaterpollution. The rest came from the production of newproducts [6].

Additional analysis is necessary for the implementa-tion of CP innovations in energy recovery & newproducts areas, for instance, to carry out market

Table 1

The distribution of the payback periods for different CP methods (%)

CP methods Payback

Up to 1 year From 1 to 1.5 years From 1.5 to 2 years From 2 to 2.5 years From 2.5 to 3 years More than 3 years

Technology modification 29 8.5 3 17 34 8.5

Process optimization 52 11 9 5 18 5

Onsite recycling 35 12 24 24 5

Energy recovery

& new products

20 20 20 20 20


Table 2

The distribution of investments for different CP methods (total and %) (1993e2003)

CP methods Investments

Up to 15 thous.

EUR

From 15 to

30 thous. EUR

From 30 to

150 thous. EUR

From 150 to

300 thous. EUR

More than 300 thous.

EUR

Technology modification 5 (14%) 5 (14%) 15 (43%) 7 (20%) 3 (9%)

Process optimization 52 (58%) 4 (5%) 17 (19%) 10 (11%) 6 (7%)

Onsite recycling 6 (35%) 1 (6%) 5 (29%) 4 (24%) 1 (6%)

Energy recovery

& new products

1 (20%) 1 (20%) 2 (40%) 1 (20%)

Thous.: thousands.

demand analysis, to receive permits, to assess environ-mental impact. In many cases, a company hired externalexperts and this caused additional costs for the CPproject (Table 4).

The investments for onsite recycling innovations didnot exceed 150,000 EUR. Implementation of theseinnovations enabled the company to save about 60,000EUR/year and to have a shorter payback period.Recently, heat regeneration from wastewater and airemissions became more applicable in many industrialsectors [7]. For example, regeneration of heat energyfrom the melting-house for damp sand drying ina metal product’s production company enabled themto save about 34 t/year of diesel fuel, 150 MWh/year ofelectricity and to minimize air emissions in the burningprocess. CP project investments, for this project, were55,000 EUR for which they obtained savings of 24,000EUR/year [6].

Additional heating of the dyeing department at a yarnproduction company using heat energy from hotcondensate enabled it to save 250 MWh/year of heatenergy or about 8000 EUR/year while the CP invest-ments were only 3000 EUR [8].

In a wool production company finishing department,1050 MWh/year of heat energy is regenerated from airemissions and wastewater. This enabled the company toreduce air emissions in heat energy production byapproximately 4000 t/year and to save about 203,000EUR/year. Project investments were 348,000 EUR [6].

As already mentioned, the main part of the imple-mented CP innovations belonged to the process

optimization methods. About 90% of the investmentsin process optimization were process control innova-tions [5]. The biggest part of the savings, about 87%,was due to reduction of the environmental costs. Thepayback periods for such process control innovationswere approximately 1 year. The economic efficiency ofthese innovations is very obvious. During the imple-mentation of these innovations it was not necessary tostop production; therefore, the production volumeduring implementation process was not decreased [7].

3.2. Comparison of the environmental efficiency ofCP methods

The following procedures have been used for theevaluation of environmental impact of implemented CPmethods [10]:

U environmental indicator system, for example, eval-uation of environmental performance improvementper production unit e on a product level, ona process level, on a company level;

U comparison of environmental effects of different CPmethods in all environmental areas;

U evaluation of environmental efficiency of imple-mented CP innovations on industrial sectors level oron regional level.

The environmental effects of applied CP methods arepresented in Table 5.

Table 3

The distribution of savings for different CP methods (total and %)

CP methods Savings

Up to 15 thous.

EUR

From 15

to 30 thous. EUR

From 30

to 60 thous. EUR

From 60

to 150 thous. EUR

From 150

to 300 thous. EUR

More than

300 thous. EUR

Technology modification 8 (23%) 5 (14%) 6 (17%) 13 (37%) 3 (9%)

Process optimization 39 (43%) 10 (11%) 12 (14%) 12 (14%) 15 (17%) 1 (1%)

Onsite recycling 4 (24%) 4 (24%) 7 (40%) 1 (6%) 1 (6%)

Energy recovery

& new products

1 (20%) 2 (40%) 1 (20%) 1 (20%)

Good housekeeping 10 (72%) 2 (14%) 1 (7%) 1 (7%)

Thous.: thousands.


