Resource Efficient and Cleaner Production Concept, Practices & - - PowerPoint PPT Presentation
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)
Surabaya, 16 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
February 2017 RECP Introductory Training 2
Concept Practices Applications
February 2017 RECP Introductory Training 3
Resource Efficient and Cleaner Production emerged as a business response to worsening (industrial) pollution and escalating use of natural resources
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disperse control recycle
prevent
pollution
replace protect recover reduce
scarcity natural resources environment Efisiensi Sumber Daya dan Produksi Bersih
– Improve productive use of materials, water and energy;
– Reduce the generation of waste, effluent and emissions;
– Improve well being of employees, consumers and community;
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February 2017 RECP Introductory Training 6
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Produktivitas Bahan Baku
Intensitas Sampah
Produktivitas Air
Intensitas Limbah Cair
Produktivitas Energi
Intensitas Emisi
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Resource Efficient and Cleaner Production can be implemented through – combinations of – different prevention practices
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Tata Kelola Area Kerja Substitusi Bahan
Peningkatan Pengenda- lian Proses
Modifikasi Peralatan Penggan- tian Teknologi
Guna Ulang Dan Daur Ulang di Lokasi Sendiri Pemanfaatan Produk Samping
Modifikasi Produk
productive workplace to eliminate avoidable ‘wastage’
– Switch off what is not in use – Repair what needs reparation – Keep workplace organized and clean – Minimize and manage inventory – Confirm right way for all tasks – Keep staff motivated
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effective and/or pose minimum harm to the environment and health
– Use renewable energy – Use sustainably-sourced renewable materials – Use of recycled materials, water and energy – Use fit for purpose materials – Use less harmful substances – Source locally
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equipment so that they always run at highest efficiency and with lowest wastage
– Standard operating procedures and process monitoring – Sub-metering water, energy and materials – Preventive maintenance
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efficient and less wasteful
– Insulation – Proper alignment of production line – Improve process temperature, pressure, speed, mixing – Automatic switch off & level controls – Combine process steps in same equipment
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that is more efficient or produces less waste
– Efficient boilers, motors, fans, compressors etc. – Change of core process, e.g. chemical to mechanical cleaning – Equipment with integrated recovery loops – Advanced separation processes – Solar dryers, heaters and lighting
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energy and/or water for similar or alternative purpose in company
use of water and energy
for outgoing products
Practices
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useful use elsewhere
water for external heating or cooling purposes
external recycling and resource recovery, such as composting
for new product development
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environmental impact during production, use and/or disposal
– Design for optimal product lifetime – Design for lower material use – Design for low-waste manufacturing – Design for refurbishment, recycling etc.
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Root Source Analysis WHERE? Quantification of the different usages and sources Root Cause Diagnosis WHY? Factors contributing to resource usage and pollution sources Option Generation HOW? Alternative ways to avoid the identified causes
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Resource Efficient and Cleaner Production has been beneficially applied in many industry sectors, including sugar and food, steel and metal products
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www.cpkenya.org
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www.cpkenya.org
February 2017 RECP Introductory Training 22 February 2017
www.cpkenya.org
February 2017 RECP Introductory Training 23 February 2017
www.cpkenya.org
February 2017 RECP Introductory Training 24
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
February 2017 RECP Introductory Training 25
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
February 2017 RECP Introductory Training 26
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
February 2017 RECP Introductory Training 27
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
February 2017 RECP Introductory Training 28
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
February 2017 RECP Introductory Training 29
66 sugar mills in Pakistan
Sustaining Growth: Cleaner Production in Pakistan, National Productivity Organization and Cleaner Production Institute, 2016)
issue with:
– new organizational structures and management systems that integrate energy efficiency in core business processes – the development of energy efficiency tools to assist in the identification and evaluation of energy efficiency opportunities – a cultural change program that aims to engage and motivate staff to use energy more efficiently.
