Cleaner Production & Industrial
Ecology
By Steve O. Nyamori – KNCPC
1
Focus of This Course
Cleaner Production
Industrial Ecology
Also to incorporate your experiences,
questions, and goals into the
presentation, exercises, and discussions
Case studies of Cleaner Production at
real facilities will be used 2
Cleaner Production
The Cost of Waste
Cleaner Production and the
environmental management hierarchy
Small group exercise on Classifying
Environmental Management Options
3
Cost Identification and
Estimation
Small group exercise on Cost
Identification
4
Cleaner Production
5
Why Cleaner Production in this
Course?
Cleaner production is a very important
tool in waste management as anchored in
the Waste Management
[Link]
6
The Cost of Waste
7
What is Waste?
Some proactive companies view waste
as: “any material or energy that leaves
a process or facility in any form other
than product”
A slightly less strict definition might
be: “any material or energy that leaves
a process or facility without first being
used as efficiently as possible”
Definitions vary — but all companies
generate waste!
8
Flow of Materials & Energy
Air Emissions
Materials,
Energy,
Water, Products,
Labour, By-Products
Capital
Solid Waste, Waste
Energy ,
Wastewater
9
Different Types of Waste
There are many words for different types of waste:
• allowance • greenhouse loss
• BOD • hidden losses
• broke • leakage
• contaminated • non-conforming
solids material
• core loss
• overfill
• customer returns
• packaging
• damage
• drainings • process loss
• dust • rework
• effluent • second quality
• evaporation • stock loss
• furnace loss • washings
Adapted from: The Kaunas Institute of Technology, Kaunas, Lithuania 10
11
12
13
14
15
The True Cost of Waste
Is Often Underestimated
For every $1 of waste cost that companies
actually measure, another $2-3 of cost
are” hidden” in the accounting records, or
are not on the books at all
Companies typically underestimate how
much waste really costs them, sometimes
by several orders of magnitude
This applies even to big, well-managed
companies
16
The “Cost” Iceberg
THE VISIBLE
COST OF WASTE
Treatment & disposal
The true
cost of waste
can be like an
iceberg, with
only a small
part visible
Manager’s time
17
So how do we melt
the cost iceberg?
...through
Cleaner Production!
Stay tuned...
18
Environmental Management
Options (shown in red below) Sell Sell or
Give Away
Prevent waste by looking
at inputs and process
Products Off-site
recycling
Raw Materials,
Energy, Water PROCESS
Labour, etc. Waste
On-site recycling Treatment
Disposal
19
Disposal
Moving waste to another
location without further use
20
Disposal Examples:
Emissions to the air
Wastewater sludge to landfill
Treated wastewater (liquid) to a
nearby stream
Product rejects, incinerator ash, and
other materials to a landfill
21
Control and Treatment
Changing the character of
waste before disposing of it (or
sometimes reusing some of it)
22
Control and Treatment
Examples:
Air pollution control device to capture
emissions
Treatment of wastewater to remove
and separately handle the water
contaminants
Incineration to reduce volume and
(sometimes) toxicity of waste
23
Off-Site Recycling and Reuse
Sending the waste elsewhere to
be treated and then reused as
a raw material
24
Off-Site Recycling and Reuse
Examples:
Scrap metals to a foundry to be melted
and formed into new metal objects
Sewage treatment sludge to farmers
for soil enrichment
Food wastes to farmers for animal and
fish feed
Office paper to a pulp mill to make
more paper
25
On-Site Recycling and Reuse
Keeping the waste at the
facility and treating it for
reuse elsewhere at the facility
26
On-Site Recycling and Reuse
Examples:
Process chemicals captured, filtered,
and returned to the process
Excess paint colours mixed into black
paint for reuse
Salvaging of defective parts to reuse
some components
Raw materials shipment packaging
reused to ship out company’s products
27
Waste Prevention
Eliminating or drastically
reducing waste or waste hazard
at the source,
before it is generated
28
Waste Prevention
Techniques:
a) Good housekeeping take appropriate managerial
and operational actions to prevent:
- leaks,
- spills,
- to enforce existing operational instructions
b) Input substitution substitute input materials:
- by less toxic or
- by renewable materials or
- by obsolete materials which have a longer service life-time in production
29
Cont.
c) Better process control modify:
- operational procedures,
- equipment instructions and process record keeping in order to
run the processes more efficiently and at lower waste and
emission generation rates
d) Equipment modification modify the existing
production equipment and utilities in order:
- run the processes at higher efficiency
- lower waste and emission generation rates
30
Cont.
e) Technology change replacement of:
- the technology
- processing sequence
- synthesis pathway
in order to minimise waste and emission generation during
production
f) Onsite Recycling reuse of the wasted materials in the same
process for another useful application within the company
g) Product modification modify the product characteristics
in order:
- to minimise the environmental impacts of the product during or after its use
(disposal)
- to minimise the environmental impacts of its production
h) Energy efficiency 31
Waste Prevention:
Examples
Product Redesign Combinations
(e.g., Design product
packaging with fewer layers) (e.g., Formulate
ink products with
Input Substitution no heavy metals)
(e.g,. Switch from solvent-based
to water/citrus-based cleaners) (e.g,. Replace a
solvent-based
Equipment Modification paint system
(e.g., Switch to high-efficiency with a powder
paint spray guns) paint system)
Good Housekeeping
(e.g., Monitor & repair
32
equipment leaks regularly)
So What About Cleaner
Production?
