Resource Efficient and Cleaner Production Concept, Practices & Applications Centre for Assessment & Development of Green Surabaya, 16 February 2017 Industry & Environment National Resource Efficient and Cleaner Production (RECP) Programme Indonesia Funded by Implemented by In partnership with Kementerian Lingkungan February 2017 RECP Introductory Training 1 Hidup dan Kehutanan
RECP for green industry Concept Efisiensi Sumber Daya dan Produksi Bersih Applications Practices February 2017 RECP Introductory Training 2
Resource Efficient and Cleaner Production emerged as a business response to worsening (industrial) pollution and escalating use of natural resources February 2017 RECP Introductory Training 3
replace scarcity protect resources natural recover Resource reduce Efficient and Cleaner environment prevent Production recycle control pollution Efisiensi Sumber Daya dan Produksi Bersih disperse February 2017 RECP Introductory Training 4
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 • ……. • …….. February 2017 RECP Introductory Training 5
Productive output per unit of resource consumption Pollution intensity per unit of productive output February 2017 RECP Introductory Training 6
RECP Issues Pemilihan Penurunan dan efisiensi dan buangan bahan baku yg aman dari Intensitas Produktivitas limbah Sampah Bahan Baku Pemilihan Penurunan dan efisiensi dan air Pengolahan Produktivitas Intensitas Air air limbah Limbah Cair Pemilihan Penurunan dan efisiensi dan energy Pengendalian Intensitas Produktivitas gas buang Emisi Energi February 2017 RECP Introductory Training 7
Resource Efficient and Cleaner Production can be implemented through – combinations of – different prevention practices February 2017 RECP Introductory Training 8
Peningkatan Substitusi Pengenda- Bahan lian Proses Tata Kelola Modifikasi Area Kerja Peralatan Modifikasi Penggan- Produk tian Teknologi Guna Ulang Pemanfaatan Dan Daur Produk Ulang di Samping Lokasi Sendiri February 2017 RECP Introductory Training 9
• Typical solutions – Switch off what is not in use – Repair what needs reparation • Maintain a clean, organized and – Keep workplace organized and productive workplace to eliminate clean avoidable ‘ wastage’ – Minimize and manage inventory – Confirm right way for all tasks – Keep staff motivated February 2017 RECP Introductory Training 10
• Typical solutions – Use renewable energy • Choose inputs that are efficient, – Use sustainably-sourced effective and/or pose minimum renewable materials harm to the environment and – Use of recycled materials, health water and energy – Use fit for purpose materials – Use less harmful substances – Source locally February 2017 RECP Introductory Training 11
• Typical solutions • – Standard operating Monitor and control processes and equipment so that they always run at procedures and process highest efficiency and with lowest monitoring wastage – Sub-metering water, energy and materials – Preventive maintenance February 2017 RECP Introductory Training 12
• Typical solutions – Insulation • Make existing equipment more – Proper alignment of efficient and less wasteful production line – Improve process temperature, pressure, speed, mixing – Automatic switch off & level controls – Combine process steps in same equipment February 2017 RECP Introductory Training 13
• Typical solutions – Efficient boilers, motors, fans, • Change over to new technology compressors etc. that is more efficient or produces – Change of core process, e.g. less waste chemical to mechanical cleaning – Equipment with integrated recovery loops – Advanced separation processes – Solar dryers, heaters and lighting February 2017 RECP Introductory Training 14
Practices Typical solutions • Use previously ‘wasted’ material, • Countercurrent or cascaded energy and/or water for similar or use of water and energy alternative purpose in company • Condensate and heat recovery • Reuse of incoming packaging for outgoing products February 2017 RECP Introductory Training 15
Typical solutions • Provision of used cooling • Convert a previous ’ waste ’ for a water for external heating or useful use elsewhere cooling purposes • Segregate recyclables for external recycling and resource recovery, such as composting • Symbiosis - use waste material for new product development February 2017 RECP Introductory Training 16
• Typical solutions – Design for optimal product • Redesign product to reduce its lifetime environmental impact during – Design for lower material production, use and/or disposal use – Design for low-waste manufacturing – Design for refurbishment, recycling etc. February 2017 RECP Introductory Training 17
RECP Method Source Root Source Analysis Root Cause Diagnosis WHERE? Option Generation WHY? Quantification of Cause the different usages HOW? Factors and sources contributing to Alternative ways to resource usage and avoid the identified pollution sources causes Option February 2017 RECP Introductory Training 18
Resource Efficient and Cleaner Production has been beneficially applied in many industry sectors, including sugar and food, steel and metal products February 2017 RECP Introductory Training 19
Kibos Sugar & Allied Industries February 2017 RECP Introductory Training 20 www.cpkenya.org
Kibos Sugar & Allied Industries February 2017 February 2017 RECP Introductory Training 21 www.cpkenya.org
Kibos Sugar & Allied Industries February 2017 February 2017 RECP Introductory Training 22 www.cpkenya.org
Kibos Sugar & Allied Industries February 2017 February 2017 RECP Introductory Training 23 www.cpkenya.org
Energy Opportunities in Sugar Mills Sustaining Growth: Cleaner Production in 66 sugar mills in Pakistan Pakistan, National Productivity Organization and Cleaner Production February 2017 RECP Introductory Training 24 Institute, 2016)
Energy Opportunities in Sugar Mills Sustaining Growth: Cleaner Production in 66 sugar mills in Pakistan Pakistan, National Productivity Organization and Cleaner Production February 2017 RECP Introductory Training 25 Institute, 2016)
Energy Opportunities in Sugar Mills Sustaining Growth: Cleaner Production in 66 sugar mills in Pakistan Pakistan, National Productivity Organization and Cleaner Production February 2017 RECP Introductory Training 26 Institute, 2016)
Water Opportunities in Sugar Mills Sustaining Growth: Cleaner Production in Pakistan, National Productivity 66 sugar mills in Pakistan Organization and Cleaner Production February 2017 RECP Introductory Training 27 Institute, 2016)
Water Opportunities in Sugar Mills Sustaining Growth: Cleaner Production in Pakistan, National Productivity 66 sugar mills in Pakistan Organization and Cleaner Production February 2017 RECP Introductory Training 28 Institute, 2016)
Materials Efficiency in Sugar Mills Sustaining Growth: Cleaner Production in Pakistan, National Productivity 66 sugar mills in Pakistan Organization and Cleaner Production February 2017 RECP Introductory Training 29 Institute, 2016)
One Steel, Newcastle Rod Mill • • Making energy a core business 11 opportunities realized in issue with: first year, resulting in 6% energy savings (~68,000 GJ/yr) – new organizational structures and management systems that • Significant co-benefits integrate energy efficiency in – Oxygen sensor in reheating core business processes furnace increased capacity by – the development of energy 0.2 %, valued at A$300,000 efficiency tools to assist in the – Energy efficient compressors identification and evaluation of have reduced operational risks energy efficiency opportunities due to higher reliability and – a cultural change program that ease of maintenance aims to engage and motivate staff to use energy more efficiently. February 2017 RECP Introductory Training 30 Energy Efficiency Opportunities, DRET, 2010
Small Scale Re-Rolling Mills • 29 small scale mills – Total energy savings: 87,819,968 MJ – Total GHG reduction: 131,738 tCO 2 • 16 companies – Investment: 7.24 million USD – Annual savings: 9.14 million USD February 2017 RECP Introductory Training 31 UNDP/GEF, India, 2012
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 http://gcpcenvis.nic.in February 2017 RECP Introductory Training 32
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