Web Recp Indicator Peru

8/6/2019 Web Recp Indicator Peru

http://slidepdf.com/reader/full/web-recp-indicator-peru 1/12

SUCCESSES FROM PERU

Taking care o materials, energy, water, waste and emissions makes good business sense. Resource Ecient

and Cleaner Production (RECP) is the way to achieve this. RECP covers the application o preventive management

strategies that increase the productive use o natural resources, minimize generation o waste and emissions,

and oster sae and responsible production. Benets are eminent in many enterprises, regardless o sector, lo-

cation or size, as demonstrated by the experiences o Metalexacto, Unique and La Pisqueña in Peru.

Successes at a glance

The Peruvian enterprises covered here demonstrate that it makes good business sense to improve resource

productivity and reduce pollution intensity.

Metalexacto is a small lead oundry that, by implementing RECP, attained annual savings in the region o almost

USD 19,000, as well as improved working practices and conditions. Even though the company ocused mainly

on decreasing energy use, the integrated approach used enabled increased materials recovery, a decrease o

hazardous substances in waste, and a reduction o greenhouse gas (GHG) emissions.

RECP implementation in the tannery La Pisqueña led to annual savings in the region o USD 11,400, a credit reim-bursement o USD 109,779, and improved product quality. While the initial intent o the company was to address

the problem o efuents, the RECP programme enabled the company to also improve their energy productivity

and reduce the quantity o GHG emissions generated per unit o production.

The benets achieved by UNIQUE, a company producing cosmetics and jewellery, ater continuously applying

RECP measures include a reduction o energy use by 6%, reduction o water use by almost 30%, and a reduction

o waste water by more than 50%, accounting or savings o more than USD 79,000 per year. Additional benets

were improvements in working practices and a reduction o the company‘s carbon ootprint.

These successes were achieved with the assistance o the Centro de Ecoefciencia y Responsabilidad Social

(CER)-Perú. CER is part o the global RECP Network established with support o the United Nations Industrial

Development Organization (UNIDO) and the United Nations Environment Programme (UNEP).

Resource Efcient and Cleaner Production (RECP)

RECP builds upon Cleaner Production and related practices to accelerate the application o preventive environmental

strategies to processes, products and services to increase eciency and

reduce risks to humans and the environment.

RECP addresses the three sustainability dimensions

individually and synergistically :

Production Eciency : optimization o the productive use o natural

resources (materials, energy and water);

Environmental management : minimization o impacts on environ-ment and nature through reduction o wastes and emissions; and

Human Development : minimization o risks to people and commu-

nities and support or their development.

•

•

•

EntErprisE BEnEfits from rEsourcE EfficiEnt and clEanEr production

Resource Efcient

and Cleaner

Production (RECP)

Human Development

Production Efciency EnvironmentalManagement



mEtalEXacto

Overview

Metalexacto is a Peruvian company that produces secondary lead by smelting and rening used lead rom used

acid batteries to obtain a rened secondary lead/antimony alloy. The plant initiated operations in March 2001

and is staed by a Chie Engineer and our workers, two in the day shit and two in the night shit. The key

benets achieved by Metalexacto ater continuously applying Resource Ecient and Cleaner Production (RECP)

measures include the additional recovery o 34,7 tons o lead per year (worth approximately USD 16,980), im-

provements in working practices and a reduction o carbon dioxide emissions. RECP has lead to savings o more

than USD 18,830 per year.

Benefts

RECP has been a great cost-saving tool or the company and the measures implemented have led to reduced

waste o materials and energy. RECP has improved the operating eciency o the plant, improved product qual-ity and has enabled the recovery o some o the materials that were previously wasted.

TABLE 1: RESULTS AT A GLANCE

Absolute Indicator Change (%) Relative Indicator Change (%)

Resource use Resource productivity

Energy use -16 Energy productivity 46

Materials use 20 Materials productivity 2

Water use 0 Water productivity 23

Pollution generated Pollution intensity

Air emissions (globalwarming, CO2 eq.)

