Anaerobic Digestion of Solid Waste

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Cleaner Production Research andCleaner Production Research and

Implementation Activities carried outImplementation Activities carried outat Middle East Technical Universityat Middle East Technical University

Prof.Dr. Gksel N. DemirerProf.Dr. Gksel N. Demirer

Cleaner Production:A tool for Green Competitiveness in the Turkish Industry

METU, MoEF, RAC/CP

31 March 2008, METU, Ankara


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Prof. Dr. Gksel N. Demirer, Department of Environmental EngineeringMiddle East Technical University, Ankara, Turkey

The first decade of the journey:The first decade of the journey:

from 1998 to 2008from 1998 to 2008


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INTEGRATED

PREVENTIVEENVIRONMENTALMANAGEMENT

TRAINING FORMUNICIPALITIESPROJECT

(1999-2003)


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The project was developed and implemented by the Union ofChambers of Turkish Engineers and Architects (UCTEA), Chamberof Environmental Engineers (CEE) and financially supported bythe Swiss Agency for Development and Cooperation (SDC).

The aim and the scope of the Project were:

(1) training all levels of personnel of municipalities in basicintegrated and preventive environmental management strategiesby organizing workshops about preventative environmentalmanagement,(2) informing the municipalities about different environmentaltechnologies,(3) establishing a base for local environmental protectionstrategies and public participation and auditing, and(4) providing a framework for the development of municipalpolicies and actions on the environment.


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Within the first phase activities of the project, the workshopswere implemented with a high level of success in el, Denizli,Van, Eskiehir, Diyarbakr and Samsun. Furthermore, aHandbook was published in Turkish distributed to all the projectworkshop participants as well as the interested individuals andinstitutions free of charge.

The contents of the Handbook included the subjects covered inthe workshops and was prepared by an experienced team ofuniversity faculty members and experts.

The workshops provided well over a thousand participants withbasic training on the fundamentals of pollution prevention

concept and its applications in different local governmentoperations.


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The workshops and the Handbook covered the following topics:

pollution prevention opportunities in local governmentoperations (pollution prevention and compliance assistance,purchasing practices encouraging regulatory compliance andpollution prevention, construction/property management,pesticide/vector management, public safety, solid wastemanagement, wastewater management, water resources

management, water supply, and vehicle/equipment maintenance) preventive municipal environmental management and publichealth overview of applicable laws and regulations case studies for preventive municipal environmental

management selected national and international resources for preventivemunicipal environmental management studies opportunities for public participation and auditing in preventivemunicipal environmental management


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GOOD HOUSEKEEPINGGOOD HOUSEKEEPINGAPPLICATIONS INAPPLICATIONS INTURKISH COMPANIESTURKISH COMPANIES

DELTA

(Developing EnvironmentalLeadership Towards Action)

Eco-Efficiency Programme

(2001-2002)


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The project was implemented by the UCTEA,Chamber ofEnvironmental Engineers (CEE) and Sustainable Business

Associates (Switzerland) and financially supported by the SwissAgency for Development and Cooperation (SDC). The aim of theProject was to:

Introduce the concepts of preventive environmental

management or eco-management to Turkish industry at SMElevel.

Lay down a foundation for launching wider efforts in the areaof industrial eco-efficiencyIntroduce practical environmental management tools related to

good housekeeping that Turkish enterprises can use to minimisewaste, conserve water, save energy, prevent pollution, andimprove organisational procedures;Promote a broad dissemination and application of theseprinciples and tools.


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PROJECT ACTIVITIES

April 2001: Good Housekeeping Guide was printed in Turkish.

May 7th-11th, 2001:DELTA Eco-Management Weekwas organised in Gebze, Turkey, incooperation with Sustainable Business Associates (SBA, Switzerland), Regional ActivityCentre for Cleaner Production (RAC/CP, Spain) and TUBITAK Marmara Research Centre(MRC, Turkey), as a part of a LIFE Project. More than 50 engineers and managers fromenterprises participated in the project.

