1

Evaluation Methodologies
in a Cleaner Production
Plant

Presenter: Ms. Julia Brown

Manager,
Process Development
Scientific Research Council
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Contents
Cleaner production–PRISM methodology
Planning and organization
Pre-evaluation
Plant evaluation
Feasibility Studies
Implementation
Generation of options of Cleaner product-
ion
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I. Cleaner produksi PRISM meto

dologi
II. Perencanaan dan organisasi
Pra-evaluasi
Plan evaluasi
Studi Kelayakan
Pelaksanaan
Generasi pilihan Cleaner-
ion produk
Evaluation for Cleaner
4

Production
It´s a systematic and planned
procedure done with the objective of
identifying the raw material, water
and energy wastes sources.
Facilitates the corporative efforts to
obtain uninterrupted environmental
improvement in the plant operations.
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Evaluation Tools
Information and evaluation compilation.
•Records
•Worksheets,
•Procedures
•Raw material, water, energy consumption
indicators, residues generation
•Generation options of Cleaner production
•National and international bibliographic
information
•Manage techniques of: storm of ideas,
team work
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Success Elements
Support and
participation of Higher
Management

Evaluation equipment
formed by staff of
different departments
Methodology applied
continually and in an
ordered way.
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Cleaner production methodology

Cleaner production interest

Planning and organization

Pre-evaluation

Evaluation

Feasibility Studies

Implementation and continuity

Evaluation
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Project Methodology

Phase 1: Phase 2:
Preparation Pre-evaluation

Phase 3.B:
Cleaner production Phase 3.C: Phase 3.A:
necessity recognition Feasibility
Implementation Evaluation
studies

New priority
System areas
Contaminant changes
minor charges
Phase 4:
Resources earnings Continuation
Phase 1:
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Planning and Organization

Recognized Necessity of Cleaner
Production/Diakui Kebutuhan Produksi Bersih

Activity 1: Obtain commitment of Management

Activity 2: Organize project equipment from
Cleaner production project
Activity 3: Define goals of Cleaner Production
in plant
Activity 4: Identify barrier and solutions

Established Evaluation Organization

Activity 1: Obtain the commitment
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of the Administration
Emphasize economical benefits! (e.g. reduction in
the costs because of the efficient use of water,
energy and residue reduction)
Illustrate environmental benefits! (e.g. emission
reduction, residual water contaminant charge and
toxic substances)
Other external benefits! (e.g. improvement in the
public image of the enterprise and comply with the
standing environmental laws)
 Promote responsible inquiries !
Activity 2: Organize the Team of
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Cleaner production (1)

Team has to be able of identify solution
opportunities, develop them and implement
them. (Characteristics: knowledge, creativity
and authority)
Size and integration of the team has to be
according to the enterprise organization (5 a 8)
Team has to coordinate the Cleaner product-
ion activities and the responsibility over the
established goals success
Activity 2: Organize the Team of
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Cleaner production (2)

Suggested members of the team

• Management representation.
• Production Manager
• Environmental area
• Motivated Supervisor
• Motivated Operator or
technician
• External Supervisor or
Advisor
Activity 2: Organize the Team of 13

Cleaner production (3)

To instruct the project team
• To assure the comprehension of the Cleaner
production concept between the members of the
team.
• To reinforce the systematic evaluation importance
and records of each process stage that may give
an environmental or economical impact. To enable
the project team.
• Create conditions for success (time, information
access, etc..).
• Assure the implementation of the options without
any cost and low price.
• To create incentives (recognitions).
Activity 3: Establish Cleaner Pro-
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duction Goals in the Plant

Considerations
• Goals have to be appropriate and measurable.
• Have to give significant environmental and/or
economical improvement.
• Short term goals have to be realistic.
• Long term goals have to be a threat.
Indicators
• Internal productivity standards.
• Water consumption, energy, generation of
residues.
• Innovative technology.
• Environmental legislation.
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Activity 4: Identify Barriers (1)

•Concepts and attitudes between

employees and the Management.
•Organizational structure of the
enterprise.
•Actual situation of the equipment
technology in the plant.
•Available and accessible information.
•Financial functioning of the enterprise.
•Absence of communication between the
different areas of the plant.
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Activity 4: Identify Barriers (2)

Diffuse the cleaner production concept between

the enterprise staff to facilitate:

• To obtain fluid information.

• Employees participation in the generation of
options and its evaluation.
• Effective implementation of the feasible options.
• Continuity in the cleaner production activities.
Phase 2: Pre-evaluation
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Planning and organization

Evaluation of the organization

Activity 5: Flow diagram development

Activity 6: Input and Output of materials
evaluation
Activity 7: Define the focus of the diagnostic.

Evaluation
Activity 5: Diagram flow develop-
18

ment
• Identify all the unit operations or process
stages.

• Check Input and Output.