Cleaner Production is the combination of
the most proactive environmental
management options
Waste On-site
Prevention + Recycling
33
Cleaner Production is Different
Much of current environmental
protection focuses on what to do with
waste and pollution after it has been
created, otherwise known as “end-of-
pipe” disposal and treatment
The goal of Cleaner Production is to
avoid generating waste in the first
place
34
Environmental Management
Hierarchy
BEST
CLEANER PRODUCTION
Waste Prevention
On-site Recycling/Reuse
Off-site Recycling/Reuse
Control/Treatment
LEAST
Desirable
Disposal
35
CP Benefits (1)
Reduced operating costs
– Higher profit margin
– More competitive prices
Reduced risk and liability, both short-
term and long-term
Improved worker health & morale
Improved productivity, product quality
and consistency, operational
efficiency, etc.
36
CP Benefits (2)
Improved company/product image
– Better access to financing
– Better access to markets
– Improved relationship with local community
Reduced regulatory compliance
problems
– Fewer penalties
– Increased production flexibility
– Better relationships with regulators
37
Cleaner Production is ...
“The continuous application of an
integrated preventive environmental
strategy applied to processes,
products, and services to increase
overall efficiency and reduce risks to
humans and the environment.”
— United Nations Environment Programme
38
Cleaner Production
Production processes
– Conserving raw materials and energy,
eliminating toxic raw materials, and reducing
the quantity and toxicity of all emissions and
wastes
Products
– Reducing negative impacts along the life cycle
of a product, from raw materials extraction
to its ultimate disposal
Services
– Incorporating environmental concerns into
designing and delivering services 39
Cleaner Production Definition
Continuous Products Processes
Humans
Preventive STRATEGY for Risk Reduction
Integrated Services Environment
40
Small Group Exercise:
Case study to be done later
41
Teamwork is Very Important!
Each person brings different,
but vital, information
42
Final Questions or Comments?
43
Industrial Ecology
44
Industrial ecology
Definition
The study of physical, chemical &
biological interactions and
interrelationships both within and
between industrial and ecological
systems
45
Goal of industrial ecology…
To promote sustainable development at
global, regional and local levels. This is
realized through changing the linear
nature of our industrial system, where
raw materials are reused as energy or
raw materials for another product or
process.
46
Industrial ecology involves…
Identifying and implementing strategies for
industrial systems to more closely emulate
harmonious, sustainable, ecological
ecosystems,
A systems approach: environmental problems
are systematic and require a systems approach
so that the connections between industrial
practices/human activities and
environmental/ecological processes can be
more readily recognized.
47
Strategies for industrial ecology …
The wastes produced by one company
would be used as a raw material for the
other
No waste would leave the system or
negatively impact natural or man-made
ecosystems
48
Linear loop system…
•Materials and energy enter one part of the system and
then leave as products or by-products/wastes.
•Because wastes or by-products are not recycled or re-
used, this system relies on a large constant supply of raw
materials and the infinite ability of the natural systems
to assimilate wastes (known as “sinks”)!!!!
49
Closed loop system type 1
Characterizes much of our present-day industrial
system, some wastes are recycled or reused within
the system while others still leave it.
50
Closed loop system type 11
This represents the dynamic equilibrium of
ecological systems, where energy and wastes
are constantly recycled and reused by other
organisms and processes within the system
51
Closed loop system type 11
cont’d
This is a highly integrated, closed
system
In a totally closed industrial system, only
solar energy would come from outside,
while all by-products would be constantly
reused and recycled within
This type of system represents a
sustainable state and is an ideal goal of
industrial ecology
52
Industrial ecology as a strategy
for environmental impact reduction
Various strategies are used by individuals, firms and
governments to reduce the environmental impacts of
industry e.g. at enterprise level, CP (already
covered!) and Total Quality Environmental
Management (TQEM) - based on well-established
principles from Total Quality Management, TQEM
integrates environmental considerations into all
aspects of a firm’s decision-making, processes,
operations, and products. Some feel that industrial
ecology could serve as an umbrella for such
strategies
53
Case studies
Can you think of local examples
where there is waste exchange
(waste heat, wastewater, solid waste
etc?
54
snyamori@[Link]
steveonyamori@[Link]
55