October 2001: First Turkish GHK case studies has been finalised and printed. A total savingof 15,000 US $/year was succeded in the 3 companies that have applied Good HousekeepingGuide in their enterprises.

21st-22nd October, 2001: A Good Housekeepingseminar was organized in Ankara, withthe participation of Sustainable Business Associates (SBA), in cooperation with KOSGEB.

Around 25 engineers from SMEs, representatives from ministries of environment and industry,and academicians participated in the seminar. 12-13 Febraury 2002: Good Housekeeping Seminar in Bursa, a highly industrialized cityin West Anatolia, in cooperation with KOSGEB Bursa and supported by TTGV and BursaInternational Textile trade and commerce Centre.


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COMPANYCOMPANY TITLETITLE ECONOMIC RESULTSECONOMIC RESULTS ENVIRONMENTAL RESULTSENVIRONMENTAL RESULTS

HOB Paint andChemicals IndustryInc., Gebze, Turkey

Rearranging theWorking hours of amachine

No investment costAnnual saving: 2000 USDImmediate payback

11800 kWh/year energy issaved

HOB Paint andChemicals IndustryInc., Gebze, Turkey

Modifying RawMaterial TransferMethod

Investment cost: 50 USD

Annual saving: 3000 USDImmediate payback

The reuse of the spilled rawmaterial avoided 2.5ton/year of waste dischargeand related pollution.

BARMEK Inc.,Ankara, Turkey

Reuse of LeakagePaints MinimisizesThe Material Loss

Investment cost: 670 USD

Annual saving: 1120 USD

Payback period: 7 months

Consideable amount of paintis resused rather than beingwasted.

12356732

220 C

SUMMARY OF SOME OF THE CASE STUDIES


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CLEANERCLEANER

PRODUCTIONPRODUCTIONOPPORTUNITYOPPORTUNITYASSESSMENTASSESSMENT

FORFOR AA MARKETMARKETMILKMILKPRODUCTIOPRODUCTIONN

FACILITYFACILITY

(2001(2001--2003)2003)


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OBJECTIVE

The aim of this study was to conduct a cleaner productionassessment (CPA) for a market milk production facility to identify theopportunities of CP, corresponding environmental and economicalbenefits.

METHODOLOGY

The methodology used in this study was prepared by compiling andreorganizing different manuals and checklists (UNEP, DEPA, EPA, SBANYSDEC) developed by several leading institutions in the field of CP.

The mass balance approach wasselected as CPA methodology orthe strategy of analysis adopted.


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StepStep TaskTask SubSub--TaskTask DescriptionDescription

11-- Planning andPlanning andOrganizationOrganization

Establishing andEstablishing andorganizing a CPAorganizing a CPAProgramProgram

A.A.Obtain management commitmentObtain management commitmentB.B.Select team members to developSelect team members to developcleaner production plancleaner production plan

22-- PrePre--assessmentassessment(qualitative review)(qualitative review)

Compilation ofCompilation ofbackgroundbackgroundinformationinformation

A.A.Develop facility profileDevelop facility profile

33--AssessmentAssessment(quantitative(quantitativereview)review)

ConductingConductingEnvironmentalEnvironmentalReviewReview

A.A.Compile facility dataCompile facility dataB.B.Conduct site inspectionConduct site inspectionC.C.Identify cleaner production optionsIdentify cleaner production options

D.D.Organize cleaner production optionsOrganize cleaner production options

44-- Evaluation andEvaluation andFeasibility StudyFeasibility Study

ConductingConductingFeasibilityFeasibilityAssessmentAssessment

A.A.Conduct feasibility assessmentConduct feasibility assessment

The outline of the methodology followed is presented below:


