Case Studies and Success Stories Swedish International Development Agency S ESSION 10 United Nations...

Case Studies and Success Stories

Swedish International Development Agency

SESSION 10

United Nations Environment ProgramDivision of Technology Industry and Economy

ACME Applying CLEANER PRODUCTION to MULTILATERAL ENVIRONMENTAL AGREEMENTS

OUTLINEObjectives of this session

1/ Cases studies on CP and UNFCCC > Case #1 - Pulp and Paper > Case #2 - Textile > Other examples

2/ Cases studies on CP and Basel Convention > Case #1 - Tannery > Case #2 - Electroplating > Other examples

3/ Cases studies on CP and Stockholm Convention > Case #1 - Pulp and Paper > Other examples

ACME - Session 10 – Cases studies and success stories - 2 / 36

Name of the Company: Agarwal Duplex LTD., Muzaffarnagar, INDIA

Production:Kraft paper and board from waste paper.

Context: Cleaner Production studies were conducted in the industry. The CP Team was formed and the entire plant was taken as focus area.

CP & UNFCCCCase #1 - Pulp and Paper


OperationSources of

wasteNature of

wasteProbable Causes of waste

generated

Electricity Generation

DG sets - GHG emissions

- Noise

- Solid

- Capacity Utilization

- Due to frequent power failures of the electricity through grid supply the paper machines use to stop and there by the waste of paper because of breaking of paper while rolling them into reels

- The capacity utilization of the machines was low

- High GHG emissions from the use of Diesel in DG Sets

- Low quality of electricity supplied

Steam Production

Coal fired Boile GHG - Use of fossil fuel


CAUSE ANALYSIS OF THE WASTE STREAM


CP technique used:

> Process optimization

> Input material change

> Technology change

CP options identified:

1. Replace the existing boiler with a new fluidised bed boiler of hogh pressure which uses bagasse as a fuel in place of coal in the old boiler.

2. Replace the diesel generating set for electricity production with a extraction cum condensing turbine and use the steam from the new high pressure boiler.


CLEANER PRODUCTION OPTIONS IDENTIFIED


RESULTS OF THE CP OPTION IMPLEMENTATION

Investment

Operational cost

Net annual savings

Payback period

Reduction in GHG emissions

2 million US$

same as earlier

1.5 million US$

16 months

~ 37.366 Tons per year



CP & UNFCCCCase #2 - Textile


Name of the Company: Luthra Dyeing and Printing Mills, Surat, INDIA

Production:Printed and dyed fabric of polyester, cotton, rayon.

Context: Cleaner Production studies were conducted in the industry. The CP Team was formed and the boiler house was taken as focus area.

OperationSources of

wasteNature of

wasteProbable Causes of waste generated

Steam generation

Boiler Flue Gases

Un-burnts in Ash

- Air-fuel ratio is not maintained

- No monitoring of relevant parameters (O2 or CO2)

- No device/method for heat recovery

- Air ingress through various portion

- Air quantity and pressure is not sufficient

- Distribution of primary air through grate

- Sizing of coal not proper

- Design of grate not appropriate

- Firing rate is not uniform

- Manual ash removal

- Poor fuel quality and combustion is not proper

CAUSE ANALYSIS OF THE WASTE STREAM (1)



OperationSources of

wasteNature of


Steam generation

Boiler Blow-down

Radiation Loss

- Bad Boiler feed water quality

- Condensate is not recovered

- Boiler drum TDS is not maintained as required

- Un-insulated portions of boiler

- Openings

CAUSE ANALYSIS OF THE WASTE STREAM (2)



CP technique used :

> Good House Keeping

> Operational Practices

> Process Optimization

> Raw Material Substitution

> New Technology

> New Product Design

> Onsite Recycle & Reuse

> Equipment Modification

CLEANER PRODUCTION OPTIONS IDENTIFIED (1)



Waste Stream CP Options

Heat Loss due to - Install air heater for recovery of waste heat

Flue gas - Plug all the air leakages into boiler furnace

Unburnt in Ash - Conversion of existing boiler to the FBC boiler

- Replacing existing boiler to FBC Boiler

- Optimize the coal sizing by proper crushing & sieving

- Modify the existing grate by reducing the gaps between the rods

- Optimize the firing rate by use of stoker firing

Blow down loss - Install water treatment system (RO) plant

- Change the water used in the boiler from tanker water to Municipal - Supply Water

