Transcript Slide 1

ACME
Applying CLEANER PRODUCTION to MULTILATERAL ENVIRONMENTAL AGREEMENTS
Case Studies
and Success Stories
SESSION 10
United Nations Environment Program
Division of Technology Industry and Economy
Swedish International Development Agency
OUTLINE
Objectives of this session
1/ Cases studies on CP and UNFCCC
> Case #1 - Pulp and Paper
> Case #2 - Textile
> Other examples
2/ Cases studies on CP and Basel Convention
> Case #1 - Tannery
> Case #2 - Electroplating
> Other examples
3/ Cases studies on CP and Stockholm Convention
> Case #1 - Pulp and Paper
> Other examples
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CP & UNFCCC
Case #1 - Pulp and Paper
Name of the Company:
Agarwal Duplex LTD.,
Muzaffarnagar, INDIA
Production:
Kraft paper and board from waste
paper.
Context:
Cleaner Production studies were
conducted in the industry. The CP
Team was formed and the entire
plant was taken as focus area.
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CP & UNFCCC
Case #1 - Pulp and Paper
CAUSE ANALYSIS OF THE WASTE STREAM
Operation
Electricity
Generation
Sources of
waste
DG sets
Nature of
waste
- GHG
emissions
- Due to frequent power failures of the
electricity through grid supply the paper
machines use to stop and there by the
waste of paper because of breaking of
paper while rolling them into reels
- Noise
- The capacity utilization of the machines
was low
- Solid
- High GHG emissions from the use of
Diesel in DG Sets
- Capacity
Utilization
Steam
Production
Coal fired Boile
Probable Causes of waste
generated
GHG
- Low quality of electricity supplied
- Use of fossil fuel
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CP & UNFCCC
Case #1 - Pulp and Paper
CLEANER PRODUCTION OPTIONS IDENTIFIED
CP technique used:
> Process optimization
> Input material change
> Technology change
CP options identified:
1. Replace the existing boiler with a new fluidised bed boiler of hogh
pressure which uses bagasse as a fuel in place of coal in the old
boiler.
2. Replace the diesel generating set for electricity production with a
extraction cum condensing turbine and use the steam from the new
high pressure boiler.
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CP & UNFCCC
Case #1 - Pulp and Paper
RESULTS OF THE CP OPTION IMPLEMENTATION
Investment 2 million US$
Operational cost same as earlier
Net annual savings 1.5 million US$
Payback period 16 months
Reduction in GHG emissions ~ 37.366 Tons per year
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CP & UNFCCC
Case #2 - Textile
Name of the Company:
Luthra Dyeing and Printing Mills,
Surat, INDIA
Production:
Printed and dyed fabric of polyester,
cotton, rayon.
Context:
Cleaner Production studies were
conducted in the industry. The CP
Team was formed and the boiler
house was taken as focus area.
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CP & UNFCCC
Case #2 - Textile
CAUSE ANALYSIS OF THE WASTE STREAM (1)
Operation
Steam
generation
Sources of
waste
Boiler
Nature of
waste
Flue Gases
Probable Causes of waste generated
- Air-fuel ratio is not maintained
- No monitoring of relevant parameters (O2 or
CO2)
- No device/method for heat recovery
- Air ingress through various portion
- Air quantity and pressure is not sufficient
- Distribution of primary air through grate
Un-burnts in Ash - Sizing of coal not proper
- Design of grate not appropriate
- Firing rate is not uniform
- Manual ash removal
- Poor fuel quality and combustion is not proper
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CP & UNFCCC
Case #2 - Textile
CAUSE ANALYSIS OF THE WASTE STREAM (2)
Operation
Steam
generation
Sources of
waste
Boiler
Nature of
waste
Probable Causes of waste generated
Blow-down
- Bad Boiler feed water quality
- Condensate is not recovered
- Boiler drum TDS is not maintained as required
Radiation Loss
- Un-insulated portions of boiler
- Openings
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CP & UNFCCC
Case #2 - Textile
CLEANER PRODUCTION OPTIONS IDENTIFIED (1)
CP technique used :
> Good House Keeping
> Operational Practices
> Process Optimization
> Raw Material Substitution
> New Technology
> New Product Design
> Onsite Recycle & Reuse
> Equipment Modification
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CP & UNFCCC
Case #2 - Textile
Waste Stream
Heat Loss due to
Flue gas
Unburnt in Ash
Blow down loss
Radiation Loss
CP Options
- Install air heater for recovery of waste heat
- Plug all the air leakages into boiler furnace
- Conversion of existing boiler to the FBC boiler
- Replacing existing boiler to FBC Boiler
- Optimize the coal sizing by proper crushing & sieving
- Modify the existing grate by reducing the gaps between the rods
- Optimize the firing rate by use of stoker firing
- Install water treatment system (RO) plant
- Change the water used in the boiler from tanker water to Municipal Supply Water
- Install conductivity meter to check boiler drum water quality and
therefore optimize the blow down rate
- Recover flash steam from boiler blow down
- Re-circulate condensate from steam separator and wherever possible
- Insulate all the bare and damaged portions
- Insulate the flanges (125 Flanges)
- Installation of Steam Traps ( Thermo Dynamic Traps)
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CP & UNFCCC
Case #2 - Textile
RESULTS OF THE CP OPTION IMPLEMENTATION
Investment 204.000 US$
Net annual savings 196.300 US$
Payback period 11 months
Reduction in GHG emissions 1300 Tons per year
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CP & UNFCCC
Other examples - A
ILUKA MINING AND MINERAL PROCESSING
Focus area Air emissions and heat from kiln
CP Option Waste heat recovery, initially thinking of installing
high-cost wet scrubber technology.