-16 Carbon intensity -31

Waste-water 0 Waste-water intensity 0

Waste -4 Waste intensity -22

Production output 23

Note: The absolute indicators provide a measurement o how much resource use/pollution output has changed in absolute terms e.g. units

o energy used or tons o waste generated. A negative percentage indicates a decrease and a positive percentage indicates an increase.

The relative indicators provide a measurement o changes in resource use/pollution in relation to production output. Resource productivity

provides a measurement o how much product output can be produced per unit o resource use, rom a sustainability perspective, productiv-

ity should increase. Pollution intensity provides a measurement o how much pollution is generated per unit o production output, rom a

sustainability perspective, intensity should decrease.



3

Metalexacto RECP Profle

Note: The RECP prole provides a visual overview o resource productivity and pollution intensity shown as change in % compared to the

baseline values. Environmental perormance is improved when resource productivity increases and when pollution intensity decreases.

Areas o improvement

Metalexacto obtains rened lead rom the oxides and sulphates rom used lead acid batteries. These are intro-

duced in a urnace and the lead is melted and then reduced until bullion o lead is obtained. The RECP options

implemented had a short payback time (generally just a ew months to one year). Most o the implemented op-

tions were low cost and were done by the sta o the company.

TABLE 2: OPTIONS IMPLEMENTED

Beore Ater

Note: The installation o the hood has led to the avoidance o the emission o gases with high lead concentration.

Principal options implemented Benefts

Economic Resource use Pollution generated

Investment

[USD]

Cost-saving

[USD/yr]

Reductions in energy use,

water use and/or materials

use (per annum)

Reductions in waste water,

air emissions and/or waste

generation (per annum)

Change o reractory bricks rom 31% to

50% aluminum oxide (Al2O3 ) and installa-

tion o a hood on the urnace.

2,470 16,986(lead sold)450 (uel)

Additional recovery o 34.7tons o lead.

19% less lead in the slag,decreased quantity o waste.

Change o burner and optimization o

residual uel and diesel, and improved mix-

ing o uel in the rening process.

965 1,215 Decrease o residual oil useby 2.66%.

Reduced air emissions byalmost 240 tons CO2 eq.

Warming o the uel by taking advantage o

the residual heat o the oven.

280 184 Decrease o electricity useby 5,760 MJ.

Note: The new reractory bricks have a higher content o aluminum oxide, which helps increase the reractory capacity o the oven (less uel

needed or heating) and also enhances the brick‘s lie per unit o lead produced



Approach taken

The Administration o the company has shown a great interest in the measures that have been implemented and

are committed to implement urther approaches aimed at improving the company‘s environmental perormance

without diminishing the quality o its products and the productivity o the plant.

The key lesson learned, is that the ollowing actors are crucial or a RECP success: involvement o employees

at all levels (which can be considered as the greatest achievement made by the company), monitoring, evalu-

ation and inormation on progress. The motto „Cleaner Production is not a destination but a way o lie“ aptly

describes the experience o Metalexacto.

„The conviction and cooperation o the whole organization are necessary or being able to make chang-

es. Cleaner Production allows achieving savings, decreasing pollution, and improving working condi-

tions as well as community relations. From this experience, we have learned to think in a dierent way,

and to ask ourselves whether the traditional way o doing things is always the right way or i we canimprove it. Finally, we conclude that we can always improve and that it is a never ending process”.

Adrian Stern, Metalexacto General Manager (December 2006).

Business case

Besides the savings mentioned above, working conditions have improved and commitment to continuously im-

prove the company‘s environmental perormance has been ensured.



5

la pisQuEÑa

Overview

The tannery La Pisqueña S.A. is a company that produces ne leather and semi-processed leather or „wet blue“

or exporting, 15% o its products are destined or the national market and 85% or the international market. The

company mainly processes cow, goat and sheep skins. The company has 46 workers and has assets o around USD

4,500,000.