- Install conductivity meter to check boiler drum water quality and therefore optimize the blow down rate

- Recover flash steam from boiler blow down

- Re-circulate condensate from steam separator and wherever possible

Radiation Loss - Insulate all the bare and damaged portions

- Insulate the flanges (125 Flanges)

- Installation of Steam Traps ( Thermo Dynamic Traps)




Investment

Net annual savings

Payback period

Reduction in GHG emissions

204.000 US$

196.300 US$

11 months

1300 Tons per year



CP & UNFCCCOther examples - A


ILUKA MINING AND MINERAL PROCESSING

Focus area Air emissions and heat from kiln

CP Option Waste heat recovery, initially thinking of installing high-cost wet scrubber technology.

Results Large investment (but feasible) especially when compared to traditional end-of-pipe treatment system.

Reduction in GHG emissions by 52.000 Tons/year

CP & UNFCCCOther examples - B


BUTTERCUP BAKERIESAUSTRALIA

Focus area Baking oven

CP Option Installation of heat exchangerfor a waste heat recovery system.

Results Investment 10,000 US$

Annual savings 2.000 US$

Reduction in GHG 20 %

CP & UNFCCCOther examples - C


G STEEL PUBLIC COMPANY LIMITEDTHAILAND

Focus area Electric Arc Furnaces (EAF)

CP Option Repositioning of EAF burner to increase consistency of injection and consumption of oxygen via oxygen lance.


Annual savings 3.839.168 US$

Reduction in GHG 42.943 Tons/year

ASSOCIATED MOTORWAYS LIMITEDSRI LANKA

CP & UNFCCCOther examples - D


Focus area Compressors and Compressed Air System

CP Option Replacement of old inefficient compressor with screw compressors.


Annual savings 43,137 US$

Reduction in GHG 102 Tons/year

CP & UNFCCCOther examples - E


HANOI CERAMIC TILESVIETNAM

Focus area Vertical dryer

CP Option Use of waste hot air from rapid and final cooling in the vertical dryer.


Annual savings 36,720 US$

Reduction in GHG 328 Tons/year

Name of the Company: Mohd. Usman Tanneries, INDIA

Production:Leather from sheep and goat skins (from raw hides to finished stage).

Context: Cleaner Production studies were conducted in the industry. The CP Team was formed and the tanning section was taken as focus area.

CP & BASEL CONVENTIONCase #1 - Tannery


OperationSources of

wasteNature of


Chrome tanning

Spent tanning bath, wash streams

Wastewater - Improper water measurement

- Chemicals weighing

- Spillages of the chemicals from the drum feeding hole

- No recovery of spent chrome




CP technique used: > Recovery, recycle and reuse.

CP options identified:> Recover the chrome by addition of magnesium oxide.





Investment

Operational cost

Net annual savings

Payback period

Reduction in toxicity and volume of hazardous waste

generation

7.500 US$

2 000 US$/year

6.500 US$

14 months

~ 15 Tons per year due to negligible amount of chrome in waste water.



Name of the Company: Atlas cycles, Sonepat, INDIA

Production:Bicycles.

Context: Cleaner Production studies were conducted in the industry. The CP Team was formed and following focus areas identified:

1. Hazardous waste generation from electroplating section.

2. Cyanide bearing waste from case hardening section.


CP & BASEL CONVENTIONCase #2 - Electroplating

Operation Sources of wasteNature of


Chrome Plating

Spent plating bath and wash streams

Wastewater with Hexa valent Chrome

- High quantity of water used

- Hexavalent chrome used

- Conversion of hexavalent chrome to trivalent chrome by ferrous sulphate

Cyanide Plating for Case hardening

Spent plating bath and wash streams

Waste water with cyanide

- Chlorine for cyanide removal

- Large amount of lime used

- Presence of ferrocyanide compounds making the sludge hazardous




CP technique used:

