Waste Minimization &>e-infohouse.p2ric.org/ref/31/30137.pdf · In putting together any waste minimization program, ... A. Major Raw Materials Consumption i) ;; 2) ... hazardous materials

Waste Minimization &>e-

In putting together any waste minimization program, it is essential that a methodical step-by-step approach be adopted to bring the various groups together and ensure effective implementation. Such an approach also ensures the exploitation of maximum waste minimization and reduction opportunities.

Louis Staff

;e Ferrante Editor, TNEJ

I WORKSHEET 1 General Information

Name of the Compan : Waste Minimization Team

Name Designation 1 . II 2.

I 3. A. Major Raw Materials Consumption

i)

;; 2) ;;

ii) Chemicals

C )

a7 Electricafenerg y b) Fuel for boilers c) Others

B. Energ Consum tion

C. Water Consumption D. Production

Installed Capacity

Actual Production

E. Type of Effluent Treatment Primary Secondary No treatment

F. Any Other Relevant Information

Getting Started - Step 1 waste minimization team is essential for coordinating the program A to get the various measures imple-

mented and to bear overall responsibility. The team should comprise personnel from operating, design engineering, management personnel.

Depending on the need, external experts can also be included. General information regarding the unit or facility and record is shown in Worksheet 1 (note that each audit study is unique and industry- or plant-specific).

Waste minimization activities require several documents and information. If these are not available, they should be gen- erated and updated. The checklist given in Worksheet 2 would help in assessing the level of information available.

List Process Steps, Identify Wasteful Streams

Dl.!ring the first study, the team shau!d identify input and output streams. Major and obvious waste generating areas should be marked as shown in Worksheet 3. Labelling the waste streams with respect to their physical state (solid, liquid or gaseous) is a subsequent help at the waste quantification stage. If possible, the reasons for the generation of wastes should also be identified and recorded. The example shown in Worksheet 3 is for a specific papermaking operation.

~

36 The National Environmental Journal September/October 1995

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I WORKSHEET 2 Available Information 4

Information Availability Remarks Process flow diagram Material balance Energy balance Water balance

Poor housekeeping alone may

of waste. This often neglected contribute a significant amount

area can be the simplest and most attractive starting point to effect waste minimization. While con- ducting the first shop-floor study, the waste minimization team should pay special attention to

WORKSHEET 3 Process Flow Diagram Indicating Waste Streams

Paper Mill Example

Plant layout Waste analysis Emission records Production log sheets Maintenance log sheets Any other information

Inputs Process Steps Waste Streams Argo residue - > > - Wet cleaning

wastewater (L)

(screening rejectslpith)

> - Others

areas with poor housekeeping. Worksheet 4 could be used to record the housekeeping status in each section. Some commonly encountered housekeeping shortcomings are indicated, and many more can often be identified.

Caustic - > > - Leakages, spills, Cooking aids - floor wash (L)

Pulping section

Water - >

Steam - >

Additives - > 1 1 >-I Dyes -

> - Pulp wash

> - Bleach wash

> - Screening rejects (S)

> - Centricleaner

> - Rejects (L)

- > - Decker filterate (L) - > - Others

> - Others Fillers -

Stock preparation > - Spills (additivesldyes) (L) t

> - Floor wash (L)

> - Excess wire pit water (L) Kerosene-LL Bioaids - > > - Centricleaner reject (L)

Alum -

> - Saveall excess water

> - Couch decker filterate Steam - >

Water - > > - Others

z - DG Set flue gas (G)

> - Boiler flue gas (G)

> - Boiler ash (S) t Utilities

= Liquid = Gas

(L > - Hypo section sludge (S)

= Solids > - Other wastes

~

It would now be possible and desirable to record some basic cost data. At this stage, it would suffice to obtain the cost of direct input materials (purchase cost), which would be easily available from purchase and store records. A sample Worksheet 5 for the pulp mill section is shown, and similar worksheets can easily be worked out for other plant sections, by replacing the first column in Worksheet 5 with the appropriate input materials for each section. A list of commonly used input materials in other sections is given below; this could be appropriately amended if necessary.

Raw material preparation Stock preparation Process equipment

Analyzing Process Steps - Preparing Process Flow Charts

The preparation of a detailed process flow diagram is the first step in the entire analysis, forming the basis for compilation of the material and energy balance. A flow chart should list and characterize (if possible) input and output streams. Special care should be taken to identify recycle streams. Free or cheap inputs for water, air, and other resources should be particularly highlighted, as these often end up being a major cause of waste. Materials that are used occasionally and/or do not appear in output streams also should be highlighted.

