V j> COMMITTEE ON
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EPA/625/R-01/002
March 2001
www.nato.int/ccms
NATO/CCMS Pilot Study
Clean Products and Processes
(Phase I)
2000
ANNUAL REPORT
Number 242
NORTH ATLANTIC TREATY ORGANIZATION
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EPA/625/R-01/002
March 2001
2000 Annual Report
NATO/CCMS Pilot Study
/Clean Products and Processes
(Phase I)
Report Number 242
S. Environmental Protection Agency
Technical University of Denmark
Lyngby, Denmark
Printed on Recycled Paper;
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NOTICE \
This report was prepared under the auspices of the North Atlantic Treaty Organization's
Committee on the Challenges of Modern Society (NATO/CCMS) as a service tp the
technical community by the United States Environmental Protection Agency (l^S. EPA).
This report was produced as a result of a cooperative agreement with U.S. EPA'| National
Risk Management Research Laboratory, under the direction of E. Timothy Oppfit, and
the Technical University of Denmark (DTU). This report was produced by Henr|;
Wenzel, Christine Molin, Michael Hauschild and Hans Henrik Knudsen of DTU|
Mention of trade names or specific applications does not imply endorsement or
acceptance by U.S. EPA or DTU.
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CONTENT
Preface, Introduction, Opening of meeting and City Hall reception v
Tour de table presentation 1
Pilot Projects updates 33
New pilot projects 67
Invited presentations: 69
Engineering, for sustainable Development -
an obligatory skill of the Future Engineer.
Membranes in Process Intensification and Cleaner Productions.
Approaches to Cleaner Production in economies in transition - the results and perspectives
of the Cleaner Production Centers.
Computer Aided Molecular Design Problem Formulation and Solution:
Solvent Selection and Substitution.
The First Step Towards sustainable Business Practice: The SB (SmithKline Beecham)
Design for Environment Tool Kit.
Biological Control of Microbial Growth in the Process Water
of Molded Pulp Production - Avoiding the Use of Biocides.
Environmental Life Cycle Assessment of Alternative Scenarios for Biological
Control of Microbial Growth in the Process Water of Molded Pulp Production.
Computer Tool Cafe 117
Poster Presentation 123
Special Topic Presentations on Product Oriented Environmental Measures 125
Technical tour 157
Mini Tutorial on the set-up of university-industry co-operation centers - do-it-yourself 163
Open forum on Clean Products and Processes 165
Future Direction for the Pilot Study 165
Summing up 166
Appendix 1 List of Participants 167
Appendix II Program 173
in
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PREFACE, INTRODUCTION AND OPENING OF THE MEETING
NATO/Committee on the Challenges of Modern Society
PILOT STUDY on
CLEAN PRODUCTS and PROCESSES
3rd meeting
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The Association of Danish Engineers Conference Center at the
Copenhagen harbor front was the venue for the 2000 meeting
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PREFACE, INTRODUCTION AND OPENING OF THE MEETING
PREFACE
The Committee on the Challenges to Modern Society (CCMS) was established by the
Council of the North Atlantic Treaty Organization (NATO) in 1969. The mission of CCMS is to
develop meaningful programs to share information among countries on important environmental
and societal issues that complement other international efforts and to provide leadership in
solving specific problems facing modern society. A fundamental role for CCMS is the transfer of
technological and scientific solutions among nations facing similar environmental challenges.
The goal of reaching sustainable development, where human activities, including
industrial manufacturing and commercial services, exist in harmony with the natural
environment, including conservation of resources and energy, is an increasingly important
aspiration for the nations of the world. With increasing populations demanding improved
standards of living comes increasing industrialization and production. Also, with an expanding
global marketplace and the explosion of information technology, social pressures on industries to
become "greener" are increasing. The challenge to nations and industries is the achievement of
sustainability while successfully competing in a global marketplace. We established this CCMS
pilot study on Clean Products and Processes to create an international forum for open discussion
on applying cleaner industrial processes and producing cleaner products around the globe. By
discussing, debating, and sharing current trends, developments, and expertise in use of cleaner
technologies and production of cleaner products, we hope that this pilot study will simulate
productive interactions among international experts, with the end result being effective
technology transfer.
The third meeting of the pilot study was held in Copenhagen, Denmark on May 7-12,
2000. This meeting maintained the momentum generated during the of the first two years of the
pilot study, focusing on progress made on several pilot projects being implemented by
participating nations and continuing to build a program of collaborative endeavors. This meeting
featured a special topical seminar titled, Product Oriented Environmental Measures, which
focused participants' attention on advances in product design and use. The meeting featured
several guest lectures on significant developments in government programs, academic research
and industrial applications. This report presents the ideas and views shared by the delegates and
invited participants at the Copenhagen meeting.
As we move ahead into the third year of this pilot study, we want to thank Associate
Professor Henrik Wenzel, Technical University of Denmark, Institute for Product Development,
for his gracious hospitality and hosting the third meeting of the pilot study. We also want to
thank Christine Molin for her tireless efforts in planning and coordinating the Copenhagen
meeting. We now look forward to continuing to build strong, cooperative relationships with our
fellow delegates as we plan the fourth meeting of the pilot study to be held in Oviedo Spain in
May 2001. ' '
Subhas K. Sikdar, Pilot Study Director
Daniel J. Murray, Jr., Pilot Study Co-Director
VII
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PREFACE, INTRODUCTION AND OPENING OF THE MEETING
INTRODUCTION
Already at the first pilot study meeting in Cincinnati in 1998, we discussed the possibility of
hosting one of the meetings in Denmark. The new Danish initiative on a product oriented
environmental initiative had been presented, and the idea was to take the opportunity to go into
more detail with product oriented measures at a later meeting hosted in Denmark. Denmark and
the rest of the Nordic and Northern European countries are known to be drivers in product
oriented environmental work, and by locating a meeting here, it would be possible to invite a
number of companies, academia and authorities and to learn from their experience in the field. A
special topic day addressing product-oriented measures was envisioned.
One year later, at the meeting in Belfast, it was decided to locate the year 2000 meeting in
Copenhagen. Key persons from companies, academia and authorities all accepted invitations to
present their product oriented work and all contributed to making the special topic day what it
was intended to be - an introduction to state-of-the-art within product oriented work in the
Nordic region. We are very grateful for their contribution and their willingness to share their
experience with us. Another Danish focus area is renewable energy, especially wind- and bio-
mass technology. We took the opportunity to present advances in both areas at the field trip to the
Technical University of Denmark. As a special event, cleaner transportation was investigated,
going back to the Viking Age and experiencing their means of transportation on land and over
sea
The network between delegates, and the benefit of the pilot study is steadily growing. So is the
volume of the annual meeting report. We have tried to keep this report focused, structured and
easily accessible. The purpose of the report is to hold on to the information presented at the
meeting and to serve as a catalyst of the ever increasing exchange of information and
strengthening of the network.
The country delegates have supported the reporting very much by providing well-structured
presentations, good abstracts and copies of slides and overheads or full papers. This has much
facilitated the compilation of the material and creation of the report. The report comprises, thus,
both elaborated abstracts, summaries of presentations and full papers.
We wish you pleasure with the reading.
On behalf of the organisers
Henrik Wenzel
Associate Professor
Meeting host
IX
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PREFACE, INTRODUCTION AND OPENING OF THE MEETING
OPENING OF MEETING
The pre-meeting opening session was held in the Danish Design Center in the heart of
Copenhagen. Surrounded by an exhibition of Danish and International designed furniture, the
NATO/CCMS pilot study director Subhas Sikdar, co-director Dan Murray and the Copenhagen
meeting host, associate professor Henrik Wenzel, bid all the delegates and guests welcome and
conveyed their expectations for the meeting to be held the four following days at the conference
center of Danish engineers on the Copenhagen harbour front.
Get-together at the Danish Design Center in Copenhagen
XI
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PREFACE, INTRODUCTION AND OPENING OF THE MEETING
Welcome by pilot study director, co-director and Danish host
Following the welcome, the delegates and guest were able to visit the exhibition TASTE in the
adjoining showroom. The TASTE exhibition was organised for the Design Center by one of the
world's most foremost commentators on design, style and culture Stephen Bayley, educated at
Manchester University and Liverpool School of Architecture.
Xll
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TOUR DE TABLE PRESENTATIONS
INTRODUCTION TO TOUR DE TABLE PRESENTATIONS
Each country delegate presents an abstract or paper on cleaner products and processes by own
choice. The trade and sector specific areas on which the CCMS meeting series focus are textile
industry, organic chemical industry, the energy sector, paper and pulp industry. The focus areas
for products and services are: transport, electronics, electro mechanical products, buildings,
packing and energy supply. However, other pollution areas may also be addressed.
The following Tour de Table presentations are given in the chronological sequences in which
they were scheduled for presentation.
SPAIN
MEMBRANE AND MEMBRANE-BASED HYBRID PROCESSES IN CLEANER PRODUCTION
Prof. Jose Coca
Spanish delegate
Pulp and paper effluent treatment by membrane processes
The actual concern about water pollution from industry has moved most of the countries to
increase restrictions over effluent disposal. Pulp and paper industry is particularly affected
because of its water requirements.
Effluent treatment and reuse is starting to be considered among the main goals for most
industries. The minimization of waste water discharge reduces the environmental impact and
increases savings in raw materials and chemicals. Many waste streams can be individually
treated, and water reused in the process depending on quality and volume needs.
ECF bleaching effluents treatment
Bleaching stages in the pulp and paper industry are responsible for more than 50% of water
pollution. Waste waters have a heavy load in terms of colour and chemical oxygen demand
(COD). Classical waste treatments reduce BOD and COD, but they usually lack of colour
reduction.
In this study different commercial tubular ultrafiltration and nanofiltration membranes are
compared in the treatment of several effluents from the bleaching plant of kraft pulp. The
research has been focused on determining the feasibility of the process in order to utilize it in
industrial scale.
Water quality has been evaluated in terms of colour, COD, lignins, ionic content and
carbohydrate content. Permeate flux and flux reduction due to both fouling and concentration
polarization have been studied as functions of the process variables: temperature, pressure and
flow rate.
Results show that nanofiltration is a reliable technique for the treatment of the bleaching effluents
and their reuse in the bleach plant.
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TOUR BE TABLE PRESENTATIONS
TCF bleaching effluents treatment
The use of membranes in Pulp and Paper industry has already proven to be effective for the
treatment of bleaching effluents and different processes. The membranes have been used mainly
to the removal of organic matter of relatively high molecular weight (10000 down to 4000
dalton). The use of nanofiltration would allow the removal of low molecular weight matter
(around 500 dalton) as well as di- and tri-valent ions. In the present case, transition metals such as
iron and manganese have been removed not in the ionic form in solution, but as a chelate formed
with an acetic acid-based chelation agent. This work shows that nanofiltration membranes can be
very useful in the reduction of waste discharges and the reuse of process water inside a pulp mill.
Membranes showed chemical and thermal stability at the process conditions providing a very
good selectivity and, thus, yielding good quality water.
Kraft black liquor fractionation
The most common use of Kraft black liquors is as an energy source, being burnt after a
concentration, in order to produce steam and recover chemicals which are recycled to the process.
An alternative process for overflows and spillages could be the recovery of lignin and its use, or
the use of some of the fractions, in the manufacture of more valuable compounds, such as
adhesives, polymeric materials as polyurethanes .or as fillers in composite materials. It has been
shown that the molar mass (MM) distribution is the key parameter, which determines the
potential use of those lignin fractions. Low MM lignin fractions could be incorporated in phenol-
formaldehyde type resins, while high MM fractions are preferred for substitution of polyols in
polyurethane manufacture.
Membrane processes are effective in the separation of both fractions and also allow recovering
the salts, that in turn could be recycled to the pulping process.
Experiments were carried out in a tubular membrane module, using ultrafiltration membranes
with nominal MWCO ranging from 4 to 100 kDa. Diafiltration experiments have been also
carried out to enrich the retentate in the high MM fraction.
Removal of waste emulsified cutting oils from effluents in the metalworking industry
Oil refining and metal-finishing industries, such as rolling mills and mechanical workshops,
produce large quantities of oily wastewaters that need to be treated before their disposal, because
of their detrimental effects on aquatic life and their interference with conventional wastewater
treatment processes. Water-based lubricants and cutting oils have gained an increasing
acceptance in the metalworking industry, replacing some petroleum-based products because of
their more efficient performance and less severe environmental problems. These fluids,
containing mainly emulsified oil and surfactants, become less effective after use because of their
thermal degradation and contamination by substances in suspension, and therefore they must be
replaced periodically.
The aim of this work is the design and construction of a modular pilot plant for the treatment of
different water-based coolants and oily wastewaters generated in metalworking processes and
steel cold rolling operations. Different treatments are considered depending on the nature of the
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TOUR DE TABLE PRESENTATIONS
oily waste emulsion, such as coagulation/flocculation, centrifugation, membrane processes
(micro and ultrafiltration) and sorption processes. The main advantage of this pilot plant is its
versatility, allowing the combination of the aforementioned treatments, being a feasible waste
management alternative from an economic point of view. This might lead to a better control of
this kind of wastes and a better reuse of water, in the case of large industrial plants, with the
resulting environmental and economic improvements.
Membrane-based hybrid processes
Membrane contactors
Membrane contactors represent a new way to carry out separation processes like gas adsorption
and solvent extraction. They are commonly hollow fibre modules used as substitutes for packed
towers. Extraction with hollow fibre modules are fast due to the large interfacial area per volume.
The interface is stabilised at the membrane pores, avoiding emulsification. Dispersion-free
solvent extraction has been recently studied and proved to have several advantages over
conventional extractors: high surface area per volume, no need for density difference between
phases to achieve phase separation, no limitations of loading or flooding, ability to handle
particulate and systems that emulsify readily, no need of agitation or moving parts, and ability to
provide several extraction stages in a single equipment. The main disadvantage is the slower
mass transfer rate, due to the resistance to mass transfer in the pores of the membrane, which is
minimised by using microporous membranes where the solute diffuses easily through the pores.
The work examined the influence of the hydrodynamics of both organic and aqueous phases on
the overall mass transfer coefficient of the extraction of organic acids and phenol from an
aqueous solution. A continuos extraction-stripping process has also been tested with satisfactory
results.
Lactic acid derivatives
About 25% of the national production of cheese is located in the region of Asturias. This implies
the production of more than 400000 t/year of whey, 87% of it coming from only seven
companies.
The management of such big amounts of cheese whey is a serious problem for the dairy industry.
Proteins are usually recovered by ultrafiltration, but treating the permeate as a waste before
dumping represents a considerable cost. Therefore, other alternatives such as production of
chemicals may be justified.
This work focuses on the valorisation of whey permeate by means of the production of lactic acid
and several valuable derivatives. It includes improvement of the continuous production of lactic
acid by lactose hydrolysis prior to fermentation, recovery of lactic acid from the fermentation
broth by membrane extraction (pertraction) and obtaining lactic acid esters by hybrid processes
involving reaction and separation.
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TOUR DE TABLE PRESENTATIONS
GREECE
STATUS OF IPPC AND LCA IN GREECE
Georg Gallios
Greek delegate
Greece as a member of EU should comply with the 96/61/EU directive concerning Integrated
Pollution Prevention and Control (IPPC). Actions that have been planned in order to help
industries undertake the necessary actions will be presented in the meeting. The attitude of the
industries towards the use of tools like LCA will be discussed. A brief description of LCA studies
completed so far will also be presented. Finally, a current research project for the development of
an electrochemical procedure for the removal of biologically non-degradable azodyes from the
effluents of industrial processes will be described.
UNITED KINGDOM
UK SUPPORT FOR CLEAN PRODUCTS AND PROCESSES
Prof. Jim Swindal
United Kingdom delegate
It continues to be a central plank of UK Government policy to encourage and support clean and
sustainable production and clean up of contaminated land.
There are a number of available initiatives including the Environmental Technology Best Practice
Programme; Bio-Wise, a new programme to encourage the applications of biotechnology in
industry with an emphasis on bioremediation; CLAIRE a public private partnership for the
remediation of contaminated land in a sustainable way, ENTRUST an organisation to distribute
revenue from landfill tax, Business in the Community which encourages companies to be more
proactive in their interaction with their communities. Each region has local initiatives such as the
Northern Ireland ERTU waste exchange, technical clubs, financial assistance for environmental
audits and funding for environmental research, the Belfast City Council sponsored SME
environmental starter pack etc.
There can be no doubt that the UK takes its responsibilities with respect to clean production very
seriously as a member of the European Union and also as a responsible member of the World
community. The UK record on the implementation of European environmental legislation is
among the best of any member state.
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TOURDE TABLE PRESENTATIONS
DENMARK
THE ROLE AND GOALS OF THE DANISH TEXTILE STAKEHOLDER PANEL WITHIN THE PRODUCT
ORIENTED ENVIRONMENTAL INITIATIVE.
Henrik Wenzel
Danish delegate
As one out of three industries in Denmark, textile industry was chosen as pilot industry for testing
the feasibility of the product oriented environmental initiative. A key element was to establish a
panel of essential stakeholders in the market for textile products, and have this panel itself draft a
strategy for the product oriented environmental measures in the industry.
The textile panel has now, early 2000, evaluated its first year of action. In Autumn 1999, the two
main activities were partly to get the industry's designers, manufacturers, ands retailers to buy the
idea of developing and marketing environmentally friendly products, partly to establish a
knowledge centre on environmentally friendly textiles. The initiative has been received positively
by these stakeholders. The panel sees it as its most important task for the coming year to get a
higher volume of environmentally friendly products with the EU Eco-label (the "flower") on the
market and to motivate the purchasers and the consumers to buy these products.
The Danish tour-de-table presentations of 1998 dealt with the product oriented initiative in
general. In 1999, the measures in textile industry in general were presented, and this year, it is
chosen to go in depth with the role, goals and actions of the textile stakeholder panel.
POLAND
SELECTED ACTIVITIES ON CLEAN PRODUCTS AND PROCESSES IN POLAND
Andrzej Doniec
Polish delegate
An understanding of the necessity of production process improvement is growing higher in
Poland. Over 200 Polish enterprises have obtained a Cleaner Production Certificate, which
endorses their environmental performance. To recognize the potential for a broader
implementation of the cleaner production concept, research has been done which also shows
incentives and barriers to cleaner production. Almost a 100% of responding companies are
interested in implementing of a waste minimization program, which is close to the number who
claimed to be familiarize with the cleaner production idea. As part of the continuing effort to
spread the idea, a waste minimization program for military equipment repairing enterprises has
been designed and a demonstration program in one of the unit has started.