Table 4

The implementation period of different CP methods (1993e2003)

CP methods Duration

Up to

1 month (%)

From 1 to

6 months (%)

From 6 months

to 1 year (%)

From 1 year

to 1.5 years (%)

More than

2 years

Technology modification 7 33 23 33 2

Process optimization 27 51 18 4

Onsite recycling 50 42 8

Energy recovery

& new products

40 40 20

During the last decade, the implementation of allprocess optimization innovations in Lithuania resultedin the following annual savings: 22,500 MWh ofelectricity, 40,000 MWh of heat energy, 600,000 m3 ofwater, 400 t of chemicals, reduction of wastewatervolume by 550,000 m3, and wastewater pollution by450 t [6]. Improvement of measurement/monitoringsystem for process parameters optimal control, imple-mentation of automatic control systems, optimization ofexisting automatic control are the most applicableprocess optimization methods [5]. For example, theimplementation of gas analyzer in heat productionprocess allows to analyze the burning process and tooptimize the process with purpose to decrease heatenergy losses and CO, NOx emissions. Implementationof a new control system for the drivers in airconditioning allows to save up to 70% of electricity.Implementation of water consumption open-loop con-trol system in textile dyeing process enables to decreaseelectricity and water consumption by 20%, dyes andchemicals e up to 30%. Optimization of the automaticcontrol systems in textile finishing process enables toreduce water consumption and wastewater volume up to5%, chemicals e 12%, energy e 10% [6].

The benefits of implemented innovations have beenevaluated several times: after CP project implementationand once per year during the payback period. Theevaluation of CP options shows that results of

implemented innovations directly linked to the size ofthe company’s production.

The waste utilization problems are solved effectivelyby using waste recycling methods (Table 5). Alternativeenergy production from organic and wood waste is themost popular innovation implemented in Lithuaniancompanies, for example, implementation of biogassystem in pig-breeding company for energy production(Case 2); the modernization of heat boiler in woodproducts manufacturing company, which allows burn-ing of all kinds of wood wastes for heat recovery. Otherexample of waste recycling could be production ofbriquettes (or granules) from sawdust at wood process-ing company. This CP innovation enables to solvesawdust utilization problem, and to improve thecompany’s economic indicators (Case 3).

Onsite recycling CP techniques enable to solve someenvironmental problems, particularly inefficient con-sumption of heat energy and water. For example, muchimprovement was realized by using the condensate fromthe steam boiler for cleaning of Ni cover (Case 4) andby implementation of heat regeneration from melting-house for damp sand drying in metal manufacturingcompany.

Water pollution and non-effective use of heat energyare solved effectively by implementation of input sub-stitution innovations. This CP method is widely used intextile dyeing processes, for example, substitution of

Table 5

The environmental improvements after implementation of different CP methods (1993e2003) (in % of total company’s consumption)

Environmental effect CP methods

Good

housekeeping

Technology

modification

Process

optimization

Onside recycling Energy recovery

& new products

Reduction of electricity consumption 13 18 11

Reduction of heat

energy consumption

5 19 9 11 5

Reduction of air emissions 19 19 18 10 27

Reduction of waste volume 3 25 52 75 73

Reduction of chemical

materials consumption

5 14 11 70

Reduction of water consumption 12 5 22 16

Reduction of wastewater volume 12 5 30 16

Reduction of wastewater pollution 11 1 30

Reduction of fuel consumption 1 14 23 17 37

Reduction of environmental fees 1 8 52


dispersion dyes by active dyes with high rate of fixationin fabric e about 80%. The dyestuffs, water and energyconsumption reduce by more than 30%. In addition,wastewater pollution after the dyeing process alsoreduced [8,11,12] (Case 5). Examples from the metalfinishing processes: implementation of electric heatingsystem instead of steam for bath heating and use of lesscontaminant citrate instead of glycine in nickel-platingprocess; use of alkaline solution instead of ammoniasolution in zinc-plating process [9,13].

Technology modification method requires large in-vestments in market research, new technology andimplementation. The sectorial documents on Best Avail-able Techniques (BAT) or BAT reference documents(BREFs) are the most popular sources for technologymodification options [15]. There are several examples ofthis CP technique implementation in galvanization pro-cesses in Lithuanian machine and instrument industry:

U implementation of electrochemical burnishing pro-cess instead of chemical burnishing or tin/leadplating processes;

U elimination of cadmium in the plating process;U implementation of powder dyeing technology in-

stead of using electroplating processes.