WORKSHEET 4 Housekeeping Status Paper Mill Example

Sections Raw material (RM)

preparation

Stock preparation

Production

Laoses in Housekeeping RM spillage from conveyor/screens Dust spillage from screens Others RM spillage during loading/unloading

Leakage/spillage of chemicals Spillage of rejects and its interference

Loss of material due to defective equipment Other

with product stream

Spillage of additives due to improper handling Overflow due to high level Splashing to low level Others Open water hoses Overflow from fan pump pit/wire pit Overflow of water Others

The National Envivonmental Jouvnal September/October 1995 37

Chemicals Cost /Ton Annual Consumption

Chemicals Chemicals Steam Electricity Water

Material and Energy Balances The second important step is to draw a

material/energy balance of the selected unit or section. Material and energy balances are important for any waste minimization program, as they make it possible to identify and quantify previously unknown losses or emissions. These balances are also useful for monitoring the advances made in a prevention program and evaluating its costs and benefits.

While it is not possible to lay down comprehensive guidelines for establishing material balances, certain pointers might be useful.

*It is better to first draw up the overall material balance across each major section: raw material preparation processing.

When splitting up the total system, simple subsystems should be chosen.

The following measurement guidelines could be useful to avoid pitfalls while preparing the material balance:

*The measurements should be carried out on a per-day basis.

*The values could then be expressed of per pound or ton produced. Wherever required, these can be extrapolated to a per-year basis, keeping a note of variations in raw material, quality, and the like, to determine annual fig- ures for a feasibility analysis.

*All measurements of raw material should be converted to dry basis. This would simplify calculations due to variations in moisture content.

Making a Component Balance It may be useful to evolve the component

balance from the overall and section-wise material and energy balance. The most useful component balances are a total solid balance and a water balance, which provide a direct indication of the efficiency of utilization of fibrous raw material, chemicals and water. They give the relative importance of different waste streams in terms of quantum of loss, and enable prioritization of various streams for developing waste minimization measures.

38

Consumption/ Ton of Product

~~

WORKSHEET 6A Material Balance

RAW MATERIALS:

1 ....... ...... 2. ...... ...... 3. ...... ......

Quantity

AUXILIARY MATERIALS: Item Quantity 1. Catalysts ...... 2. Lubricant ...... 3. ...... ......

PROCESS

PRODUCTS: Item Quantity 1 ....... ...... 2. ...... ...... 3. ...... ......

I I

SOLID WASTE:

1 ....... ...... Quantity

....... ...... I I

I I WASTEWATER: Item Qty Contaminant 1. Process ...... ...... 2. Condensate ...... 3. Cooling ...... ...... 4. Overflow ...... ...... 5. Cleaning ...... ......

......

WATER CONSUMPTION: Item Quantity 1. Showers ...... 2. Washing ...... 3. Dilution ...... 4. Cleaning ...... 5. ...... ......

AIR EMISSIONS: Item Qty Contaminant 1 ....... ...... ...... 2. ...... ...... ......

WORKSHEET 6B Energy Balance

I I I STEAM: PRODUCTS: Quality Quantity Item Heat Content Quantity

...... 1. ... ...... ...... ...... ...... 2. ... ...... ...... ...... ...... 3. ... ...... ......

1 2. 3.

.......

I I I

ELECTRICITY: ENERGY LOSSES: Quantity 71 PROCESS 1. ... ......

...... ...... 2. ... ...... I FUEL CONSUMPTION: Item 1. Coal 2. Oil 3. Agroresidues ...... 4. ...... ......

WASTEWATER:

...... 2. Condensate ...... 3. Cooling

The National Environmental Journal September/October 1995

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WORKSHEET 7 Summary and Waste Streams and Possibilities of Waste Minimization

L

* ’

Section I Waste I Possibility of Stream

I

Source reduction Recycling

House- Input Better Equipment Technical Onsite Creation keeping Material Process Modification Change Reuse/ of By-

Control Recycle product

I Assign Costs To Waste Streams

In order to establish the profit enhancement potential of waste streams, a basic requirement is to assign cost to them. This cost essentially reflects the monetary loss due to waste. A waste stream does not appear to have any quantifiable cost except where direct raw material product loss is associated with it - for example, raw material content in the wastewater, unused material loss in waste liquor, chemical loss in wash water, etc. However, a deeper analysis would show several direct and indirect cost components associated with the waste stream. A list of possible cost components is given below.

Cost of waste transportation Cost of waste disposal

The above, and others, if present, should be worked out for each waste stream/emission and finally as the total cost per unit of waste.