The main target o the Resource Ecient and Cleaner Production (RECP) programme implemented at La Pisqueña

S.A. was the treatment o efuents. Even though the company increased its production by more than 30%, energy

productivity increased by 18%, and waste water intensity was decreased by 28%. The recycling and water treatment

system will allow the company signicantly to increase its production capacity. Moreover, the implementation o RECP

options generated savings o around USD 11,400, as well as leading to a credit reimbursement o USD 109,779.

Benefts

The project was mainly ocused on efuent treatment, but special attention was also paid to energy issues, material

use and processes. RECP not only enabled La Pisqueña S.A. to achieve savings rom the decreased use o energy and

resources, but also made it possible or the company to decrease their pollution o the environment and to act in a

more responsible way.

TABLE 1: RESULTS AT A GLANCE

Absolute Indicator Change (%) Relative Indicator Change (%)

Resource use Resource productivity

Energy use 14 Energy productivity 18

Materials use 33 Materials productivity 1

Water use -4 Water productivity 40

Pollution generated Pollution intensity

Air emissions (globalwarming, CO2 eq.)

12 Carbon intensity -17

Waste-water -4 Waste-water intensity -28

Waste 0 Waste intensity 0

Production output 34

Note: The absolute indicators provide a measurement o how much resource use/pollution output has changed in absolute terms e.g. units o

energy used or tons o waste generated. A negative percentage indicates a decrease and a positive percentage indicates an increase. The rela-

tive indicators provide a measurement o changes in resource use/pollution in relation to production output. Resource productivity provides

a measurement o how much product output can be produced per unit o resource use, rom a sustainability perspective, productivity should

increase. Pollution intensity provides a measurement o how much pollution is generated per unit o production output, rom a sustainability

perspective, intensity should decrease.



La Pisqueña RECP Profle

Note: TThe RECP prole provides a visual overview o resource productivity and pollution intensity shown as change in % compared to the

baseline values. Environmental perormance is improved when resource productivity increases and when pollution intensity decreases.

Areas o improvement

The results were achieved through the implementation o the ollowing measures:

Making the peeling process without destroying the ur.

Reducing the percentage o water in the initial washing and in the rinse process.

Improving production processes with the purpose o reducing losses.

Decreasing the percentage o salt use.

Recycling water rom dierent processes.

Timing the processes by measuring water eeding.

Improving the eciency o the boilers.

Insulating the pipes to avoid heat losses.

Installing a hydro pneumatic tank.Implementing a complete efuent and waste treatment management plan.


Note: In absolute terms, energy use and carbon dioxide emissions increased due to a 34% increase in production output. However, the increase

was signicantly lower that it would have been i RECP measures had not been implemented. The values presented and marked with * are calculated

values o the reductions/savings achieved taking into consideration changes in production output. I RECP measures had not been implemented,

then energy use would have been in the region o 902,800 MJ higher and carbon dioxide emissions would have been more than 50 tons higher.

•

•

•

•

•

•

•

•

•

•


Economic Resource use Pollutiongenerated

Invest-

ment

[USD]

Cost Saving [USD/yr] Reductions in energy

use, water use and/or

materials use (per an-

num)

Reductions in

waste water,

air emissions

and/or waste

generation (per

annum)

Improving production processes with the purpose o

reducing losses.

990 4,230 * Reduction o electric-

ity consumption by

453,600 MJ *

16.5 tons o CO2 *

Improving the eciency o the boilers. 200 2,860 * Reduction o uel

consumption (2,860

gallons corresponding

to almost 449,000 MJ ) *

35 tons o

CO2 *Insulating the pipes to avoid heat losses.

Installing a hydro pneumatic tank. 5,700 4,360

Including 30% reduc-

tion o waste-water

treatment costs

Reduction o in water

use by 2,492 kl

Reduction o

waste water by

2,492 klImplementing a complete efuent and waste treatment

management plan.




7

Approach taken

The managers o La Pisqueña S.A. were worried about the efuents and wastes o their tannery. For this pur-

pose the managers wanted to implement a recycling system and efuent treatment processes in their plant.