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Check valve ithtime control

olding

ipes

CW

a

ilk torage Tanks

Clari ier

lass

ackaging

lo

meter

W

CW

asteurization

Cream

eparator

W dor

omogenizator

alanceTank

alanceTank

1

T

ilter

CW

Clari ier ludge

Clari ier

1

Cartoon ackaging asteurized

ilk

torageTanks

CW

Channel

Not al ays inoperation

ump

T

ixing

iston

Deodorization eparator

sludge

a

milkCooling lates

a ilk Tank ilter

!.

a

ilk Intake

rocess

. ilk asteurization

RRaw milkaw milkintakeintake

PPasteurizationasteurization

Flow Diagram of the FacilityFlow Diagram of the Facility


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CPOpportunities forCPOpportunities for

Market Milk ProductionMarket Milk Production

Clean water recycles

GHK/repair

Off-site reuse/ milk sludge

Off-site reuse/ milky water

GHK/ small equipment

change/ water & milk

GHK/operating Practices

CleanerProductionOpportunities

CPOpportunities forCPOpportunities for

Cleaning Operations

Cleaning Operations

Change of Technology-Clean In

Place (CIP) System

Off-site reuse/ Milky rinse

Change Equipment/ Shut-off

nozzle use

GHK-change in operating

practices

Chemical change

Reuse-Alkaline water reuse


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The results could be summarized as follows:

Eliminatedwater use(kg/day)

Eliminateddischarge(kg/day)

EliminatedChemical use(kg/day)

RecycledWater(kg/day)

RreducedCO(kg/day)

ReducedTSS(g/day)

Reducedalkalinity

(kg/day)

reducedrecycling(kg/day)

47329.7 9089.2 101.1 18636.9 181.9 20727.2 40.1 102.8

Alternatively, the results can be presented as:

50% of the service water used,

9.3% of the current wastewater discharge,

65.4% of the chemical use,

discharge of181.91 kg/day ofCOD, and

20.7kg/ day of TSScould be eliminated, and

19.6% of the service water used

could be recycled/reused.


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CLEANERCLEANER

PRODUCTIONPRODUCTIONOPPORTUNITYOPPORTUNITYASSESSMENTASSESSMENT

STUDYSTUDY FOR AFOR APULP ANDPULP ANDPAPER MILLPAPER MILL

(1999(1999--2001)2001)


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OBJECTIVEOBJECTIVE

The objective of this study was to apply Cleaner Production concepts toa Turkish pulp and paper mill to introduce the concept as well as toprovide a framework to future initiatives.To this purpose a comprehensive waste reduction audit was conducted.

METHODOLOGYMETHODOLOGY

Several waste audit guides from different sources (UNEP, UNIDO,

USEPA and others) were examined and compiled leading to themethodology implemented in this work.

The collected data were alsocompared with internationalenvironmental performanceindicators from other companiesin Europe, USA, Canada,and Australia. This comparisonprovided the specific opportunitiesfor improvement at differentprocesses in the mill.


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ProcessProcess FlowFlow DiagramDiagram


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InputsInputs Ton/annumTon/annum

WoodWood LogsLogs 151151,,666666

KraftKraft 1212,,778778

ChemicalsChemicals 1212,,352352WaterWater 33,,365365,,000000

SteamSteam 186186,,800800

TotalTotal 33,,728728,,596596

OverallOverall MillMill OperationsOperations (Debarking(Debarking andand Chipping,Chipping,

Pulping,Pulping, PaperPaperMachine)Machine)

OutputsOutputs ton/annumton/annum

NewsprintNewsprint 7979,,998998

BarkBark andand SawSaw DustDust toto

HogHog FuelFuel BoilersBoilers

1818,,447447

BarkBark andand SawSaw DustDust lostlost 11,,523523

WastewaterWastewater 33,,253253,,000000

FiberFiber lossloss 33,,750750

SteamSteam ExhaustedExhausted 200200,,000000

TotalTotal 33,,556556,,718718

MATERIALBALANCE


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Parameter (a) (b) (c) (d) (e) MeanSt.

Dev.