• Relate process stages and material´s flow

(incomes, forms water consumption, energy,
amount of solid wastes, liquids, gaseous
emissions, etc..)
Process Flow Example
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Returned Bottles

Soak water containing:

Water First soak - Caustic soda residues
by aspersion - detergent residues
- organic and inorganic matter
Water Labels + caustic solution absorbed by
Caustic soda Caustic soda labels
Detergent bath Residual bath
Vapor Mud (organic or inorganic matter)
Condensates (discharged)

Water
Caustic soda Caustic soda Residual bath
Detergent bath Mud (organic or inorganic matter)
Vapor Condensates (discharged)

Water Soak by Condensates (discharged)

Vapor immersion

Water Final soak Condensates (discharged)

Vapor by aspersion

Washed bottles
 Diagram Flow Example
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Water
Sugar cane
Batey Sanitary disposal

Sanitary disposal
Fat and cooling water Mills
Bagasse

Chemicals
Clarification Chemical excess
First froth on cane
juice when bolied
Water vapor
Chemicals Evaporation
Displacing water

Cristalization Water vapor

Molasses
Centrifugation
Sugar to Refinery

Drying
Standard Sugar
Activity 6: Evaluation of Entrances
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and Exits of Materials (1)

• In each stage of the process: enlist inputand
output (raw materials, energetic and wastes)
• Assign costs to input and output by raw
material, water consumption, energy, residues
manage, etc.
• Check operation and maintenance practices.
• Materials selection practices.
• Used criteria for the selection of the
products and incomes.
• Number of products used for each stage of
the process.
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Activity 6: Evaluation of Entrances

Exits of Materials (2)
• Inventory manage practices: inventory
movements of first input, first output, package
conditions and storage.
• Internal costs: Manage and recollection of
residues, value of the incomes. Treatment
facilities operation, raw material losses and
intermedium products.
• External costs: Discharge fares, taxes, license
costs, etc..
Activity 6: Evaluation of Entrances
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Exits of Materials (3)

Operation and maintenance practices:
Obvious fails in the process control in the
work procedures.
Spills and leaks.
Obvious lacking in equipment maintenance.
Begin to improve order and cleanliness:
Obtain the support of the administration to
solve obvious problems.
Communicate with the workers involved.
Example: evaluation of Inputand
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Output
Input Process: bottles washing Output

Raw Annual Annual Unit Secondary Annual Annual

Materials Quantities costs operation Products costs $ Quantities
(kg, m3) $ (kg, m3
•Soak water
Water
•Caustic soda
Soda Bottle
Washing •Detergent
residues
Detergent
•Organic and
Vapor
inorganic
matter

•Labels

•Condensates
Activity 7: Select the Cleaner 25

production Diagnosis Focus (1)

•Economical considerations
• Economical losses related to residues
• Elevated energetic consumption, tap water
treated.

•Technical considerations
• Expected improvement potential.
•Possibility to apply cleaner production standards
in the operative activities.

•Environmental considerations
• Volume and composition of the residues.
• Actual situation in the environmental
management program.
 Cleaner Production Example
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Returned bottles

Soak water Soak water(45ºC) containing:

First soak - caustic soda residues
By aspersion - detergent residues
- organic and inorganic matter
Reposition soft water Caustic soda
Caustic soda Labels + caustic solution absorbed by labels
Detergent bath
Vapor 70°C, 2.5% NaOH
Residual bath (discharge of 8 m³each 3 months)
Mud (organic and inorganic matter)
Condensates
Reposition soft water Caustic soda
Caustic soda bath Residual bath (discharge of 8 m³each 3 months)
Detergent Mud (organic and inorganic matter)
Vapor 60°C, 2.0% NaOH Condensates

Soak water
Soak by
Vapor immersion Condensates
50°C

Soak water

Soft water(15°C) Final soak

Vapor By aspersion Condensates
30°C

Washed bottles
Activity 7: Select the Cleaner
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production Diagnosis Focus (2)

Process unit Economical Environmen- Technical Other
priority tal priority potential considerations

Residues Dangerous waste

generation 3 1 2 EIA - SETENA

Fuel change Other fuels costs

2 3 1

Water 3 2 Treatment costs

recovering 1 Operative report

3. High 2. Medium 1. Low

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Phase 3: Evaluation
Pre - Evaluation

Selected evaluation focus

Activity 8: Make material balance

Activity 9: Evaluate the causes of the residues
generation, energetic inefficiency or excessive
water consumption.
Activity 10: Generate Cleaner production options.
Activity 11: Select Cleaner production options.

Cleaner Production complete

options package

Feasibily studies
Activity 8: 29

Make Material Balance (1)

Process Input Process Output

Raw materials, Products,sub products,

water, energy and Residues and emissions
others records records.