The company got the approval o the Green Credit Trust (a credit supported by the Swiss State Secretariat or

Economic Aairs, SECO) in November 2005 to implement these improvements. In order to get the credit, the

company carried out a Cleaner Production program to ull the requirements o the Green Credit Trust. The credit

was or 278,310 USD and due to the great environmental perormance the company got a reimbursement o USD

109,779.

RECP is a great cost-saving tool that has enabled the company to reduce the waste o raw materials and energy.

Through the implementation o measures, the company has been able to improve the operating eciency o

the plant, improve product quality and recover a part o materials that were wasted. The work at the company il-lustrates the principle o Pollution Prevention Pays especially since the investments needed to achieve improve-

ments had short payback times (a ew months to 1 year).

Business case

Although the project was mainly ocused in efuent treatment, a direct positive consequence was also obtained

in the peeling process, which has increased the value o the nal products. RECP not only allows companies to

achieve savings rom decreased resource use, but also decreases pollution to the environment, which benets

the surrounding community.

Ex-post evaluation, chrome sampling New equipment installed at the plant



9 Enterprise-Level Indicators or Resource Productivity and Pollution Intensity — A Primer or Small and Medium-Sized Enterprises

Unique S.A. RECP Profle

Note: The RECP prole provides a visual overview o resource productivity and pollution intensity shown as change in % compared to the

baseline values. Environmental perormance is improved when resource productivity increases and when pollution intensity decreases. The

main reason or the decrease in energy productivity is the decrease in production output by 357.8 tons.

Areas o improvement

The Plant in Lurin has production processes that can be continuous, batch or a combination o both. The plant

divides its production in three lines: the solid line dedicated to compact manuacturing; the liquid line dedi-

cated to perume manuacturing; and the semi solid line dedicated to cream, gel, shampoo and deodorant

manuacturing.

The RECP results were achieved through the implementation o the ollowing measures:

Energy

Improving the eciency o the boilers.Recovering heat rom the fue gases in the chimney.

Insulating the water tanks.

Decreasing the heat losses in the steam distribution line.

Reducing the electricity bill by changing the peaks o the company demand to hours out o the peak time.

Reducing electricity consumption by regulating and maintaining the compressors.

Taking advantage o natural light.

Reducing electricity consumption with good housekeeping.

Changing bulbs with more ecient lamps.

Water

Maximizing the recovery o condensates.

Increasing the eciency o water use or the cleaning and sanitation o equipment.Reusing output water rom Reverse Osmosis process.

Reusing treated waste water rom the plant.

Materials

Reusing alcohol rom the cleaning process.

•

•

•

•

•

•

•

•

•

•

•

•

•

•



10

Workers perorming with recycled materials at the presentation o the program at UNIQUE

Logo implemented by the company or the awareness campaign


Economic Resource use Pollution

generatedInvest-

ment

[USD]

Cost Saving

[USD/yr]

Reductions in energy use,

water use and/or materi-

als use (per annum)

Reductions in waste

water, air emissions

and/or waste genera-

tion (per annum)

Improving the eciency in the boilers. 7,230 5,670 Reduction o uel use.

Reduction o energy use

by more than 847,000 MJ.

Reduction o CO2emissions by 374tons.Recovering heat rom fue gases in the chimney.

Insulating the water tanks.

Reusing water rom the rejects rom the reverse osmosis

equipment.

700 73,475.4 Reduction o water use by

almost 20,000 m³.

Reduction o waste

water by more than

20,000 m³.

Reusing treated waste water rom the plant.


Note: Energy use was decreased by minimizing thermal losses. Also, in order to pay less or electricity, the plant does not produce at peak

times when the cost o electricity is higher. Thereore, the plant has just changed its production schedule to hours when electricity costs

are lower.




