Cleaner Production Manual ASIE/2006/122-578 Improving the living and working conditions of people in and around industrial clusters and zones IVAM 2008 PROFITING FROM CLEANER PRODUCTION Saving costs and natural resources by Environmental Efficiency Cleaner Production Manual CONTENT 1 INTRODUCTION ON CLEANER PRODUCTION .......................................................................... 7 1.1 Sustainable development and environmental strategies ....................................................... 7 1.1.1 Passive environmental strategy: pollution and dispersion ................................................. 7 1.1.2 Reactive environmental strategy: end-of-pipe treatment ................................................... 8 1.1.3 Constructive environmental strategy: recycling and recovery ........................................... 8 1.1.4 Proactive environmental strategy: cleaner production ...................................................... 8 1.2 What is cleaner production?................................................................................................... 9 1.2.1 Change of input materials ................................................................................................ 10 1.2.2 Technology change ......................................................................................................... 11 1.2.3 Good operation practises ................................................................................................. 11 1.2.4 Product modification ........................................................................................................ 12 1.2.5 On site re-use and recycling ............................................................................................ 12 1.3 The profits of cleaner production ......................................................................................... 13 1.4 The barriers for cleaner production ...................................................................................... 15 1.5 Cleaner production approach ............................................................................................... 15 1.5.1 Planning and organisation ............................................................................................... 16 1.5.2 Assessment ..................................................................................................................... 16 1.5.3 Feasibility analysis ........................................................................................................... 17 1.5.4 Implementation ................................................................................................................ 17 2 PLANNING AND ORGANISATION ............................................................................................. 19 2.1 Obtaining management commitment and participation ....................................................... 19 2.2 Organising a cleaner production project team ..................................................................... 20 2.2.1 Selecting the leading team members .............................................................................. 20 2.2.2 Selecting the assessment team members ....................................................................... 21 2.2.3 Selecting a facilitator ........................................................................................................ 22 2.3 Identify possible barriers and solutions ................................................................................ 22 2.4 Setting objectives ................................................................................................................. 23 2.5 Pre-assessment ................................................................................................................... 23 2.5.1 Investigate the present status .......................................................................................... 23 2.5.2 Perform on-site investigation ........................................................................................... 24 2.5.3 Compile a process flow chart ........................................................................................... 24 2.5.4 Selecting the assessment focus ...................................................................................... 25 2.5.5 Set cleaner production targets ......................................................................................... 26 2.5.6 Bring obvious options into operation ............................................................................... 27 2.5.7 Making an assessment plan ............................................................................................ 27 3 ASSESSMENT ............................................................................................................................. 29 3.1 Making the material and energy balances ........................................................................... 29 3.1.1 Unit operation as a basis for the balance ........................................................................ 30 3.1.2 The material balance ....................................................................................................... 31 3.1.3 The energy balance ......................................................................................................... 33 3.2 Assessing process in- and outputs ...................................................................................... 34 3.3 Inputs .................................................................................................................................... 35 3.3.1 Raw materials and auxiliaries .......................................................................................... 35 3.3.2 Water ............................................................................................................................... 35 3.3.3 Energy .............................................................................................................................. 36 3.4 Outputs ................................................................................................................................. 37 3.4.1 Products and by-products ................................................................................................ 37 3.4.2 Waste and emissions ....................................................................................................... 37 3.4.3 Energy .............................................................................................................................. 38 3.5 Complete the balance .......................................................................................................... 39 3.6 Presenting and interpreting the data .................................................................................... 40 3.7 Conduct a cause assessment .............................................................................................. 41 3.8 Option generation ................................................................................................................. 43 3.8.1 Implement the obvious options ........................................................................................ 43 3.8.2 Structuring the option generation..................................................................................... 43 3.8.3 Creative thinking techniques ............................................................................................ 43 3.9 Option screening .................................................................................................................. 45 4 FEASIBILITY STUDY ................................................................................................................... 50 ©IVAM Research and Consultancy on Sustainability 3 Cleaner Production Manual 4.1 Technical evaluation ............................................................................................................ 50 4.2 Environmental evaluation ..................................................................................................... 51 4.3 Economic evaluation ............................................................................................................ 52 4.3.1 Pay back period ............................................................................................................... 53 4.3.2 Net present value and return on investment .................................................................... 54 4.3.3 Risk considerations .......................................................................................................... 54 4.3.4 Market considerations ...................................................................................................... 55 4.4 Decision making ................................................................................................................... 56 5 IMPLEMENTATION...................................................................................................................... 58 5.1 Project preparation ............................................................................................................... 58 5.1.1 Planning ........................................................................................................................... 58 5.1.2 Fund raising ..................................................................................................................... 59 5.2 Project execution and evaluation ........................................................................................