Make Material Balance

1.- To collect information

2.- Make preliminary balance
3.- Evaluate and accurate the balance
Activity 8: 30

Make Material Balance (2)

Divide procedures in process stages.
Information sources:
• Measures in place over normal
conditions of line service operations
(e.g., time, temperature, pressure, flow,
chemicals, water consumption, etc.)
• Raw materials purchase and products
sales records.
• Production records
Activity 8: 31

Make Material Balance (3)

Quality evaluation of
data
Reliability
Precision
Representatively
Activity 9: Evaluation of Inefficiency
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Causes (1)
Equipment
design and
Process its plant
Technology distribution Product
specifications

Raw materials
Process discharges of raw
Type and
material intermedium
Quality of
products and end
Raw materials
products

Process
capacity Materials
Equipment,
losses
operation and
maintenance
Activity 9: Evaluation of Inefficiency
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Causes (2)
To implement obvious options:
•Raw material and energy management
•Production technologies and plant design
•Actual situation of the maintenance operation
•Optimum process conditions control
•Potential water reuse and recycling
•Abilities and employees motivation
Activity 10: 34

Generation of Cleaner production

options Equipment
modification Products
Technological
change formulation
modification

PROCEDURE Recovering
Raw & materials
materials reuse in
substitution plant

Improvement Production of
“Clean house” usable sub
in the process
products
practices control
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Activity 10:
Cleaner production generation options (1)

Information sources

• Storm of ideas developed in

the working team.

• Ask for ideas out of the

working team.

• Check options of cleaner pro-

duction examples.
• Check technology.
Activity 11:
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Select Cleaner production options

• Organize options for
operation unit.

• Evaluate obvious mutual

interferences.

• Implement measures
obviously possible.

• Eliminate those not feasible.

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Phase 4: Feasibility studies

Evaluation
Complete options pack

Activity 12: Preliminary evaluation.

Activity 13: Technical evaluation.
Activity 14: Economical evaluation.
Activity 15: Environmental evaluation.
Activity 16: Feasible selection of options.

Feasible options list

Implementation and Continuity
Activity 12:
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Preliminary evaluation

Options are based on persons

or in teams?

Are they simple or complex?

Are they cheap or expensive?

Activity 13:
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Technical Evaluation (1)

Verification List
• Team availability and reliability.
• Effect over the product quality and its
productivity.
• Maintenance and services requirements.
• Operators and supervisors abilities.
Activity 13:
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Technical Evaluation (2)

Before After
Consumption
Implementation Implementation

Input
Raw materials
Energy, Water
Hand work
Output
Solid Residues
Residual Waters
Gaseous emissions
Activity 14:
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Economical evaluation (1)

Evaluate the economical impact of the cleaner
production recommendation
Investment Costs and operation benefits

Realize economical calculations, (e.g., Investment

recovering period)
Investment Investment
recovering = -------------------
Earnings

Rapid method for small projects.

It´s an approximate indicator for high risk
projects.
Activity 14:
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Economical evaluation (2)

Time of investment recovering:

1 year (simple project)
< 3-4 years (medium cost project)
> 4 years (high cost project)
Activity 16:
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Selection of the Cleaner production

measurements
Combine results of technical, economical and
environmental evaluations
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Phase 5: Implementation and

Continuation
Feasibility
Feasible options list

Activity 17: Prepare a Cleaner production plan.

Activity 18: Implement Cleaner production options.
Activity 19: Progress advisement.
Activity 20: Cleaner production sustainability.

Cleaner production pursuit

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Activity 17: Cleaner production Plan

Responsible Implantation Key

Option End date
Person factors
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Activity 18:
To Implant Cleaner Production Options
Details Preparation
Detailed technical specifications.
Appropriate planning to reduce the
installation time.
Financing.
Installation.
Appropriate control of installation.
Preparation for the beginning of
operation.
Activity 19: Cleaner production
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Progress program Advisement.

Selection of measurement method:

 Changes in the amount of residues.

 Changes in the resources consumption
(water and energy).
 Profit change.
 Productivity change.
 Labor conditions changes.
Activity 20:
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Cleaner Production Sustainability

Quantify wastes generation, water and energy
consumption.
Incorporate Cleaner production in the
technical development, training.
To assure that employees may get involved.
Establish a preventive maintenance program.
Verify the environmental impact of new
equipments.
Cleaner production in Research and
Development.
Spread the results.
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Cleaner production strategies

Cleaner production

Reduction in source Internal Recycling

Product Change Process Change

Entrances Substitution Good Practices

Technological Modification
 Prism Methodology
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Recognize the necessity of

increasing competitivity with Obtain commitment from Management.
Establish the evaluation organization.
Cleaner Production Propose general objectives.
Overtake barriers.
Begin a preliminary study.

Planning and
Organization

Fund obtention.
Enterprise data and
Equipment installation.
its processes.
Advisement and
Flow of materials,
evaluation of results.
Plant wastes and emissions.
Project adaptation. Implementation
Evaluation Create work groups.
Planning of new
Generate Cleaner
projects
production options.

Feasibility
Technical evaluation. Study
Economical evaluation.
Environmental evaluation.
Organizational evaluation.
Selection of options.