In a separate, more general approach, a list of cleaner production options for the food processing
industry has been developed. The first step was done to describe waste streams currently
generated by dairy sector. Some environmental and effectiveness indicators differ slightly from
those of highly developed countries.
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CZECK REPUBLIC
CZECH NATIONAL CLEANER PRODUCTION PROGRAM (NCPP)
Dagniar Sucharovova
Czech Republic delegate
By signing the Declaration in 1999, the Czech Republic endorsed the global program of cleaner
production. Government Resolution No. 165 of February 9, 2000 created the framework for
meeting this commitment.
The purpose of the National Cleaner Production Program (NCPP) of the Czech Republic is to
change the approach of enterprises, the state administration and the public to the choice of
measures providing for protection of the environment in industrial and other activities, including
the provision of services. The program is based on the conviction that the generation of waste and
pollution must be limited in the process of the activity through the implementation of changes in
the technology and procedures employed. The change in the approach simultaneously
enables limitation of construction of end technology to an essential minimum,
ensures a higher level of utilization of input materials and energy (and consequently a
decrease in demand for material resources and energy),
optimizes expenditures for investments and for management of waste and pollution (and
consequently reinforces innovative trends and the competitiveness of the product on domestic
and foreign markets).
NCPP should create conditions for the implementation of voluntary activities of enterprises and
organizations in the area of preventative environmental protection. The Program is based on
analysis of projects and programs of cleaner production; if a business entity or other organization
voluntarily implements its own program of cleaner production and the results of this program are
reflected in its plans and practice, the requirements on protection of the environment, following
from the Laws, can be fulfilled in an economically effective manner and can exceed the
framework of these Laws. Simultaneously, the resources employed are saved and thus the
effectiveness of the processes is increased.
Implementation of NCPP offers
an improvement in the environment as a whole and introduction of an integrated approach to
environmental protection as required by the IPPC Directive (Council Directive 96/61/EEC)
an increase in competitiveness in innovation processes and a decrease in economic losses
increased qualification of workers and the creation of new working opportunities in the area
of management systems, monitoring of material, energy and financial flow in processes and
in regions and also in the area of development, implementation and maintenance of cleaner
production measures
the creation of preconditions for integration of economic, social and environmental aspects of
development in the individual regions and sectors.
In the Czech Republic, there is sufficient professional capacity required for commencement of
implementation of NCPP, especially in the framework of the Czech Cleaner Production Centre
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TOUR DE TABLE PRESENTATIONS
(CPC) and its regional centers, training cleaner production centers at universities, enterprises and
cities, which introduce cleaner production programs, and the Association of cleaner production
managers or professionals, who have been trained in this area as consultants and instructors.
However, it will be necessary to train further professionals for every-day application of the
principles of cleaner production at all levels. ,
Aims and Targets of the National Cleaner Production Program
The target of NCPP is to utilize information and create conditions for voluntary application of ,
cleaner production projects (as instruments in the prevention approach) in the framework of
programs announced by the individual sectors. The creation of NCPP thus reacts to the fact that
ซ it is necessary to ensure systematic assistance from the state in the area of protection of .the
environment; which will be based on preventative measures . ,
the increasing demands on protection of the environment as a whole require new approaches:
these approaches are economically effective if they are integrated into production processes
and products (they thus improve the environment and simultaneously increase the
competitiveness of enterprises)
these new approaches are complex and must be the result of close cooperation amongst the
individual special-interest groups.
Thus, in the long term, NCPP will support the new trend in the "product/service - user needs"
relationship, which is characterized by an increase in the importance of provision of services &t
the expense of the importance of the product itself. This change will be dependent on user
requirements. The proposed increase in the effectiveness of the system of satisfying needs will
not mean that the needs of human beings will be satisfied less, but that they will be satisfied with
new quality. ',.''
The short-term target of NCPP consists in decreasing the environmental impacts of processes,
products and services, with a simultaneous increase in the competitiveness of the economy. Every
sector will set its own specific targets.
SLOVAC REPUBLIC
CLEAN PRODUCTS AND PROCESSES, SLOVAC REPUBLIC
Lubomir Kusnir ,
Slovac Republic delegate
It follows from todays economy status that following the 10 years of transformation Slovak
industry and the whole economy face the need for sweeping and deep-seated restructuring.
Slovakia s specific is the fact that industrial policy has to be implemented in the situation where
much of the economy has to be subject to restructuring.
Under this situation, also the application of sectoral programs will be considered to help the
industries that need to undergo restructuring (e.g. mechanical engineering, mining, metallurgy,'
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TOUR DE TABLE PRESENTATIONS
textile industry, woodworking). If such an instrument is used, it will be done so in strict
compliance with the EU rules on granting state aid and competition protection rules.
Companies in the Slovak republic are under the increasing competitive pressure of free-market
economy, while facing the shortage of available funds and tougher environmental legislation.
Companies have to operate under unstable tax and business regulations, compete for qualified
working power with foreign firms, satisfy increasing compulsory fees and deliveries, manage
inherited environmental problems, and incorporate new social issues.
The Slovak Cleaner Production Center had been established, aiming not only to assist in solving
environmental problem for these companies, but also to achieve a change of values and priorities
in relation to environment protection. As a tool to systematic approach, management and
improvement, the Slovak Cleaner Production Center (SCPC) effectively uses standards for
management systems -QMS according ISO 9002 and EMS according ISO 14001. Through its
activities, the SCPC mainly supports project implementation mainly in small and medium-size
enterprises and prefers complex solutions on regional basis.
MOLDOVA
ENERGY SUPPLY, -COMSUMPTION AND -SAVING POTENTIALS
Sergiu Galitchi
Moldovan delegate
SUMMARY
Moldova, like other countries in transition is facing many challenges. Moldova is located
between the Ukraine and Rumania, and has approx. 5 mio inhabitants. The main sources of
income are agriculture, product processing, electronic manufacturing, machine building, building
material (cement) production.
An UNEP supported assessment was made concerning the different branches contribution to
climate change. Fossil fuels account for approx. 75% of CO2 emissions. Combustion of fossil
fuels and biomass account for approx. 65-75% anthropogenic emissions of NO2. However,
production facilities are only working at approx. 40% of the full capacity
Energy supply is a major problem in Moldova. Energy is needed both for production and to
improve quality of life and is essential for economical development. Moldova is dependent on
electricity from the Russian Federation. Alternative energy source are interesting, i.e. solar power
(Moldova has 310 days per year with sunshine), and biogas.
Energy efficiency regulation must be dynamic to evolve the technology. Savings in energy can be
obtained by substituting old equipment with less energy consuming equipment. A project has
been planned on substituting old pumps in municipal plants with Grundfos pumps using 30% less
electricity. The pay-time for such a venture is approx. 6 months, but there has been bureaucratic
hold ups. There are also large saving potentials in house hold electric appliances. Overall, energy
saving potentials are very large and in many circumstances cost-effective.
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The end user will see his energy bill decrease and at the same time his comfort will enhance.
Energy efficiency regulation will also reduce emissions, the utility companies will easier meet
energy demand and it will delay new investments on the supply side.
ISRAEL
STANDARDIZATION AS INCENTIVE - WATER SUBSIDIARIES - HAZARDOUS WASTE
Chaim Forgacs .
Israeli delegate
SUMMARY
Standardization
One of the most important single issues for large companies in Israel is to obtain the ISO 14000
certification. Very large part of the Israeli production goes to export and it becomes increasing
important that exporting companies have ISO9000 and ISO 14000 certification. ISO standards
might be a more effective driving force in clean products and clean processes than any
governmental regulation.
: (/
Water shortage
Israel has implemented large-scale seawater desalination. There is an ongoing discussion between
the Treasury and Department of Agriculture and the Water Commission concerning water .
shortage. The Treasury argues that there is no problem with water shortage in Israel, the problem,
is that water is subsidized for agricultural production, and agricultural goods are exported. If the
subsidies are cut, it will put a stop to the water shortage.
However, stop of subsidies will end agriculture in Israel as know today, and it will reduce the
green zones of the country, which already is under pressure due to massive constructions
activities in the middle part of the country. Ways must be found to maintain agriculture in these
parts of the country. Minor solutions have recently been implemented in few places e.g. small :,
electrodialysis plants for selective removal of nitrate from municipal wells. -.
Hazardous waste
Waste collection stations are being set up, and waste collected all over the country is transported
by train to national plants for treatment.
EDUCATION IN ENVIRONMETAL ENGINEERING AT BEN-GURION UNIVERSITY, ISRAEL
SUMMARY
The goal of the M.Sc. program in the Environmental Engineering Unit is to educate professionals
to cope with environmental problems within
- enforcement governmental, municipalities
- Obeying regulations - industrial entities etc.
- Offering special environmental services
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Enrolment in the courses was in 1997ซ 50, in 1998 ซ 25 and in 1999 ซ 25. The unit has 5 Ph.D.
students. Core courses are
1. Introduction to environmental engineering
2. Environmental chemistry
3. Environmental biology
4. Waste water control
5. Air pollution control
6. Solid waste and hazardous materials
7. Environmental laws and regulations
8. Environmental Engineering laboratory
9. Seminars with guest lectures from industry and government
Below a partial list of elective courses:
1. Environmental analytical chemistry
2. Advanced waste water control
3. Advanced air pollution control
4. Environmental management
5. ISO 14000 workshops
6. Membrane processes
7. Chemical plant design with environmental considerations
8. Green chemicals
9. Toxicology
10. Renewable energy sources
11. Environmental acoustics
12. Mathematical modelling
ITALY
RESEARCH FOR CLEAN PRODUCTIONS IN PROGRESS
E. Drioli
Italian delegate
Significant efforts are devoted to environmental control in various industrial production lines.
The tentative to introduce innovative technologies along the production line in Italy and not only
at the end of the pipe is becoming more traditional .than in the past. National research projects
under the leadership of industrial groups are in progress in the agrofood industry, in the textile
industry, in the chemical industry, where the environmental aspects are very well present in each
research projects.
Educational programs are carried out in parallel to each one of these projects. The sponsorship is
mainly from the Ministry of University and Research.
The IRMERC - CNR is active in some of the activities with the specific objective of evaluating
the possibility of membrane engineering in the razionalization of industrial production.
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TURKEY
REPORT ON THE STATUS OF CLEANER PRODUCTS AND PROCESSES IN TURKEY
Akin Geveci
Turkish delegate
Turkey does not yet have an organization to promote the Cleaner Production. This is because the
Turkish Legislation still foresees the end-of-pipe treatment not the pollution prevention.
This situation will change with the establishment of National Cleaner Production Centre in the
very near future.
With the directive issued by The Science and Technology Supreme Committee in its meeting in
June 2, 1998 a Working Group was formed to advise the national policy to promote
environmental friendly technologies and environmental management systems. As a result of two
years working of the group the establishment of NCPC was decided to be within TUBITAK-
MRC.
The responsibilities of NCPC will be as;
-Advise the authorities on the C.P Policies and Strategies,
-Conduct and/or assign R&D on C.P. And whenever possible manage technology
transfer,
-Test, analysis and certification (ISO 9000 and 14001 ),
-Technical and managerial consultancy,
-To establish C.P information centre,
-C.P training.
The industries which will be dealt with are textile, leather tanning, food, metal working, paper
and chemical.
PORTUGAL
THE PORTUGUESE TEXTILE INDUSTRY- CLEAN TECHNOLOGY AND WASTE MANAGEMENT
Susete Martins Dias
Portuguese delegate
The Portuguese textile industry comprises about 17 000 companies operating in different sub-
sectors from cotton, wool and synthetic fibres to cloth manufacturing, woollen and home textiles.
Although the Representatives of the Textile Associations only refer 5196 companies with 250
000 employees.
The Portuguese textile industry represents 22% of Portuguese manufacturing industry, accounting
for 20-25% of annual exports, which amounts to 50 million EURO.
Most of the companies are located in the North of Portugal, in the Ave river basin, namely in
Famalicao, Santo Tirso and Guimaraes. The competitiveness of these companies is threatened by
the textile market liberalisation in 2005. Efforts to overcome this problem focus on process
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technology innovation, accomplished by a rationalisation of the implemented capacity, marketing
and human resources.
The textile industry technology innovation is being supported by The Technological Centre for
the Textile and Garment Industries of Portugal (CITEVE), The National Institute for Engineering
and Industry Technology (INETI), Minho and Beira Interior Universities and Institute Superior
T6cnico in Lisbon, on issues like clean technology, process integration and environmental
management. Several projects aimed at innovation in the textile industry were undertaken under
the SIMIT programme (Incentive System for the Textile Industry Modernisation), since 1995, co-
financed by the EC. An Integrated Decontamination System for River Ave region was developed
which includes the wastewater treatment of more than 250 textile companies by the Public
Administration.
BULGARIA
CLEAN ENVIRONMENT AND IT'S SUSTAINABLE DEVELOPMENT. WATER RESOURCES IN
BULGARIA
Stefka Tepavitcharova
Bulgarian delegate
During the last years Bulgarian national policy in the field of ecology aims at: (i) preservation of
the environmental status of the unpolluted and with kept natural resources areas; (ii)
improvement of the quality of environment in polluted areas with disrupted natural balance.
The water resources are main part of the national nature wealth and their conservation is of
extreme significance. A draft law on water has been elaborated. There are a number of national
and international projects which purpose is to improve the status of water resources in Bulgaria.
The investments in construction and reconstruction of wastewater purification stations and in
technological renovation of production processes are defined as priority. The quality of the
Bulgarian water resources (surface, ground as well as Black sea coastal water) is characterized
for 3 years period using physicochemical and biological monitoring data. The result is water
resources status improvement in Bulgaria in the last years.
UKRAINE
CLEANER PRODUCTION STRATEGY AND TACTICS, DEFINITION TOOLS AND METHODS BASED ON
SYSTEMATIC APPROACH TO SUSTAINABLE PRODUCT DEVELOPMENT FOR SYSTEMATIC
REDUCTION OF ENVIRONMENTAL LOADS (ECOLOGIZING OR "ECOLOGIZATION")
William Zadorsky.
Ukrainian delegate
This presentation is continue of 1999 year presentation "A Ukrainian's Version of a systems
Approach to Sustainable Development in Environmentally Damaged Areas: Cleaner Production
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and Industrial Symbiosis as Major Ways to Pollution Prevention". NATO/CCMS Pilot Study
"Clean Products and Processes (Phase 1)" 1999 Annual Report, Number 238, pages 45-48.
Introduction
Cleaner Production is conceptual and procedural approach to production, demanding that all phases
of a product or process life cycle be addressed with the objective of preventing or minimizing short-
and long-term risks to the humans and the environment. Cleaner Production utilizes improvements
in product design, raw materials production, selection and their efficient use, as well as production
and assembly of final products, consumer use of the products, waste and disposal recycling,
transportation of raw materials and products, and energy savings. Specifically, adoption of Cleaner
Production principles offers industry opportunities to promote operating efficiency while improving
environmental performance. Source waste reduction eliminates costly post-production effluent
control or bolt-on treatment. This conserves raw materials and energy, eliminates usage of toxic
materials and reduces quantity and toxicity of all emissions and wastes in a closed-cycle process. For
products, Cleaner Production spans the entire process life cycle from raw material procurement to
disposal of byproducts of industrial material processing. Cleaner Production is achieved by applying
know-how, by improving technology and changing attitudes. Cleaner Production is generally cost
effective due to potential improvements of both process efficiency and improved product quality.
These economic advantages of CP are especially evident when compared with other environmental
protection strategies, for example such as end-of-pipe waste water treatment, waste processing, and
exhaust gas treatment. Apart from cleaner production in industry, it is possible also to survey
opportunities and constraints for cleaner energy conversion and improved energy utilization.
Part 1. Cleaner production strategy and TACTICS based on systematic approach to
sustainable product development
Main principles of the cleaner production concept are as follows:
All ecological problems should be solved in cooperation with a unified comprehensive planning.
Ecologizing economy supposes modernization of objects, which are real or potential pollutants
of environment.
The prosperity of ecologizing implies existence of professionals skilled in the theory and
practice of ecologizing, cleaner production and ecological management.
The creation of civilized ecological market is a necessary prerequisite for ecologizing of
economy and sustainable development of the country.
As known, the cleaner production concept as and sustainable development concept includes three
aspects: ecological, economic and social. Underestimating any one of these components will bias the
whole equation and infringe strategy of sustainable development. Indeed, reassessment of an
economic force having underestimed ecological and social implications, results in infringement of
stability of development, for it is impossible to ensure improvement of conditions of life of the next
generation if the improvement of economy will not be accompanied by reduction of technogenic
loads per capita, and mastering social problems of a community. Therefore, only mutually balanced
simultaneous comprehensive tackling of the three tasks (economical growth with simultaneous
improvement of ecological conditions and decision of social problems) will allow to realize
progressive CP strategy.
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The system analysis shows strong interaction and feedback among the mentioned three factors of CP
strategy. In this regard, the strongest parameters determining stability of development are just those
that render influence on at least two out of the three factors of Cleaner Production concept.
The increase of manufacture cleanliness renders influence on the economic and ecological
characteristics of system, and, consequently, can be regarded as one of the basic Cleaner Production
factors.
The set of engineering techniques and methods for Cleaner Production seems somewhat limited and
lacking diversity. The reason may be in unwillingness to disclose know-how by some practitioners,
or simply absence of new approaches. Anyway, a simple analysis shows that our western partners
can offer only Cleaner Production tools and methods as follows: recycling, use of biotechnology,
separative reactions, systemic approach, and industrial symbiosis. That is about all. Yet, effective
methods to increase product cleanliness is something much bigger. For example, we are using the
following Cleaner Production tools and methods:
Recirculating flow of the least hazardous agent taken in excess over its stoichiometric value;
Controlled heterogenization of the contacting phases for softer conditions and improved
selectivity;
Separative reactions: removal of reaction products at the moment of their formation;
Synthesis and separation hi an aerosol to increase intraparticle pressure and reaction rate;
Self-excited oscillation of reacting phase flows at frequencies and amplitudes matching those at
the rate-limiting tiers of the system;
Flexible synthesis systems and adaptive equipment to embody them;
Process engineering for high throughput to cut processing time and reduce byproducts and wastes,
and industrial symbiosis as a basis for management of secondary materials and energy.
Some of these methods are little known in the West. But they may be used for joint development of
Cleaner Production concept in the Ukraine and other countries. New environmental and Cleaner
Production challenges in transition economies must be included in Cleaner Production concept
realization. For example, there are severe environmental effects of restructuring, military conversion,
privatization and economic transition. In any case, transition economies have no mechanisms for
stimulating Cleaner Production technologies. It is desirable to use the systems approach in Cleaner
Production Concept Implementation (or Cleaner Production Strategy and Tactics) for transition
economies.