After implementation of the techniques mentionedabove in the electroplating processes, wastewatervolume was decreased, and it is no more economicallyand environmentally feasible to use the old wastewatertreatment processes due to ineffective use of energy andmaterials [9]. Technology modification is the mostusable CP method for modernization of the wastewatertreatment processes. After optimization of the electro-plating processes in the bicycle production company, itwas decided to eliminate Ni and Cr plating and tooptimize phosphitization process. The optimization ofthe wastewater treatment plant was the next step ofmodernization (Case 6).

3.3. Application of CP methods in theimplementation of the national energy program

One of the main directions of the Revised andInnovated National Program for Increasing the Efficien-cy of Energy Consumption is to implement sometechniques for the effective use of energy within productionprocesses [16,17]. It was estimated that from 20 to 50% ofthe energy recourses could be saved in Lithuanian sectorsof the economy [17]. More precisely, the energyconsumption and possible energy savings potential wereevaluated in 1999. The analysis of the results showed thatthe Lithuanian industrial sector could save about2.3 TWh/year ( from a total consumption of 9.73 TWh)and the transport sector could save about 1.8 TWh/year

( from a total consumption of 13.7 TWh/year) of energyresources [17]. The results of the evaluation of intensityof energy consumption in the different Lithuaniansectors of the economy are presented in Table 6 [18].The generally positive tendency is estimated: the volumeof consumed energy in relation to the GDP (Grossdomestic product) unit has been decreasing.

As stated earlier, implementation of CP in theLithuanian industrial sector enabled them to use energyresources in production processes more effectively;consequently, they have been able to decrease the priceof their products and to become more competitive.

The results of the implementation of CP innovationsin 61 Lithuanian production companies in the last decadeare the following: electricity savings e 28,000 MWh/year, heat energy savings e 62,700 MWh/year. Thisconstitutes almost 1% from the total energy consump-tion in the Lithuanian industrial sector [7].

The results of CP implementation in the Lithuaniantextile industry analysis are the following:

� Energy savings is vitally important for textilecompanies. The difference in energy consumptionfor one unit of textile product in Lithuania and, forexample, in Germany is significant: for linen fabrics,approximately, it is about 18.4% more in Lithuaniathan in Germany (in Lithuania it was 17.3 MJ/m2

while in Germany it was 14.1 MJ/m2), for cottonfabrics e 20.3% (in Lithuania: 18.7 MJ/m2, inGermany: 14.1 MJ/m2), for woollen fabrics e60.4% (in Lithuania: 56.5 MJ/m2, in Germany:22.4 MJ/m2), for stockings e 14.9% (in Lithuania:3.4 MJ/pair, in Germany: 1.5 MJ/pair) [8];� The technical level of processes is crucial for achievingsavings. The situation of the 1980se1990s, when theprice of raw and auxiliary materials was the basicfactor in product price, has changed. Currently,electricity and heat energy costs comprise the mainpart of the product price. The most efficient way toimprove this situation is production optimization ortechnology modification;� During the last decade, 39 CP innovations have beenimplemented and significant improvement of the

Table 6

Energy intensity in Lithuanian sectors of economy (1996e2001) (kgne/

thous. Lt)

Lithuanian sectors

of economy

1996 1997 1998 1999 2000 2001

Industrial 122 114 103 101 93 86

Transport 460 471 495 462 418 385

Agricultural 64 49 47 38 33 32

Trade and service 56 49 41 42 37 35

Notes: energy intensity Z energy consumption (kgne) per GDP (Gross

domestic product) unit (thous. Lt); kgne e kilos of oil equivalent;

1000 Lt Z 289.62 EUR.

Thous.: thousands.


Table 7

Indirect environmental effect due to minimization of energy consumption in Lithuania (1993e2003)

CP methods Reduction of air emissions in energy production (t/year)