SEKA

Balkesir

Mill

Water onsumption (m3/ton of ADP

produced)

1.5 1.5 1.5 1.0 1.38 0.25 4.2

Power onsumption (kWh/ton of

ADP produced)

20.0 20.00 0.00 25.7

BOD5 (kg/ton of ADP produced) 2.3 1.0 1.0 1.0 1.0 1.26 0.58 2.3

OD (kg/ton of ADP produced) 4.2 4.0 5.0 4.0 4.30 0.48 5.3

TSS (kg/ton of ADP produced) 5.0 4.0 2.0 2.0 3.0 3.2 1.30 29.9

Wastewater Generation (m3/ton of

ADP produced)

1.0 1.0 1.0 0.8 0.95 0.10 4.2

Comparison of Pollution Loads with EnvironmentalComparison of Pollution Loads with EnvironmentalPerformance Indicators forPerformance Indicators for

(1) Woodyard &C

hipping Operations, (2)CTM

P Process(1) Woodyard &C

hipping Operations, (2)CTM

P ProcessOperations, and (3) PaperMachine OperationsOperations, and (3) PaperMachine Operations


Dev.

SEKA

Balkesir

Mill

Water Consumption (m3/ton of

ADP produced)

15.0 12.0 15.0 15.0 14.25 1.50 21.1

Power Consumption (kWh/ton ofADP produced)

2100.0 2100.00 0.00 2551.2

BOD5 (kg/ton of ADP produced) 11.3 35.0 30.0 25.0 40.0 28.26 11.00 47.2COD (kg/ton of ADP produced) 100.0 90.0 100.0 80.0 92.50 9.57 175.4TSS (kg/ton of ADP produced) 6.8 10.0 8.0 10.0 7.0 8.36 1.56 25.3Wastewater Generation (m3/ton ofADP produced)

15.0 12.0 15.0 15.0 14.25 1.50 19.4


Dev.

SEKA

Balkesir

Mill

W a t e r C o n s u m p t i o n (m3

/ t o n

o f p a p e r p r o d u c e d )

1 5 . 0 1 7 . 0 1 7 . 0 1 5 . 0 1 6 . 0 0 1 . 1 5 1 9 . 6

P o w e r C o n s u m p t io n

( k W h / to n o f p a p e r p r o d u c e d )

2 3 0 . 0 2 3 0 . 0 0 0 . 0 0 3 8 4 . 5

B O D 5 ( k g / t o n o f p a p e r p r o d u c e d )

3 . 0 2 . 0 3 . 5 3 . 5 3 . 0 3 . 0 0 0 . 6 1 1 2 . 7

C O D ( k g / t o n o f p a p e r p r o d u c e d )

1 4 1 5 1 3 . 5 1 5 1 4 . 3 8 0 . 7 5 2 2

T S S ( k g / to n o f p a p e r p r o d u c e d )

3 . 0 3 . 0 4 . 0 4 . 0 4 . 0 3 . 6 0 0 . 5 5 1 2 . 7

W a s te w a t e r G e n e r a ti o n( m 3 / to n o f p a p e r p r o d u c e d )

1 5 . 0 1 7 . 0 1 7 . 0 1 5 . 0 1 6 . 0 0 1 . 1 5 1 9 . 8

( 1 ) ( 2 )

( 3 )

(a ) Source: Handbook of Environmental Control (Bond and Straub, 1974)

(b) Source: A benchmark of Current Cleaner Production Practices (Aquatech, 1997)

(c) Source: Development Document for Proposed Effluent Limitations and Standards for the

Pulp, Paper and Paperboard Point Source Category (USEPA, 1993b)

(d) Source: Pollution Prevention and Abatement Handbook (World Bank Group, 1998)

(e) Source: Pollution Prevention and Abatement Guidelines for the Pulp and Paper Industry

(UNIDO, 1993)


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ParameterParameter Max. Estimated Decrease byMax. Estimated Decrease by Max. TotalMax. TotalEstimatedEstimatedDecreaseDecreaseRecycle of Log FlumeRecycle of Log Flume

