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Introductory Resource Efficient and February 2017 Cleaner Production Training Resource Efficient and Cleaner Production Sector Applications Centre for Assessment & Development of Green Bekasi, 7 February 2017 Industry & Environment

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 1

Resource Efficient and Cleaner Production Sector Applications

Bekasi, 7 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

Root Source Analysis WHERE? Quantification of the different usages and sources Root Cause Diagnosis WHY? Factors contributing to usage and sources Option Generation HOW? Alternative ways to avoid the identified causes

Literature, checklists In House Innovation

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February 2017 RECP Introductory Training 2

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 2

Efisiensi Sumber Daya dan Produksi Bersih

Glass Industry Ceramic Industry Metal Products Industry

February 2017 RECP Introductory Training 3

RECP for green industry

February 2017 RECP Introductory Training 4

Glass industry is energy and resource intensive

  • sector. Diverse set of measures available to

improve productivity and energy efficiency, and reduce waste and emissions (GHG, NOx).

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 3

Glass Industry in Gujarat (India)

  • 1. Optimize combustion efficiency of furnace
  • Target 2-6% O2, 8-11% CO2, <400ppm CO and minimum

excess air

  • Measure O2 and regulate air flow (VFD on fan)
  • Investments typically 30-45,000 USD (up to 100 tpd)
  • Payback period typically 3-8 months

February 2017 RECP Introductory Training 5 February 2017 GCPC (2016), Cleaner Production in Glass Sector

Glass Industry in Gujarat (India)

  • 2. Electricity savings
  • Variable Speed Drives on large motors (blowers)

– Investment USD1-4,000 – Pay back 2-9 months

  • Optimize compressed air usage

– Eliminate unnecessary use and leaks – Reduce pressure variations – Efficient compressors – Reduce air inlet temperature (3oC decrease saves 1% energy)

February 2017 RECP Introductory Training 6 February 2017 GCPC (2016), Cleaner Production in Glass Sector

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 4

Glass Industry in Gujarat (India)

  • 3. Oxygen Enhanced Combustion

– Better glass quality, lower emissions (NOx and PM), higher throughput, energy savings (10-50%) and no air-preheating – Investments 180-300,000 USD – Pay back 18-30 months

  • 4. Batch and Cullet Preheating

– Direct or indirect – 10-20% reduction of specific energy consumption – 10-15% increase in throughput – Investments 75-225,000 USD – Pay back 28-34 months

February 2017 RECP Introductory Training 7 GCPC (2016), Cleaner Production in Glass Sector

Energy Use in Glass Industry

  • Over the past twenty years, glass demand has

grown more quickly than GDP and is still growing at nearly 4% per year.

  • About 0.5-0.8 EJ of energy is used for glass

production worldwide, and the energy used in the production of container and flat glass results in emissions of about 50-60 Mt CO2 per year.

  • With the adoption of best available technologies,

energy efficiency of the sector can be improved by as much as 40% in developing countries and up to 35% in industrialized ones.

February 2017 RECP Introductory Training 8 February 2017 http://www.iipnetwork.org/

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 5

Energy Benchmarks

February 2017 RECP Introductory Training 9

Sector Furnace Type/Capacity Furnace Energy Consumption (GJ/tonne melted glass) Overall Energy Consumption (GJ/tonne finished product) Container Glass Bottles & Jars <100 t/d 5.5 – 7 <7.7 >100 t/d 3.3 – 4.6 Electric furnaces 2.9 – 3.6 Flacconage <100 t/d 7 – 9 <16 >100 t/d 4.8 – 6 Flat Glass All capacities 5 – 7 <8 Continous filament glass fibre All capacities 7 –14 <20 Domestic glass Conventional furnaces < 24 for capacities < 100 t/da < 18 for capacities > 100 t/d <100 t/da 6.7 – 9.5 >100 t/d 5 – 6 Electric furnacesb 3.4 – 4.3 Special glass All products Electric furnacesb 3.9 – 4.5 20 < Soda-lime glas Conventional furnaces 5 – 10 Borosilicate glass 10 – 15

February 2017 http://www.iipnetwork.org/

Best Available Techniques

February 2017 RECP Introductory Training 10 http://www.iipnetwork.org/

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 6

Process-Related Energy Efficiency

February 2017 RECP Introductory Training 11 February 2017

Worell e.a (2008), Energy Efficiency Improvement and Cost Savings Opportunities in Glass Industry