Cost of raw materials in waste Cost of product in waste Cost of steam and electricity consumed in processing the waste Cost of waste treatment to comply with regulatory requirements

Cost of maintaining required work environment Cost due to waste excess and its handling pumping

requirements

GATES

DOORS ODOR CONTROL MANHOLES

FLUMES

CONSOLES


Review of Process to Identify Causes The process can be reviewed in the context of most cost-inten-

sive wastes. Through the material and energy balances developed, a cost analysis should be carried out to locate and pinpoint the causes of waste generation. These causes would subsequently become the tools for evolving waste minimization measures. There could be a wide variety of causes for waste generation ranging from simple housekeeping lapses to complex technological reasons, as indicated below:

Poor Housekeeping Leaking taps/valves/flanges

Overflowing tanks

Spillage of chemicals. Operational and Maintenance Negligence

Low bath ratios Suboptimal loading of reactors

Unnecessary running of equipment Improper maintenance

',

Continuous running of hose pipes Excess water and or raw material uses

Spillage of raw material from worn-out transfer belts Contamination due to spillage of raw material

Sub-optimal conditions - improper temperature control

Wearing out/absence of insulation of reactors, steam pipes,

Improper maintenance of steam traps Worn out wire mesh, resulting in leakage/loss of materials

condensate pipes

Low and uncontrolled pressure of water in nozzles and cleaning showers

Continuance of worn-out press rolls with uneven surface, resulting in increased press picking and consequent production loss

Improper maintenance of condensate removal system from steam dryers

Poor Raw Material Quality

Poor layout Unplanned expansion Improper collection and handling Location of equipment

pressure drop Managerial Cases

Inadequately Trained Personnel

Employee demotivatinn Lack of appreciation Absence of reward/punishment policies Emphasis only on production

Use of dirty and degraded raw materials Use of low grade chemicals Improper storage of raw material.

Improper routing of steam pipes, resulting in unnecessary

Increased dependence on contract labor Lack of a formal training system and/or training facilities High turnover of senior technical personnel Understaffing at the technical personnel level

Lack of commitment and attention by top management

Developing Opportunities Having identified and assigned causes to waste genera-

tion, waste minimization measures can be determined. Sum- marizing waste streams as shown in Worksheet 7 would help in making a quick qualitative estimate of the possibilities of waste minimization.

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The National Environmental Jouvnal September/October 1995 41

Waste Minimization Opportunity

Raw material section Material preparation section Stock preparation Production section

In this step, techniques such as brainstorming and group discussions can be used to determine all the possible options. Finding the potential options depends on the knowledge and creativity of team members. The range of waste minimization measures could also be of help in developing specific opportunities. Some other sources of help in developing waste minimization opportunities might be other personnel from similar plants, associations of task groups, and outside consultants.

Workable Waste Minimization Selection

The options developed are subsequently examined to assess their technical and economic feasibility. The weeding-out process should be simple, fast, and straightforward, and is often only qualitative. There should not be any ambi- guity or bias. Objectives should be to avoid the unnecessary effort of undertaking detailed feasibility analyses of opportunities that are impracti- cal or non-feasible.

Worksheet 8 would help in identifying which waste minimization opportunities:

*Can be implemented without any feasibility analysis (obvious measures).

*Require further detailed feasibility analysis. *Can be rejected. The selection of a waste minimization solution

for implementation requires that it should not only be technically and economically viable, but also environmentally desirable. The shortlisted opportunities that require further detailed analysis should be studied from the following perspectives.

Determining Technical Feasibility The technical evaluation determines whether

a proposed waste minimization option will work for a specific application. The evaluation often begins with an examination of the impact of the proposed measure on process, product, production rate,and safety. In case there is significant deviation from the present process practices, laboratory testing and trial runs might be required to assess the technical feasi-

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Implementable Further Analysis

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WORKSHEET 9 Technical Feasibility Analysis

I

Requirement - YedNo I Indigenous Availability

4. Shutdown B. Technical Impact

. Area Impact

Equipment Instrumentation Technology

2. Space 3. Manpower

I Production Capacity Product Quality Energy Conservation

Steam Electrical

Chemical Consumption Safety Maintenance Operational Flexibility Others

II I Positive I Neeative

cally attractive. Such a strategy helps in creating more interest and commitment. The economic analysis can be conducted using a variety of meth- ods, including the payback period method, internal rate of return method, or net present value method. For low-investment, short-duration measures with attractive economic viability, the simplest-the pay back period method-is usually good enough.

A typical worksheet (Worksheet 10) that would help in working out techno-economic viability is given. It may have to be modified to suit different options, but care should be taken to keep it as sim-

are not economically viable should not be dropped out. It could be possible that some of these options might have a significant impact on the environment and may therefore warrant implementation even if they are economically unattractive.

ple and transparent as possible. Even measures that ~~

Environmental Aspects The measures that are technically not feasible due to unavail- able technology, equipment, space, or other reasons should be listed separately for future studies by technical personnel. Tech- nically feasible should next be subjected to an economic analysis.