At the same time it is necessary to help Cleaner Production movement meet its economic goals in
transition economies which have development features as follows:
1. Methodology for application of CP philosophy to economic restructuring, military conversion,
privatization and economic in transition at a national or regional level.
2. Practicable program for embodying CP concept under sweeping changes in the NTS and other
transition economies. (May be it desirable to launch a Special Pilot Project on Systems Approach to
CLEANER PRODUCTION Concept Implementation (or CP Strategy and Tactics) for Transition
Economies. In any case, transition economies have no mechanisms for stimulating CP technologies).
3. CP oriented priority-based investment programs for attracting investors to NTS.
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We have some specific problems in the transition economies that need to be solved. For sample,
CP approaches are concerned not only with production but also with transportation. The traffic has
dramatically increased in Ukraine due to market development and occurrence of a great many of
trade intermediaries and small businesses. This resulted in aggravated negative influence of
transportation on environment, making cleaner transport a matter of survival and urging immediate
and competent decisions. The "free" market has displaced regular grades of petrol for cheaper ones
containing aromatics, that is hazardous byproducts of coke industry. These include benzene, toluene,
xylene and others and their combinations. Expert judgment is that these aromatics cannot be burned
in an engine completely and are massively discharged to air with exhaust gas. No research into
amounts of aromatics in exhaust has been conducted. The analyses of government bodies generally
do not include these compounds. Meanwhile, the content of aromatics like benzene in a fuel is
limited by standards of advanced countries.
Cleaner Production main goal and objectives are:
1. Systematization of cleaner production general theory, strategy and tactics, search of the tools
and methods based on a systematic approach as a foundation of sustainable product
development in Pridneprovie.
2. Searching and elaboration of the economic mechanisms stimulating transition to CP technologies
in conditions of transition economy.
3. Organizing of international collaboration, association, coordination and information of
organizations and individuals dealing with CP.
Besides we need the specific steps and tasks to be proposed
1. Terms and definitions, unification of the terminology of Clean(er) Production.
2. Writing and editing in Russian and English a handbook or practical manual of CP.
3. Organizing of an online CP Help and Consulting Service.
4. A compendium of the best CP practices at a pilot project of transportation environmental
problem realization for a large industrial city (for example, Dnepropetrovsk).
5. Launch a CP technology incubator or greenhouse.
Then we can receive some concrete results (deliverables) and expected outcomes:
1. A pilot project for demonstration of transportation environmental problem solving for a large
Industrial city (for example, Dnepropetrovsk).
2. Handbook or practical manual of CP practices tools and methods.
3. Review to identify economic mechanisms stimulating transition to CP technologies in conditions
of transition economy.
4. Online CP Help and Consulting Service.
5. CP technology incubator or greenhouse.
Main directions of PCPC's activities now are:
ซ elaboration of strategy and tactics for cleaner production, waste management, pollution
prevention;
system ecologizing of acting manufactures;
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development and introduction of methods of adaptation and rehabilitation of the population in
conditions of the increased technical loads;
development and realization of the program of sustainable development of an industrial
region;
continuous ecological training and education, based on the concept of active constructive
ecology;
development of the information at cleaner production technology and equipment.
to demonstrate the economic benefits of pollution prevention and recycling to industry business
operations.
For the decision of problems of information exchange we are ready together with other organization
realize the following programs:
Creation of computer information base at ecological engineering and technologies of cleaner
production;
Issue a periodic regional ecological electronic newspaper, distributing ecological information
and experience of use of cleaner production in a region and in the world (with use of
networks);
Realization of active contacts to world community on exchange by the ecological
information;
Retraining of the experts of acting manufactures on directions resource saving and ecological
technologies .
It's necessary to give the main attention not so much to cleaning of gases and liquids as to many
non-waste technologies for processing of raw materials including but not limited to concurrent
reaction-dividing processes, new effective methods of recycling using capillary and porous
impregnation of waste materials, electric aerosol technology, and flexible chemical engineering.
And at last an important advantage in solving ecological problems is interdisciplinary approach
via experience of various experts from different organizations with the purpose of the best
decision making regarding specific problems.
Part 2. Cleaner production definition tools and methods based on systematic approach
FOR systematic reduction of environmental loads (ECOLOGIZING OR "ecologization")
There is methodology and algorithm for systematic reduction of environmental loads
(ecologizing or "ecologization"), based on the system analysis. This has allowed to formulate
main strategic principles and define a tactical receiving to their realization.
Finally, this concept is not connected to fight with damage wastes pollution, but to deliver a
process so that they were formed in the minimum amount (waste minimization).
The main strategic principles of proposed methodology:
L. The System approach prescribed in the base of proposed strategy for systematic reduction of
environmental loads. It expects that previously, than problems on methods of industrial waste
conversion or utilization choose will be solve, it is necessary to consider questions for
systematic reduction of environmental loads at the tier of strictly production. It's very
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important to realize economic justified variants of removal or essential waste reducing by
selectivity of main process raising at the lowest hierarchical object tiers.
The System approach is shown in the next table:
1
2
3
4
5
6
TIER OF
HIERARCHY
Manufacturing
Plant item
Installation
Apparatus or
machine
Contact device
Molecular level
Frequency
order
0.001-0.01
s-1
0.1-1 s'1
0.1-1 s'1
1-10V1
1-104 s'1
105...108 s'1
Dimension
order, m
102
1
1
1
10'3...10-6
io-9...io-12
CLEANER PRODUCTION TOOLS AND
METHODS
Industrial Symbiosis, Waste Management.
Pollution Prevention, Recirculating, Local
neutralization of emissions
Flexibility and adaptability of technology and
equipment
Recirculating flow of the least hazardous
agent, Isolation (close-looping in structure) of
flows of substance and energy
Synthesis and separation in an aerosol,
Controlled heterogenization of the contacting
phases
Minimization of time of processing, Surplus
less toxic reagent, Oscillation of reacting
phase flows, Separative reactions organizing
There should be a match between a tier in a hierarchy and the methodology of characterization,
assessment or influence used at this tier.
1. We will have an maximum of cleaner production effect if to move on tiers in rising mode
(from the lower tier to upper-level of system. In the event of above hierarchies of system
levels it is necessary to move toward from 8 tier to 1 one.
2. At the choice of methods of influence to the system on limiting tier, it is necessary to follow a
principle of correspondence, i.e. ensure a correspondence their parameters to the scale of
limiting tier (for instance, it is necessary to select methods of influence, corresponding
defining dimension order -frequency features on limiting tier).
3. One of the the most efficient cleaner production principles is integrated approach to the
solving of the problems of industrial installations pollution decreasing. It is not only by
using of low-waste technologies, not only by using an equipment for the local cleaning of
gases and liquids, but, first of all - a decision of a complex problem on making an ecological
engineering as unites of technology and equipment. Thereby, principle of integrated
approach in this interpretation implies a simultaneous decision on a matter of apparatuses
and technological optimization of processes.
4. For clean production raising it is necessary to ensure sufficiently high its flexibility level.
Under flexibility is implied quantitative factor, reflective possibility of a technology and
equipment functioning in the broad range of changing of external and internal parameters of
installation with given values of level of forming the by-products. So, it's possible to act upon
the object, changing its flexibility.
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5. It's possible to influence on the object to its intensify, using principle "repetitions in use
resources and energies"
6. Maximum selectivity of syntheses and division principle is one of the most efficient one
under the deep conversion of initial materials .
Algorithm for systematic reduction of environmental loads with some explanatory basing on
stated above reasons is resulted below.
1. DECOMPOSITION. The analysis of the initial information including inspection of industrial
manufacture, with the purpose of its decomposition on typical levels of hierarchy (for example,
manufacture - plant item - installation -apparatus or machine - contact device - molecular level).
The system analysis recognizes that any system, including nature-technical, consists from taking
place in hierarchical dependence under and upper-level subsystems. And the problem of
maintenance of required ecological parameters at each hierarchical level carries individual
character, while for realization of a general purposes - for systematic reduction of environmental
loads of all system- it is necessary to establish the basic determining components of system, their
external and internal connections, laws of functioning of system and connection of individual
ecological parameters of a subsystem with a general integrated parameter of all system.
2. IDENTIFICA TION of an initial level. Revealing of the bottom level of hierarchy limiting
from the point of view of pollution to an environment.
3. SELECTIVITY INCREASE. Increase of selectivity of actually technological stages of
processing at a limiting level of hierarchy.
For a choice of methods of influence it is expedient to use a database on tactical ecologizing
receptions. Some of its principles have a common for technique character (repeated using, waste
recycling and resource saving).Besides this database has also specific receptions for processing
industries, in particular, for chemical, metallurgical, food branches of industry.
Except for ecologizing principles, the most common receptions for their realization, in particular,
with reference to processing branches of manufacture are given in a database. Among them it is
necessary to differentiate two closely connected among themselves groups of methods: regime-
technological and apparatus - constructive ones. Alongside with traditional for any area of
engineering methods (isolation of structure and multifunctionality of the equipment,
intensification) the features of processing branches predetermine use of some special ecologizing
methods.
Among them:
Minimization of time of processing and surplus less toxic reagent, resulting all to increase of
selectivity and reduction of formation of by-products,
Synthesis and separation in an aerosol to increase intraparticle pressure and reaction rate,
Self-excited oscillation of reacting phase flows at frequencies and amplitudes matching those
at the rate-limiting tiers of the system,
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Recirculating flow of the least hazardous agent taken in excess over its stoichiometric value,
Isolation (close-looping in structure) of flows of substance and energy by recirculating,
resulting to "idealization" of modes of synthesis and significant reduction of speed of by-
processes,
Separative reactions organizing (synthesis and dividing processes organizing in the same
palace and in the same time), allowing to reduce formation of by-products by removal of a
target product from a reactionary zone at the moment of its formation,
Controlled heterogenization of the contacting phases for softer conditions and improved
selectivity,
Flexibility and adaptability of technology and equipment allowing to ensure reliable work of
technical system by "internal" reserves (flexibility) of installation using, that reduces an
opportunity of harmful substances pollutions or reception of a sub-standard product.
If the expert is not satisfied with the result of work at this level, he has to rise to the next more
high tier and to continue work.
Transition on next higher tier.
In connection with change of determining amplitudes and the frequencies at this tier, are used
other cleaner production tools and methods.
First of all it's Pollution Prevention and Recirculating. Modern ecologizing provides not
neutralization of emissions "in general" in mixed polluting liquid or gas flows, but the local
neutralization of emissions first whenever possible by each component, and secondly, as is
possible closer to a source of their formation. This approach is alternative in relation to the
principle, accepted in FSU (of creation of global clearing structures for neutralization or
recycling at once of all scale of harmful emissions). So, the local for each component clearing as
much as possible approached to sources of emissions, as has shown world experience, has
appeared much more effectivecleaner production direction.
Transition on next higher tier.
Only after end of an actually manufactures CP stage it is necessary to begin the decision of
questions of complex processing and recycling of sub-standard products and waste of
manufacture. Here main methods are Industrial branch and interbranch Symbiosis and Waste
Management.
The market economy requires thus, that the waste producer has ensured their transformation in
secondary technqgenous raw material. At the modern approach of installation of clearing or the
recyclings should be a component of industrial object included in the basic technological line.
The following stage of the work is the realization of the technical and economic analysis of the
chosen CP directions and methods with drawing up of accounts which are taking into account not
only an expenses on CP and its results in sphere of manufacture, but also payments for resources,
payments for above permitted standard emissions and other ecology-economic parameters.
The purpose of these accounts to determine priorities in the field of the investments in CP at all
stages of life cycle of object and at all hierarchical tiers of object.
Only after that the experts make the choice of the ecology-economically justified CP variant.
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For processing industries the especially important parameter of a CP degree is achieved and
achievable results of performance of manufacture, as the increase of waste quantity promotes
increase of expenses both on manufacturing, and on increase of total emissions of harmful
substances in an environment.
Pu-P2i
K = ;
JI 3
Pmaxi " Pli
where P\\, P2i, Pmaxi - accordingly, final, initial and maximal size of the factor determining
calculated parameter.
The size ,- can be as a uniform parameter quantitatively describing this or that property of
system (for example, degree of dust-cleaning, factor of extraction etc.), and complex integrated
parameter which is taking into account at once e of the some basic characteristics of object. Use
or additive CP parameters in the latter case is expedient:
n
Pi = S Kj PJJ ,
j=i
where Kj - the importance of a j-parameter (is estimated by experts and changes within the limits
of 0 + 1), or multiplicate CP factor:
J= Ji,
i=l
Having the quantitative characteristics of an ecological level of production, it is possible to
compare the various technical decisions, to choose optimum and even to project new systems
with the beforehand given level of influence on an environment. It will promote transition from
"about-cleaner production" conversations to creation of actually cleaner installations,
manufactures and enterprises.
UKRAINIAN COOPERATION PROPROSAL
Following the Ukrainian tour-de-table presentation, the Ukrainian delegate introduced the
following cooperation proposal to the NATO/CCMS meeting for further consideration:
Proposals about cooperation
1. We would like to be included in a list of NATO/CCMS Project participants with one of the
themes:
Systematization of cleaner production general theory, strategy and tactics, search of the tools
and methods based on a systematic approach as a foundation of sustainable product
development.
(Terms and definitions, unification of the terminology of Clean(er) Production. Writing and editing
in Russian and English a handbook or practical manual of CP, elaboration of strategy and tactics
for cleaner production, waste management, pollution prevention; system ecologizing of acting
manufactures; development and introduction of methods of adaptation and rehabilitation of the
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population in conditions of the increased technical loads; development and realization of the
program of sustainable development of an industrial region; continuous ecological training and
education, based on the concept of active constructive ecology; development of the information
at cleaner production technology and equipment, demonstration the economic benefits of
pollution prevention and recycling to industry business operations).
Searching and elaboration of the economic mechanisms stimulating transition to CP technologies
in conditions of transition economy.
Organizing of international collaboration, association, coordination and information of
organizations and individuals dealing with CP with use of modern information technologies (
Russian - English CP Information - Consulting Net, organizing of an online CP Help and
Consulting Service, Virtual INTERNET CP Exhibition - Market of CP Technology, CP
Digest English - Russian version of "Constructive Ecology and Business Journal", Creation of
computer information base at ecological engineering and technologies of cleaner production;).
Launching a CP technology incubator or greenhouse.
Retraining of the experts of acting manufactures on directions energy -resource saving and
CP technologies (solving ecological problems on the base of interdisciplinary approach via
experience of various experts from different organizations with the purpose of the best decision
making regarding specific problems).
2. We are ready to organize one of the next NATO ARWs (jointly with one of the NATO member
country):
Methodology for application of CP philosophy to economic restructuring, military conversion,
privatization and economic in transition at a national or regional level.
(Practicable program for embodying CP concept under sweeping changes in the NTS' and other
transition economies. May be it desirable to launch a Special Pilot Project on Systems Approach to
CLEANER PRODUCTION Concept Implementation (or CP Strategy and Tactics) for Transition
Economies. In any case, transition economies have no mechanisms for stimulating CP technologies.
CP oriented priority-based investment programs for attracting investors to NIS).
Problems of Cleaner urban transportation. A compendium of the best CP practices at a pilot
project of transportation environmental problem realization for a large industrial city .
(We have some specific problems in the transition economies that need to be solved. One of them,
CP approaches are concerned not only with production but also with transportation. The traffic has
dramatically increased in Ukraine due to market development and occurrence of a great many of
trade intermediaries and small businesses. This resulted in aggravated negative influence of
transportation on environment, making cleaner transport a matter of survival and urging immediate
and competent decisions. The "free" market has displaced regular grades of petrol for cheaper ones
containing aromatics, that is hazardous byproducts of coke industry. These include benzene, toluene,
xylene and others and their combinations. Expert judgment is that these aromatics cannot be burned
in an engine completely and are massively discharged to air with exhaust gas. No research into
amounts of aromatics in exhaust has been conducted. The analyses of government bodies generally
do not include these compounds. Meanwhile, the content of aromatics like benzene in a fuel is
limited by standards of advanced countries).
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CP and energy - resources saving at the military technique and rocket plants (on the base of NASA
(USA) and NSA (Ukraine).
ROMANIA
ONE MORE STEP TO POLLUTION PREVENTION
Viorel Harceag
Romanian delegate
Sustainable development requires real economic growth because only such growth can create the
capacity to solve environmental problems. Steel is essential for economic development. It is the
most important construction and engineering material available to modern society. The demand
for steel grows at a high rate in developing countries. Each activity in the cycle of steel has a
different perspective on its relationship with the complete system.
The natural and longest established closed cycle of steel explains the interest of steel in using life
cycle assessment techniques as a valuable environmental management tool. Life cycle involves
the evaluation of the impact of a steel-using product over its complete life cycle from raw
material assembly through to steel production, the manufacture of the steel-using product, the
working life of that product, the end of life disposal and the recycling of the steel it contains. The
concept of life cycle assessment (lea) is to evaluate the environmental effects associated with any
given activity from the initial gathering of raw material from the earth until the point at which all
residuals are returned to the earth. Lea is a technical tool to identify and evaluate opportunities to
reduce the environmental effects associated with a specific product, production process, package,
or activity. Implementation of opportunities pointed out in the third stage of lea can be. made
using pollution prevention techniques.
In NATO/CCMS meeting held in 1999 in Belfast, I described LCA study in metallurgical field,
in a sintering plant. It was conducted using US EPA methodology (LCA, how to do it, UNEP -
Industry and Environment, ISBN 92-807-1546-1).
In the current paper is presented next step, LCA in iron production in blast furnace, conducted in
the same manner. Iron production occurs in a blast furnace and involves the conversion of iron
ores into molten iron by reduction with coke and separating undesirable components such as
phosphorus, sulfur, and manganese through the addition of limestone.
The blast furnace is a counter-current reactor, loaded or charged from the top with layers of feed
and coke, the molten iron and slag being drawn off from below. Hot air is injected in the opposite
direction from the bottom of the furnace. Residual materials (waste) such as oily metal chips and
oily rolling scale can be introduced after sintering. The principal emissions, residues and waste
materials are:
top gas, with the following potentially environmentally relevant components: CO,
CO2, SO2, NOX, H2S, HCN, CH4, As, Cd, Hg, Pb, Ti, Zn
top gas dust (dry) from the gas cleaning plant with high iron contents (35 - 50%)
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slag with the following major components : SiO2, A12O3, CaO, MgO
sludge from the waste gas cleaning system
wastewater from the waste gas cleaning system, with the pollutants: cyanides,
phenols, ammonia
The waste gases from the blast furnace are pre-treated in mass force separators (dust catchers or
cyclones) and, in a second stage, finally cleaned with a high-pressure scrubber or wet
electrostatic precipitators. Clean gas dust concentrations from 1 to 10 mg/m3 are achieved. Other
dust emissions in the blast furnace area, particular from the burdening process, pig iron
desulphurisation and the casting house must also be identified and cleaned.
