The Life Cycle Management Navigator Cleaner Production Assessment Optional Training Session

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The Life Cycle Management NavigatorCleaner
Production Assessment Optional Training Session
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Cleaner Production AssessmentWhat is CPA?
What?
The purpose of CPA is to identify options for
preventing or reducing wastes and emissions at
source.
1. What types and quantities of wastes and
emissions are being generated?
2. How much do these wastes and emissions cost?
CPA
5. How can they be prevented?
3. Where exactly are these wastes and emissions
generated?
4. Why are they generated?
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Cleaner Production AssessmentWhat is CP?
What?
Cleaner Production is the continuous improvement
of industrial processes, products and services to
reduce the use of natural resources, prevent
pollution at the source and reduce waste
generation at the source in order to minimise
risks to human population and the environment.
Source Van Berkel, R.
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Cleaner Production AssessmentWhat is CP?
What?
Services/ Products
Human beings
Continuous
Preventative
Strategy for
Risk reduction
Processes
Environment
Integrative (air, water, land)
Source UNEP Industry and Environment
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Cleaner Production AssessmentWhat is CP?
What?
One gram of prevention
is better than
a kilogram of cure
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Cleaner Production AssessmentIntegrated,
Preventative Environmental Protection
What?
START
Reduction of Waste
Re-use of Waste
Level 1
Level 2
Level 3
Reduction at Source
Internal Recycling
External Recycling
Biogenous Cycles
Product Modification
Process Modification
Structures
Materials
Good Housekeeping
Changed Material Selection
New Technologies
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Cleaner Production AssessmentAreas of Application
Where?

• CPA concentrates on
• the unit operations of a company!
• Assessment of the preventative options are
  performed in the order of
• Plant operations Production Dept.
  layout
• Process design Production Logistics
  Dept.
• Product design Marketing Design Dept.
• Research RD

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Cleaner Production AssessmentBenefits
Why?

• It is a pro-active approach!

• Environmental Management Programme
• Not necessarily preventative.
• Audits focus on regulatory requirements and known
  environmental impacts.

• Assessment in a Cleaner Production Programme
• Preventative.
• All wastes and emissions are considered,
  irrespective of their impacts.

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Cleaner Production AssessmentBenefits
Why?

• The main gain occurs through
• conservation of resources!

• A small Lebanese Olive Oil Bottler
• realised significant cost savings
  (4,000/year with lt3 days payback period)
• reduced its end-of pipe impact and requirement
  for treatment
• Just by applying good housekeeping measures
  (automatic control of filling of a reservoir)

Source GTZ
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Cleaner Production AssessmentBenefits
Why?
Product Quality
Compliance with the Regulations
Working Environment
Improvements in ...
Company Product Image
New Market Opportunities
Environmental Cost Reduction
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Cleaner Production AssessmentHow to implement
How?
Adapted from UNEP DTIE UNEP Indian National
Productivity Council Stone
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Cleaner Production AssessmentStep 1 - Get
Started!
How?

• A. Gather a CPA team.
• B. Carry out on-site inspection.
• C. Try to list roughly
  
  the process steps of
  the
  complete operation.
• D. Identify and select
  
  the most wasteful process steps.

1. Get Started!
2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options
4. Select CP Solutions via EnTA

OUTCOME OF STEP 1 Selection of area of focus
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Cleaner Production AssessmentStep 2 - Analyse
your Process Steps
How?

• A. Prepare process flow chart for the focus area
• B. Make material and energy balances
• C. Try to assign costs to the amount of waste
  generated
• D. Depending on the analysis, locate the cause
  of waste generation.

1. Get Started!
2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options
4. Select CP Solutions via EnTA

OUTCOME OF STEP 2 Listing of causes of waste
generation
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Cleaner Production AssessmentStep 3 - Generate
CP Options
How?
1. Get Started!

• A. Develop CP opportunities.
• B. Eliminate the unworkable ones.

2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options

4. Select CP Solutions via EnTA
OUTCOME OF STEP 3 A List of CP Opportunities
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Cleaner Production AssessmentStep 4 - Select CP
Options through EnTA
How?

