Cleaner production Considers your Technologies Employees Raw materials Processes Emissions

1. Cleaner production • Considers your • Technologies • Employees • Raw materials • Processes • Emissions • Partners and • Products

2. Elements of a CP-project • Data collection Mass flow Energy flow Costs and safety • Reflection: Where and why do we generate waste? • Option generation • Feasibility • Implementation • Controlling, continuation, EMS

3. Common waste treatment: Waste is generated! What’sthat got to do with me? Cleaner production: Waste is generated! Where does it come from?

4. OBSERVED SYSTEM PRODUCTS Primary and secondary MATERIAL EMISSIONS • ENERGY CARRIERS • Fuels, e.g. gas, oil, coal Solid waste, gases, wastewater • ENERGY • Mass free, e.g. electricity or district heating • ENERGETIC • EMISSIONS • Waste heat, noise • MATERIAL • Raw material, process material, other material

5. No Waste or liquid or gaseous Annual Unit Purchasing cost Disposal cost Total cost emissions q uantity 1 Waste water 180,000 m³ 6 10 2,880,000 2 Spent grain (wet) 5,000 t around 800 - 350 - 1,750,000 (2,250,000) 3 Malt dust 447 t 4,000 ? 1,788,000 4 Wast e barley 220 t 4,000 ? 880,000 5 Bottoms 30 t - 250 7,500 6 Glass/broken glass 92 t 2,400 350 253,000 7 Plastic containers 18 t 10,000 2,000 216,000 8 Labels (wet) 50 t 30/1000 pcs 600 3,600,000 30,000 9 Cardboard / paper 35 t 5,000 - 175,000 10 Wood pallets 24 t 6,000 40 144,960 11 Plastic film 1.5 t 22,000 4,500 39,750 12 Industrial waste 104 t ? 800 83,200 13 D iatomaceous earth 45 t 8,000 930 401,850 14 Waste from maintenance, 200 kg ? 11 2,200 greasy 15 Contents of oil separator 3,200 kg ? 2. 8 8,960 16 Waste oil 1,000 kg 50 2 52,000 17 Waste paints 50 kg 100 15 5,750 18 Fluorescent lamps 20 kg 120 12 2,640 19 Accumulators 25 kg 70 2.8 1,820 20 Waste gas, steam boiler 1,000,000 m³ - - -

6. Reasons for an environmental team • Becausethere are many different departments/machines in a company, it is difficult to get the necessary overview and the detailed technological knowledge. • Becausethere are motivated and competent employees in a company. • Becauseas a TEAM – with a common goal – it is possible to work more efficiently than a lone ranger. Gather people from differnet departments: production, maintenance, technology, purchasing, management, quality, accounting, research and development, environment, health and safety, legal branch, etc.

7. Material flow analysis Sankey-diagram: www.sankeyeditor.net

8. Material flow analysisDetailed description of the material and energy use • Which waste and emission streams are generated? • Which raw materials are lost? • Where and why does this happen? • Where are the weak points? • Where are potentials for improvement? • Which materials can be reused?

9. Within the production process, there are many points where materials and energy are lost. • These points are also environmental and economic weak points. • A material flowanalysis identifies the points where materials are lost and their amount.

10. A comparison with the best available technology shows process weaknesses. • The material flow analysis facilitates the evaluation of the "production costs" of waste and emissions. • Eco-efficiency:the best use of materials reduces emissions.

11. Strategies for cleaner production

12. Product change • Substitute the product • Increase the product life-time • Change the materials • Change the product design • Use recycled materials • Avoid critical components

13. Good housekeeping • Improve information • Change dosage/concentration • Increase the utilization of process capacities • Check cleaning and maintenance period • Foster standardization/automation • Improve purchasing, storage and distribution • Carry out a material flow analysis

14. Waste logistics Separation of waste and wastewater to • Set up closed cycles • Facilitate recovery and re-utilization • Minimize quantities of hazardous waste • Minimize disposal costs • Minimize cleaning expenses (wastewater, exhaust gases, etc.)

15. Technological modification • Substitute thermo-chemical processes by mechanical alternatives • Use countercurrent cascades instead of single-static rinse techniques • Manage separate waste and wastewater streams • Improve process conditions • Foster recovery and reuse of materials • Increase life time of chemicals/materials • Reduce the infiltration of impurities • Ensure airtight sealing of equipment

16. Energy efficiencyTypical areas of improvement • Cooling/refrigeration • Heating • Compressed air • Insulation • Heat recovery • Separation processes • Lighting • ...

17. Internal recycling • Reuse materials (solvents, etc.) • Reuse materials for different purposes (paper, solvents for lower-quality use, e.g. pre-cleaning, etc.) • Close internal loops (water) • Use returnable systems (packaging materials) • Reclaim materials with high value

18. ECOPROFIT Graz 2000Realized and planned options In total 594 options, thereof: 60 %; 355 = realized options 2000 40 %; 240 = planned options 2001

19. Anodizing company • Use of spray rinses • Reconstruction of water pipes • Longer drag-out time • Daily check • Reduction in water consumption by 46% (14,000 m³)

21. Car repair shop • Installation of an ultrafiltration unit • Modified cleaning equipment • Saving of washing agent by 76 %, of water by 80 %