From Cleaner Production to Zero Emissions at „Integrative Approaches Towards Sustainability“

1. From Cleaner Production to Zero Emissions at „Integrative Approaches Towards Sustainability“ Jurmala, May 11-14, 2005, Latvia Mickael Planasch Institute for Resource Efficient and Sustainable Systems Graz University of Technology

2. Why Zero Emissions? What is Zero Emissions? Description of our methods and instruments to achieve Zero Emissions EMA –Environmental Management Accounting ZEPRA – Mass Balancing Software Data base for Experts Pinch Analysis for Energy Optimisation Case Studies Summary

3. We want to strengthen companies and help them on their way to a sustainable future Why Zero Emissions?

4. Emissions = Input - Product gaseous EMISSIONS PRODUCT INPUT solid EMISSIONS fluidic EMISSIONS

5. Why reducing Emissions? …if you want to strengthen companies? 2/3 of the costs in german car manufacturing companies are material costs! To reduce theses costs means strengthening the companies, making them fit for a sustainable future and is the way to Zero Emissions!

6. Emissions are unused raw materials and they cause Material costs Operating costs Personnel costs Investment costs Public Authority Proceedings Traditional Production

7. Zero Emissions instead means No disposal costs Less costs for Material, Auxiliary materials, Operating materials Less investment costs for environmental protection plants Easier Public Authority Proceedings Zero Emissions Production

8. Methods and Instruments 1. Step: EMA Workshop EMA = Environmental Management Accounting

9. EMA combines financial and physical data and calculates the environmental costs of companies Physical data on material and energy input, material flows, products, waste and emissions financial data on expenditures, costs, earnings, savings related to company activities with potential environmental aspects or impacts EMA – Environmental Management Acounting

10. Environmental Protection Costs (Emission Treatment and Pollution Prevention) + Costs of wasted material + Costs of wasted capital and labour = Total corporate environmental costs What are Environmental Costs?

11. EMA – water related

12. ZEPRA – Balancing Software Applicable to different companies Quick calculation of variants to the existing process A visual pleasing output Be able to get results without the exact knowledge of chemical reactions (rules of thumb, experimental data, experience) Calculation of the composition of sludge to find possibilities for further use and for closing of water cycles or for removing valuable components Easily adaptable to incorporate new knowledge

13. Data base for experts • solutions for waste water treatment • decision support system • support for consultants • sustainable solutions (avoiding end of pipe decisions)

14. Next step: Process Synthesis Meat-and-Bone Meal Utilization

15. EMA - energy related

16. Energy Efficiency – Pinch Analysis Solar

17. Pinchtemperature: 292,5 K Minimal heat demand: 623,86 kW Minimal cooling demand: 95,28 kW Energy Efficiency – Pinch Analysis

18. Case Study: Wire manufacturing company Before optimisation After optimisation (calculated) Implemented: 35% reduction of water consumption with no costs In implementation: 17% reduction of water consumption with low costs Starting in Summer: 10% reduction of water consumption with low costs

19. Case Study: Wire manufacturing Next step: Closing water cycles with in-house equipment and implementing an effluent free production! Optimisation of HCl-ething bath in laboratory scale: Extension from 1 week up to 3 weeks Testing different inhibitors

20. Anodising Company Long term reduction of water consumption in an anodising company

21. At this time: Zero Emissions project with 7 companies We want to proof, that it is Technically and Economically possible to run three branches on Zero Emissions! Branches are: Textile, Metal Treatment, Food Next Steps