Results Large investment (but feasible) especially when
compared to traditional end-of-pipe treatment
system.
Reduction in GHG emissions by 52.000 Tons/year
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CP & UNFCCC
Other examples - B
BUTTERCUP BAKERIES
AUSTRALIA
Focus area Baking oven
CP Option Installation of heat exchanger
for a waste heat recovery system.
Results Investment
Annual savings
Reduction in GHG
10,000 US$
2.000 US$
20 %
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CP & UNFCCC
Other examples - C
G STEEL PUBLIC COMPANY LIMITED
THAILAND
Focus area Electric Arc Furnaces (EAF)
CP Option Repositioning of EAF burner to increase
consistency of injection and consumption
of oxygen via oxygen lance.
Results Investment
Annual savings
Reduction in GHG
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10,000 US$
3.839.168 US$
42.943 Tons/year
CP & UNFCCC
Other examples - D
ASSOCIATED MOTORWAYS LIMITED
SRI LANKA
Focus area Compressors and Compressed Air System
CP Option Replacement of old inefficient compressor with
screw compressors.
Results Investment
Annual savings
Reduction in GHG
29,500 US$
43,137 US$
102 Tons/year
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CP & UNFCCC
Other examples - E
HANOI CERAMIC TILES
VIETNAM
Focus area Vertical dryer
CP Option Use of waste hot air from rapid and final
cooling in the vertical dryer.
Results Investment
Annual savings
Reduction in GHG
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21,500 US$
36,720 US$
328 Tons/year
CP & BASEL CONVENTION
Case #1 - Tannery
Name of the Company:
Mohd. Usman Tanneries,
INDIA
Production:
Leather from sheep and goat skins
(from raw hides to finished stage).
Context:
Cleaner Production studies were
conducted in the industry. The CP
Team was formed and the tanning
section was taken as focus area.
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CP & BASEL CONVENTION
Case #1 - Tannery
CAUSE ANALYSIS OF THE WASTE STREAM
Operation
Chrome
tanning
Sources of
waste
Nature of
waste
Spent
Wastewater
tanning bath,
wash
streams
Probable Causes of waste generated
- Improper water measurement
- Chemicals weighing
- Spillages of the chemicals from the drum
feeding hole
- No recovery of spent chrome
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CP & BASEL CONVENTION
Case #1 - Tannery
CLEANER PRODUCTION OPTIONS IDENTIFIED
CP technique used:
> Recovery, recycle and reuse.
CP options identified:
> Recover the chrome by addition of magnesium oxide.
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CP & BASEL CONVENTION
Case #1 - Tannery
RESULTS OF THE CP OPTION IMPLEMENTATION
Investment 7.500 US$
Operational cost 2 000 US$/year
Net annual savings 6.500 US$
Payback period 14 months
Reduction in toxicity and ~ 15 Tons per year due to
volume of hazardous waste negligible amount of chrome in
generation waste water.
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CP & BASEL CONVENTION
Case #2 - Electroplating
Name of the Company:
Atlas cycles, Sonepat, INDIA
Production:
Bicycles.
Context:
Cleaner Production studies were conducted
in the industry. The CP Team was formed
and following focus areas identified:
1. Hazardous waste generation from
electroplating section.
2. Cyanide bearing waste from case
hardening section.
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CP & BASEL CONVENTION
Case #2 - Electroplating
CAUSE ANALYSIS OF THE WASTE STREAM
Operation
Sources of waste
Nature of
waste
Probable Causes of waste generated
Chrome
Plating
Spent plating bath
and wash streams
Wastewater
with Hexa
valent
Chrome
- High quantity of water used
- Hexavalent chrome used
- Conversion of hexavalent chrome to
trivalent chrome by ferrous sulphate
Cyanide
Plating for
Case
hardening
Spent plating bath
and wash streams
Waste water
with cyanide
- Chlorine for cyanide removal
- Large amount of lime used
- Presence of ferrocyanide compounds
making the sludge hazardous
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CP & BASEL CONVENTION
Case #2 - Electroplating
CLEANER PRODUCTION OPTIONS IDENTIFIED
CP technique used:
> Process optimization
> Input material change
> Technology change
CP options identified:
1. Replacing use of ferrous sulphate by sodium met-bi-sulphite for
reduction of hexavalent chrome to trivalent chrome.
