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Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 1
Resource Efficient and Cleaner Production
Business Case, Concept & Practices
Bekasi, 7 February 2017
February 2017 RECP Introductory Training 1
National Resource Efficient and Cleaner Production (RECP) Programme Indonesia
Funded by Implemented by In partnership with
Kementerian Lingkungan Hidup dan Kehutanan
Centre for Assessment & Development of Green Industry & Environment
February 2017 RECP Introductory Training 2
Efisiensi Sumber Daya dan Produksi
Bersih
Business Case
ConceptPractices
RECP for green industry
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 2
February 2017 RECP Introductory Training 3
Resource Efficient and Cleaner Production canin multiple ways improve productivity andcompetitiveness of enterprises inmanufacturing and related productive sectors
Rathkerewwa Desiccated Coconut Industry
February 2017 RECP Introductory Training 4
National Cleaner Production Centre Sri Lanka
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 3
RECP@ Chea Hap Rice Mill
February 2017 RECP Introductory Training 5
Small Scale Rice Mills• Typical energy saving options– Individual drive system– Efficient separator– Efficient paddy cleaner– Plastic buckets in elevators– Voltage stabilizers– Energy efficient motors
• Low cost options with pay back of 18 – 24 months
February 2017 RECP Introductory Training 6
Bureau of Energy Efficiency (n.d.), Manual on Energy Conservation Measures in Rice Mills cluster of Ganjam, Delhi, India
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 4
Bradken Engineering
• RECP measures taken:• Use of less toxic sand binders
• Use of better refractory materials (tripled lifespan)
• Improved dry mechanical sand recovery (to 75%)
• Strengthened scrap acceptance criteria
• Changed melting regime
• Power factor improvement» Energy savings exceeding A$ 570,000 achieved with one
year pay back on investment
February 2017 RECP Introductory Training 7
Van Berkel (2007), Cleaner Production and Eco-Efficiency, Int Hdbk on Ent Techn Man
Metal Finishing Shops
February 2017 RECP Introductory Training 8
• Insulation of heated baths with polypropylene balls
• Invested USD120, saving annually USD15,000
• Installation of water cascading system• Invested USD150, saving annually USD15,000
• Replacement of wires with jigs in electroplating
• Invested USD15,000, saving annually USD12,600
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 5
Tarasima Apparels • Key measures
– Installation of thermal oil heaters to cut down steam consumption– Installation of a 2-ton incineration boilers resulting in savings in natural gas
consumption– Using skylights in the cutting, washing and finishing units– Installation of Electro Catalytic Reactor in Effluent Treatment Plant– Establishment of biogas plant, producing 56m3 biogas from canteen waste
February 2017 RECP Introductory Training 9
www.textilepact.net
Sky High Knitwear• Key options
– Installed wood based boiler
– Replacing 400 lux T8 fluorescent lights (40W) with 500 lux LED tubes (18W)
• Economics– Invested USD109,100– Annual savings
~USD395,000
• Environment– 36% increase in specific
energy consumption– 31% decrease in specific
GHG emissions
February 2017 RECP Introductory Training 10
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 6
De La Paix Hotel, Luang Prabang
February 2017 RECP Introductory Training 11
52% reduction of energy and water use per guest night (2012-2014)
Business Case
February 2017 RECP Introductory Training 12
Cost savings
Productivity enhancements
Quality improvements
Organizational efficiency
License-to-operate
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 7
February 2017 RECP Introductory Training 13
Resource Efficient and Cleaner Productionemerged as a business response to worsening(industrial) pollution and escalating use ofnatural resources
February 2017 RECP Introductory Training 14
disperse
control
recycle
Resource
Production
Resource Efficient and
Cleaner Productionprevent
pollution
replace
protect
recover
reduce
scarcity
natu
ral reso
urces
enviro
nm
ent
Efisiensi Sumber Daya dan Produksi Bersih
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 8
Efisiensi Sumber Daya dan Produksi Bersih
• Finding and implementing ways to– Improve productive use of materials,
water and energy;• Thereby
– Reduce the generation of waste, effluent and emissions;• Thereby
– Improve well being of employees, consumers and community; • Thereby• …….• ……..
February 2017 RECP Introductory Training 15
February 2017 RECP Introductory Training 16
Productive output per unitof resource consumption
Pollution intensity per unitof productive output
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 9
RECP Issues
February 2017 RECP Introductory Training 17
February 2017 RECP Introductory Training 18
Resource Efficient and Cleaner Production canbe implemented through – combinations of –different prevention practices
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 10
February 2017 RECP Introductory Training 19
Tata KelolaArea Kerja
Substitusi Bahan
Peningkatan Peningkatan Pengenda-lian Proses
Modifikasi Peralatan
Penggan-
Teknologi
Penggan-tian
Teknologi
Guna Ulang
Lokasi Sendiri
Guna Ulang Dan Daur Ulang di
Lokasi Sendiri
Pemanfaatan Pemanfaatan Produk
Samping
Modifikasi Produk
• Maintain a clean, organized andproductive workplace to eliminateavoidable ‘wastage’
• Typical solutions– Switch off what is not in use
– Repair what needs reparation
– Keep workplace organized and clean
– Minimize and manage inventory
– Confirm right way for all tasks
– Keep staff motivated
20February 2017 RECP Introductory Training
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 11
• Choose inputs that are efficient, effective and/or pose minimum harm to the environment and health
• Typical solutions– Use renewable energy
– Use sustainably-sourced renewable materials
– Use of recycled materials, water and energy
– Use fit for purpose materials
– Use less harmful substances
– Source locally
21February 2017 RECP Introductory Training
• Monitor and control processes andequipment so that they always run athighest efficiency and with lowestwastage
• Typical solutions
– Standard operating procedures and process monitoring
– Sub-metering water, energy and materials
– Preventive maintenance
22February 2017 RECP Introductory Training
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 12
• Make existing equipment more efficient and less wasteful
• Typical solutions– Insulation– Proper alignment of
production line– Improve process
temperature, pressure, speed, mixing
– Automatic switch off & level controls
– Combine process steps in same equipment
23February 2017 RECP Introductory Training
• Change over to new technologythat is more efficient or producesless waste
• Typical solutions– Efficient boilers, motors, fans,
compressors etc.