Solid particles SO2 CO NOx CO2 Total

Input substitution 0.5 16 5 1 101 123.5

Technology modification 24 915 305 73 5741 7058

Process optimization 181 7096 2364 564 44,508 54,713

Onsite recycling 19 749 249 59 4696 5772

Good housekeeping 6 240 80 19 1504 1849

Total 231 9016 3003 716 56,550 69,516

environmental performance have been achieved(Table 8). Implementation of CP projects saved2.46 million EUR/year. Innovations in wastewaterminimization offer the highest economic benefits e37%. Economic benefits of energy saving innova-tions generate approximately 36% of all savings.Process optimization and improvement of processcontrol constitute 37% of the implemented CPprojects in the energy saving area [6];� The results of analysis of process optimizationinnovations show that implementation of processcontrol innovations enabled the companies to saveabout 10% of heat energy and about 9% ofelectricity [6]. For example, the implementation ofheat energy regeneration systems in the finishingdepartment and optimization of the sizing process inthe biggest Lithuanian textile company decreasedthe energy consumption for 1 m2 of cotton fabric by30%. In 2002, this textile company completedanother CP project on optimization of the condi-tioning system of the production departments.Reduction of electricity consumption in the compa-ny by 8000MWh/year (or 11% of the total companyconsumption) is one of the most important environ-mental benefits. Currently, their energy consumptionindicator (MJ/m2) is at the European level.

Additionally, there is an indirect environmentalbenefit of energy saving e minimization of air emissions.When companies produce heat energy themselves, theycontrol air emissions in accordance to Lithuanianenvironmental requirements. Results of the reductionof air emissions in the energy production processcalculations are presented in Fig. 5. The companies,which purchase heat energy from the municipal heatsupply system do not assess the air emissions inthe burning process. Therefore, the calculation method-ology for different energy supply systems was included inthe database. It enables them to evaluate automatically,the indirect environmental effects due to heat energysavings for all implemented CP measures (Fig. 6).

Table 7 presents the information on the minimizationof air emissions after the implementation of processcontrol innovations in Lithuanian production compa-nies in the last decade. Implementation of various CP

methods can solve one of the most important issues eminimization of green house gas emissions.

3.4. Sectorial evaluation of CP efficiency

First of all, sectorial evaluation of CP efficiency couldbe very useful for the companies, which are implement-ing the CP concept, because it enables comparativeanalysis of energy, raw and additional material con-sumption for production units among the companieswithin the same industrial sector (both nationally andinternationally) [7]. Established environmental indica-tors for a particular sector of the economy could beapplied for environmental performance improvementevaluation on the company level.

Tables 8 and 9 summarize the environmental andeconomic efficiency of implemented CP innovations in18 sectors of the economy in Lithuania in the lastdecade. The analyses revealed that:

U The Cleaner Production concept in Lithuania ismost actively implemented in textile companies. Themain part of the CP investments (81%) has beenmade in textile process optimization [8]. Theseinvestments enabled the textile companies to achievegood results in the areas of more efficient use ofelectricity, heat energy and water, minimization ofwastewater volume and contamination;

51500

10400 90004000

0

10000

20000

30000

40000

50000

60000

Energy recovery& new products

Technologymodification

Onsite recycling Processoptimization

CP methods

t/ye

ar

Fig. 5. Minimization of air emissions by implementation of various CP

methods in Lithuanian companies (1993e2003).


62000

1610011500

4000100 -3000

-10000

0

10000

20000

30000

40000

50000

60000

70000

Processoptimization

Onsite recycling Technologymodification

Goodhousekeeping

Inputsubstitution

Energy recovery& new products

CP methods

MW

h/ye

ar

Fig. 6. Energy savings from application of different CP methods (1993e2003).

U CP investments in the food industry companies aremainly directed to the minimization of energy andchemicals consumption and waste volume reduction[7]. The food and drink production companies haveintensively modernized or optimized their techno-

logical processes and equipment. CP investments inthe technology modification of these companiesconstitute 49%;

U Waste generation in the production processes is themain environmental problem in the food, wood and

Table 8

CP implementation and economic results in Lithuanian industries (1993e2003)

Lithuanian industries The number of

companies

The number of

CP proposals

The number of

implemented innovations

Investments to

CP (million EUR)

Savings

(million EUR/year)

