Lecture No.

11-12

By;

Dr. M. Safar Korai

Associate Professor
Institute of Environmental Engineering and Management, Mehran UET,
Jamshoro
 CLO-2, TL-C4 and PLO-11

Topics

1.Development/methodology of cleaner production plans

2.CP management system

Cleaner Production procedures
The recognized need
to minimise waste

The first Planning and

step Organization

The second Assessment

step Phase

The third Feasibility Analysis

step Phase

The fourth
step Implementation

Successfully implemented CP projects 3

 1. Planning & Organization

• Obtain management commitment

• Identify potential barriers and solutions

• Set plant-wide goals

• Organize a project team

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 2. Assessment

• Identify sources

• Identify waste/ pollution causes

• Generate possible options

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Material and energy balances

Heat Power The

Energy
Balance

Raw The Industrial Products

& Waste
Materials Process

The
Cooling Mass
Balance

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 Why are material and energy
balances so important?
The material and energy balances are not only used to identify the
inputs and outputs of mass and energy but their economic
significance is related to costs, such as:
1. cost of raw material in waste
2. cost of final product in waste

3. cost of energy losses

4. cost of handling waste

5. cost of transporting waste

6. cost of solid wastes disposal

7. cost of pollution charges and penalties 7

 Possible causes for waste
generation

Choice of Technical Product

Production Status of Specifications
Technology Equipment

Choice &
Quality of Process Process
Efficiency
Input Materials

Management
Personnel
Planning & Wastes &
Skills &
Information Emissions
Motivation
Systems

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 Option generation (1)

• Creative Problem Solving (CPS):

- Find facts

- Identify the problem

- Generate ideas to solve the problems

- Define criteria to be used to select solutions/ideas

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 Option generation (1)

• Screening of ideas / options:

- Select all ideas/options that may be implemented
immediately

- The remaining options/ideas should then be divided

into three boxes:
- Good housekeeping
- Interesting options but more analysis is needed
- Waiting box + Rejected

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 Option generation (1)
• Weighted sum method to prioritise options in second
group:
1. What are the main benefits to be gained by
implementing this option?

2. Does the necessary technology exist to implement

the option?

3. How much does it cost? Does it appear to be cost

effective, meriting in depth economic feasibility
assessment?

4. Can the option be implemented within a reasonable

timeframe without disrupting production?
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 Option generation (2)
Traditional brainstorming

• Formulate problem (problem identification)

• Define objective of the brainstorming session

• Follow the rules of brainstorming:

- Select a secretary to write down all ideas (The secretary can't take
part in the idea generation)
- Select a group leader (the group leader shall control that the four
main rules are followed)

• Close the idea generation after 30-40 minutes

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 CP assessment practices

Good Input Better Process

Housekeeping Substitution Control

Equipment
Modification
Process Technology
Change

On-site Production of
Recovery/ Product
Useful Modification
Reuse By-Product

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 3. Feasibility Studies

• Preliminary evaluation
• Technical evaluation
• Economic evaluation
• Environmental evaluation
• Selection of feasible options

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 3. Feasibility Studies

• Preliminary evaluation

➢ The quickest and easiest method of evaluating the different

options is to form a group, consisting of the project team and
management personnel, and discuss the possible solutions
one by one.

➢ This process should give a good indication of which projects

are feasible and what further information is required.

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 3. Feasibility Studies
• Preliminary evaluation

1. Is the Cleaner Production option available?

2. Can a supplier be found to provide the necessary
equipment or input material?
3. Are consultants available to help develop an alternative?
4. Has this Cleaner Production opportunity been applied
elsewhere? If so, what have been the results and
experience?
5. Does the option fit in with the way the company is run?

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 3. Feasibility Studies

• Technical evaluation
➢ The potential impacts on products, production processes
and safety from the proposed changes need to be
evaluated before complex and costly projects can be
decided upon.

➢ A technical evaluation will determine whether the

opportunity requires staff changes or additional training or
maintenance.

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 3. Feasibility Studies
• Technical evaluation

1. Will the option compromise the company's product?

2. What are the consequences for internal logistics,

processing time and production planning?

3. Will adjustments need to be made in other parts of the

company?

4. Does the change require additional training of staff and

employees? 18
 3. Feasibility Studies

• Economic evaluation
➢ The objective of this step is to evaluate the cost
effectiveness of the Cleaner Production opportunities.
Economic viability is often the key parameter that determines
whether an opportunity will be implemented.

➢ When performing the economic evaluation, costs of the

change are weighed against the savings that may result.

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 3. Feasibility Studies
• Economic evaluation
1. What are the expected costs and benefits?

2. Can an estimate of required capital investment be made?

3. Can an estimate of the financial savings be made…..?

• such as reductions in environmental costs,
• waste treatment costs,
• material costs or improvements to the quality of the
product?

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 3. Feasibility Studies

• Environmental evaluation
1. What is the expected environmental effect of the option?

2. How significant is the estimated reduction in wastes or

emissions?

3. Will the option affect public or operator health (positive or

negative)? If so, what is the magnitude of these effects in
terms of toxicity and exposure?

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 3. Feasibility Studies
• Environmental evaluation
➢ The objective of the environmental evaluation is to determine the positive
and negative environmental impacts of the option.
➢ For a good environmental evaluation, the following information is
needed:
✓ changes in amount and toxicity of wastes or emissions;
✓ changes in energy consumption;
✓ changes in material consumption;
✓ changes in degradability of the wastes or emissions;
✓ changes in the extent to which renewable raw materials are used;
✓ changes in the reusability of waste streams and emissions;
✓ changes in the environmental impacts of the product.

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 3. Feasibility Studies

• Selection of feasible options

• The most promising options must be selected in close

collaboration with management.

• A comparative ranking analysis may be used to priorities

opportunities for implementation.

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 4. Implementation &
Continuation

• The objective of the last phase of the assessment is to

ensure
– that the selected options are implemented, and
– that the resulting reductions in resource consumption
and waste generation are monitored continuously.

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 4. Implementation &
Continuation
• Prepare a CP plan

• Implement feasible CP measures

• Monitor CP progress

• Sustain Cleaner Production

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 METHODOLOGY
CP Development/methodology
> Obtain management commitment The recognized need
> Organise project team for Cleaner Production
> Identify barriers & solutions
> Set objectives 1.Planning and
> Pre-assess Organization

> Identify sources (WHERE) Sustain

> Analyse causes (WHY)
2.Assessment
&
> Generate possible options (HOW) Continue
3.Feasibility (EMS)
> Evaluate options on: Analysis
Technical, environmental
and economic feasibility
> Select best options
4.Implementation

> Option implementation

> Monitoring and evaluation Successfully implemented
> Sustain and continue
Cleaner Production projects
 CP management system
Marketing

Top management
commitment

Pre-assessment

CP policy
declaration

Start CP project

Top Management reviews Project organization

Final report Assessment

The continuous
CP loop
Measure progress CP options

Project implementation Feasibility analysis

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Assessment report
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CONCLUSION
End of session 2

Thank you for your attention…

Any questions?