WaterWaterStormWaterStormWaterManagementManagement

Water Consumption (mWater Consumption (m33/ton of ADP produced)/ton of ADP produced) 33 -- 33

BODBOD55 (kg/ton of ADP produced)(kg/ton of ADP produced) 22 -- 22

COD (kg/ton of ADP produced)COD (kg/ton of ADP produced) 33 -- 33

TSS (kg/ton of ADP produced)TSS (kg/ton of ADP produced) 11.511.5 44 15.515.5

Wastewater Generation (mWastewater Generation (m33/ton of ADP/ton of ADPproduced)produced)

33 -- 33

Summary of waste reduction estimates

for wood yard and chipping operations

ParameterParameter

Max. Estimated Decrease byMax. Estimated Decrease byMax. TotalMax. TotalEstimatedEstimatedDecreaseDecrease

ImprovedImprovedRaw MaterialRaw Material

SelectionSelection

ImprovedImprovedChipping &Chipping &

ScreeningScreening

ExtendedExtendedDelignificationDelignification

SpillSpillControlControl

Water Consumption (mWater Consumption (m33/ton of ADP/ton of ADPproduced)produced)

33 -- -- 33 66

BODBOD55 (kg/ton of ADP produced)(kg/ton of ADP produced) 99 1111 1313 55 3838

COD (kg/ton of ADP produced)COD (kg/ton of ADP produced) 2828 2020 32.532.5 2020 100.5100.5

TSS (kg/ton of ADP produced)TSS (kg/ton of ADP produced) 6.56.5 88 -- 55 19.519.5

Wastewater Generation (mWastewater Generation (m33/ton of/ton ofADP produced)ADP produced)

33 -- -- 33 66

for CTMP process operations


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Summary of waste reduction estimates

for paper machine operations

Max. Estimated Decrease byMax. Estimated Decrease by

Max. TotalMax. TotalEstimatedEstimated

DecreaseDecreaseParameterParameter

AdditionalAdditional

VacuumVacuumExtractionExtractionTanksTanks

ReducingReducing SealSeal

WaterWaterUtilized inUtilized inVacuumVacuumPumpsPumps

Reducing FreshReducing Fresh

Water UsageWater Usagein Feltin FeltShowersShowers

ReplacinReplacinggGlandGlandSealsSeals

Water Consumption (mWater Consumption (m33/ton of/ton ofpaper produced)paper produced)

-- 11 11 0.50.5 2.52.5

BODBOD55 (kg/ton of paper(kg/ton of paper

produced)produced)

77 -- -- -- 77

COD (kg/ton of paperCOD (kg/ton of paperproduced)produced)

1515 -- -- -- 1515

TSS (kg/ton of paperTSS (kg/ton of paperproduced)produced)

1010 -- -- -- 1010

Wastewater GenerationWastewater Generation(m(m33/ton of ADP produced)/ton of ADP produced)

-- 11 11 0.50.5 2.52.5


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Implementation oImplementation off

EUsEUs IPPC DirectiveIPPC Directiveiin a Turkish Denimn a Turkish DenimManufacturing PlantManufacturing Plant

(2005(2005--2007)2007)


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IPPPPC| Integrated Pollution PreventionPollution Prevention and Control

IPPC Directive (96/61/EC ) states to:

Prevent pollution from industrial production through raw

material substitution, clean technologies, etc.and

Control the pollution from industrial production throughtreatment facilities


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Under the management of Prof.Dr. lk Yeti of Dept. ofEnvironmental Engineering, METU, this project aimed to implementthe IPPC Directive for a major textile plant, as the first time in the

country.

This project had investigated the applicability of BATs for textilemill investigated. As a part of this project, many pollutionprevention opportunities were also evaluated such as:

Water use efficiency and recycling/reuse Energy efficiency Chemical substitution (or alternative chemical use) Recycling and reuse of caustic

There has been major success in terms of pollution prevention,water reuse, recycling, etc. among others.

Details of this project will be provided in two differentpresentations during the Workshop.