Textile industry 14 42 39 2.74 2.47

Leather industry 2 7 3 0.18 0.23

Manufacture of food

products and drinks

13 27 25 2.03 1.37

Manufacture of chemicals

and chemical products

6 15 14 0.43 0.49

Manufacture of machinery

and equipment

5 5 5 1.03 0.39

Manufacture of fabricated

metal products

3 10 10 0.41 0.36

Manufacture of electrical

machinery apparatus,

appliances and supplies

2 6 6 1.48 0.61

Manufacture of measuring

and controlling equipment

2 6 6 0.36 0.15

Manufacture of non-metallic

mineral products

3 5 4 0.72 0.4

Furniture production 6 10 10 1.03 0.42

Manufacture of wood

and wood products

3 6 6 1.43 1.07

Wholesale trade of oil

products

1 2 2 0.51 0.17

Petroleum refineries 1 4 4 1.3 0.39

Transport and storage 4 7 7 0.31 0.27

Electricity, steam and

water supply

3 5 5 0.54 0.33

Manufacture of glass

and glass products

1 1 0 0.21 0.1

Agriculture and forestry 1 1 1 0.49 0.17

Municipal services 1 4 4 0.12 0.05

Total 71 163 151 15.32 9.44


Table 9

The distribution of CP investments related to different environmental areas and CP methods in % (1993e2003)

Sectors of economy Environmental areas CP methods

Waste Energy Wastewater Air Water OHSa Technology

modification

Process

optimization

Onsite

recycling

Energy recovery

& new products

Textile industry 0.1 63 3,4 19 4.5 10 5 81 13 1

Leather industry 80 13 7 19 2 79

Manufacture of food

and drinks

24 56 6 10 4 49 26 7 18

Manufacture of chemicals

and chemical products

66.8 33.2 7 31 62

Manufacture of machinery

and equipment

44 37 19 90 10

Manufacture of fabricated

metal products

79 18 3 37 49 14

Manufacture of electrical

machinery

100 18 68 14

Manufacture of measuring

and controlling equipment

59 41 5 95

Manufacture of non-metallic

mineral products

89 2 9 89 11

Furniture production 56 4 44 33 23

Manufacture of wood

and wood products

93 7 2 7 10 81

Wholesale trade of oil

products

100 100

Petroleum refineries 12 88 5 95

Transport and storage 16 62 18 4 79 21

Electricity, steam and water

supply

19 8 21 52 81 19

Manufacture of glass and

glass product

100 100

Agriculture and forestry 100 100

Municipal service 100 100

a OHS: Occupational health and safety.

stockbreeding companies in Lithuania. Therefore,CP investments of these industrial branches weredirected to the implementation of waste processingand reuse methods [6];

U Due to rapid changes in the machinery andequipment market, electronics and metal finishingcompanies are forced to invest capital in the tech-nologies modification, equipment improvement andoptimization of existing technological processes inorder to increase environmental efficiency and,herewith, to comply with environmental, technolog-ical, quality and other requirements. Investments ofthese companies for technology modifications con-stituted 42% of the total investments, for theprocess optimization, it was 51% [9];

U Alternative energy production projects are widelyimplemented in the furniture and wood manufactur-ing companies. These companies modernized orreconstructed their existing boiler houses in order toburn all types of wood wastes for heat production;

U In the last 2 years, a number of Lithuanian textile,electrochemical and furniture production companieshave implemented chemicals-related risk manage-ment systems [14]. The chemicals-related risk

assessment at the workplace and for the environ-ment enabled them to identify risk prevention andreduction possibilities in accordance with the CPstrategy. Several risk reduction techniques related tointolerable levels of risk at two textile companiesare at the stage of implementation. Therefore, thisinformation is not included in the tables.

4. Conclusions

1. Since 1993, 153 CP innovations have been success-fully implemented in 71 Lithuanian companiesfrom 18 sectors of economy. The investments inCP innovations are more than 15 million EURwhich generate annual savings of more than 9 millionEUR.

2. In order to systemize all available information onCleaner Production implementation in Lithuaniancompanies from different sectors of economy, CPinnovations database ‘‘Implementation of CleanerProduction in Lithuania’’ was created in 2002. Usingthe database, the analysis of CP efficiency wasperformed to compare economic, environmental andtechnical efficiency of various CP methods and to


evaluate CP efficiency in the different industrialsectors.

3. The results of sectorial analyses of CP efficiency showthat Cleaner Production is widely implemented in allLithuanian sectors of the economy. Each sector hasspecific environmental problems, therefore, differentapproaches are used during evaluation of CP oppor-tunities and different CP methods are implementedfor the environmental performance improvement.

4. The analysis of the efficiency of CP methods showsthat implementation of new technologies has positiveeffects on environmental efficiency, but not alwaysprofitable and useful for the Lithuanian companies.The optimization of existing technological processby the implementation of various engineering tech-niques could be more economically justified.

5. Successful implementation of process optimizationtechniques showed that:� Process control techniques such as implementationof new measurement systems, automatic controlsystems or improvement of existing systems couldhelp to optimize technological efficiency and toimprove environmental performance in economi-cally viable way.

