Cp gp day02 session 8 waste cause analysis & cp techniques2012
- 1. Waste Cause Analysis and CP Techniques Samantha Kumarasena Deputy Director National Cleaner Production Centre, Sri Lanka 12/16/2015 1Samantha Kumarasena
- 2. Option generation An organized, participative activity! Brainstorming is a good tool!! 12/16/2015 Samantha Kumarasena 2
- 3. Cause Analysis (Reasons for Waste)
- 4. How Do We Find Waste Causes Ask Questions What, Why, Where, When, How Never WHO Make Observations with CP Team Conduct Brainstorming sessions Use suitable Tools such as Fishbone Diagram
- 5. Is the waste caused due to… Choice & quality input material Choice of technology Technical status of equipment Operation & maintenance Personal skills & motivation Product specification Management planning & information systems Design & layout of plant & machinery Waste Cause Categories 12/16/2015 Samantha Kumarasena 5
- 6. Choice & Quality of Input Material • low quality • Impurities • Composition • Size of material • Cleaning requirement • Toxicity / hazardousness IS THIS THE BEST RAW MATERIAL?
- 7. Choice of Production Technology Obsolete technologies Available technologies Modern technologies Appropriate technology
- 8. Obsolete equipment Absence of indicator instruments Improperly working controllers Technical Status of Equipment
- 9. Design and Layout of Equipment Arrangement at the production floor Placement and arrangement of stores Material conveying method Long distance distribution Capacity balance Service / utility needs
- 10. Product Specification Dimensions (size) Colors Surface finish Packaging requirement Performance properties
- 11. • Inefficient process controls • Cleanliness / housekeeping • Correct load / parameters • Frequent down time • Power failures • Improper maintenance / lack of maintenance planning Operation & Maintenance
- 12. • Lack of production planning • Wrong information • Inadequate information • Inventory management • Absence of record keeping culture Management Planning & Information Systems
- 13. • Attitudes • Carelessness • Short cuts • Incomplete work Personal Skills & Motivation
- 14. Cleaner Production techniques Input substitution Good housekeeping Better process control Product modification Equipment modification Technology change On-site recovery/reuse Creation of useful by products 12/16/2015 Samantha Kumarasena 14
- 15. 15 Classification of CP Techniques CP TECHNIQUES PRODUCT MODIFICATION RECYCLING Onsite recovery and reuse Creation of Useful by- products SOURCE REDUCTION Process Changes Good House- Keeping Input Material change Better process control Equipment modification Technology change
- 16. Good housekeeping 12/16/2015 Samantha Kumarasena 16
- 17. Good Housekeeping Take appropriate operational actions to prevent: - leaks - spills Formulate & enforce to practice appropriate operational instructions
- 18. • Tighten valves, check & repair leaking pumps, valves, pipes to reduce/ avoid leaks • Store chemicals in appropriate places • Insulate steam pipes and design proper steam distribution system
- 19. 19 Spills The spilling of dyes and chemicals at a washing plant amounted to Rs 37,600/- per month Drips In a rubber factory the dripping of a chemical was estimated to be Rs 46,000/- per month Leaks The steam leaks in a textile industry was equivalent to 9300 liters of furnace oil (Rs 67,000/-) per month (23% of total cost)
- 20. Input substitution 12/16/2015 Samantha Kumarasena 20
- 21. Input Substitution Substitute input materials where ever possible with - less toxic materials - renewable materials - materials with longer lifetime
- 22. 22 • Replace organic solvents with water • Replace Formic acid by Hydrochloric Acid in textile dyeing • Replace chlorine bleaching with O3 bleaching • Use of soft water for preparation of dye bath: Higher dye exhaustion levels lower dye consumption
- 23. Better process control 12/16/2015 Samantha Kumarasena 23
- 24. Better Process Control Modify: - operational procedures - equipment instructions Process record keeping in order to run the processes more efficiently and at lower waste and emission generation rates
- 25. Improving process controls – e.g. 25 • Optimize and control operating parameters in the plant to reduce product reprocessing rate eg: pH, temperature, time • Optimize the boiler operations Combustion (CO2> 12%, O2< 2%) Reduce heat losses (surface, flue gas) therefore reduce fuel consumption • Optimize fabric : liquor ratio for dyeing Reduce energy, water and chemical consumption
- 26. Equipment modification 12/16/2015 Samantha Kumarasena 26
- 27. 27 Equipment Modification Modify the existing production equipment and utilities to - run the processes at higher efficiency - lower waste and emission generation rates Repair faulty equipment to reduce losses and rejects Replace obsolete equipment or parts
- 28. 28 • Multiple countercurrent rinsing • Installation of hood above dryer drums for faster moisture withdrawal • Replace solvent cleaning with mechanical cleaning • Use of high pressure jet nozzles for for screen washing in printing - efficient cleaning and save water
- 29. Technology Change Change the product & process technology in order to minimize waste and emission generation and optimize the resource efficiency
- 30. Technology change 12/16/2015 Samantha Kumarasena 30
- 32. Product Modification Modify the product characteristics in order: - to minimize the environmental impacts of the product during or after its use (disposal) - to minimize the environmental impacts of its production
- 33. 33 Product Modification Raw Material Extraction Manufacture Transportation Use End-of-life
- 34. On-site recovery/reuse Water, Packaging, containers !!!!
- 35. On site Recovery/Reuse Reuse/recovery or recycling of the wasted materials in the same process or outside, for same or another application
- 36. Recovery, reuse, recycle • Water of last rinse for the first rinse • Chrome recovery in leather industry • In plastic injection moulding the waste is recycled • Condensate recovery in boilers
- 37. 37 Production of Useful By-products Reuse of the wasted materials for manufacturing of another product. eg: • Waste tyres are used for energy recovery • Use of fabric cuttings for mattress manufacturing • Coconut water from DC mills - Juice Preparation - Vinegar production
- 38. Creation of useful by products 12/16/2015 Samantha Kumarasena 38