The top gas contains between 10 and 30, though possibly as much as 60 g/m3 dust with 35 to
50% iron, i.e. 30 to 80 kg/t iron, in older plants 50 to 130 kg/t pig iron. The dust is separated in
the dry state in mostly multistage separators, from where it goes to the sintering plant and from
there back to the blast furnace. In view of the zinc and lead content and other factors, the top gas
scrubbing water sludge must be disposed of by dumping, unless there is a special hydro-cyclone
separation system. With higher concentrations, it should be transferred to a non-ferrous metal
works. Recycling in this way would leave the blast furnace process practically free of residues.
Dumping involves the risk of leaching and hence penetration of the soil and groundwater by
compounds of zinc, lead and other heavy metals. The dump must be permanently and verifiably
sealed and the seepage water must be collected and chemically processed. The special
requirements imposed on such a dump must be laid down in the project planning stage. The top
gas can be used as a fuel for heating purposes within the works, in view of its high carbon
monoxide content due to the reducing atmosphere in the blast furnace, though this will inevitably
result in the formation of carbon dioxide, with its climatic implications. Excessive levels of
sulphur dioxide and nitrous oxide gases can be reduced by flue gas desulphurisation and
denitrification.
Slag produced by the blast furnace process accounts for roughly 50% of the overall waste
materials from iron and steel production. This slag is mostly used in road building. Part of the
molten slag is granulated by quenching in water. This so-called slag sand is also used in road
building. Part is used to produce iron slag portland cement and blast furnace cement. Slag heaps
sometimes produce seepage water with high levels of dissolved sulphides and strong alkaline
reaction, posing a hazard for the groundwater. Slag heaps must be sealed and any seepage water
must be treated.
Wastewater is generated by top gas scrubbing and simultaneous wet de-dusting. The wastewater
is normally clarified in settling tanks and, where necessary, gravel bed filters and recirculated.
The wastewater contains suspended matter (dust) and sulphides, cyanides, phenols, ammonia and
other substances in dissolved form. The last three substances must be removed from the
wastewater using appropriate physical and chemical treatment processes.
Carbon monoxide concentrations in the workplace pose a particular problem. Where top gas
pipes are not perfectly leak proof there is a danger of poisoning with possible fatal consequences
for workers present at the furnace throat. Close attention must also be paid to co concentrations
23
-------
TOUR DE TABLE PRESENTATIONS
by carrying out measurements and ensuring that protective breathing equipment is worn during
repair and maintenance work on shut-down blast furnaces or gas cleaning systems.
Noise in blast furnace plants comes mainly from the combustion air fans and the charging
process; also there is the noise generated upon changeover from blast to heating operation.
Suitable abatement measures include silencers, enclosure of the furnace throat or encapsulation of
all valves and shields. The noise level from the blast furnace plant is in the range of 110 to 125
db(a); the level of background noise in the immediate vicinity may be 75 to 80 db(a). Possible
noise reduction measures should be selected as early as the blast furnace planning phase. Their
effect can be determined by advance calculation, taking care to ascertain the significance of the
emission sources (plant sections and operating processes). One should preferably begin by
damping or eliminating occurrences and noise sources which arise only periodically.
Emissions produced by the iron and steel industry requires particularly extensive measures and
systems for air protection. Above all, dusts containing substances hazardous to health and the
environment, such as lead, cadmium, mercury, arsenic and thallium, must be cleaned by high-
performance separation systems. Nowadays, not only the primary emission sources, such as
sintering plants, but also secondary sources such as blast furnace casting bays can be intercepted
and dedusted. In the case of gaseous emissions, attention must be paid primarily to reducing
carbon monoxide and sulphur dioxide, as well as nitrous oxides and fluorine compounds.
ELECTRICITY STEAM HOT AIR OXYGEN
Ore
Coke
Sinter
Fine divided coal
IRON
PRODUCTION
Molten iron
Granulated slag
Furnace dust
Furnace gas
Wastewater
Suspended solids
SULPHIDES, CYANIDES
PHENOLS, AMMONIA
Solid waste Emissions
Slag Particulate containing heavy metals
SLUDGE CO, CO2
S02, NOX
24
-------
TOUR DE TABLE PRESENTATIONS
Iron fabrication flow chart
The execution of inventory stage results in a set of data sheets and growing insight into the
availability of information. So, in the following tables is shown the environmental data sheets
that includes raw materials, energy inputs and air pollutants outputs of the process fabrication for
one ton of iron.
Environmental data sheet
PROCESS: Iron fabrication
Furnace no.2
Product Molten iron
Co-products
Furnace gas (Nm3)
Furnace dust
Fine treatment sludge
Granulated slag
Wastes -
Dumped slag
Wreckage
Metallic wastes
Technological losses
Kg/tone
1,000
2,189
10
5
151
280
5
10
92.2
Quantity (tones)
404,000
884,356
4,040
2,020
61,004
113,120
2,020
4,040
37,245
Notice
recycled
recycled
recycled
recycled
At the dump
At the dump
recycled
Difference
Furnace no.3.
Product - Molten iron
Co-products -
Furnace gas (Nm3)
Furnace dust
Fine treatment sludge
Granulated slag
Wastes
Dumped slag
Wreckage
Metallic wastes
Technological losses
Kg/tone
1,000
2,074
10
5
148
275
5
10
107.3
Quantity (tones)
454,482
942,595
4,545
2,272
67,263
124,982
2,272
4,545
48,766
Notice
recycled
recycled
recycled
recycled
At the dump
At the dump
recycled
Difference
Furnace no.4
Product Molten iron
Co-products -
Furnace gas (Nm3)
Furnace dust
Fine treatment sludge
Granulated slag
Wastes
Dumped slag
Wreckage
Metallic wastes
Technological losses
Kg/tone
1,000
2,070
10
5
144
267
5
10
112.6
Quantity (tones)
547,551
1,133,431
5,475
2,738
78,848
146,196
2,738
5,475
61,654
Notice
recycled
recycled
recycled
recycled
At the dump
At the dump
recycled
Difference
25
-------
TOUR DE TABLE PRESENTATIONS
Furnace no. 5
Product - Molten iron
Co-products -
Furnace gas (Nm3)
Furnace dust
Fine treatment sludge
Granulated slag
Dumped slag
Wreckage
Metallic wastes
Technological losses
Kg/tone
1,000
2,104
10
5
150
240
5
10
91.4
Quantity (tones)
1,025,220
2,157,062
10,252
5,126
153,782
246,052
5,126
10,252
93,705
Notice
recycled
recycled
recycled
recycled
At the dump
At the dump
recycled
Difference
Furnaces 2-5
Product Molten iron
Co-products -
Furnace gas (Nm3)
Furnace dust
Fine treatment sludge
Granulated slag
SLAG FOR BRICKS
Wastes -
Dumped slag
Wreckage
Metallic wastes
Technological losses
Kg/tone
1,000
2,130
10
5
151
-
259
5
10
97.5
Quantity (tones)
2,431,253
5,178,569
24,312
12,156
367,119
1,082
629,694
12,156
24,312
237,047
Notice
recycled
recycled
recycled
recycled
used
At the dump
At the dump
recycled
Difference
Each input component of iron fabrication coming with its own energy and raw materials
consumption and its own pollutant emissions, data which are similarly centralized in
environmental data sheets (not presented in this paper) for the main following components
processes: iron ores preparation, coke production, sinter production and electricity production.
All data from the environmental data sheets were centralized in the inventory table.
Iron production
Plant: Furnace no. 5
Year: 1999 April - May
Energy resources
(GJ)
Electricity
Coke
Fine divided coal
5,465,250
66,364
19,519
KW
T
T
Product and
Co-products
Molten iron
Granulated slag
Furnace gas
Furnace dust
Air emissions
156,150
21,861
327,915xl03
2,342
t
t
Nm3
t
26
-------
TOUR DE TABLE PRESENTATIONS
Raw material
resources
Sinter
Pelettes
Ore
Hot air
Steam
Oxygen
234,225
17,177
18,738
202,995x1 03
2,030
48,406,500
T
T
T
Nm3
T
Nm3
Particulate (Partic.)
CO
CO2
Waste water
Suspended solids (SS)
Solid wastes
Fine treatment sludge
Dumped slag
Wreckage
30
3,771,023
3,934,980
0.008
1,093
40,599
781
t
Nm3
Nm3
t
t '
t
t
The contribution of each main process was adjusted, using a contribution factor, which
represents the relative contribution of that process to the fabrication of one ton of iron.
Inventory table for 1 ton of iron
Energy resources
(GJ)
Electricity
Coke
Fine divided coal
Raw material resources
Sinter
Pelettes
Ore
Hot air
Steam
Oxygen
35
425
125
1,500
110
120
13
1,300
310
kW
kg
kg
kg
kg
kg
kg
Nm3
Nm3
Product and
Co-products
Molten iron
Granulated slag
Furnace gas
Furnace dust
Air emissions
Particulate (Partic.)
CO
CO2
Waste water
Suspended solids (SS)
Solid wastes
Fine treatment sludge
Dumped slag
Wreckage
1,000
140
2,100
15
0.2
24.15
25.20
0.051
7.00
260
5.00
kg
kg
Nm3
kg
kg
Nm3
Nm3
g
kg
kg
kg
Inventory analysis results are the base of impact assessment. This stage of LCA consist in:
classification specifies which environmental problems are to be included in the analysis of iron
fabrication, characterization quantifies the environmental impacts, and valuation of
classification and characterization results.
Raw materials consumption and pollutant releases for iron fabrication, according with the
inventory table, can produce following environmental problems: Global warming (GW),
Photochemical oxidant creation (PO), Human toxicity (HT), Eco-toxicity (E), Abiotic depletion
(AD), Energy depletion (ED), Acidification potential (AP), Nitrification potential (NP), Ozone
27
-------
TOUR DE TABLE PRESENTATIONS
depletion (OD). To estimate the environmental impact of iron fabrication, for each environmental
problem presented, has used an equivalency factor, measured as follows:
- GW = measured relative to the effect of 1 kg CO2;
- PO = measured relative to the effect of 1 kg ethylene;
- HT = measured as the human body weight that toxicologically acceptable limit by 1
of the substance;
- E = volume of water that would be polluted to a critical level by 1 kg of substance;
- AD = measured relative to global supplies;
- ED = measured as MJ/kg or MJ/m3;
- AP = measured relative to the effect of 1 kg SO2;
- NP = measured relative to the effect of 1 kg phosphate;
- OD = measured relative to the effect of 1 kg CFC.
The values of each impact parameters in the inventory table were multiplied by the values of
equivalency factor correspondents. The results are presented in table below; note that one
parameter may score under several environmental problems simultaneous. The final result
consists in a score for each environmental problem analyzed, which can give an image of
possible impact produced by iron fabrication.
Classification and characterization for 1 ton sinter fabrication
kg
Inventory
Analysis
Raw
materials
Kg
3,600.50
Ener-
gy
GJ
14.74
Equivalence factors
GW(kg/kg)
PO (kg/kg)
HT (kg/kg)
E (kg/kg)
AD (-/kg)
ED (GJ)
AP (kg/kg)
NP (kg/kg)
OD (kg/kg)
_
_
.
_
IxlO'12
.
_
.
.
_
-
.
-
_
1
_
.
.
Air emissions
kg
Partic.
70.91
.
-
4.75
3,500
.
-
.
.
-
CO2
402.55
1
-
-
-
-
-
-
-
-
CO
24.82
-
-
0.01
-
-
-
-
-
-
NOx
3.33
-
-
0.78
-
-
-
0.7
0.13
-
SOx
6.59
-
-
1.2
-
-
-
1
-
-
cov
1.94
-
0.38
-
-
-
-
-
-
-
Wastewater
kg
ceo
0.44
-
-
-
-
-
-
-
0.02
-
ss
0.89
-
0.02
-
-
-
-
0.33
-
Multiplied characterization results
GW(kg/kg)
PO (kg/kg)
HT (kg/kg)
E (kg/kg)
AD (-/kg)
ED (GJ)
AP (kg/kg)
NP (kg/kg)
OD (kg/kg)
3.6-10-9
-
14.74
-
336.8
248,185
-
402.55
-
0.25
-
2.60
2.33
0.43
-
7.91
6.59
-
0.74
-
0.009
-
0.018
0.30
-
TOTAL
402,55
0.74
347.58
248,185 :
3.6X10'9 :
14.74
8.92
0,74 '
-
28
-------
TOURDE TABLE PRESENTATIONS
Classification and characterization provides an environmental profile of a product, which consists
in a set of scores on environmental problems in absolute figures. So, for iron fabrication, the
greatest problems are lied by the ecotoxicity (E), due to the presence of heavy metals in the
particulate emissions. Particulate are also responsible for human toxicity (HT), which obtained a
high score, like the environmental problems lied by the global warming (GW), due to the great
CC>2 quantity from pollutant emissions. A smaller score was obtained by energy depletion (ED),
because of energetic consumption and acidification potential (AP), caused by SOx and NOx
emissions from gases released in the sintering and iron production process. Very small scores
have presented by photochemical oxidant creation (PO) and nitrification potential (NP), abiotic
depletion (AD).
The results of the inventory analysis and impact assessment conduced to study the effects on the
environment produced by processes components of iron fabrication system (iron ores preparation,
coke production, electricity production and sintering), in the frame of improvement analysis. We
can remark that:
the greatest particulate quantity arises from iron ores preparation process;
- the greatest quantity of pollutant gases arises from sintering and coke production;
- the greatest consumption of energy is achieved in the sintering and iron production;
- the greatest quantities of waste water arises from coke production;
the greatest quantities of solid wastes arises from iron production process.
The finding of this interpretation may take the form of conclusions and recommendations to
decision-makers, grouped in:
actions to reduce electricity;
- actions to minimize pollutant emissions.
It is necessary to take the following measures:
ฉ Efficiency increasing as a result of sintering installation improvement by:
- advanced control of burning front
* best distribution of coke granulation in sintering bed;
* best gases permeability through sintering bed as a result of good
preparation of raw materials;
* reduction of false air exhausting;
* modernization of ignition system with the purpose of fast start burning at
high temperatures (lead to a decreasing of coke-oven gas consumption).
- increasing of heat use efficiency
* reusing of gas heat for preheating of combustion air (this is lead to an
increasing of flame temperature) and raw materials;
* reusing the heat of sinter cooling air for preheating of combustion air and raw
material - when cooling air have low temperature - or for steam production -
when cooling air have high temperature;
# reduction of heat losses as a result of decreasing of sinter returned material;
* recirculation of sintering gases.
ฉ Diminution of energy spending and of wastewater and gases emissions, by fractional
replacing of coke with fine divided coal (up to 200 kg / tone of iron produced).
29
-------
TOUR DE TABLE PRESENTATIONS
ฉ Reduction of dust emissions can be done first of all by best handling operations of raw
materials. So, reusing of fine blast furnace dust and fine sintering dust must be forbidden
without a previous pelletising.
Taking in consideration the big quantity of dust, which is in preparation shops, must be
installed, where there are not, a hood, or resizing the exhaust system.
Because the dust is in a great quantity in the zones where air, respective the cool air have high
temperature, an efficient method to reduce the level of dust emissions is recovery of heat
eliminated with cooling air.
ฉ Reduction ofSOx emissions to stack can be realized by using raw materials and fuels with
low level of sulphur (when that is possible).
ฉ Reduction ofNOx emissions in combustion gases is possible by diminishing the volume of
false air exhausted and by improving the burning.
Few months after the end of this assessment, some people have cleaned an annex facility of
examined furnace no. 4. They do not respected technological prescriptions and an explosion took
place killing 2 people and hurting other 8. Conducted LCA do not contain any data about this
possible accident.
In the impact assessment stage of LCA we have used US EPA criteria to estimate the
environmental impact of iron fabrication. The accident occurrence impels me to make the
proposal to supplement the above mentioned criteria with one more item, related to industrial
accident potential (AP). It have to be multiplied with a statistic (probabilistic) coefficient, and can
be measured in kg TNT in case of explosion potential or in terms of toxicity if the potential
accident can release toxic substances:
AP X k (occurrence probability) = measured relative to the effect of 1 kg TNT
USA
SUSTAINABLE DEVELOPMENT - NEW CHALLENGES TO ENVIRONMENTAL R&D
Subhas K. Sikdar
Pilot study director and US delegate
Several significant events in the past year presented newer challenges to environmental R&D in
the US EPA. The National Risk Management Research Laboratory has begun asking questions
on sustainable development that require answers from science, technology, and economic
perspectives. There are two focus areas for these queries. First, we want to develop a scientific
framework for sustainability, which can perhaps be defined and measured. Second, we would
attempt to identify a small set of robust criteria for describing place-based sustainability, be it a
watershed or an urban setting. Emission of mercury from coal-fired power plants has surfaced as
a big issue recently. Elemental Hg escapes through electrostatic precipitators and ends up in soil
and water bodies. Mercury in fish poses danger to consumers. A cleaner power plant would
have to remove the mercury from the flue gas itself, perhaps by adsorption on finely divided,
high surface area, sorbents. Methyl t-butyl ether (MTBE) used in gasoline for octane boosting
30
-------
TOUR DE TABLE PRESENTATIONS
and for reducing tropospheric ozone in urban areas, has come under stiff consumer resistance.
The State of California has declared a phased withdrawal of MTBE from the market, with the
Federal Government following suit. Banning does solve the longer-term problem, but the urgent
concern is to remove it from drinking water sources, perhaps at the point of use in the water
works. Technologies in the latter two areas are critical needs.
31
-------
-------
PILOT PROJECT UPDATES
INTRODUCTION TO PILOT PROJECTS UPDATES
The following pilot projects vere presented in Belfast 1999 and scheduled for updating
in Copenhagen 2000:
1. Danish Products Oriented Environmental Measures in the textile industry
Denmark
2. Pollution Prevention Tools
USA
3. Energy efficiency in Moldova
Moldova
4. Water Conservation and Recycling in Semiconductor Industry: Control of Organic
Contaminaiton and Biofouling in Ultra Pure Water systems
USA and United Kingdom
5. Clean Processes in the Turkish Textile Industry
Turkey
6. Cleaner Production through the Use of Intelligent Systems in the Pulp and Paper
industry
Canada
7. Clean Products and Processes in the Textile Industry
USA
8. Cleaner Energy Production With Combined Cycle Systems
Turkey
In the following abstracts and/or papers present the status and progress of the pilot projects,
presented in the chronological sequence in which they were scheduled for presentation for the
Copenhagen meeting (not all pilot project managers were present in Copenhagen).
