Programme René VAN BERKEL Chief Cleaner and Sustainable Production Unit United Nations Industrial Development Organization November 2014 Resource Efficient and Cleaner Production 1 Resource Efficient and Cleaner Production ID: 803670
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Regional Resource Efficient and Cleaner Production (RECP) Demonstration Programme
René VAN BERKELChief, Cleaner and Sustainable Production UnitUnited Nations Industrial Development Organization
November 2014
Resource Efficient and Cleaner Production
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Slide2Resource Efficient and Cleaner Production
Continuous application of preventive environmental strategies to processes, products and services to increase efficiency and reduce risks to humans and the environmentRECP addresses three sustainability dimensions individually and synergistically:
Production efficiency Through improved productive use of natural resources by enterprises
Environmental management Through minimization of the impact on nature by enterprises
Human development
Through reduction of risks to people and communities from enterprises and supporting their development
RECP= RECiPe
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Slide3Resource Efficient and Cleaner Production
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Slide4Resource Efficient and Cleaner Production
ReCiPE withIngredients ’practices’
Process ‘
continuous improvement’Outcomes ‘
indicators
’
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Slide5RECP Practices
Resource Efficient & Cleaner Production
Good House-keeping
Input Material Change
Better Process Control
Equipment
Modifi-cation
Technology Change
Onsite Reuse & Recycling
Production of Useful Byproduct
Product
Modifi-cation
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Slide6Changes in operational procedures and workplace management to reduce unnecessary ‘
wastage’Heritance Kandalama Hotel in Sri Lanka improved water and energy efficiency and reduced waste by operating equipment at full load, segregation of waste flows, switching off unnecessary lights/equipment, no-change towel policies, etc.
Good House-keeping
www.unido.org/cp
Practices
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Slide7Use of alternative inputs so that less or less problematic waste is created and/or renewable and less harmful materials are used
Metalexacto in Peru started to use more appropriate refractory materials and installed hood on furnace to save energy and increase lead recoveryInvestment of USD 2500 saves USD 17,000 annually
Input Material Change
www.unido.org/cp
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Slide8Improve control over processes and equipment as to operate these continuously at highest efficiency and lowest wastage
Haco Industries in Kenya achieved significant water and energy savings by sub-metering and routine monitoring of consumption relative to production output
Better Process Control
www.unido.org/cpNovember 2014
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Slide9Improve production equipment to avoid wastage (through overruns) and improve efficiency
G Steel in Thailand repositioned EAF burner to increase efficiency of oxygen use and improved operability of casting machineInvested USD210,000 for reported annual savings of ~15MUSD
Equipment Modifi-cation
www.energyefficiencyasia.org
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Slide10Replacement of (process) technology with more efficient and/or less wasteful technology
HTO Olive Mill in Morocco replaced 3 phase olive extraction to 2 phase extraction and pomace dryer to substitute fuel.Invested 4 MEUR, improved product quality, eliminated waste water and organic waste
Technology Change
www.cmpp.mo
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Slide11Useful application of waste (material, energy, water) within the same company for similar or alternative purpose
Rathkerewwa coconut industries in Sri Lanka recovered coconut shells and started to reuse these as alternative fuel in its boiler. Invested <USD2,000 to save ~USD165,000 annually
On Site Reuse
www.unido.org/cp
Practices
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Slide12Convert a previously wasted material into a substitute input material for another company or user
Spent grains from brewery can be reused to produce fibre-rich nutritional breadNovember 2014
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Production of Useful By-Product
www.zeri.org
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Slide13Redesign product in order to reduce its environmental impact during production, use and/or disposal
Short length seagrass was converted into twisted rope to create new products and markets for grass roots handicraft producers in Viet Nam
Product Modif-ication
www.unido.org/cp
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Slide14November 2014
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Slide15Productive output per unit of material consumptione.g
in ton product /ton material
Indicators
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Slide16Productive output per unit of energy consumptione.g
in ton product /MWhr
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Slide17Productive output per unit of water consumptione.g
in ton product /Gl
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Slide18Waste generation per unit of productive outpute.g
t waste/ton product
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Slide19Air emissions per unit of productive outpute.g
t CO2/ton product
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Slide20Effluent generation per unit of productive outpute.g
kl/ton product
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Slide21RECP
IndicatorsResource EfficiencyProductive output per unit of resource consumptionTotal energy useTotal water use
Total materials use
Pollution IntensityWaste and emission generation per unit of productive outputAir emissionsWaste water volume
Waste quantity
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Slide22RECP Logical Framework
Van Berkel (1995), Introduction to Cleaner Production Auditing,
UNEP Industry and Environment Review
Systematic root source and cause analysis guides the identification, evaluation and implementation of RECP opportunities
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Slide23Plan-Do-Check-Act
Systematic procedure for controlling processesit can be adjusted to implement RECP