Process-Related Energy Efficiency

February 2017 RECP Introductory Training 12 February 2017

Worell e.a (2008), Energy Efficiency Improvement and Cost Savings Opportunities in Glass Industry

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 7

Process-Related Energy Efficiency

February 2017 RECP Introductory Training 13 February 2017

Worell e.a (2008), Energy Efficiency Improvement and Cost Savings Opportunities in Glass Industry

Cross Cutting Energy Efficiency

  • Energy Management Systems (ISO

50001)

  • Compressed Air Systems
  • Motor Systems
  • Lighting
  • Heat and Steam Systems
  • Building Management, including HVAC

February 2017 RECP Introductory Training 14

Worell e.a (2008), Energy Efficiency Improvement and Cost Savings Opportunities in Glass Industry

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 8

February 2017 RECP Introductory Training 15

Ceramics sector produces variety of products (bricks, tableware, sanitary ware, tiles etc.). Energy and resource use are high, as are air emissions and waste generation.

Nguon Sam Ath Brick Company (Cambodia)

February 2017 RECP Introductory Training 16

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 9

Angkor Brick Kiln (Cambodia)

February 2017 RECP Introductory Training 17

Ceramics Industry in Gujarat (India)

  • 1. Optimize combustion efficiency of furnace
  • Target 2-6% O2, 8-11% CO2, <400ppm CO and minimum

excess air

  • Measure O2 and regulate air flow (VFD on fan)
  • Investments typically < 1,000USD
  • Annual cost savings up to ~USD65,000

February 2017 RECP Introductory Training 18 February 2017 GCPC (2016), Cleaner Production in Ceramic Sector

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 10

Ceramics Industry in Gujarat (India)

  • 2. Optimize combustion efficiency of spray

dryer furnace

  • Installation of O2 analyzers for 3 spray dryers

» Invested ~USD110,000, pay back in 4 months

  • Solar greenhouse drying of coal

» Reduce moisture from 30 to 5% » Investment of ~USD40,000 with pay back in 5 months

February 2017 RECP Introductory Training 19 February 2017 GCPC (2016), Cleaner Production in Ceramic Sector

Ceramics Industry in Gujarat (India)

  • 3. Modifying kiln cars for efficient transfer of

heat (reduction of mass)

– Replace solid shelves with extruded shelves

  • Invested USD8-20,000, payback < 5 months

– Use light weight filling materials

  • Invested ~USD4,500, payback < 5 months

– Redesign spacers/holding racks

  • Invested ~USD3,600, with payback < 1 month

February 2017 RECP Introductory Training 20 February 2017 GCPC (2016), Cleaner Production in Ceramic Sector

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 11

Ceramics Industry in Gujarat (India)

  • 4. 100% reuse of water and sludge in process

(zero effluent discharge)

  • Material recovery and water conservation at very

low cost

  • 5. Electricity conservation
  • Power factor improvement with capacitators
  • Variable speed drive on ball mill motors
  • On-off timers and other controls
  • Reduce and optimize use of compressed air
  • Improvement in kiln wall insulation

February 2017 RECP Introductory Training 21 February 2017 GCPC (2016), Cleaner Production in Ceramic Sector February 2017 RECP Introductory Training 22

Metal products industries employ comparable processes to produce wide variety

  • f

components and products. Energy consumption is high in most processes, whilst chemicals’ use, generation of waste and effluents vary. Multiple common RECP approaches are well known and proven.

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 12

Shining Engineers & Founders

  • Grey iron foundry, using cupola furnaces

– Replaced cupola and change to Divided Blast Cupola (DBC) operation

  • Reduced reject from 7 to 5%
  • Coal use reduced by 30%
  • Eliminated need for alloying ferro-nickel and ferro-

manganese

  • Cost savings ~USD13/ton product
  • Investment of ~USD15,000 recovered within 1 year

February 2017 RECP Introductory Training 23

http://gcpcenvis.nic.in

Ceylon Heavy Industries & Construction Company

  • Steel rolling mill
  • Improved fuel oil quality control
  • Replacement of fuel nozzles and recuperation tubes
  • Installed flue gas analyzer to optimize fuel-air ratio
  • Installed high tension transformer

– Invested USD58,000 to achieve annual cost savings of USD75,000 – Enabled production capacity increase by 25% – Achieved GHG emission reduction of 444 ton

February 2017 RECP Introductory Training 24 Energy Efficiency Guide for Industry in Asia– www.energyefficiencyasia.org