POLLUTION PREVENTION TOOLS
Subhas K. Sikdar
USA
Last year we discussed the utility of several design tools that were in development at the National
Risk Management Research Laboratory. PARIS II, a solvent design software, has been
completed and transferred to TDS, Inc. (New York City) for marketing. Beta testing has just
started with 50 companies participating. PARIS II program designs, in the computer, solvent
mixtures with reduced environmental impact (such as toxicity and other measures) that match the
property profile of the solvent mixture being used currently. Further information on PARIS II is
available in chapter on Computer Tool Cafe. Waste Reduction (WAR) algorithm was developed
for flow sheet-based cleaner process design. The measure used to express a degree of
"cleanliness" is potential environmental impact (PEI), which is a user-chosen composite of a set
of chemical and non-chemical impacts, such as human toxicity, eco-toxicity, ozone depletion,
global warming, etc. WAR has been incorporated in the latest version of the commercial process
simulator Chemcad (Houston, TX). A more advanced product has been recently completed. This
is an integrated design tool that combines WAR with Aspen Plus and the commercially available
33
-------
PILOT PROJECT UPDATES
costing package Icarus. The EPA Office of Enforcement and Compliance is planning to use this
tool in helping industry to reduce waste generation and emissions. With this integrated tool, a
complete analysis (including production, cost, and, environmental) of a process facility can now
be done. For more information, please enquire at cabezas.heriberto@epa.gov and
young.douglas@epa.gov.
DETECTION AND CONTROL OF MICROBIOCONTAMINATION IN ULTRAPURE
WATER PROCESSES
J.Swindall and M J Larkin.
The QUESTOR Centre, Queen's University of Belfast, Belfast BT9
SAG, UK.
Bacterial contamination of water is a common problem that threatens many of its industrial uses;
particularly in the microelectronics industry where ultrapure water is utilized in the rinsing stage
of microchp manufacture. Although ultrapure water is an environment almost completely
depleted of nutrients, a group of microorganisms, termed oligotrophs, can adapt to these stringent
conditions. The objective of this project is to detect and control the bacterial contamination in an
ultra-pure water (UPW) system. The project is carried out in collaboration with laboratories in the
University of Arizona, New York State University at Buffalo and the New Jersey Institute of
Technology (NJIT). The project is coordinated By Professor John O'Hanlon at the University of
Arizona Centre for Microcontamination Control (CMC) and much of the work is based around
their substantial "state-of the-art" microprocessor research and pilot production facility and its
ultrapure water (UPW) system. Described here will be the role of the QUESTOR Centre group in
identifying contaminant microorganisms by using sophisticated microbiological analysis and in
the development of microbiological expertise for the other laboratories. Initially this has
involved characterisation of microbial contaminants in the CMC UPW system then validation of
detection systems developed at Buffalo and control systems developed at NJIT.
Tel: +44 (0)28 90 27490/274388/272288 (message 335577)
Fax: 661462
email: m.larkin@qub.ac.uk
ALSO: mlarkin26@netscape.net
Homepage:http://www.qub.ac.uk/bb/mlpage/pagel/index.html
Questorhomepage:http://www.questor.qub.ac.uk/
34
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PILOT PROJECT UPDATES
REVIEW OF PROGRAMS IN CLEANER PRODUCTION (POLLUTION PREVENTION)
Professor Michael Overcash*
Chemical Engineering Department
North Carolina State University
Raleigh, North Carolina 27695-7905
U.S.A.
Introduction
Cleaner production and pollution prevention are relatively new concepts in the environmental
field, but are now advancing within NATO and other European countries. Defining cleaner
production is often best done with the use of a hierarchy, Figure 1. Technologies, operational
procedures, and management techniques that are nearer the top of the hierarchy are referred to as
cleaner production. However these approaches also generally meet two other criteria,
1) technologically feasible
2) cost-effective
This double hurdle has focused pollution prevention to a series of case studies or projects that
have evolved rapidly and innovatively. One of the largest collection (about 13,000) of these case
studies can be accessed at http://www.P2PAYS.org. With this conceptual definition of cleaner
production there are several terms that identify closely related activities:
In order to better understand the contribution that pollution prevention has made, a study was
made of the development of this field among the members of a NATO/CCMS project (Sikdar,
1998). The author wishes to acknowledge that this study would not have been possible without
the exceptional assistance of all the individual members of this project.
Methodology
The NATO/CCMS project represented initially about 18 countries. This has expanded to 23 and
these countries serve as the database for this study. Review of the data tables of this paper
indicates the participating countries. Each country representative participated in defining the
parameters used to characterize cleaner production overall and within the textile industrial sector.
This definition lead to a standardized set of questions from which the answers could be analyzed
to present a picture of the evolution and the partial nature of cleaner technology. The selection of
textiles coincided with a related emphasis of other studies in the NATO/CCMS project.
* (Acknowledgement of NATO/CCMS Fellowship support. Conclusions are those of the author
and do not necessarily represent views of the CCMS or of NATO member countries)
35
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PILOT PROJECT UPDATES
WASTE MINIMIZATION
PROCESS
MODIFICATION
RECYCLE
REUSE
CONVERSION OF HAZARDOUS TO LESS OR NON - HAZARDOUS
LAND
TREATMENT
INCINERATION
THERMAL
TREATMENT
CHEMICAL,
PHYSICAL, 8
BIOLOGICAL
OCEAN a
ATMOSPHERIC
ASSIMILATION
LANDFILL
PERPETUAL STORAGE
UNDERGROUND
INJECTION
WASTE
PILES
SURFACE
IMPOUNDMENTS
SALT
FORMATIONS
ARID REGION
UNSATURATEO
ZONE
Figure 1
Relationship of alternate waste reduction concepts to overall
hierarchy of hazardous waste management
Results
The development of a pollution prevention program within a State (as illustrated by the US), a
region (as illustrated by the Dnieper River/Black Sea Project for the Ukraine), or a whole country
generally occurs with several initial events or activities. These include
Concept Conference
Legislation
Education and training of industrial or consulting personnel
Demonstration of clean technology in industry
For each country, the approximate date and activities initiating their clean production program
are given in Table 1. Using five year time periods, the initiation of cleaner production is
illustrated in Figure 2 and 3. There were a smaller number of countries in the first decade and
now a much greater penetration in 1990 - 2000. In Figure 2, the time to organize and complete
the initial pollution prevention activities appears to be 3 - 5 years. Such information can help
countries to realistically judge the time a resource requirements for a cleaner production program.
Resources are required to successfully introduce the concepts and benefits of cleaner production;
and then, to have these adopted more widely by industry. A number of organizations
36
-------
PILOT PROJECT UPDATES
(government and non-government) have been committed to stimulate pollution prevention in
various countries. These resources seem to have been successful. A listing of such early
financial and technical support for cleaner production is given in Table 2. An number of
countries and the U.N. are repeatedly recognized as having provided resources to begin the shift
toward cleaner production approaches in the environment.
As pollution prevention evolves within a country, various industrial sectors appear more active in
adopting and implementing cleaner production. This also changes with time. The survey
identified the three industrial sectors with significant pollution prevention activity in 1999, Table
3. Across all participating countries, the frequency of current planning and/or use of cleaner
production, by sector, are given in Figure 3. A wide variety of industrial types are presented.
The most common are chemicals, metal finishing/electroplating, and textile manufacturing, as
these represent both large numbers of facilities and areas with extensive pollution prevention case
studies to gain credible ideas. The industrial progress, Figure 3, is often the result of cleaner
production advocacy, which has made resources available, increased the awareness, and
encouraged technical innovation. Which groups are currently the more prominent advocates of
cleaner production was surveyed, Table 4. Again ;a great deal of diversity is found, but
universities and government organizations appear to be the most active advocates during the
latest years.
37
-------
-------
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PILOT PROJECT UPDATES
Textiles
This industrial sector has emerged as an active arena for the development and implementation of
cleaner production concepts. Some of these changes have occurred over as many as twenty years
and thus a success profile or widely adopted (as commercially attractive) technology profile has
emerged. These widely accepted cleaner production practices for textiles were summarized,
Table 5 and Figure 4. The three most successful practices are,
1) water (and hence energy) conservation thus reducing the volume of effluents
2) a methodical evaluation and demand for reduced toxics in the large number of specific
chemicals or proprietary formulations used in textile facilities
3) a recapitalization to obtain more efficient dye equipment.
The dynamics of new developments in cleaner production for textiles led to R & D concepts
which appear promising. These emerging concepts were surveyed in each country and a number
of technologies were identified, Table 6. -However, the most frequently identified , as an
emerging technologies, were the following:
1) use of membranes to achieve further water conservation
2) supercritical COa processing.
One aspect of this NATO/CCMS project is to stimulate technology transfer. Such activity is
facilitated by the broader knowledge of individuals with specific interest and expertise in textile
cleaner production. Hence this project has sought to identify a pollution prevention network in
the textile field. The results, Table 7, provide names and affiliation, but also means of direct
contact (preference given to email, then fax, and then snailmail). This current work has
facilitated the creation of a specialist network by the assembly of information. Network uses
might be to summarize work and experience of each individual, to promote some joint projects
such as collection or transfer of specific cleaner production information, development of new,
leading edge cleaner production techniques for the textile field, or serving as experts in helping
small and medium textile firms throughout the world.
48
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Conclusions
The progress in development of cleaner production in various countries has occurred for about
twenty years and continues even in the last five years. The typical process of bringing cleaner
production to a country involves training and industrial demonstrations. A period of three to five
years appears as average to achieve an introduction of pollution prevention, although the extent
of adoption or implementation varies. In 1999, as a measure of current cleaner production
activity, the most active sectors appear to be chemicals, metal finishing/electroplating, and
textiles manufacturing; while universities and government organizations remain the most widely
perceived advocates.
As a specific industrial sector, textiles is one of the most active over the last decade. Across
numerous countries, the most types of cleaner production success (technically viable and
economically feasible) were found to be
1) water conservation
2) methodical reduction of toxics through supplier requirements
3) more efficient dyeing equipment.
In the next decade, the development of technologies for membrane systems leading to water or
energy conservation and supercritical carbon dioxide were felt to be likely candidates. Finally a
network of about thirty textile cleaner production specialists was identified.
References cited
Sikdar, Subhas, Clean Processes and Products, NATO/CCMS Project, 1998-2002, Brussells,
Belgium.
CLEANER PRODUCTION IMPLEMENTATION FOR WET PROCESSES OF COTTON TEXTILES
Nilgim Kiran
TUBITAK-MRC Energy Systems and Environmental Research Institute
Gebze 41470 Kocaeli - TURKEY
e.mail: kiran@mam.gov.tr
Introduction
Turkey's textile and ready wear sector plays a key role in the country's industrialisation. In 1997,
20% of the total industrial establishments operating in the textile sector employed 30% of all
industrial workers. The most successful sub-sector of the Turkish textile industry has been the
cotton sector. Turkey is the seventh largest cotton producer in the world with a share of 4%.
Because of having a very important impact on the country's economy, textile industry has been
given priority from the point of Cleaner Production (CP) implementations. The qualitative and
quantitative patterns of both the production process and the related resource utilisation are of
great importance within the framework of CP. This study is carried out within the frame of
project " Conducting Research and Development aimed at Developing Cleaner Production
Technologies to Assist Textile Industry to Manufacture in Compliance with International
56
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PILOT STUDY UPDATES
Standards". It has been the first activity of the implementation of Cleaner Production
Methodology Cleaner Production in Turkey.
Cleaner Production in Cotton Textile Industry for Turkey
The CP program for the textile industry in Turkey has to comprise of a set of organisational,
administrative and planning activities that aim at enhancing the CP approach throughout the
production the production of fabric.
Three of the six selected enterprises in this project are engaged with wet treatment processes of
cotton textile industry. For this reason, the "possible CP options" are selected with special
emphasis on wet processes.
Wet processing stages were taken into account from the point of resource(s) conservation. In
general, wet treatment processes such as bleaching, dyeing and finishing are very important in
terms of the environmental aspects of textile production, not only because of the vast quantity of
water and variety of chemicals used, but also because of a high thermal energy requirement.
Water and energy are, therefore, also significant cost elements for most production units.
The costs associated with the material and energy in and outflows were investigated. During the
evaluation of water costs, both industrial water preparation and wastewater treatment were
considered. Furthermore, discharge costs for treated wastewater were also included. With a clear
insight into these costs, management can be usually convinced to agree to rapid implementation
of CP, particularly with respect to chemical substitution. Within this framework, extensive CP
options were subsequently developed.
Before the Feasibility Stage, the generated set of CP options were prioritised. The prioritised
options which seemed to be most promising were then submitted to a feasibility study. The
feasible options could subsequently be recommended to the enterprise, with implementation
carried out under a regime of continuous monitoring and evaluation.
Evaluation of Possible CP Options
After the assessment phase being carried out to select the CP options for feasibility study, it has
been observed that there are variety of operations leading to different types of energy and water
consumption. Also dye stuff and chemical consumption due to teh differences in the processes
vary to a high degree. For this reason it was quite hard to develop a reliable mass and energy
balances for the whole and selected product systems . As a result of the feasibility study was
carried out on the prioritised CP options by taking into account the environmental, technical and
economical issues.
Since technology changes tend to be capital intensive, the selected CP options are preferred to be
focused on modification of the existing processes and substitution of chemicals. The priority is
always given to prevent the effects on the quality of the fabric.
57
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PILOT STUDY UPDATES
The process that has been implemented frequently is selected for reduction in chemicals. In Table
2 the chemical and dyestuff input for one t-shirt in comparison with a more environmentally
friendly t-shirt are compared. For the recipe reactive dye is used. The fixation of reactive dyes
differ between 50-80%. The type of reactive dye used for this process has a fixation value of 48%
which is very low in comparison with the range of the reactive dye stuff.
High amounts of salt is added during dyeing to increase the fixation values. The reactive dye stuff
result in high content of Chloride (9800mg/l) color (3890) and disolved solids (12500 mg/1).
For an environmentally friendly t-shirt production dyestuff and auxiliary material consumption
should be minimised. For this reason, detergent and acetic acid consumption is reduced. Forly
BS-C has adverse effects on the wastewater. It has both ecotoxicity impact potentials and human
toxicity impact potentials. It is usage is omitted completely (Table 2).
Table 2. Inputs and outputs of chemicals and dyestuff for the selected wet treatment recipe of the
knitted conventional t-shirt and the environmentally friendly t-shirt.
Process
Bleaching
Dyeing
Finishing
Inputs
Wetting agent
(AlbegalNF)
Anticrease
(Imacol S)
Hydrogen peroxide
Acetic acid
Anticrease
(Imacol S)
Sequestrant
(Uniperol SE)
Sodium Chloride
Antiperoxide
(Perzym Red DC)
Dye (2%Ambifix
Brillant Orange V-
3R(reactive dye)
Sodium Carbonate
Detergent (Forly
BS-C)
Caustic
Softener (Rottamin
RC)
Acetic acid
Soap (Imerol XN)
Conventional t-shirt
Input amounts
(g/ t-shirt)
3.21
1.73
3.45
1.73
1.73
0.86
108.7
1.73
4.96
4.96
1.57
8.62
1.16
0.22
0.15
Output amounts
(g/ t-shirt)
2.56
1.38-
2.76
1.38
1.38
0.69
87
1.38
2.58
3.96
1.25
6.89
0.93
0.18
0.12
Environmentally friendly t-shirt
Input amounts
(g/ t-shirt)
3.21
1.73
3.45
1.38
1.73
0.86
108.7
1.73
4.96
4.96
-
8.62
1.16
-
0.06
Output amounts
(g/ t-shirt)
2.56
1.38
2.76
1.10
1.38
0.68
86.96
1.38
3.96
3.96
-
6.89
0.92
-
0.05
Table 3. Information related to the "Material Safety Data Sheets (MSDS) of some chemicals).
58
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PILOT STUDY UPDATES
Auxilaries
Imerol XN
Rottamin RC
Badena 243
Roflex
GA/PN
Physical
Form
Liquid
Liquid
dispersion
Liquid
dispersion.
Liquid
dispersion
Hazard
Symbol
None
None
None
According to
EEC Biological
Elimination
>80%
100%
>90
>90
LD50
(mg/kg) x
>2000
>3000
>2000
>2000
LCso
(mg/kg)
XX
22
10-100
>1000
>1000
ECso
(mg/kg)
XXX
>100
>5000
>100
>100
* rat-oral
"" fish toxicity-salmo gairdneri, oncorhynchusmykiss,
routine bioassay method of 1.11.74
xx* testofOECD209
X,, ; contains etoxylated fattyalcohol. Contains nonylphenol
Xi : contains salt of phophated fatty alcohol
None : No hazard classification according to EU Guidelines
After addition to the reduction in the chemical amount, research for substitution of chemicals is
carried out. For this purpose Imerol XN (soap) and Rottamin RC (softener) are substitute with
Roflex PAD (soap) and with Badena 243 (softener) respectively. From Table 3 it can be seen that
with the substitution of chemicals the adverse impacts on the environment can be reduced.
In addition the Cp option mentioned above another option for which feasibility study was also
done can be summarized as follows:
Description: To reduce the liquor ratio of the baths without creating any negative effect on the
result of the process is the main target of this option. For the machine with 600kg capacitythe
liquor ratio is decreased from 1:7 to 1:4. Also the enterprise has to pay 0.3884 DM/m3 to Istanbul
Sewage and Water Organization.
Investment: Neither capital investment nor running investment is necessary for this CP option.
Net income: 16.86 DM/day.
Others: There will be a labour work reduction by 0.9 DM/day.
In order to investigate the saving in chemicals and conservation of water and energy, the results
are evaluated by taking into account the production per day and results can
be seen in Table 4.
Table 4. Reduction on liquor ratio of baths for rinsing processes.
Input
Electricity
Chemicals
H2S04,
Lime, FeCl3
(Kwh/d)
(kg/day)
(DM/day)
Before
implementation
880.2
1,923.08
291.32
After
implementation
874.332
1,909.58
289.30
saving
5.868
13.5
2.02
Environmental
evaluation
Energy Conservation
Reduction of chemicals
that are used for in the
wastewater treatment
plant.
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PILOT STUDY UPDATES
Water
(nvYday)
(DM/day)
Output
Chemicals
H2SOซ,
Lime, FeCl3
(kg/day)
(DM/day)
Wastewater (DM/day)
1,800
1,818
1,162.5
160.5
1176.6
1,788
1,805.88
1,153.2
159.22
1167.19
12
12.12
9.3
1.28
9.41
Water conservation
Reduction of chemicals
that are used for in the
wastewater treatment
plant.