The options for waste minimization must be assessed with respect to their impact On the environment. In many the environmental advantage is obvious: there is a net reduction in the toxicity and/or quantity of waste. Other effects could be changes in treatability of the waste or changes in applicability of environmental regulations. In the initial stages, environmental Economic Viability

Economic viability often becomes the key parameter for

sure. For a smooth takeoff, it is essential that the first few waste minimization measures reported to management are economi-

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Implementation Solution Following the technical, economical, and environmental

assessment, waste minimization measures may be selected for implementation. Understandably, the most attractive ones would be those with the greatest financial benefits, provided technical feasibility is favorable. However, in a growing number of cases, specially when active pressure groups are present, environmental factor can take priority.

stopped, etc); several others, though, might require a sy$temati$- plan of implementation. The waste minimization t2am needs to prepare itself to take on the job of implementation. The prepa?ation would include seeking financial approvals, obtaining concurrence from concerned departments, establishing linkages in case of multi- department solutions, etc. These tasks require, in addition to the technical aspects, a careful handling of the concerned persons to ensure their support and cooperation throughout implementation.

Good liaison, awareness, and information dissem- WORKSHEET 10

Economic Viability Analysis Name/Description of the Waste Minimization Measure

Water

Land

Investment

Hardware Pumps Piping Civil Circulation tank Holding tank Equipment (specify) Land requirement Others Total

Annual Operating Cost

Interest (8.11%) Depreciation Maintenance (2.4%) Manpower Skilled Unskilled Energy Steam Electricity Chemicals Cost due to shutdown Others

Total

Gaseous Others BOD COD TS Others Solid Waste Organic In or e ani c

Savings

Energy Steam Electrical Chemicals Caustic Bleaching chemicals Additives Fiber Raw material Manpower Due to increased production Reduced environmental costs Treatment cost Waste transport cost Waste disposal cost Others

Total

Net Savings = (Savings - Operating cost)

PAYBACK = (Investment/Net Savings) x 12 = ... Months

In cases where a large number of waste minimization measures have been developed, it could be confusing to decide and allocate priority to them with respect to implementation. It would help in rating and prioritizing the measures for implementation. It would also be useful in determining the resources required (finances, manpower, time, etc.) and in evolving an implementation plan. A certain amount of subjectivity is intentionally introduced to enable the team to grade the measures even if they fall in the same category during the feasibility analysis.

It would be desirable to document the work done so far. Apart from becoming a reference document for seeking approvals and in implementation, the document would also be useful in obtaining finances from external institutions, reporting status to other agencies and establishing base levels for performance evaluation review.

The selected solutions should next be taken up for implementation. A large number of solutions can be implemented as soon as they are identified (leakages sealed, taps closed, idle running

ination assist implementation. Checklists of tasks involved, agencies/departments to be approached, contacts need, and the like also provide useful help.

Implementing waste minimization solutions is analogous to any other industrial modification and does not require elaboration here. The tasks comprise layout and drawing preparation, equipment fabrication/procurement, transportation to the site, installation and commissioning. Whenever required, simultaneous training of manpower should be undertaken, for an excellent measure may fail miserably if not backed by adequately trained people. To the extent possible, the implementation team should be aware of the job and its purpose, as several useful suggestions have often emerged from the implementation crew.

Monitor and Evaluate Results Finally, the solutions implemented need to be

monitored for performance evaluation. The results obtained should be matched with those esti- mated/worked out during technical evaluation; any causes for deviation should be established.

Shortcomings shouid be specifically highlighted and taken care of. A comprehensive report should be prepared to inform management and concerned personnel should be made aware of the results. Implementation is considered to be over only after success- ful commissioning and sustained stable performance over a reason- able length of time.

The biggest challenge in waste minimization in small industry lies in sustaining a program. The euphoria of a waste minimization program soon dies out and the situation returns to where it started. The zeal of the waste minimization team also tends wane. Often, top management is responsible for such lackluster ends. Backing out on commitments, emphasizing production at any cost, absence of rewards, and appreciation for performers and shifting priorities are some of the commonly encountered reasons that need to be checked and avoided.

The monitoring and review of the implemented measures should be presented so that the desire to minimize waste is encouraged. Efforts should be made to integrate waste minimization with the

WORKSHEET 11 Environmental Aspects Analysis

Namemescription of the Waste Minimization Measure Medium I Parameter I Impact on Environment

Qualitative Quantitative Air I Particulates I I

normal planning process of the company. The involvement of as large a number of employees as possible and rewarding the deserving is a sure key to long-term sustenance. In a nutshell, a philosophy of minimizing waste must be developed within the organization so that waste minimization becomes an integrated part of the organization’s activities.

For additional information, contact the author, Louise Ferrante, The National Environmental Journal, 230 Terrace Avenue, Has-

cl brouck Heights, NJ 07604, Phone: 201 -288-5992.


Documents

Waste Minimization &>e-infohouse.p2ric.org/ref/31/30137.pdf · In putting together any waste minimization program, ... A. Major Raw Materials Consumption i) ;; 2) ... hazardous materials