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 13

Greening Thai Automotive Supply Chain

  • 74 SMEs achieved

– Annual monetary savings of 7.9M EUR – Waste reduced by 2,161 ton/yr, average of 49% – Waste water reduced by 118,230 m3/yr, average of 51% – Energy reduced by 27%, contributing to 16,431 ton reduction of GHG emissions – Improved rankings in GreenMark Certification – Improved access to financing

February 2017 RECP Introductory Training 25

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 L O M G K Q F N D I J H A P B E C R

EAF Steel Sector (Vietnam)

RECP Introductory Training 26

  • Energy intensity significantly higher then international good practice
  • Low scrap quality
  • Insufficient process monitoring
  • Lacking slag analysis

–  compounded by limited basic furnace and metallurgical knowledge

2 are within good practice range (2.1-2.4 GJ/t) 9 use 20-80% more energy then good practice

Viet Nam EAF steel sector

Energy intensity (GJ/t)

UNIDO (2012): Towards Green Growth though Green Industry Development in Vietnam

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 14

  • 35%
  • 30%
  • 25%
  • 20%
  • 15%
  • 10%
  • 5%

0% 5% 10% K D A G J F C P B E

  • 25.00%
  • 20.00%
  • 15.00%
  • 10.00%
  • 5.00%

0.00% 5.00% 10.00% G K F D J A P B E C

Energy Reductions GHG Reductions

7 improved, 4 thereof reduced energy by 6-21% 8 improved, 6 thereof reduced GHG emissions by 10-30%

EAF Steel Sector (Vietnam)

February 2017 RECP Introductory Training 27

UNIDO (2012): Towards Green Growth though Green Industry Development in Vietnam

Key Concerns

  • Large variety of processes each

with their own environment and resource use footprint

  • Foundry & casting
  • Cutting, forming & welding
  • Parts cleaning
  • Parts finishing
  • Assembly

February 2017 RECP Introductory Training 28

Metal Products Scrap Energy Use Chemicals Use Water and Waste Water (Hazardous) Waste (Fugitive) Emissions

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 15

RECP Starters

Foundry/casting

  • Reduce ‘fixed’ scrap from risers,

re-work, etc.

  • Energy efficiency in melting and

holding of hot, liquid metals

  • Improve feed and melting

regimes

  • Use appropriate binder systems –

molds and cores

  • Increase recycling rates in sand

systems

Cutting/forming/welding

  • Reduce ‘fixed’ scrap through
  • ptimization of nesting
  • Energy efficient equipment
  • Use appropriate welding

techniques and aids

February 2017 RECP Introductory Training 29

RECP Starters

Machining

  • Reduce ‘fixed’ scrap by matching

inputs with final parts specification

  • Management and maintenance of

machining tools

  • Fit for purpose machining

coolants

  • Treatment and continuous reuse
  • f coolants
  • Scrap drainage

Parts Cleaning

  • Reduce cleaning need by

avoiding contamination and

  • ver-cleaning
  • Select appropriate cleaning

method, mechanical, water- based, chemical, etc.

  • Design appropriate cleaning

process

  • Minimize and manage

resulting cleaning wastes

February 2017 RECP Introductory Training 30

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 16

RECP Starters

Metal Finishing (electroplating)

  • Optimize process sequence and

conditions

  • Minimize and/or eliminate

processes depending on hazardous chemicals (Cr VI, Cd, CN, etc.)

  • Energy efficiency – rectifiers,

heaters, blowers, etc.

  • Water efficiency – counter-current

use, efficient nozzles, carry-over reduction etc.

  • Metal recovery and treatment of

waste water

Metal Coating (Painting)

  • Select paint system that matches

parts specifications

  • Select appropriate application

process – spray, roll, water-based, electrostatic etc.

  • Optimize application process
  • Good operating practices
  • Minimize change overs
  • Minimize and manage paint

waste, waste water and fugitive emissions

February 2017 RECP Introductory Training 31 February 2017 RECP Introductory Training 32

RECP for green industry

Efisiensi Sumber Daya dan Produksi Bersih

Glass Industry Ceramic Industry Metal Products Industry

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Introductory Resource Efficient and Cleaner Production Training February 2017 RECP applications in manufacturing sector 17

Terima kasih banyak!

February 2017 RECP Introductory Training 33

National Resource Efficient and Cleaner Production (RECP) Programme Indonesia

Funded by Implemented by In partnership with

Kementerian Lingkungan Hidup dan Kehutanan

www.recpindonesia.org www.recpnet.org

Centre for Assessment & Development of Green Industry & Environment