Teknik

Produksi Bersih
 Human Activity
RM INDUSTRIES Product
Water (Physical, Chemical,
Biological Processes) Side Prod.
Energy RM →P+Wastes
Waste Communities
WWT?
Waste
Natural
Resources
Environment
Waste→Nat Res
 t> →P& C>
→W>
→NR<

NR

with CP

Without CP
tQB tQCP
Time
 Overview

Traditional enviromental thinking focuses

on what to do with wastes and emissions
after they have been created.
Cleaner production avoids or minimizes
waste and polluton even before it is
generated !
Therefore it is called “pollution reduction
at source”
 Anatomy of Chemical Process industries

Raw RM
Reactor Separation
Material Preparation

Product Purification

Wastes
Old Paradigm
 Anatomy of Chemical Process Industries
New Paradigm

Raw RM Separation
Reactor
Material Preparation

Product Purification

Waste
 Overview

The key difference between pollution control

and cleaner production is one timing.
Cleaner prodction can be seen as recognition of
the need to consider the complexity of
sustainable production.
While the earlier focus on pollution control was
an after-the event, „react and treat‟ approach,
cleaner production is a proactive, „anticipate
and prevent philosophy‟. Prevention is, as is
well known, always better than cure.
 Cleaner
Production
Sustainable
development
Pollution
prevention
Recycling
Pollution
control
Dispersion

1960 1980 1990

Environmental Management History

Cleaner Production - Timeline
 Late 1980‟s
 Environmental managers in the U.S. and Europe realized the
importance of pollution prevention at the source
 Stress on reducing waste and pollution at source rather than
treating waste produced
 Combined effort of production, administration and
environmental specialist teams to reduce waste generation
and improve efficiency
 1990‟s
 EPA decided on Pollution Prevention (P2)
 National Pollution Prevention Act passed by Congress
 P2 – the top priority for protecting the environment from
pollution
 Established that recycling is not P2 but finding use for
something that’s already waste
 New P2 programs established in many states
 The United Nations Environment Programme (UNEP) in Paris
made similar observations about the need for Pollution
Prevention
Cleaner Production
 In Developing Countries
 Weak or no regulations regarding treatment of pollution
 UNEP - major resource for Environmental Policy
 Decided on cost effective prevention through improved efficiency
and business management as the means to reduce industrial
pollution
 UNEP called this “CLEANER PRODUCTION”
 Cleaner Production (CP) is the international term for reducing
environmental impacts from processes, products and services by
using better management strategies, methods and tools
 A global movement for improving business performance and a
profitable, cleaner, sustainable future
 CP called Pollution Prevention, waste minimization, green
productivity
 The US Office of Technology reported to the
Congress that :
“By considering pollution prevention
separately from other manufacturing needs,
such as productivity and quality improvements,
most pollution prevention programs fail to
develop the vital synergies and working
relationships with manufacturers that are
essential to drive both pollution prevention and
manufacturing competitiveness”
Cleaner Production (CP) :

Is defined as the continuous application of

an integrated preventive environmental
strategy to processes, products and services
to increase the overall efficiency and to
reduce risks to humans and environment.
In production processes, CP includes the
saving of rm and energy, the elimination of
toxic rm and the reduction in the quantities
and tocicity of wastes and emissions.
Cleaner Production (CP)
In product development and design, CP
aims at the reduction of negative impacts
throughout the life cycle of the product :
from rm extraction to ultimate disposal.
In services, CP advocates the incorporation
of environmental considerations into the
design and delivery of services.
 Cleaner Production

is a Preventive Integrated Environmental Policy

applied to the entire Production and Service cycle

Products: Processes:
•Reduction of waste •Conservation of raw materials, Services:
through better design energy, water •Efficient environmental
•Use of waste for •Reduction of emission at source management in design
new products •Evaluation of technology option and delivery
•Reduction of costs and risks

Impacts:
Improved efficiency
Better environmental performance
Increased competitive advantage
Critical CP Factors
 Management Systems
 Ensures right tools are used properly
 Environmental Management Systems (EMS) most common tool for CP and P2
 Other Management systems such as Balanced Scorecard and Balridge Quality
Award are also in use, Proper

 Assessments
 To identify CP and P2 opportunities
 Assessments get integrated with the management system as a continual
improvement process over time

 Measurements
 To obtain data on what‟s happening in an organization before applying CP and
P2
 Performance indicators linked with the mission and strategy developed
 Accounting tools used for developing the right data
 CP and P2 projects evaluated financially and by risk and impact assessments
Critical CP Factors (Contd.)
 Design
 Product design - ultimate driver for CP and P2 process improvements
 Process improvement follow proper Product Design

 Purchasing
 Critical for CP and P2
 Green Purchasing or Environmentally Preferred Procurement creates
demand for better products that in turn creates better supply

 Reporting
 Public reporting of CP and P2 and social performances
CP Assessments in Industries
 Cleaner Production assessment
methodology is used to
systematically identify and evaluate
the CP opportunities and facilitate
their implementation in industries