first year, resulting in 6% energy savings (~68,000 GJ/yr)
– Oxygen sensor in reheating furnace increased capacity by 0.2 %, valued at A$300,000 – Energy efficient compressors have reduced operational risks due to higher reliability and ease of maintenance
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Energy Efficiency Opportunities, DRET, 2010
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UNDP/GEF, India, 2012
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http://gcpcenvis.nic.in
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
RECP Introductory Training 33
– 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
0% 5% 10% K D A G J F C P B E
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%
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UNIDO (2012): Towards Green Growth though Green Industry Development in Vietnam
February 2017 RECP Introductory Training 35 http://www.iipnetwork.org/
February 2017 RECP Introductory Training 36 February 2017 http://www.iipnetwork.org/
5 November 2015 Green Industry Training (Ministry of Industry) 37
Process
State of the Art Clean Technologies
Sinter Plant
Sinter Plant Waste Heat Recovery Sinter Plant Waste Reuse (e.g. district heating) Dust Emissions Control Exhaust Gas Treatment through Denitrification, Desulphurization and Activated Coke Packed Bed Absorption Exhaust Gas Treatment through Selective Catalytic Reduction Exhaust Gas Treatment through Low Temperature Plasma Improvements in Feeding Equipment Segregation of Raw Materials of Pellets Multi-Slit Burner in Ignition Furnace Equipment to Reinforce Granulation Biomass for Iron and Steel Making Exhaust Gas Treatment through Additive Injection and Bagfilter Dedusting
Coke Making
SCOPE21: Super Coke Oven for Productivity and Environmental Enhancement towards 21st Century Coke Dry Quenching Coal Moisture Control High Pressure Ammonia Liquor Aspiration System Modern Leak Proof Door Land Based Pushing Emission Control System Coke Plant Automation and Process Control Heat Recovery from Coke Battery State of the Art Clean Technologies for Steelmaking Handbook, 2010
5 November 2015 Green Industry Training (Ministry of Industry) 38
Process State of the Art Clean Technologies Blast Furnace Iron Making Top Pressure Recovery Turbine Pulverized Coal Injection System Blast Furnace Heat Recuperation Improve Blast Furnace Charge Distribution Blast Furnace Gas and Cast House Dedusting Cast House Dust Suppression Slag Odor Control Blast Furnace – Increase Hot Blast Temperature (>1100 C) Blast Furnace – Increase Blast Furnace Top Pressure (>0.5 Bar) Optimize Blast Furnace Process Control (Expert System) Blast Oxygen Furnace Use BOF Exhaust as Fuel Fully Enclose BOF Control and Automation of Converter Operation Exhaust Gas Cooling System (combustion based) Dry Cyclone Dust Catcher Optimize BOF Refractory Life Time (laser contouring) BOF Bottom Steering Pressured Steam Aging for Steel Slag
State of the Art Clean Technologies for Steelmaking Handbook, 2010
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Cost savings Productivity enhancements Quality improvements Organizational efficiency License-to-operate
RECP implementation at scale and at speed in Indonesia
Replication
Innovation
Sectors (food, textile & metal) Industrial Zones (Makassar & Batam) Micro- Industries (rice milling & TBC) Tourism Destinations (Sleman/ Magelang & Lake Toba) February 2017 RECP Introductory Training 40
Programme activities in East Java
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4 experts from East Java trained and being coached to execute RECP assessments
– Obtain a catalogue of RECP
resource efficiency and reduce pollution with recommendations for implementation – Improve awareness, understanding and capacity to manage and minimize resource consumption and pollution generation
– Gain practical experience in conducting RECP assessments in sector, under guidance of RECP expert team – Complete basic RECP assessment training and
expert
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First assessments undertaken in four sugar mills under PTPN X and PTPN XI
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for RECP option identification, evaluation and implementation
& Waste
Effluents
& Emissions
plan
Expressions of interest sought
Other Elements (TBD)
Bandung Declaration 8 Nov 2016 Vibrant network of Indonesian RECP professionals that work together to expand and improve the awareness, knowledge and application of RECP in Indonesia An action partnership of organizations that commit to promote RECP and implement RECP within their activities and/or sphere of influence Local Practitioners Forums
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February 2017 RECP Introductory Training 47
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