� The process optimization on a company levelallows them to save an average of 18% ofelectricity, 22% of water consumption, 30% inwastewater volume, 23% in fuel consumption, and52% in expenditure for environmental taxes.

6. The implementation of CP methods for energyefficiency showed that:� Implementation of various CP techniques inLithuanian production companies enabled themto save about 1% of their total energy consump-tion. Of this, 68% of the energy saving wasachieved by implementing process optimizationinnovations and 18% by implementing onsiterecycling innovations;� Energy recovery and new product measuresenabled companies to produce 700MWh/year ofelectricity and 79,000MWh/year of heat energy byalternative methods, e.g. by burning wood andorganic wastes.

7. The documented results on CP implementation inLithuanian companies created a prerequisite for CPintegration in Environmental Management Systemand for minimization of environmental impactsduring the entire life cycle of their products.

Case 1. Reconstruction of heat supply system for yarn production

CP method: process optimization

Problem description

1) Manually controlled steam input valve operated not effectively, with steam losses. Flow meter dataand evaluation of the devise error showed the steam losses about 52 kg/h. This valve was closedapproximately 12 h/week. Production losses were approximately 30 t/year. Steam losses wereapproximately 32 t/year.

2) Steam produced in the boiler house had pressure of 11 bars and was reduced to 6 bars (for thetechnological process) in the company’s heating centre. Steam reduction equipment (steamregulator) could not maintain the required pressure and there were fluctuations, G1.5 bar. Theproduction process requirements were not fulfilled, causing damages of final product and steamlosses were approximately 310 t/year.

3) Pressure regulators in twisting department could not maintain required pressure of 1 bar. Thepressure of steam flow ranged from 0.7 to 1.3 bars. The production process requirements were notfulfilled, causing damages to equipment and steam losses were 170 t/year. Yarn spoilages due toone ineffective pressure regulator were approximately 16 t/year.

Technical solution

1. Reconstruction of heat supply system by:� Replacement of manually controlled valve by automatic one;� Installation of a new system for steam reduction.

2. Reconstruction of steam supply system in twisting department:� Replacement of ineffective steam pressure regulators;� Replacement of ineffective steam traps.

(continued on next page)


Case 1 (continued )

Environmental benefit

Implementation of this CP project resulted in heat energy savings e 800 MWh/year. That constitutes11% of the total heat energy consumption in the company.

Economic benefit

CP investments e 46,000 EUR; estimated savings e 30,000 EUR/year, including savings due toreduction of environmental costs e 26,000 EUR/year; payback period e 1.5 years.

Case 2. Implementation of biogas system for the heat energy and electricity production to solveorganic waste utilization problem in a pig-breeding company

CP method: energy recovery & new products

Project description

The main problem of the company was organic waste from slaughterhouse, meat department andpiggery. The organic waste from the slaughterhouse and meat department was transported to the glueproduction company, where they were used as a raw material. Dung was collected in the dung-pit andused as a fertilizer. Wastewater was transported to the municipal wastewater treatment plant. Organicwaste from the piggery was transported as fertilizer to farms. The total expenditure for organic wasteutilization was 73,000 EUR/year.

It was decided to install a biogas generation system, which helped them to solve two importantproblems in Lithuania:

� Organic waste utilization;� Alternative energy production to minimize air emissions.

In addition, the company collects organic waste from the nearest piggeries and settlements. Organicwaste is used as raw material for electricity and heat production and for high quality fertilizer (bio-compost) production.

Experimental analyses have showed that 1120 m3/day of biogas can be produced in the bioreactor(methane tank). It means that the company can produce more than 6 MWh/day of energy. Practically, 1/3of this energy could be converted to electricity in the cogeneration equipment, another 2/3 of the energyare heat energy and losses to the air.

Environmental benefits

Reduction of company’s organic waste by 9000 t/year; production of alternative energy (2200 MWh/year); excluding coal in heat production (50 t/year); reduction of diesel fuel consumption by 10,137 l/year; direct and indirect reduction of air emissions by 1100 t/year.

Economic benefits

CP investments e 557,518 EUR; estimated savings e 178,000 EUR/year, including savings due toreduction of environmental costs e 110,000 EUR/year; payback period e 3.13 years.