Water conservation and
reduction in wastewater.
The same process modifications of liquor reudction are calculated for one knitted cotton t-shirt
(Table 5).
Table 5. The comparison between conventional and environmentally friendly processes from
the point of water and energy conservations.
Process
Bleaching
Dyeing
Finishing
Input
Energy
kW/t-shirt
Water
1/t-shirt
Energy
kW/t-shirt
Water
1/t-shirt
Energy
kW/t-shirt
Water
1/t-shirt
Conventional t-shirt
Input
13.93
1.37
44.04
5.47
35.18
5.47
Output
13.93
1.09
'44.04
4.38
35.18
4.38
Environmentally friendly t-shirt
Input
13.91
1.23
42.38
4.87
34.17
4.87
Output
13.91
1.0
3.9
3.9
Conclusions
A textile plant has been investigated thoroughly by means of a step-wise CP Methodology
Application. The evaluation of the feasibility studies revealed that it is worth implementing CP
options from the point of resource conservation and chemical substitution. The benefits obtained
were not only attributed to cost savings, but better environmental awareness as well.
It should be noted that the CP options studied are feasible only for that production system for that
selected enterprise.
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PILOT STUDY UPDATES
It is concluded that the successful application of CP methodology in the Turkish textile sector
will encourage other industrial sectors to take similar actions. It should also be noted that the
managerial commitment of any enterprise is of utmost importance in CP, since without their
commitment and financial support, there will be no real actions and no real results.
References
[1] Electrical Works Research Office. National Energy Conservation Centre. (1997). Principles
of Energy Management in Industrial Sectors, Vol.1, Annex 2.
[2] DTI International, Cleaner Technology Assessment. (1995). Danish Technological Institute.
Taastrup, Denmark.
[3] Unlu G. Arikol M. and Kaptanoglu D. (1985). Survey of Industrial Energy Requirements:
Findings for Turkish Textile Industry. TUBITAK-Marmara Research Centre. Rep. No:40.,
Kocaeli, Turkey.
[4] Laursen S. E. Hansen J. Bagh J. Jensen O. K. and Werther I. (1977). Environmental
Assessment of Textiles. Miljoproject No.20, pp. 132-174.
[5] K ran N. and Ozdogan S. (1998). Integration of Process Energy Supply Options into Cleaner
Production in Textile Industry. Proc. of the Kriton Curi International Symp. On
Environmental Management in the Mediterranean Region. June 18-20. Antalya, Turkey, pp
947-955. .
[6] Cooper S. G. (1978). The Textile Industry Environmental Control and Energy Conservation,
ndc Press, pp. 104-117, 151-180.
CLEANER ENERGY PRODUCTION WITH COMBINED CYCLE SYSTEMS
Aysel T. Atimtay
Middle East Technical University, Environmental Engineering Department,
06531 Ankara, TURKEY
Energy demand in the world is increasing everyday due to the increase in population and
economic developments. Electrical energy is the most favorable clean energy which is generally
produced by conventional systems known as Pulverized Coal-Fired or Stoker-Fired Boilers with
steam turbine and generator systems. In these systems, the energy conversion efficiency is around
30-35 %. Only about one-third of the heat generated can be converted to electrical energy.
There is a great amount of research going on in several countries to increase the energy
production efficiency as well as the development of new processes and equipments which use
much less energy than the ones developed decades ago.
A new technology for generation of electrical energy in a cleaner and more efficient way is the
Combined Cycle (CC) system. The conversion efficiency of the system is about 50-53 %, which
is considerably higher than the conventional systems. The presentation summarized the energy
production capacity in Turkey with combined cycle systems by using several fuels. Updates were
given on the development of sorbents used for gas cleanup of the IGCC systems by using the
waste materials of the iron and steel industry.
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PILOT STUDY UPDATES
THE DANISH CENTRE FOR INDUSTRIAL WATER MANAGEMENT - UPDATE
Henrik Wenzel
Technical University of Denmark
e-mail: \venzel@ipt.dtu.dk
The Danish Centre or Industrial Water Management (Danish acronym: CEVI) is a co-operation
between five large Danish companies, three technological institutes and two universities. The aim
of the centre is to develop concepts and solutions for reclamation and reuse of water and
waterbome energy and chemicals in water consuming industry. Generic methods and tools must
be developed for future anchoring and dissemination of the developed know-how, and solutions
must be implemented within the industrial partners, being representatives from textile industry,
industrial laundering, paper industry and food industry.
CEVI has been running now for one year out of four, and a number of results have been achieved
ranging from generic methods to implementation of solutions. Among the methods developed,
adjusted and/or applied are: Methods for mass-, energy-, and cash flow analysis, methods for
characterising and specifying water quality and product quality, methods for process integration
and pinch analysis, and methods for environmental feasibility analysis in shape of a simplified
Life Cycle Assessment method.
In industrial laundering, being one of the case industries, direct water reuse saving 40% of the
water has been implemented through establishment of central tanks for reuse water at one
laundry. Moreover, biological treatment has been installed for further water reuse. Ultrafiltration
of the wash baths has been successfully tested in lab- and pilot scale, and test are under
conduction for full scale washing in UF permeate saving thus both the water and the energy and
chemicals remaining in the water.
Present and future R&D comprises recovery of surfactants and phosphorus from UF concentrates
from wash water, drying in overheated steam, membrane filtration (NF/RO) of process water
from polyester yarn dyeing, aerobic and anaerobic digestion of process water from moulded pulp
production, and much more. The following tables give an overall view of research, development
and implementation progress.
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PILOT STUDY UPDATES
Table 1. Status on generic methods May 2000
Type of method
Overall procedures
Inventory
Analysis and system design
Modelling
Feasibility study
Method/tool elements
Process optimisation
Equipment modernisation
Chemical substitution
Reuse of water, energy and chemicals
Processes
Mass flows
Energy flows
Cash flows
Water quality characterisation
Product quality characterisation
Product quality specification
Water quality specification
Process integration/energy
Process integration/mass
Database of separation techniques
Guidelines in choice of water reuse
Concepts and techniques
.Database of residue management
Options
Guideline in residue management
Water- and product quality in water reuse
scenarios
Technical feasibility
Economic feasibility
Environmental feasibility
Robustness/sensitivity analysis
STATUS
Conceptually defined
Initially defined
Adjusted and applied
Adjusted applied
Developed and applied
Developed and tested
Developed and tested
Not defined
Defined on case basis
Adjusted and tested
Adjusted and tested
Under consideration
Under consideration
Under consideration
Under consideration
Existing tools tested
Excel tool developed
and successfully tested
Under consideration
Applied
Developed and applied
Developed and tested on a case basis
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PILOT STUDY UPDATES
Table 2. Berendsen Industrial Laundry Group. Status on research, development and
implementation, May 2000
PROCEDURE LEVEL
Activity
Status
Optimisation
Various water, energy and chemical
savings
Automatic weighing of textile for
optimal chemical dosing
Established at 3 laundries. Pinch analyses
conducted
Suggested
Modernisation
Substitution
Reuse
Direct reuse via central water reuse
tanks. Around 40% water savings
Biofilter for reclamation and reuse of
wash water
Membrane filtration of the wash water
Membrane biofiltration of the wash
'water
Environmental comparison of alternative
water reuse concepts
Heat recovery from drying. Drying in
superheated steam
Implemented in one line (8 washing machines) at
one laundry
Installed at two laundries. Test of operation
ongoing
Successfully tested in lab-scale and pilot-scale.
Washing tests with permeate ongoing
Successfully tested in pilot-scale
Conducted
Under consideration
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PILOT STUDY UPDATES
Table 3. Neckelmann polyester yarn dyehouse. Status on research, development and
implementation, May 2000
PROCEDURE LEVEL Activity
Status
Optimisation
Spray system for CIP installed - substitutes two
complete tank fillings
Liquor displacing unit used when cleaning dyeing
apparatuses
Established in one out of 14 dyeing
apparatuses
Constructed and tested
- minor reconstruction ongoing
Modernisation
Reduction of water cany-over by vacuum suction
of the yarn cones between the batches of the
recipe
Under consideration
Substitution
Reuse
Direct reuse via central water reuse tanks
Reduce volume of oily UF concentrate by salt
addition and subsequent gravitational separation
Membrane filtration of the heaviest polluted water
types
Evaporation techniques and heat recovery
Heat recovery from drying. Drying in superheated
steam
Reuse of water from last rinse as input
to first rinse successfully tested
Successfully tested and installed
Successfully tested in lab-scale. Pilot-
scale tests ongoing
Process integration/pinch analyses
carried out. Feasibility study ongoing
Under consideration
Table 4. Hartmann moulded pulp producer. Status on research, development and
implementation, May 2000
PROCEDURE LEVEL
Optimisation
Modernisation
Substitution
Reuse
Activity
Reduction of water content of products before drying
Substitution of biocides by dispersing agents
Direct reuse via flotation and central water reuse tanks
In-line aerobic biological treatment for microbial growth
control and for reducing use of biocides
In-line aerobic biological treatment for microbial growth
control and for reducing use of biocides
In-line NF/RO membrane filtration for microbial growth
control and for reducing use of biocides
Environmental comparison of alternative water reuse
concepts
ซ Heat recovery from drying. Drying in superheated steam
Status
Under investigation
Tests ongoing
Implemented for many years
Successfully tested in pilot
scale
Lab- scale tests ongoing
Unsuccessfully tested in pilot
scale
Conducted
Under consideration
CEVI-newsletter and further information available on www.cevi.org
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NEW PILOT PROJECTS
INTERNATIONAL EXCHANGE AND DISSEMINATION OF INFORMATION ON CLEAN PRODUCTS AND
PROCESSES: WITHIN THE PILOT STUDY AND TO INDUSTRY AND THE PUBLIC
DanielJ. Murray, Jr.
US Environmental Protection Agency
Cincinnati, Ohio
Summary
At the Belfast meeting in 1999 there was a discussion on how to improve communication and it
was suggested to launch a new pilot project on communication. Horst Pohle, Germany, Adrian
Steenkamer, Canada and Dan Murray have since discussed how to proceed, and the suggestion is
to try and establish a web-page for the pilot study and use that as a focal point for
communication.
The proposed procedure was to start up by establishing the new web site, and see how it goes and
then discuss it again at coming meetings. The web page has been established at:
http://www.epa.gov/ORP/NRMRL/nato/
The suggestions are to have a front-page giving
overview of NATO CCMS Mission,
description of Pilot Study,
Link to NATO CCMS web site,
and Annual reports
And secondary pages containing information on
participating nations and delegates
national program descriptions
- delegate's organization description and resources
Links to research centers, governmental organizations etc.
Pilot project descriptions and information
Pilot study participation information and announcements
Other Cleaner Production information and links
EPA in Cincinnati can offer to maintain the pages.
Further ideas from the delegates for the web page were i.e. to have a discussion forum, to be able
to advertise free jobs and to have procedures to ensure a reasonable frequent updating of
information. Overall, the key being that everyone provides information to the page.
The main purpose of the web page is for communication and information sharing among the
delegates and participants. In addition also to refer people to the work done within the pilot study
and provide Cleaner Production information to others. A long-range goal is to make the page
looked upon by many nations and individuals as one of the places to look for information on
Cleaner Production and Cleaner Products.
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INVITED PRESENTATIONS
INTRODUCTION TO INVITED PRESENTATION
A number of specially appointed speakers were invited by the Pilot Study directors and by the
meeting host. Papers or summaries of these presentations are given in the following in the
chronological sequence in which they were presented at the meeting.
ENGINEERING FOR SUSTAINABLE DEVELOPMENT - AN OBLIGATORY SKILL OG THE FUTURE
ENGINEER
Leo Alting
Professor
Department of Manufacturing Engineering and Management
Technical University of Denmark
Introduction
In the last few years it has become clear that our present industrial production and consumption
culture is facing dramatic changes in the future due to:
- pollution and waste problems
non-renewable resource consumption
- rapid growth in world population
The developing countries are fighting poverty and health problems and we have no choice but to
support their struggle for economic growth, which is a prerequisite for a more stable world.
Our best contribution is to develop a new sustainable industrial culture, which can be scaled up
by a factor of 5 - 6 compared to the present level without creating unacceptable environmental
and resource problems. The term sustainability appears more and more often in literature, public
debates, as research issues, etc., but it is used in many different meanings. Broadly, the content of
the term is determined by the different value criteria of the various interest groups around a
company (share holders, suppliers, employees, local community, national and international
community, political interest groups etc.). A closer study of these criteria results in the conclusion
that the term sustainability includes the three main responsibilities:
economic
environmental
social/societal
The economic responsibility has for many years been the dominating one, but in the last few
years the environmental and the social/societal responsibilities are surfacing more and more to
parallel the economic responsibility. These responsibilities are interlinked and all have a major
influence on business opportunities.
Product Life Cycle Management
In the last few years the environmental focus in industry and legislation has shifted from the
production processes to the products themselves throughout their entire life cycles (material
extraction, material production, product production, usage and disposal). This is due to the fact
that environmental impacts are created in all life cycle phases. Therefore, it is necessary both
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INVITED PRESENTATIONS
from an environmental and resource viewpoint as well as from a business viewpoint
(manufacturer is responsible for the whole life cycle) to consider the product's life cycle in a
holistic way with the aim of optimising the product performance. [ 1 ]
For this purpose a product life cycle management (PLCM) system should be adopted. Table 1
shows the main elements in a PLCM system and each company will have to - based on its own
market and objectives - adopt these elements to its own management structure.
Table 1: Main elements in a PLCM system
Element
A. Strategic
management issue
B. Life cycle
assessment (LCA
C. Life cycle
engineering (LCE)
D. Life cycle
information (LCI)
E. Technological
plat-forms
Purpose
Integration in the management structure
Environmental focus; product development; documentation;
internal & external communication
Definition of business objective, engineering methods and
activities to support all product life cycle issues
Information flow and data to support life cycle management
Monitoring technological developments
Each of the elements in the PLCM system will be discussed in the following.
A strategic management issue
It is a top management responsibility to ensure that the company has full awareness and
knowledge of the products' life cycles and the consequences they have in all life cycle phases
(environmental impacts, resource consumption). The company must clearly define its business
objectives seen in relation to the products' life cycle and identify and describe the interaction and
transfer between the "owners/partners" of the product in its life cycle phases. Introducing the
PLCM will ensure that the company has all the necessary documentation of the products to be
used internally as well as externally (interest groups, authorities, purchasing, marketing, etc.). It
is the responsibility of the management to have full knowledge of the products and their
consequences in all life cycle phases, and to show how they are dealing with these consequences.
Management focus on the subject will in itself create a better performance, but introduction of the
necessary engineering methodologies/tools in the various company functions will provide more
significant results.
It is necessary that the PLCM system is integrated in the overall company management system.
Life cycle assessment of products
As mentioned previously, the environmental focus has shifted from the manufacturing processes
to the products themselves in their life cycles. For this purpose a methodology for assessing
environmental impacts and resource consumption associated with the existence of products
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INVITED PRESENTATIONS
throughout their entire life cycles has been developed. It is called LCA (Life Cycle Assessment)
and is a result of many years of international scientific development. The procedure is now being
documented in the ISO standards:
14040 Principles and framework (1997)
, 14041 Goal and scope definition, inventory (1998)
14042 Life cycle impact assessment (draft, 1999)
14043 Life cycle interpretation (draft, 1999)
SET AC (The society of Environmental Toxicology and Chemistry) has made important
contributions to the methodology development.
Based on the LCA the environmental focus for the product development can be established and
design guidelines can be developed. LCA results can be used for various purposes both internally
as well as externally.
Life cycle engineering
The term life cycle engineering is used to cover the activities, methods and tools that are used to
develop the products for their entire life cycle. The main issues are:
business objective
life cycle design/design of life cycle
Business objectives (new opportunities)
It is very important that a company very clearly defines its business objectives. Here it is
important to recognise that the physical part of many products is becoming a smaller and smaller
part of the value chain in a product's life cycle. The service parts are increasing and the company
must decide what is its business objective:
the product
the function/service of the product, i.e. maintain control of the life cycles . ,
after sales service, maintenance, online monitoring/maintenance, availability
take back (to remanufacture)
The life time of the product is determined based on the objectives. It must be remembered that
the product manufacturers are responsible for the impacts and consequences of the products in
their entire life cycle, and therefore it must be investigated if this also means that it is
advantageous to make usage and disposal part of the business. It is important that
"ownership/responsibility" for the different parts of a life cycle is visible and that the partners
having ownership optimise their collaboration.
New business objectives may arise seen in the product life cycle perspective and new
technologies (micro/nano/sensor technology, telecommunication, supply chain management, etc.)
may offer possibilities of re'alising these.
Life cycle design
When designing the product for all life cycle phases, it is important to optimise its total
performance. Many issues/requirements have to be considered at the design stage, here mainly
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INVITED PRESENTATIONS
environmental and other life cycle related topics are mentioned. These topics must be balanced
against all other product requirements.
Design for environment
Based on the life cycle assessment it is found what the problem is (effect potentials, main
contributors, etc.). The designer can now look at what can be changed (materials, processes,
functional elements, structure etc.) and what the environmental improvements are. Seen from the
costs and the competitive position of the product, it must be decided which improvements should
be implemented in the new product. Design rules may be developed based on the LCA results,
for example energy reduction in usage, certain materials preferred, avoid following chemicals,
etc.)
Design for X
Many other environmental and life cycle related issues have to be dealt with at the design stage
and they can be listed as design for X. The following design issues (X) must be considered:
distribution including packaging and transport
installation (facility requirements, self-integration, plug & play function, etc.)
maintenance (self-diagnosis, self-repair, online services, monitoring, teleservices,
upgrading etc.)
ease of manufacture (materials, processes, assembly etc.)
remanufacture (reuse/repair, dismantling, recovery)
take back (reuse in new products, upgrading, downgrading etc.)
These design considerations are very important and their contents depend on the type of product
and on the defined business concept.
Product life cycle information
Information supply and communication among the different life cycle partners is an important
aspect. Information has to be provided regarding design, materials, processes, components,
service concepts, operating strategies, etc. A product state model must be developed
accumulating all information about a product at the present time. This enables documentation of
the product, service and operating manuals, usage information and disposal information.
For many products it will be of value at any life cycle state to have access to all data.
Therefore questions about:
product data management (design data, LCA data, production data, maintenance/repair
data, etc.)
database (structure/access)
tele-/multimedia services (installation, plug & play, monitoring, online services, diagnosis,
repair, etc.)
must be answered.