2. Adoption of new technology to replace case hardening by cyanide
plating to gas carburizing.
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CP & BASEL CONVENTION
Case #2 - Electroplating
RESULTS OF THE CP OPTION IMPLEMENTATION
CP OPTION
INVESTMENT
SAVINGS/ BENEFITS
PAY BACK
1
NIL
No monetary savings in process
but hazardous sludge reduced by
30% (15 Tons/year).
IMMEDIATE
2
US $ 10,000
No direct monetary savings but
hazardous waste sludge reduced
by 74% (50 Tons/year).
IMMEDIATE
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CP & BASEL CONVENTION
Other examples - A
DUTCH IRON FOUNDRIES
Focus area Sand reclamation
CP Option Optimisation of the sand dosing system.
Results Investment: 0 US$
Annual savings: 40.000 US$
Reduction in hazardous wastes:
- 560 Tons/year
Reduction of raw material used: - 7,5%
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CP & BASEL CONVENTION
Other examples - B
DINTEX DYECHEM LTD.
Vinyl Sulphone Intermediate Manufacturer.
INDIA
Focus area Unit processes : Sulfonation, Condensation
CP Option Acid recovery system and spray drier.
Results Investment
Annual savings
Reduction in hardous wastes
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355.260 US$
415.790 US$
- 6.100 Tons/year
CP & BASEL CONVENTION
Other examples - C
Manufacture of Chemicals and Chemical Products
UNITED STATES
Focus area Reactor wash solution with alcohol, phenols
formaldehyde resins and water.
CP Option On site recycling and recovery by distilling and
reusing the alcohol.
Results Investment
Annual savings
Reduction in hardous wastes
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Not reported
15.000 US$
- 67%
CP & BASEL CONVENTION
Other examples - D
Manufacture of Lead Acid Battery Plates
FRANCE
Focus area Battery Plate Manufacturing line.
CP Option Process optimization of the manufacturing line by
changing to automatic plant.
Results Investment
Annual savings
Reduction in hardous wastes
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214.000 US$
Not reported
- 85%
CP & BASEL CONVENTION
Other examples - E
Manufacture of Fabricated Metal Products
(Solar Cell Wafers, Submarine silencer, satellite dish components)
UNITED STATES
Focus area Chemical Etching on stainless steel and Nickle.
CP Option Baking soda/water developer has been substituted for a
combination of methylene chloride, 1,1,1 trichloroethane and
perchlorethylene solvent ; Alkaline cleaners have been
substituted for methanol ; sulfuric acid-hydrogen peroxide mix
has replaced a chrome-based brightener Process optimization
of the manufacturing line by changing to automatic plant.
Results Investment
Annual savings
Reduction in hardous wastes
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Not reported
Not reported
- 20% (135 Tons)
CP & STOCKHOLM CONV.
Case #1 - Pulp and Paper
Name of the Company:
ITC, Bhadrachalam Papers Ltd.
Bhadrachalam, INDIA.
Production:
Paper.
Context:
Cleaner Production studies were
conducted in the industry. The CP
Team was formed and the paper
bleaching section was taken as
focus area.
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CP & STOCKHOLM CONV.
Case #1 - Pulp and Paper
CAUSE ANALYSIS OF THE WASTE STREAM
Operation
Bleaching
Sources of
waste
Bleaching
process
Nature of waste
- Hazardous Air
Emissions
- Water Pollution
Load
- Energy Loss
Probable Causes of waste
generated
- Use of elemental chlorine in form
of bleaching powder/ NaOCl
- Old Technology
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CP & STOCKHOLM CONV.
Case #1 - Pulp and Paper
CLEANER PRODUCTION OPTIONS IDENTIFIED
CP technique used:
> Input material change
> Technology change
CP options identified:
1. Installation of a new R8 process chlorine dioxide generation plant of
7 tons per day capacity.
2. Modify the bleaching sequence to “chlorine dioxide / ozone / chlorine
dioxide”.
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CP & STOCKHOLM CONV.
Case #1 - Pulp and Paper
RESULTS OF THE CP OPTION IMPLEMENTATION
Investment 10,32 million US$
Net annual savings 4 million US$
Payback period 2,15 years
Results - Reduction in AOX emissions.
- Improved brightness quality
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CP & STOCKHOLM CONV.
Other example
Polyerethane manufacturing
GERMANY
Focus area Adsorption of CCl3F.
CP Option Use of charcoal bed for adsorption of CCl3F.
Results Investment 350000 US $
Elimination of CCl3F from the environment
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CONCLUSION
End of session 10
Thank you for your attention…
Any questions?
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