– Change of core process, e.g. chemical to mechanical cleaning
– Equipment with integrated recovery loops
– Advanced separation processes
– Solar dryers, heaters and lighting
24February 2017 RECP Introductory Training
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 13
• Use previously ‘wasted’ material, energy and/or water for similar or alternative purpose in company
Typical solutions
• Countercurrent or cascaded use of water and energy
• Condensate and heat recovery
• Reuse of incoming packaging for outgoing products
Practices
25February 2017 RECP Introductory Training
• Convert a previous ’waste’ for a useful use elsewhere
Typical solutions
• Provision of used cooling water for external heating or cooling purposes
• Segregate recyclables for external recycling and resource recovery, such as composting
• Symbiosis - use waste material for new product development
26February 2017 RECP Introductory Training
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 14
• Redesign product to reduce its environmental impact during production, use and/or disposal
• Typical solutions– Design for optimal product
lifetime– Design for lower material
use– Design for low-waste
manufacturing– Design for refurbishment,
recycling etc.
27February 2017 RECP Introductory Training
RECP Method
Source
Cause
Option
February 2017 RECP Introductory Training 28
Root Source Analysis
WHERE?
Quantification of the different usages and sources
Root Cause Diagnosis
WHY?
Factors contributing to resource usage and pollution sources
Option Generation
HOW?
Alternative ways to avoid the identified causes
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 15
February 2017 RECP Introductory Training 29
Efisiensi Sumber Daya dan Produksi
Bersih
Business Case
ConceptPractices
RECP for green industry
Indonesia RECP Programme• Networked initiative to foster
RECP implementation at scaleand at speed in Indonesia
1. RECP Capacity & Network
2. RECP Implementation & Replication
3. RECP Policy & Strategy
4. RECP Technology & Innovation
5. RECP Finance & Investment
Sectors
(food, textile & metal)
Industrial Zones
(Makassar & Batam)
Micro-Industries
(rice milling & TBC)
Tourism Destinations
(Sleman/ Magelang & Lake Toba)
February 2017 RECP Introductory Training 30
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 16
February 2017 RECP Introductory Training 31
Training
RECP Experts’ Competency
RECP Thematic Introductions
RECP Advanced Topics
Advocacy
Consultations (experts, regions,
sectors)
Business Cases and Primer
Thematic Forum Series
Network
Expert Society
Multi-Stakeholder
Alliance
February 2017 RECP Introductory Training 32
Sectors
Food (10) (sugar and palm mills)
Textile
(15)
Metal (tbc)
Zones
Makassar (10)
Batam (9)
Tourism
Sleman & Magelang
(18)
Lake Toba (tbc)
Micro-Industry
Rice milling (8)
TBC
# demonstration enterprises
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 17
February 2017 RECP Introductory Training 33
Environment
IndustryTourism
Green Industry(Award & Standards)
Trai-ning
Sustainable Sustainable Consumption &
Production
Sustainable Sustainable Tourism
Destination Development
PROPERAMDAL
February 2017 RECP Introductory Training 34
RECP
Cradle to Cradle
Industrial Symbiosis
Green Chemistry & Engineering
Improvement
Innovation (full return to
nature of discardedproduct)
Innovation (benign chemicals &resource efficient processes)
Innovation (closure of wastecycles in industrialpark)
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 18
February 2017 RECP Introductory Training 35
• Debottleneck finances for implementation of RECP investments
• Cooperation with domestic and international financial intermediaries
5.1 Financing Gap Assessment
5.2 Financing Instruments
Proposals
Implementing Partners
February 2017 RECP Introductory Training 36
Indonesia Cleaner Production Centre (ICPC) Centre for Assessment and Development of Green Industry and Environment (CADGIE)
Centre for Textiles Bandung (CTB)Centre for Resource Efficient and Cleaner Production Indonesia (CRECPI)
Intrroductory Training in RECP Methods and Practices
February 2017
Resource Efficient and Cleaner Production (RECP) 19
Terima kasih banyak!
February 2017 RECP Introductory Training 37
National Resource Efficient and Cleaner Production (RECP) Programme Indonesia
Funded by Implemented by In partnership with
Kementerian LingkunganHidup dan Kehutanan
www.recpindonesia.orgwww.recpnet.org
Centre for Assessment & Development of Green Industry & Environment