Case 3. Production of granules from the sawdust in a wood processing company

CP method: energy recovery & new products

Project description

About 55% of wood waste (35% of wood scrap, 15% of sawdust and 5% of bark) or 11,000 m3/year aregenerated during the production of double sawed wood. The wood scrap was sold with very narrowprofit margins. Sawdust and bark were stored in the wood waste site near the company. Wood wasteutilization was the main environmental problem in the company. After the feasibility analysis of severalalternative CP options, it was decided to implement granule production technology. The granules havethe following advantages in comparison with other types of fuel: higher caloricity, easily transported,environmentally friendly (less air emissions from burning process), which is a big demand in Europeancountries.

The main company environmental problem was solved, and wood sawdust became raw material forgranules production, wood barks e raw material for heat energy production.

The air emissions decreased by 99.7%: CO2 e 100%, NOx e 15%, SO2 e 83%.

Economic benefit

CP investments e 218,000 EUR; savings e 142,500 EUR/year, including savings due to reduction ofenvironmental costs e 10,000 EUR/year; payback period e 1.53 years.

The company’s productivity was increased by 2.5%, export volume by 6%, annual turnover by 10%.

Case 4. Condensate recycling from the steam boiler for Ni covers cleaning during nickel-plating process

CP method: onsite recycling

Problem description

Approximately 320 m3/year of distilled water was used for Ni covers cleaning in metal finishingprocess. The price of water after distillation increases 9e10 times. Furthermore, condensate generatedin the steam production process was directed to the sewerage system.

Technical solution

To use condensate from the steam boiler for the nickel-plating process. The condensates technicalcharacteristics correspond to the requirements for cleaning water. Condensate hardness is about 0.4equiv./l, permissible norm e 1.18 equiv./l.

Environmental benefit:

Distilled water consumption and wastewater volume decreased by 320 m3/year. This constitutedabout 45% of the total distilled water consumption in the company.

Economic benefit

CP investments e 9000 EUR; savings due to reduction of environmental costs e 15,000 EUR/year;payback period e 0.6 year.


Case 5. Scratchy textile dyeing by active dyes, using one-bath method instead of dispersive dyes usingthe two-bath method

CP method: input substitution

Problem description

Inefficient use of dyes and energy as well as wastewater polluted by dyes and salt were the mainenvironmental problems in a textile company finishing department.

Technical solution

To use new active dyes with 80% fixing instead of active dyes with 45% fixing.It allows to decrease the number of cycles of dyeing process, water, dyes and chemical consumption,

wastewater volume and pollution, labour expenditure and to increase productivity.


The implementation of CP innovation enabled to reduce water consumption by 50%, salt e by 75%,dyes e by 44%, energy e by 50%. Water pollution decreased almost 75%.

Economic benefit

Costs of dyeing process have decreased by 6%. Savings e 20,000 EUR/year, including savings due toreduction of environmental costs e 5000 EUR/year.

Case 6. Modernization of metal finishing department at bicycle company

CP method: technology modification

Project description

Ineffective use of energy, raw materials (dyes, chemicals) losses were the main reasons formodernization of electroplating processes. It was decided to apply technology modification. Ni and Crplating processes were eliminated, and phosphatization process was optimized. The reduction ofgalvanic bath volume (from 0.6 m3 to 0.43 m3), the implementation of electrical water heating, reductionof HCl use were the main steps of modernization.

As wastewater volume and quality have changed, it was no longer economically and environmentallyfeasible to use the old wastewater treatment facilities. The reconstruction of wastewater treatment plantand implementation of an automatic control system were the next step of this project. A new coagulantwas selected for better precipitation of the sediments.


The implementation of CP project enabled the company to save 80 MWh of electricity annually (2% ofthe total company consumption), 300 MWh of heat energy (1%), 2 t of chemicals (1.5%), to reduce wastevolume by 12 t/year (4%), and potable water consumption by 200 m3/year (5%).

Economic benefit

CP investment e 185,000 EUR resulted in savings of 73,000 EUR/year, including savings due toreduction of environmental costs e 63,000 EUR/year. The overall payback period was 2.5 years.


References

[1] Economic and environmental benefits of the waste minimization

in Estonian, Latvian and Lithuanian industry. In: Case studies.

WEC, ISBN 9986-13-384-X; 1996.

[2] Stasiskiene Z. Major principles and development of cleaner

production follow-up system. Journal of Environmental Re-

search, Engineering and Management 2000;2(12):51e61.