11 Enterprise-Level Indicators or Resource Productivity and Pollution Intensity — A Primer or Small and Medium-Sized Enterprises

Approach taken

The lesson learned is that there are some key conditions that are needed or a successul RECP implementation

programme. These conditions include: involvement o employees at all levels, monitoring, evaluation and inor-

mation o the progress made. The success o the programme was ensured by the commitment and support o the

management o the company. Plant workers were the most important stakeholders during the RECP programme;

they showed a lot o commitment and also replicated their knowledge o cleaner production to their own houses.

The motivation or change came rom the Directors o Yanbal International who provided the guidelines or the

programme, while the Corporate Industrial Department o Yanbal International supply chain was in charge o the

implementation. One o the key successes o the programme is that sta at all levels was involved and commit-

ted to the process.

„We really eel very happy and motivated or this implementation; we believe it is our job. I hope that,

in the uture, when looking or ways to improve processes, there will also be an awareness o the need

or taking care o the environment and preserving resources. The benets are numerous, we are con-

dent that we are getting more productive, more ecient, and at the same time more careul with the

environment. For the community is good to know that they have an environmentally riendly partner in their neighbourhood. Our company is not necessarily a actory that aects the environment, but a

actory that contributes to take care o the environment which also refects our behaviour in the whole

community“

Gonzalo Ravago, Corporate industrial Manager, May 2008

Business case

Besides all the benets mentioned above, the RECP programme brought improvements in working practices and

a reduction o the company‘s carbon ootprint. This successul case can be a great chance or Unique to urther

improve its image as a responsible company, which could contribute to their eorts to increase market shares

and revenues in the uture.



ABOUT THESE SUCCESS STORIES

The United Nations Industrial Development Organization (UNIDO) and

the United Nations Environment Programme (UNEP) cooperate in their

joint Resource Ecient and Cleaner Production (RECP) Programme.

The RECP Programme aims at improving the resource productivity and

environmental perormance o businesses and other organizations in

developing and transition countries. The Programme is implemented

in partnership with a network o National Cleaner Production Centres

(NCPCs) that have currently been established in some 50 countries.

This series o enterprise success stories documents the resource pro-

ductivity, environment and other benets achieved by enterprises in

developing and transition countries through the implementation o

RECP methods and practices.

The success stories employ the indicator set described in Enterprise

Level Indicators or Resource Productivity and Pollution Intensity. A

Primer or Small and Medium Sized Enterprises, published by UNIDO

and UNEP in 2010. The primer with accompanying calculator tool and

urther case studies are available at www.unido.org/cp and www.

unep.r/scp/cp.

Centro de Ecoefciencia y Responsabilidad Social (CER)-Perú

The CER Peru was established in 2002, and is hosted by the non-gov-

ernmental organization Grupo GEA. The centre oers services in theareas o Resource Ecient and Cleaner Production (RECP), Corporate

Social Responsibility (CSR) and carbon neutral markets. By mid 2010,

the centre had conducted cleaner production assessments, includ-

ing carbon ootprint measurements, in 55 enterprises and helped 28

enterprises with CSR related strategic planning. The centre was is ac-

tively working with ministries and local governments and participates

in the administration o the Green Credit Trust Fund (supported by the

Swiss State Secretariat or Economic Aairs) which has nanced in-

vestments in 17 enterprises - amounting to a total o USD 3.35 million

(www.cer.org.pe).

This publication was made possible with the generous support o the

State Secretariat or Economic Aairs, Government o Switzerland.

UNITED NATIONS ENVIRONMENT PROGRAMME

Division o Technology, Industry and Economics

15 rue de Milan, 75441 Paris Cedex 09, France

Telephone: (+33-1) 4437 1450, Fax: (+33-1) 4437 1474

E-mail: [email protected], Internet: www.unep.r

UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

Vienna International Centre, P.O. Box 300, 1400 Vienna, Austria

Telephone: (+43-1) 26026-0, Fax: (+43-1) 26926-69

E-mail: [email protected], Internet: www.unido.org

Web Recp Indicator Peru

Documents

Transcript of Web Recp Indicator Peru