It could be considered to have the product itself carry the information in a chip. The coming
sensor technology also enables easy data collection. It seems that the possibilities in the modern
communication technology will provide new and advantageous solutions.
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INVITED PRESENTATIONS
Technological developments/technology platforms
The technological development is progressing very fast, and it is mandatory that the company all
the time closely monitors its technological platform to ensure the full potentials of its products.
Typical trends are:
miniaturisation of products (saving energy and resources)
micro-/nanotechnology (sensors, functional units)
new materials and processes
information technology
networking
virtual reality/virtual enterprise
telecommunication
plug & play software
better energy efficiency in functional units
communication capabilities in functional units
production is becoming a project in the product life cycle
These trends show that many new possibilities are presented to the companies and it is important
that the company always has an updated technology platform combined with an updated business
objective.
Conclusion
The presentation indicates that the technical contribution to sustainability is closely linked to the
life cycle perspective, and that large improvements compared to the present situation can be
obtained.
Product life cycle management is an important tool that focuses the company's attention on the
business objectives seen in the product life cycle perspective as well as on all activities that
optimise the co-operation between the life cycle "owners".
, Life cycle engineering covers methods and tools to support development, manufacture, usage and
service and disposal of products to optimise business and sustainability.
References
[1] E. Westkamper, L. Alting & G. Arndt: "Life Cycle Management and Assessment", CIRP
General Assembly, Sidney, Australia, August 2000
[2] H. Wenzel, M. Hauschild & L. Alting: "Environmental Assessment of Products", Kluwer,
1997
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INVITED PRESENTATIONS
MEMBRANES IN PROCESS INTENSIFICATION AND CLEANER PRODUKTIONS
Enrico Drioli,
Institute on Membranes and Modelling of Chemical Reactors - CNR,
and Department of Chemical Engineering and Materials,
University of Calabria, Arcavacata di Rende (CS), Italy.
Introduction
Research progresses in Chemistry and Chemical Engineering have been made during the last
decades with important contributions to the industrial development and to the quality of our life.
An interesting case is related to the membrane science and technology continuous impact to
innovative processes and products, particularly appropriate for a sustainable industrial growth.
Reverse osmosis is today a well recognized basic unit operations, together with ultrafiltration,
cross-flow microfiltration, nanofiltration, all pressure driven membrane processes. Already in
1992 more than 4 millions m3/day were the total capacity of RO desalination plants and in 1995
more than 180.000 m2 of ultrafiltration membranes were installed for the treatment of wheys and
milk. In early 2000 the overall desalinated water produced worldwide by RO is overcoming the
amount produced by thermal methods.
The concept of asymmetric structures realized with composite polymeric membranes made
possible in the early 80s the separation of components from gas streams. Billions of cubic meters
of pure gases are now produced via selective permeation in polymeric membranes.
The possibility of combining in a single step a molecular separation with a chemical conversion,
realizing a membrane reactor, is offering new important opportunities for improving the
efficiency of important productive cycles particularly in biotechnology and in the chemical
industry. In September '97 five large petrochemical Companies made public their alliance for a
research project devoted to the development of inorganic membranes to be used in the syngas
production. This action came in parallel to the announcement of a 84 million dollars similar
project, partly supported by the DOE in the USA, having Air Products and Chemical Inc.
working together on the same objective. The availability of new high temperature resistant
membranes and of new membrane operations as the membrane contactors is offering a important
tool for the design of alternative production systems appropriate for a sustainable growth.
The basic properties of membranes operations make them ideal for a rationalization of the
industrial productions; the fact they are athermal, (except membrane distillation) and don't
involve phase changes or chemical additives, simple in their conception and in their operations,
modular and easy in their scaling up, suggests significant reduction in energy consumption with a
potential more rational utilization of raw materials and recovery and reuse of by-products. The
membrane technologies, compared to those commonly used today, respond efficiently to the
requirements of the so-called "process intensification", because they permit to bring drastic
improvements in manufacturing and processing, substantially decreasing equipment-
size/production-capacity-ratio, energy consumption and/or waste production and resulting in
cheaper, sustainable technical solutions .
The potentialities of redesigning innovative integrated membrane processes in various industrial
sectors characterized by low environmental impacts, low energy consumption and high quality of
final products have been studied and in some cases realized industrially.
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INVITED PRESENTATIONS
Interesting examples are in the dairy industry or in the pharmaceutical industry. Research projects
are in progress, in the leather industry or in the agrofood industry based on the same concept.
Membrane Operations
It can be said that the existing membrane technology covers the widest spectrum of applications
than any other single separation technology. In table 1 are summarized the most relevant
processes and some examples of their mature applications.
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Table 1: Applications of membranes operation in some industrial branches
Branch
Chemistry
Petrochemistry
Paper industry
Textile industry
Leather industry
Electronics
Metal industry
Transport
Energetic
Fuel
Food industry
Sugar industry
Beverages
Diary industry
Examples of matured implementations
Concentration and recovery of substrates, catalyst's recycling,
removal of organic components from water solutions,
fractionation of hydrocarbons, crystal cleaning, recovery of
cleaning agents, emulsion break-up, recovery and
concentration of polymers, filtration of amines and glycols,
purification and concentration of acids, purification of
glvcerin
Fractionation of hydrocarbons, wastewater treatment, fuel
dewatering, separation of azeotropes
Recovery of chemicals and reagents: pigments, chelating
agents, emulsifiers, latex, defoaming agents, neutralization of
wastewater
Recovery of oil finish, polyvinyl alcohol, latex, dyes and
detergents
Recovery of tannin agents and chemicals from unhairing baths
and tanning baths
Preparing of ultra-pure water for flushing of integrated
circuits, air filtration, water recycling
Regeneration of cooling emulsions for cutting, rolling drilling,
etc, separation of condensates from compressors,
neutralization of galvanic wastes, recovery of oils and greases
from degreasing baths, concentration of washings with diluted
electrophoretic paints
Removal of oil from washings after cleaning of transportation
means and tanks
Water softening, decarbonization, removal of radioisotopes
Manufacturing of ethanol from cellulose and starch, methane
from agricultural and municipal wastes, hydrogen and
hvdrocarbons
Recovery of proteins from animal and plant by-products,
recovery of proteins from plants, soybeans, potato juice during
starch manufacturing, desalting of vegetable dye,
concentration of pectin and gelatin, cold sterilization of
products
Sugar refining, molasses removal, purification and
concentration of cat and cane juice
Clarification of juices, syrups, wines spirits and liquors,
concentration of fruit and vegetable juices, purification of
organic acids, glucose and fructose. Cold sterilization of beer,
wine and spirits
Sterilization of milk, concentration of skim milk and whole
milk during cheese making and powdered milk production,
milk desalting, concentration of sweet and sour whey,
manufacturing of protein concentrates from milk, recovery of
lactose from whey
Process
RO,NF,
UF,MF,
PV,ED,
DL
PV,MD
RO,NF,
UF,MF
RO,NF,
UF,MF
RO,NF,
UF,MF
RO,NF,
UF,MF
RO,NF,
UF, MF
UF,MF
MF,RO,
UF
UF, GS
UF,MF
RO,NF,
UF
RO, NF,UF
MF,UF,
ED
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Table 2
Sales of membranes & modules in various membrane processes
Membrane
process
Dialysis
Microfiltration
Ultraflltration
Reverse osmosis
Gas exchange
Gas separation
Electrodialysis
Electrolysis
Pervaporation
Miscellaneous
Total
Sales 1998
[MioUS $]
1,900
900
500
400
250
230
110
70
>10
30
4,400
Growth
[% p.a.]
10
8
10
10
2
15
5
5
?
10
>8
Membrane operations shown their potentialities in molecular separations, clarifications,
fractionations, concentrations, etc. both in liquid phase, gas phase, or in suspensions.
They cover practically all existing and requested unit operations used in process engineering. All
the operations are modular, easy in their scale up and simple in their plant design. No moving
parts; working totally unattended; lower cost; operational flexibility and when necessary,
portability are other important aspects.
Several examples of successful applications of membrane technology as alternative to a
traditional process may be mentioned.
The use of ion exchange membrane cells in chloro-soda production represent an interesting case
study for analyzing the potentialities of membrane operations and one of the first success of their
electrochemical application in minimizing environmental impact and energy consumption.
The success of this process suggested recently another interesting applications still based on
cation transporting membranes as Nafion: the anhydrous electrolysis for chlorine recovery.
The recent development of nanofiltration and low pressure reverse osmosis membranes with
interesting selectivity and fluxes, higher chemical and thermal resistance has been rapidly utilized
for realizing innovative processes in various industrial sectors.
An interesting case studied in Italy is represented by the lopamidol preparation in the
pharmaceutical industry.
Also the integrated membrane processes proposed for the chromium recovery in the leather
industry and the treatment of secondary textile effluents for their direct reuse, show efficient
applications of nanofiltration and low pressure reverse osmosis operations.
In addition to the already mentioned membrane operations, gas separation, pervaporation and
some others membrane processes which are showing in the last years significant potentialities for
their application in various industrial areas must be cited; among these a class of membrane based
unit operations (already known membrane systems and new ones) identified as membrane
contactors, membrane bioreactors and catalytic membrane reactors.
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APPROACHES TO CLEANER PRODUCTION IN ECONOMIES IN TRANSITION - THE RESULTS AND
PERSPECTIVES OF THE CLEANER PRODUCTION CENTRES
Vladimir Dobes
Czech Cleaner Production Centre
Cleaner production is concept, which reflects general trends in environmental management:
- Increasingly clear limitation of environmental effectiveness and economic inefficiency of
end of pipe solutions
- Increasing need for dematerialisation and increase of efficiency of processes, products
and services
- Increasing need for avoidance of use of toxic materials
- More clear need for integrated and holistic approach to environmental protection.
These are trends, which are already starting to be reflected in new environmental policies and
regulations worldwide (in Europe for example EC directive on Integrated Pollution Prevention
and Control). There is also a broad understanding that these trends should be reflected in
transformation of economies in transition and in restructuralisation of their industries as well.
Donor programs
The above mentioned trends together with high potential for reducing pollution through increased
efficiency of industrial processes in economies in transition (CEEC's) were one of the reasons
why there were launched different donor programs in this field. Programs were focused on
implementation of preventive environmental management in CEEC's starting at beginning of
nineties. These programs were at the beginning fully donor driven.
Practical implementation of preventive approach was promoted under different terms like cleaner
production, pollution prevention, waste minimisation or clean technologies. We will utilise term
cleaner production in this paper to refer to all these approaches and methodologies.
We can distinguish two basic approaches1 in launching these programs:
1) Demonstration of technology - programs in field of direct assistance to concrete
industrial branch and/or individual enterprise to solve concrete problem through
technology transfer focused mainly on demonstration of hardware. This approach has
impact mainly in innovation of equipment.
2) Demonstration of methodology - programs in field of capacity building with focus on
training of trainers on demonstration projects in industry. This approach has impact
mainly in developing local technical assistance, lecturing and managerial capacities.
The programs were normally mixture of these two approaches. They have created many concrete
projects demonstrating double benefit of preventive environmental management in industrial
enterprises (for example see enclosure, table 1).
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Results and impacts
The programs were successful concerning their goals to demonstrate potential for cleaner
production and to train domestic professionals in cleaner production (CP) methodology. There
are being often discussed two problems related to these programs, which are interesting for our
discussion.
"The first is connected with reliability of presented results both in terms of environmental benefits
and economic evaluation of measures. This was problem especially in cases in which the reports
were developed by enterprise staff without reliable independent verification. However, we can
see it also in cases in which international consultants developed reports without deeper
questioning of data provided by enterprises.
We do not see this as a fundamental problem for two reasons:
- We have seen the not accurate presentation of results to vary on both sides (being higher
or lower) and we estimate that the real theoretical results will be in sum corresponding
with the presented ones. This difference is caused both by intentional and not intentional
miscalculations and enabled by complexity of cleaner production measures. These
measures have impact on different costs within and outside production process. We can
state that many savings are omitted just because of poor identification of all aspects
influenced within total costs assessment.
- There were already some improvements done in this area (for example verification of
results through opposition of enterprise top management which has to pay percentage of
savings from implemented measures and is therefore committed not to exaggerate the
results).
The second problem, which we consider more serious, is problem of implementation of proposed
measures, poor maintenance of implemented measures and lack of follow up actions. Many
evaluation programs reported limited and or no follow up of activities implemented in enterprises
after the external assistance is over. Enterprise managers perceived CP as tool, which is difficult
to integrate into enterprise management and daily practice. This is especially perceived in
situation in which enterprise face day by day survival problems (and this is normal situation of
most of CEEC's enterprises). There is a question if there are not the survival problems of these
enterprises caused among others by lack of good strategical and preventive management and poor
management of material and energy flows.
To understand better the second problem it is useful to make closer look on enterprises, which
were successful in maintaining CP program ongoing after the external assistance was over. There
were some common features like:
- management committed to strategical development of enterprise
- effort to involve employees into improvement of enterprise performance
- system approach to enterprise management and understanding importance of continuous
improvement
integration of CP with other activities within enterprise.
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Concerning the question of general success of the donor programs we can conclude that the
existing results proved and very well demonstrated that there is a high potential for double
benefits from cleaner production measures in all different sizes and branches of industry.
On the other hand it become clear that it is much more difficult to achieve a broad spread of CP
in respective countries than originally assumed. Training and demonstration does not lead to
integration of CP into daily practice of industry and other stakeholders on its own.
Cleaner production centres
Some donor programs, which were aiming at broad integration of cleaner production into the
industrial environmental management in target countries, introduced into their programs
establishment of cleaner production centres (here we use term cleaner production also in its
general meaning referring to all types of centres with different names).
The general purpose of these centres is not only to organise training and demonstration but also
to go beyond demonstration and play key role in sustaining cleaner production programs in
country after the international assistance is over.
We can distinguish two basic types of centres with understanding that the real centres are
normally mixture of these two types:
1) Commercial consultant
The main functions of such a market driven centre are to provide information, training and
technical assistance to industry and other stakeholders in such a way that this service recovers its
costs and make it financially self sustaining. We can see that the successful centres, which have
had this mission, are today operating as consultancy firms.
The main limitations here are:
- These centres are in order to survive in competition pushed by market to focus more and
more on activities which are far from promotion of cleaner production.
- They are forced by market to keep their know-how for themselves to be able to sell it to
their clients and therefore there is very limited or no multiplication effect.
2) Subsidised promoter
The main functions of such a mission driven centre beside basic promotional activities, training
and technical assistance includes broad dissemination of the concept to different stakeholders,
providing platform for cooperation of stakeholders, providing policy advice and facilitating
establishment of financial mechanisms for investment needing cleaner production measures.
The main limitations here are:
- Donors and governments in CEEC's are not committed for long-term financing of basic
operation of any organisation even with very useful mission.
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Fully subsidised services are not so motivating both for providers and clients (there is a
general perception in many CEEC's that what is free of charge is not valuable).
Critical success factors
The centres, which survived and succeeded to keep their mission of focal point and source of
know-how in field of cleaner production in their countries, are having features of both subsidised
promoter but also of commercial consultant. The survival challenge for them is to keep revenue
generating activities in field of cleaner production to be able to maintain their promotional
functions. Other common strategy is to rise project based funding for the promotional activities.
There are some factors that we see critical for successful implementation of mission of cleaner
production centres. They are illustrated on case of the Czech Cleaner Production Centre2 in the
enclosure.
1) To build critical capacities within all stakeholder groups so that they can continue
implementation of cleaner production on their own.
Completion of this task is crucial for fulfilling the centres mission. We have to stress that the
centre creates through this its own competitors. To cope with this challenge, the centre has to
integrate the next success factor.
2) To be source of new know how infield of cleaner production in the country.
As the yesterday pilot activities are becoming standard ones and different stakeholders feel their
ownership, centre can refrain from continuing in their direct implementation and has to come
with something new what will be new interesting product to be spread.
This challenge is closely connected with experience that needs of enterprises are developing very
quickly. The offer of cleaner production centre should follow this demand and changing
conditions.
3) To develop demand for cleaner production.
This is the last and most complex success factor. We have already stressed that cleaner
production programs in CEEC's were donor driven at the beginning. We can see a slow-down of
process of promotion of cleaner production in many CEEC's due to a lack of domestic driving
forces. Donors are withdrawing and new driving forces are not in place yet. These driving forces
should be related to demand of local stakeholders, mainly governments and industry and should
be reflected in relevant policies. For example investors or owners could play a driving role as
well, however, there are not many precedents here yet.
There is a large set of tools, which can promote cleaner production to industry and create needed
demand, which would utilise and enlarge cleaner production capacities developed within the
initial programs. These tools can vary from soft information tools to compulsory systems, which
work on principle of public access to benchmark information, or from market based economic
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tools to normative regulation based (for example on consideration of best available techniques
within permitting system under Integrated Pollution Prevention and Control).
Commitment of governments is crucial here. Many have for example different schemes for
support of end of pipe technologies. They can use cleaner production capacities for assessment of
cleaner production potential before investing into end of pipe measures. The size of these
measures and related investments would be significantly minimised as well as environmental
risks.
The final goal concerning policies promoting cleaner production is to integrate them into sectoral
policies. The "action ministries" are responsible for efficiency of their resorts and ministry of
environment can play mainly facilitating and coordinating role here.
Conclusions
We can conclude that:
- Basic capacities in cleaner production were already developed or their development
including establishment of cleaner production centres already started in many CEEC's.
- CP programs have survival problems in many CEEC 's today as the driver of donor
support is diminishing and domestic drivers are not in place yet.
- Governments and donors can play crucial role in establishment of self-sustainable cleaner
production programs in CEEC's through support of three critical factors mentioned
above.
This support includes at the beginning building of domestic capacities, especially of consultants
and lecturers. Institutionalisation through establishment of cleaner production centre proved to be
very efficient. Centre plays role of an independent promoter and focal point, which brings
different stakeholders together.
Development of new know how is very important as the next step. This can include for example:
- amendment of cleaner production methodologies, development of assessment tools etc.
- local authority cleaner production programs
- integration of cleaner production with quality and/or environmental management systems
eco-design of products.
The third area of needed support is in field of governmental policies promoting cleaner
production. This includes for example use of cleaner production for introduction of integrated
pollution prevention and control or conditioning support for end of pipe measures by utilisation
of preventive potential.
Cleaner production centres can develop their financial sustainability based on mix of products
paid partly by clients and partly subsidised from public resources. This scheme often works only
on a project base. This situation causes high uncertainty in centres strategical planning.
We can conclude that spread of cleaner production is an inevitable process considering the trends
described at the very beginning of the paper. Cleaner production centres and other initiatives
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promoting preventive environmental management play important role in lowering our loses
connected with slow adaptation of our processes, products and services to new demands.