[3] Staniskis J, Stasiskiene Z. Promotion of cleaner production

investments: international experience. Journal of Cleaner Pro-

duction 2003;11:619e28.

[4] Stasiskiene Z. Evaluation of cleaner production Development

possibilities in Lithuanian Industry. PhD thesis. Kaunas Techno-

logical; 1999 [in Lithuania].

[5] Staniskis J, Kliopova I. Process control for cleaner production:

possibilities and efficiency. Journal of Environmental Research,

Engineering and Management 2001;2(16):32e41.

[6] Kliopova I. Cleaner production through Process Control:

analysis, methodical and implementation. PhD thesis. Kaunas

Technological; 2002 [in Lithuania].

[7] Staniskis J, Stasiskiene Z, Kliopova I. Cleaner production:

systematic approach. Monograph. Kaunas: Technologija, ISBN

9955-09-312-9; 2002.

[8] Kliopova I. Cleaner production in Lithuanian textile industry.

Journal of Environmental Research, Engineering and Manage-

ment 2000;3(13):42e51.

[9] Kliopova I, Bagdonas A. Optimization of electroplating processes

in Lithuanian machine and instrument industry. Journal of

Environmental Research, Engineering and Management 2003;

3(25):29e37.

[10] Staniskis J, Stasiskiene Z, Arbaciauskas V. Introduction to

cleaner production concepts and practice. Kaunas: Technologija,

ISBN 9955-09-019-7; 2001.

[11] Van Berkel R, Walstra J. Implementation of cleaner production in

Lithuanian textile industry, technical information. IVAM Envi-

ronmental Research University of Amsterdam; 1997.

[12] Van der Meer J, Van Berkel R. Experiences of cleaner production

in the Lithuanian textile industry. IVAM Environmental Re-

search University of Amsterdam; 1998. EU/LIFE Technical

Assistance program Lifetcy 95/LT/875.

[13] Tarozaite P, Giliene O. Regenerative citrate solution in chemical

nickel e plating process. Journal of Technology and Construction

in Electronic Equipment 2002;4(5):43e6.

[14] Kruopiene J, Staniskis JK. Chemicals control and management.

Kaunas: Technologija, ISBN 9955-09-526-1; 2003.

[15] Activities of the European Integrated Pollution Prevention

and Control Bureau. Reference Documents on Best Available

Techniques !http://eippcb.jrc.es/pages/FActivities.htmO.

[16] National Energy Strategy, approved by Seimas of the Republic of

Lithuania on 10 October 2002 No IX-1130. Vilnius; !http://www3.

lrs.lt/cgi-bin/preps2?Condition1Z197078&Condition2ZO.

[17] National Energy Efficiency Program. Resolution No 319 of the

Ministry of Economy of the Republic of Lithuania, 19 September,

2001; !http://www.ena.lt/en/main_veikla_vartojimas.htmO.

[18] Juska A, Bartkus S. Energy in Lithuania. Kaunas: Lithuanian

Energy Institute, ISBN 9986-492-71-8.!http://www.lei.lt/lith3/

Energy%20in%20LT-2001.pdfO; 2002.

Dr. Irina Kliopova, lecturer at the Institute of Environmental

Engineering, Kaunas University of Technology.

Main research areas: process control in cleaner production, cleaner

production financing; environmental management.

Address: Teatro str. 8-16, LT-2009 Vilnius, Lithuania. Tel.: C370 5

2649174; fax: C370 5 2649175; E-mail: [email protected].

Prof. Dr. hab. Jurgis Staniskis, Director of the Institute of

Environmental Engineering, Kaunas University of Technology.

Main research areas: environmental systems, life cycle management,

cleaner production, financial engineering, industrial ecology.

Address: K. Donelaicio str. 20, LT-44239 Kaunas, Lithuania.

Tel.: C370 37 300760; fax: C370 37 209372; E-mail: jurgis.staniskis@

ktu.lt.

http://eippcb.jrc.es/pages/FActivities.htm

http://www3.lrs.lt/cgi-bin/preps2?Condition1=197078&Condition2=>

http://www3.lrs.lt/cgi-bin/preps2?Condition1=197078&Condition2=>

http://www.ena.lt/en/main_veikla_vartojimas.htm

http://www.lei.lt/lith3/Energy%20in%20LT-2001.pdf

http://www.lei.lt/lith3/Energy%20in%20LT-2001.pdf