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MICROTRAINING:SUSTAINABLE TECHNOLOGICAL INNOVATION

PARTNERSDelft University of Technology, The Netherlands

Technical University of Catalonia, Spain

Aachen University, Germany.

Middle East Technical University, Turkey

Royal Institute of Technology/KTH, Sweden


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MICROTRAINING: SUSTAINABLE TECHNOLOGICAL INNOVATION

An increasing number of companies find Sustainable Development

(SD) important; this is mainly due to the growing attention from politicsand society.

Nowadays technology and innovation play important roles in the

approaches to sustainability related problems.Exchanging of new

knowledge and insight is therefore important.

Daily practise proves that it is difficult for companies to regularly make

time to transfer knowledge internally. Therefore it is necessary for

companies to have a practical approach on improving the level of

knowledge of Sustainable Technological Innovation (STI) within theorganisation.

MICROTRAINING offers a flexible approach focussed on stimulating

feedback, coupled on various learning styles and participants.


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Related topics are taught in series of

modules of 15 to 30 minutes,. Thechoice of topics covered will bedetermined by the knowledgerequirements of the employees of thecompany.

The MICROTRAINING approach isdeveloped and tested by sixcompanies in the Netherlands, DelftUniversity of Technology andInnovadersAmsterdam, and in

corporation with BecoRotterdam.


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MICROTRAINING APPROACH


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Parallel DevelopmentParallel Development

oof Industrial Productivityf Industrial Productivityaand Environmentalnd EnvironmentalPerformancePerformance aat St SMEMEss

LevelLevel(2007(2007--))

in cooperation with

Turkish NationalProductivity Centerand ankaya University


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The aim of the project is to demonstrate the industrial productivityand environmental performancecan beenhanced together.

To this end the specific objectives of this project can be summarizedas:

Compiling and developing an eco-efficiency guide for SMEs withrelevant environmental performance and industrial productivity

indicators

Training 20 SMEs from different sectors about the use of thisguide

Conducting 5 case studies and monitoring and correlating the

environmental performance and industrial productivity

Demonstrating that environmental management is not a burden, butit is an activity increasing productivity of thecompany throughdissemination activities.


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http://144.122.60.76/people/gndemirer/links/temizuretim/index.htm

Prof. r. Gksel emirerProf. r. Gksel emirerOrta ou Teknik niversitesiOrta ou Teknik niversitesi

evreevre MhendisliiMhendislii BlmBlm

AnasayfaAnasayfa || Temiz retimTemiz retim || Temiz retim AralarTemiz retim Aralar || Temiz retim SzlTemiz retim Szl || rnek Uygulamalarrnek Uygulamalar|| lgili Kurumlarlgili Kurumlar|| Yararl KaynaklarYararl Kaynaklar

AnasayfaAnasayfaTemiz retimTemiz retimTemiz retim AralarTemiz retim AralarTemiz retim SzlTemiz retim SzlEndstriyel UygulamalarEndstriyel Uygulamalarlgili Kurumlarlgili KurumlarYararl KaynaklarYararl Kaynaklarletiimletiim

zellikle 20. Yzyln ikinci yarsnda ba dndrc bir hza ulaan teknolojik ve endstriyelgelimelerin beraberinde getirdii evresel deerlerin tahribi ve yenilenemeyen kaynaklarn hzla azalmasgnmzdeivmelenerek srmektedir.

Endstrileme ve yaam biimlerindeki deimeye paralel olarak ortaya kan atklar, zaman iindelogaritmik bir art gstermi ve bu atklardan kaynakl yaanlan yerel evre sorunlar kresel bir boyut

kazanmtr. Ozon tabakasndaki delinme, kresel snma, asit yamurlar, eitli doal alc ortamlara -zmseme kapasitelerinin ok zerindeki miktarlarda- yaplan toksik ve tehlikeli atk dearjlar bukapsamda saylabilir.

A WEB PAGE IN TURKISHA WEB PAGE IN TURKISH


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