• A. Carry out Environmental
  Technology
  Assessment (EnTA)
• B. Select options for implementation

1. Get Started!
2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options

4. Select CP Solutions via EnTA
OUTCOME OF STEP 4 A List of CP Solutions
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Cleaner Production AssessmentENTA Process
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Source UNEP DTIE
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Cleaner Production AssessmentStep 5 - Implement
CP Options
How?

• A. Prepare for implementation
• B. Implement CP options
• C. Monitor and evaluate results

1. Get Started!
2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options

4. Select CP Solutions via EnTA
OUTCOME OF STEP 5 Payback of CP applications
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Cleaner Production AssessmentStep 6 - Close the
Loop and Maintain CP!
How?

• A. Keep on with the CP solutions
• B. Continuously identify
  select
  wasteful process steps.

1. Get Started!
2. Analyse your process steps
6. Maintain CP
5. Implement CP solutions
3. Generate CP Options

4. Select CP Solutions via EnTA
OUTCOME OF STEP 6 On-going CP efforts
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Cleaner Production AssessmentHow to implement
How?
Adapted from UNEP DTIE UNEP Indian National
Productivity Council Stone
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Cleaner Production Assessmentin Hotel Caravane
Serail
Case Study

• Hotel Caravane Serail profile
• Location Nefta,Tunisia
• Personnel 50
• 399 beds 300 000 guests/year
• Cleaner Production Audit identified the following
  key areas
• Water consumption
• Water quality
• Electricity consumption
• Propane

Water scarcity in the area - the hotels
principal attraction Water charges represent 43
of total utility expenditures

Source INEM
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Cleaner Production Assessmentin Hotel Caravane
Serail
Case Study

• Examples of recommended measures (total
  cost-savings up to US10100 per year)
• Installation of a pool cover in the swimming pool
  for reduction of evaporation
• Investment of US150 / financial benefit of
  US380/year / payback period 5 months
• Installation of water aeration devices in the
  rooms
• Investment of US580 / financial benefit of
  US1025/year / payback period 7 months
• Additionally, the hotel requested assistance in a
  training and communication programme for the
  hotels employees.

Source INEM
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Cleaner Production Assessmentin Raval Paper Mills
Case Study

• Raval Paper Mills profile
• Location Uttar Pradesh, India
• Personnel 300
• Sector agricultural residue-based paper mill
• Main products unbleached semi-kraft paper and
  bleached and dyed writing paper
• Operating capacity 25 t/day

CP Demonstration Project
Waste minimisation team (Raval, NPC UNIDO)
Process steps Material energy
balance Causes of waste generation Waste
minimisation measures Prioritisation of measures
implementation plan





Source INEM
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Cleaner Production Assessmentin Raval Paper Mills
Case Study
Economic benefits the investment of US80000
made in 30 measures generated savings of
US88000 per year (US451.68/day)
Area of saving (examples) Before CP After CP Cost Savings (US/day)
Production capacity 25 t/day 27 t/day 88.24
Water consumption 4400 m3/day 3443 m3/day 15.35
Energy consumption 1190 kWh/t paper 1150 kWh/t paper 83.38
Source INEM
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Cleaner Production Assessmentin Beverage
Production - Nicaragua
Case Study

• Cleaner Production Centre Nicaragua, in close
  cooperation with companies employees (260)
  suggested CP measures, resulting in savings
  around US 50 000 annually.
• Some results following implantation
• Water use dropped from 11 litres to around 5
  litres for every litre of finished product
• Electricity savings
• For refrigeration 12
• For air conditioning 30
• Employees training resulted in 30 reduced costs
  for broken bottles
• Enterprise staff is now able to continuously
  improve the environmental performance of
  production process.

Source UNIDO
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Cleaner Production AssessmentTips for Action!
Tips

• Common sense and willingness are the only
  ingredients for CP application!
• Use rough but explanatory figures and sketches!
• Do not get buried under documentation!
• Have an organised approach! Develop CP Culture!
• Delegate responsibilities
• Fix targets
• Review progress
• Develop an ambitious but realistic time schedule.
• Development of an Action Plan is a way to an
  organised
• approach.