 Assessment methodology is useful

in organizing the CP program in a
company and bringing together
persons to be involved with the
development, evaluation, and
implementation of Cleaner
Production measures
Phase 1: Planning & Organization
 Elements important for the successful start of a Cleaner Production
program:
 Management commitment
 Employee involvement
 Cost awareness
 Organize a project team
 Identify barriers and solutions
 Set plant-wide goals

 Effective CP Planning Process ensures

 Selection & implementation of the most cost effective CP

options
 Broader business planning investment analysis and decision-

making (such as capital budgeting and purchasing)

 Cleaner Production objectives and activities are consistent

with those identified in the organization‟s broader planning

process
Phase 2: Assessment Procedure
 Source Identification –
material flow diagram with
associated costs made to identify
sources of waste and waste
generation
 Cause Diagnosis –
investigation of factors that
influence the volume and
composition of waste and
emissions generated
 Option Generation –
 create a vision on how to
eliminate or control each of
the causes of waste and
emission generation
 Option generation in turn
considers the following
elements
 Technological Good Operating
Change Practices

Change in
PROCESS Product
Changes
Raw Materials

Onsite Reuse
& Recycling
 Teknik PB

Pengurangan Sumber Pencemar Daur Ulang

Pengubahan Produk Pengendalian Penggunaan Pengambilan Kembali

•Penggantian produk di Sumber Kembali Diproses untuk :
•Penghematan produk Pencemar •Pengembalian ke •Mendapatkan
•Pengubahan komposisi Proses asal kembali bahan asal
•Penggantian BB •Memperoleh produk
untuk Proses lain samping

Pengubahan Bahan Masuk Pengubahan Teknologi Tata Cara Operasi :

•Penggantian Bahan •Pengubahan Proses •Tindakan-tindakan Prosedural
•Pemurnian Bahan •Pengubahan Tata Letak, •Pencegahan Kehilangan
Peralatan atau Perpipaan •Sistem Manajemen
•Otomasi Peralatan •Pemisahan Aliran Limbah
•Pengubahan Tatanan •Peningkatan Penanganan Bahan
dan Kondisi Operasi •Penjadualan Produksi
Phase 3: Feasibility Studies
Evaluates the technical and economic feasibility of options
 Preliminary Evaluation
 Options are sorted to identify additional evaluation needs for complex processes
 Technical Evaluation
 Availability and reliability of equipment
 Effects on product quality and productivity
 Expected maintenance and utility requirements
 Operating and supervising skills
 Economic Evaluation
 Collection (regarding investments and operational costs, and benefits)
 Evaluation criteria (pay back period, Net Present Value (NPV) or Internal Rate of
Return) and feasibility options
 Environmental Evaluation
 Determine the positive and negative impacts of the option for the environment
 Selection of Feasible options
 Elimination of technically non-feasible and environmentally insignificant options
 Selection of the right option in case of competing options or limited funds
 Phase 4: Implementation and Continuation

Evaluates the feasible prevention measures which are implemented

and provisions taken to ensure the ongoing application of CP

Results of this phase include:

 Implementation of feasible CP measures
 Monitoring and Evaluation of the progress achieved by the
implementation of the feasible options
 Initiation of the ongoing CP activities
bb
 A=40 P=40
A=80 A=80 AP+R R=40
K=20 H=40
50% (P,T) A=40
R=40
K=20

A=16
A=80 A=80 AP+R R=64
P=64

K=20 80% (P,T) H=64

A=16
R=64
K=20

A=20 P=80
A=80 A=100 AP+R R=80
K=20 80% (P,T) H=80

K=20 R=80
A=20 Hs1=80
Hs2=20
 Kemira Statoil heat Greenhouse
sulfur
(sulfuric acid) (oil refinery)
gas District
water
Steam Gas heating
CW WW
heat
Lake Tissa Gyproc
Asnaes (Coal-fired electric gypsum (gypsum
(freshwater
water power generating station) wallboard
source)
plant)
water heat
Steam
Fly ash
Fish farming

Novo Nordisk
Fertilizer Cement and road
(pharmaceutical plant)
sludge

Industrial Ecosystem in Kalunborg Denmark

 Benefits of Cleaner Production

 Improved production efficiency

 More efficient use of raw materials, water and
energy
 Recovery of valuable by products
 Less pollution
 Lower costs for waste disposal and wastewater
treatment
 Improved image
 Improved occupational health and safety
 Reduced enviromental liability
The Goal of Program
 Buku Acuan

 Allen, D.T. and Rosselot, K.S., 1997, ”Pollution Prevention for

Chemical Processes”, John Wiley & Sons Inc., New York.
 Allen, D.T. and Shonnard, D.R., 2002, “Green Engineering :
Environmentally Concious Design of Chemical Processes”,
Prentice Hall PTR, Upper Saddle River, NJ.
 Anastas, P.P., and Warner, J.C., 1998, “Green Chemistry :
Theory and Practice”, Oxford University Pers Inc, New York.
 Curran, M.A., 1996, “Environmental Life-Cycle Assessment”,
McGrawHill Book Company, New York.
 DeVito, S.C. and Garret, R.L., 1996, “Designing Safer
Chemicals”, American Chemical Society, Washington.