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Slide24Plan
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Gov of Queensland, Brisbane, 2004
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Slide25Do
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Gov of Queensland, Brisbane, 2004
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Slide26Check
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Gov of Queensland, Brisbane, 2004
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Slide27Act
Eco-Efficiency Toolkit for Queensland Food Processing Industry, Gov of Queensland, Brisbane, 2004
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Slide28RECP Method
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Slide29Assessment Procedure
Better resource productivity
& environmental performance
Cost , productivity and
quality benefits
Awareness & interest
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Slide30Preparation
PREPARATIONSecure management commitmentOrganize project teamEstablish baseline RECP profile
Initial interest in RECP
1. Management commitment
2. Operational project team
3. Confirmed baseline
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Slide31Initial Assessment
INITIAL ASSESSMENTDevelop flow diagram & eco-mapDo plant walk-throughEstablish actions & priorities
Completed Preparations
Immediate RECP actions
Factory-wide RECP assessment focus
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Slide32Detailed Assessment
DETAILED ASSESSMENTDevelop material and energy balancesAssess root causes of inefficiencies and wastesGenerate RECP optionsScreen RECP options
Initial Assessment Completed
Process-based quantification of wastes & inefficiencies
Set of potential solutions
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Slide33LOW
Resource Efficiency & HIGH Environmental
Impact
WASTE
PLANT
PROCESS INPUTS
Technology Choice
Equipment Design
Process Control
Internal Value
External Value
3.2 Analysis of Root Causes
PEOPLE
PRODUCT
Slide34HIGH
Resource Efficiency & LOWEnvironmental
Impact
UTILIZATION
PLANT MODIFICATION
INPUT CHANGE
Technology Change
Equipment
Modification
Better
Process Control
On Site
Reues
Useful Byproduct
3.3 Generate RECP Options
HOUSEKEEPING
PRODUCT MODIFICATION
Slide35Feasibility Studies
FEASIBILITY STUDIESTechnical & operational evaluationEconomic evaluationEnvironmental evaluation
Detailed assessment completed
Listing of achievable RECP options
Documentation of projected benefits
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Slide36Implementation
IMPLEMENTATIONPlan and implement feasible optionsMonitor RECP benefitsIntegrate RECP in management
Feasibility studies completed
Continued improvements in resource productivity and environmental performance
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Slide37Recap:
Assessment Procedure
Better resource productivity
& environmental performance
Cost , productivity and
quality benefits
Awareness & interest
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Slide38RECP Training
AimEquip trainee experts with necessary methods and skills to undertake RECP assessments in enterprisesModality Class room training (twice, three days each)Practical assignment (RECP assessments in four demonstration enterprises by team of 3 experts)Expert coaching and guidance UNIDO CP Award
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Slide39Training Contents
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Slide40Training Contents
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Slide41RECP Pilot Demonstrations
Assist the demonstration enterprises with the identification, evaluation and implementation of RECP opportunitiesBaseline RECP profileInitial assessmentDetailed assessmentFeasibility studiesImplementation supportImpact RECP profile
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Slide42(Indicative) Timeline
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Slide43Associate Experts
TasksSupport promotion of RECP implementation by industries, in particular in the designated chemical sector;Undertake comprehensive RECP assessments in two nominated enterprises , including data collection, materials and energy balance calculation and chemicals management assessment, option generation, feasibility analysis and report writing (local language with English language summary); and
Support and where possible facilitate the implementation of the recommended RECP options for implementation; andMonitor and review the business and environmental benefits achieved through RECP implementation in the demonstration companies and compile on the basis thereof company success stories for publication and general distribution
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Slide44Associate Experts: Requirements
Recruitment Qualifications
Education
University degree in process, chemical, industrial or environmental engineering or chemistry; and
Excellent communication, analytical and drafting skills
Experience
Demonstrated familiarity with the operation of enterprise sector, in particular of Small and Medium Sized Enterprises, in the Republic of Moldova
Three years professional experience desired with relevance to industrial/business management, in particular in area of energy and/or environment
Languages
National language (mother tongue) and excellent spoken and written English
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Slide45Associate Experts: Deliverables
Summary for ManagementSummary of conclusions and recommendations from the in-plant assessment with respective business cases3-4 pages, national language and English (for company only)Technical ReportComprehensive findings of the in plant assessment, including material and energy balance, source and cause diagnosis, option generation and evaluation can be done in local language (for company only)Impact/Success Story
Public summary of the RECP activity and achievements at the company, including company profile, RECP indicators (before and after RECP implementation), summary of key options and management response~4 pages, national language and English (for public use)
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Slide46r.vanberkel(at)unido.orgwww.unido.org/cp
www.recpnet.org Thank You
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The Regional RECP Demonstration Project
is co-funded by Government of Slovenia,
Development Bank of Austria and UNIDO