> Process optimization


> Technology change


1. Replacing use of ferrous sulphate by sodium met-bi-sulphite for reduction of hexavalent chrome to trivalent chrome.

2. Adoption of new technology to replace case hardening by cyanide plating to gas carburizing.




CP OPTION INVESTMENT SAVINGS/ BENEFITS PAY BACK

1 NIL No monetary savings in process but hazardous sludge reduced by 30% (15 Tons/year).

IMMEDIATE

2 US $ 10,000 No direct monetary savings but hazardous waste sludge reduced by 74% (50 Tons/year).

IMMEDIATE




DUTCH IRON FOUNDRIES

Focus area Sand reclamation

CP Option Optimisation of the sand dosing system.

Results Investment: 0 US$

Annual savings: 40.000 US$

Reduction in hazardous wastes: - 560 Tons/year

Reduction of raw material used: - 7,5%

Other examples - ACP & BASEL CONVENTION


DINTEX DYECHEM LTD. Vinyl Sulphone Intermediate Manufacturer.

INDIA

Focus area Unit processes : Sulfonation, Condensation

CP Option Acid recovery system and spray drier.

Results Investment 355.260 US$


Reduction in hardous wastes - 6.100 Tons/year

Other examples - BCP & BASEL CONVENTION


Manufacture of Chemicals and Chemical Products UNITED STATES

Focus area Reactor wash solution with alcohol, phenols formaldehyde resins and water.

CP Option On site recycling and recovery by distilling and reusing the alcohol.

Results Investment Not reported


Reduction in hardous wastes - 67%

Other examples - CCP & BASEL CONVENTION


Manufacture of Lead Acid Battery Plates FRANCE

Focus area Battery Plate Manufacturing line.

CP Option Process optimization of the manufacturing line by changing to automatic plant.

Results Investment 214.000 US$

Annual savings Not reported

Reduction in hardous wastes - 85%

Other examples - DCP & BASEL CONVENTION


Other examples - ECP & BASEL CONVENTION

Manufacture of Fabricated Metal Products (Solar Cell Wafers, Submarine silencer, satellite dish components)

UNITED STATES

Focus area Chemical Etching on stainless steel and Nickle.

CP Option Baking soda/water developer has been substituted for a combination of methylene chloride, 1,1,1 trichloroethane and perchlorethylene solvent ; Alkaline cleaners have been substituted for methanol ; sulfuric acid-hydrogen peroxide mix has replaced a chrome-based brightener Process optimization of the manufacturing line by changing to automatic plant.

Results Investment Not reported

Annual savings Not reported

Reduction in hardous wastes - 20% (135 Tons)


Name of the Company: ITC, Bhadrachalam Papers Ltd.Bhadrachalam, INDIA.

Production:Paper.

Context: Cleaner Production studies were conducted in the industry. The CP Team was formed and the paper bleaching section was taken as focus area.


CP & STOCKHOLM CONV.Case #1 - Pulp and Paper

OperationSources of

wasteNature of waste

Probable Causes of waste generated

Bleaching Bleaching process

- Hazardous Air Emissions

- Water Pollution Load

- Energy Loss

- Use of elemental chlorine in form of bleaching powder/ NaOCl

- Old Technology




CP technique used:


> Technology change


1. Installation of a new R8 process chlorine dioxide generation plant of 7 tons per day capacity.

2. Modify the bleaching sequence to “chlorine dioxide / ozone / chlorine dioxide”.





Investment

Net annual savings

Payback period

Results

10,32 million US$

4 million US$

2,15 years

- Reduction in AOX emissions.- Improved brightness quality



Other exampleCP & STOCKHOLM CONV.

Polyerethane manufacturing GERMANY

Focus area Adsorption of CCl3F.

CP Option Use of charcoal bed for adsorption of CCl3F.

Results Investment 350000 US $

Elimination of CCl3F from the environment


CONCLUSIONEnd of session 10

Thank you for your attention…Any questions?


Case Studies and Success Stories Swedish International Development Agency S ESSION 10 United Nations...

Documents

Transcript of Case Studies and Success Stories Swedish International Development Agency S ESSION 10 United Nations...