Litterature
1) Rodhe, H.: Preventive environmental strategies in Eastern European industry, draft of
doctoral dissertation. IIIEE, Lund University, 2000.
2) Christianova, A.: Industry and Cleaner Production - Making Business Profitable. Czech
Cleaner production Centre, 2000.
3) Arbaciauskas, V.: Cleaner Production Centres in Central and Eastern Europe - Present
situation and Future Directions, MSc Thesis. EIEE, Lund University, 1998
4) Dobes, V.: Five Key Factors for Ensuring Sustainability of Cleaner production
Programmes within a Country. Proceedings of Fourth European Roundtable on Cleaner
Production, Oslo, 1997.
5) Kisch, P., Lindhqvist, T., Ryden, E.: Evaluation of UNIDO/UNEP National Cleaner
Production Programme. IIIEE, Lund University, 1996.
6) OECD: Policy Statement on Environmental Management in Enterprises in CEEC/NIS.
EAP Task Force, Paris, 1998.
7) Staniskis, 1, Stasiskiene, Z.: CP Follow-up System in Lithuania. Proceedings of Sixth
European Roundtable on Cleaner Production, Budapest, 1999.
CRITICAL SUCCESS FACTORS
EXAMPLE OF THE CZECH CLEANER PRODUCTION CENTRE
Vladimir Dobes
Czech Cleaner Production Centre
The Czech Cleaner production centre (CPC) was established in 1994 as an independent not for
profit organisation within a framework of the Czech-Norwegian Cleaner Production Project. It
broadened its activities within the five-year support of the UNIDO/UNEP Program for National
Cleaner production Centres. CPC has headquarter in Prague and two branch offices in the Czech
Republic. It also created large pool of domestic lecturers and consultants who are being involved
in different cleaner production projects. Close cooperation with four universities secures training
capacities and integration of CP into curricula. Here follows description of selected CPC
activities related to the critical success factors presented within the paper.
Building capacities
In the first years of its existence the CPC has been focusing on technical assistance and training
with implementation of concrete projects in industrial enterprises in the Czech Republic. Projects,
which constituted a core part of CPC activities, were carried out in the form of long-term training
courses consisting of lectures and the on-job training.
The results of these projects showed high potential for cleaner production in the Czech industry.
We present summary of the main results here to support statements given within the paper in the
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Table 1. We have to stress that the results does not include all benefits as they represent only the
first annual gains and they do not include for example avoided investments to end-of pipe
measures.
Environmental benefits (it is reduction of emissions, wastewaters, waste and dangerous waste)
were achieved by both non-investment good housekeeping measures and by investments, which
has typically a short to payback.
Tabel. 1 : Summary of results of CP projects in the Czech Republic
Year
Number of long-term projects
Number of participating firms
Number of people trained
Environmental effects
VOC emission reduced
(Ton per year)
Waste water reduced
(Thousand m3 per year)
Non hazardous waste
reduced
(Ton per year)
Hazardous waste reduced
(Ton per year)
Financial savings at firms
(Million CZK per year)
1993
1
7
27
0
0
51
8172
9,7
1994
1
6
31
1982
5
9216
110
30,5
1995
2
10
64
151
7
6481
1335
43,9
1996
4
23
74
335
907
413
595
103,9
1997
1
7
21
10
3438
30
198
20,5
1998
4
21
71
237
77
630
574
39,1
Being resource of new know how
Regional projects
The most important new approach in dissemination of CP especially to small and medium size
enterprises was development of projects in cooperation with municipalities, following model of
successful program ECOPROFIT Graz and closely cooperating with Stenum Graz developer of
the know-how.
Regional cleaner production projects make use of natural relationships among local enterprises,
state administration and self-government and other interested parties. All the local stakeholders
have common interest in the improving quality of environment in their city or region and in the
increasing competitiveness of the local companies. Projects are carried out in form of several-
months interactive course, in which 6-10 enterprises are involved.
After municipalities have seen the results of the projects there were committed to contribute
financially to their follow up. This was important contribution to sustainability of there projects
based on financing from local industry and municipality. A good example of fruitful co-operation
can be seen, for instance, in the established relationship with the National Network of Healthy
Towns.
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Integration of CP and EMS
Another important new know-how was integration of CP and Environment Management Systems
(EMS). The need for changes in management system to sustain CP program in enterprises was
clear already after implementation of the first projects. This proven to be one of the differences in
comparison with enterprises in countries where the concept of CP come from. They could
integrate CP into functioning management system. However, we have found in our projects that
most of enterprises need to develop such a system and CP methodology alone does not provide
tool to do it.
EMS focuses on changes in the management system of enterprises and provides an appropriate
framework for the long-term implementation of the CP programme within them. CP methodology
focuses on the optimisation of the operating system and represents a tool for the continual
improvement of the enterprises environmental performance - the very purpose of EMS
implementation.
CPC started with integration of CP and EMS already in 1995 again with support of Stenum Graz
within the UNIDO/UNEP program. The first enterprise with the intergraded CP/EMS; system was
certified against ISO 14001 in 1997. First regional CP/EMS project was implemented in 1998 in
three enterprises in Zlin - in two municipal companies (Technical services and Water supplies
and sewerage) and a small building company. In 1999 another projects started in the co-operation
with Carl Bro (Denmark) in Ro nov following the EM AS standard.
The aim of CP demonstration projects is to show the benefits of CP and build professional teams
within companies so that they will initiate a process of continuous improvement of CP. This aim
is totally met only by those enterprises, which have integrated CP into their management system.
The principle objective of the CPC's new projects is to develop a CP methodology, which will
integrate voluntary strategies in the environmental protection. A special attention will be paid to
eco-design. The CPC will develop drafts of demonstration projects for individual production
branches and will focus on the environmental impact of their activities.
International projects
CPC amended methodologies, which are being used in other countries to the Czech conditions.
Acquired long-term experience and results of demonstration and training programmes in the
Czech Republic were the basis for assistance in building the base for cleaner production in
Croatia during the period of 1997-1999 and in Uzbekistan during 1997-1998. The project in
Croatia was implemented in the framework of multilateral development assistance programme of
the Czech Government under the UNIDO/UNEP NCPC Programme.
Developing demand for cleaner production.
There were some important milestones in development of demand for CP through governmental
support in the Czech Republic. The first was establishment of CP Program at the State
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Environmental Fund. The program supports investment needing CP measures through soft loans.
CPC provides technical assistance to the fund within this program.
The Minister of Environment has signed the International Cleaner Production Declaration Within
the High Level Meeting of NCPC in Prague in March 1999.
The Czech government in February 2000 adopted the Governmental Decree on Cleaner
Production. Part of the Decree is the National Cleaner Production Programme. The Program
provides guidelines for each governmental sector. The adoption of the program started integration
of CP programs into development and implementation of policies of particular ministries.
The promotion of CP concept to governments is a process, which is for the time being in CEEC's
very much driven by concrete individuals. In case of the Czech Republic the achievements
presented above were possible only because of strong commitment of concrete people at Ministry
of Environmental of the Czech Republic.
COMPUTER AIDED MOLECULAR DESIGN PROBLEM FORMULATION AND SOLUTION: SOLVENT
SELECTION AND SUBSTITUTION
Rafiqul Gani & Peter M. Harper*
CAPEC, Department of Chemical Engineering
Technical University of Denmark
DK-2800 Lyngby, Denmark
* Current Address: IP-SOL, Gentofte, Denmark
Abstract
A framework for the identification of environmentally benign and alternative solvents is
presented. The methodology for solvent design and selection contains multiple phases: pre-
design, design and post-design. A multi level CAMD method capable of generating a selection of
candidates meeting the required specification without suffering from combinatorial explosion is
presented and the entire framework is illustrated with a case study. The case study identifies
alternative solvents for Oleic acid methyl ester as replacements for Ethyl ether and Chloroform.
Keywords: Solvent, substitution, CAMD, group contribution, pollution prevention, process
synthesis
Introduction
One of the principal causes of pollution is the presence of a substance (or substances) in amounts
higher than the allowed maximum in one or more streams released to the surroundings.
Substitution of the polluting substance (or substances) by another that performs the same function
in the process but is environmentally benign is one way of dealing with such environmental
problems. Computer Aided Molecular Design, commonly known as CAMD, is well suited to
solving this class of environmental problems (pollution prevention and/or treatment) because it
can design/find the candidate replacements more efficiently than other search techniques.
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Current application's of CAMD within this area have addressed environmental concerns and
constraints using simple property estimation methods based on the group contribution approach.
Also, most CAMD methodologies so far have designed relatively simple compounds by
collecting fragments into group vectors (Mavrovouniotis (1998) lists a series of examples with
references in his review of CAMD). While the generation of group vectors suits property
prediction using group contribution approaches, the generated compound descriptions do not
contain the additional structural details needed for the QSPR or QSAR methods, for example, a
3D representation of the molecular structure: It is therefore necessary to generate more detailed
molecular descriptions in the CAMD algorithm. In this paper, a process systems engineering
approach" is applied to prevention and/or treatment of pollution through an integrated set of
computer aided tools.
Solution methodology
The method of solution for the compound design and selection problem is an iterative process
consisting of 3 phases: pre-design, design and post-design. The result of a successful completion
of the algorithm is a list candidate molecules. All the candidates fulfil the property requirements
set as design criteria.
Pre-design Phase ' '
In the pre-design phase, the causes of pollution are identified together with the polluting
substances and their undesirable properties. Once the causes have been identified it is necessary
to formulate the strategy for solving (curing) the pollution problem. The routes of information
leading to the identification include simulation, engineering knowledge, regulatory requirements,
and observations of existing practices as well as changes in environmental policy.
CAMD can be used in the instances where the cure either involves the replacement of a process
fluid or removal of a pollutant by using a solvent based separation technique. In the case of
replacement solvents the general process equipment and operations have already been fixed and
the substitute riiust function in all of them. If the search is aimed at finding a compound for use in
a removal (cure) operation there are additional degrees of freedom since the separation method
has not been fixed. In such cases different searches can be performed for the various feasible
separation techniques. Determining the set of feasible separation techniques to consider is a
separate sub-problem involving process design techniques.
After the problem has been identified and a solution strategy selected the pollution prevention or
treatment problems are formulated in terms of desirable and undesirable properties. From an
environmental point of view it is obvious that the properties of interest include environmentally
related properties. It is however also necessary that the compound fulfils its operational role and
there are therefore additional specifications that depend on the type(s) of operation(s) the
compound is to take part in. A knowledge base is used to assist in the selection of the application-
related properties and their values.
Desigri Phase
Iri the design phase the identification of compounds possessing the desired properties is
performed by generating compounds matching the specifications. This is achieved by assembling
building blocks. The evaluation of properties is performed using predictive techniques. By
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combining fragments to form molecules a wide range of compound can be generated and
screened.
The. methodology used for the generation approach is a multi-level approach. The computational
complexity is controlled using two techniques: (a) Partitioning: by subdividing the generation
procedure into several successive levels with a screening step between each level (allowing only
the most promising candidates to progress to the next level) ensures that computational efficiency
is maintained, (b) Feasibility: ensuring that only chemically feasible structures are generated not
only improves the quality and ease of interpretation and analysis of the results but also eliminates
the computational resources spent on false solutions. The method consists of four levels. The first
two levels operate on molecular descriptions based on groups while the latter two rely on atomic
representations (Harper, 2000). In outline form the individual levels has the following
characteristics:
Level 1
In the first level, a traditional group contribution approach (generation of group vectors) is used
with its corresponding property prediction methods. Group vectors are generated using a set of
building blocks as input. The employed approach does not suffer from the so-called
"combinatorial explosion" as it is controlled by rules regarding the feasibility of a compound
consisting of a given set of groups (Harper, 2000). Only the candidate molecules fulfilling all the
requirements are allowed to progress onto the next level.
Level 2
At the second level, corrective terms to the property predictions are introduced. These terms (so
called second-order groups) are based on identifying substructures in molecules. At this level
molecular structures are generated using the output from the first level (first-order description) as
a starting point. The generation step of this level is a tree building process where all the possible
legal combinations of the groups in each group vector is generated.
Level 3
In the third level, molecular structures from the lower levels are given a microscopic (atomic)
representation by expanding the group representations in terms of the atoms each group is made
up from. This can generate further structural variations. Furthermore the conversion into an
atomic representation (including connectivity) enables the use of QSAR/QSPR methods as well
as structural analysis methods. The possibility of using QSAR/QSPR methods and structural
analysis significantly increases the applicability of CAMD in environmental applications since
many environmental properties are only possible to estimate using such techniques and the
available techniques are very specific with respect to the compound types they are applicable to.
As an added benefit the structural analysis enables the re-description of the candidate compounds
into other group contribution schemes thereby further broadening the range of properties that can
be estimated as well as giving the opportunity to estimate the same properties using different
methods for comparison.
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Level 4
In the fourth level the atomic representations from level three are further refined to include the
3D position of the individual atoms. This conversion gives the opportunity to create further
isomer variations (cis/trans and R/S) and is performed in a way that the output is compatible with
most molecular modelling applications. Since property prediction using molecular modelling is a
task difficult to automate the estimation and screening process is done interactively.
Post-Design Phase
In the post-design phase, the final selection from the generated list of feasible candidates is made.
The final selection is done after careful analysis of the identified candidate molecules. Even
though the results from the design phase fulfil the property requirements there are properties and
criteria that are difficult to handle using automated prediction methods. Examples of such criteria
and properties are: Availability, Price, Regulatory restrictions, Long term health effects, Detailed
environmental fate and Process-wide behaviour.
The methods used to assess the additional considerations include external databases as well as
other computational tools such as process simulators, environmental fate models and phase
behaviour calculators. Which tools to use depend to a large extent on the type of application the
compound is being designed for and the available range of applicable tools. After analysing the
candidate compounds the final candidates must be selected for experimental testing or rigorous
simulation. Regardless of the approach used for the selection of final candidates, the primary
function of CAMD identifying a set of candidates having the properties needed for a particular
application - has been achieved.
Case study
The fatty acid ester "Oleic acid methyl ester" ((Z)-9-Octadecenoic acid, Methyl ester) is an
important compound in a variety of applications, such as: intermediate for detergents, emulsifiers,
wetting agents, stabilizers, textile treatment, plasticizers for duplicating inks, rubbers, waxes,
biochemical research and as a chromatographic reference standard (NTP, 1999). Reported pure
component solvents for Oleic acid methyl ester are: Diethyl ether and Chloroform (NTP, 1999)
with Diethyl ether being reported as the best solvent. While both of the reported solvents are
effective they also have unwanted properties. Diethyl ether is very volatile and flammable
(including the risk of formation of explosive peroxides) and Chloroform is a suspected
carcinogen. It is therefore desirable to identify alternative solvents that are safer and more
environmentally benign than the above mentioned.
Pre-Design Phase
Determine a solvent having the following characteristics: (a) Liquid at (ambient) operating
conditions, (b) Is non-aromatic and non-acidic (stability of ester), (c) Has low environmental
impact and poses limited health and safety problems, (d) Is a good solvent for Oleic acid methyl
ester.
The goals can be formulated as property constraints using the following values: Melting Point
(Tm) < 280 K, Boiling Point (Tb) > 340 K.
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The requirement of low environmental impact can only be addressed in part using property and
molecular type constraints (non-aromatic compounds). The true environmental behaviour of a
candidate compound must be assessed in the post-design phase as part of the analysis. However,
it is possible to address some environmental considerations via a property constraint: (a)
Compounds must be acyclic and must not contain Cl, Br, F, N or S. (b) Octanol/Water Partition
coefficient (logP) < 2 (lower is better).
The determination of solvent ability towards Oleic acid methyl ester should ideally be calculated
using an activity coefficient approach. However, since the solute in question is quite complex and
very few predictive methods (e.g. UNIFAC, ASOG) are capable of handling large compounds the
solubility requirement is addressed using a solubility parameter approach. Based on the theory of
solubility parameters, a good solvent has a solubility parameter that is close to that of the solute.
In the case of Oleic acid methyl ester the solubility parameter is 16.95 (MPa)0'5. The solubility
criteria than then be formulated as: 15.95 (MPa)0'5 < Solpar < 17.95 (MPa)0'5
Design Phase
Using the formulated CAMD problem with the added constraint of only allowing two functional
groups in a compound (prevents generation of very complex and thereby expensive compounds)
the following results are obtained:
In level 1 of the CAMD procedure 2691 vectors of groups were created. After screening
against the constraints 425 representations remained and were passed onto the next levels.
4593 molecular structures were created in level 2 based on the input from level 2. After
screening 1351 candidates were passed on to level 3.
No additional isomer forms were generated in level 3 and no screening was necessary (all
properties had been handled in level 2).
The final result from the CAMD approach was a total of 1351 compounds.
Stage 4
In order to select the prime candidates from the 1351 alternatives obtained from the CAMD
solution an extensive analysis must be performed on the candidates. If only performance
considerations are taken into account (i.e. how close the solubility parameter matches that of the
solute) the following candidates are the most promising: Formic acid 2,3-dimethyl-butyl ester, 3-
Emoxy-2-methyl-butyraldehyde, 2-Ethoxy-3-methyl-butyraldehyde.
A more rigorous analysis has been performed but cannot be reproduced here due to the page
limitation. The results are obtainable from the authors on request.
Conclusion
The algorithm outlined above provides an opportunity to solve pollution prevention and/or
treatment problems in a more rigorous manner since widely used and more accurate property
estimation methods can be used without sacrificing efficiency of the method of solution. This
enables the user to find solutions that not only protects the environment but also has a high
environmental benefit and/or process efficiency. The process systems engineering approach has
combined aspects of computational chemistry, property prediction and process design for the
solution of problems of current and future interest. A case study involving replacement of
solvents with environmentally acceptable substances has been presented.
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References
NTP, 1999 "Chemical Health & Safety Data", National Toxicology Program, Online database.
Harper, P. M., 2000,"A Multi-Phase, Multi-Level Framework for Computer Aided Molecular
Design", Ph.D. Thesis, Dept. Chem. Eng., Tech. Univ of Denmark.
Mavrovouniotis, M.L., 1998, "Design of chemical compounds", Computers and Chemical
Engineering
; THE SB "DESIGN FOR
THE FIRST STEP TOWARDS SUSTAINABLE BUSINESS PRACTICES:
ENVIRONMENT" TOOL KIT
Virginia L. Cunningham. Ph.D.. Director. David J. C. Constable, Ph.D., Manager, AlanD.
Curzons, Manager, Environmental Product Stewardship; Corporate Environment and Safety,
SmithKline Beecham, 2200 Renaissance Blvd., Suite 105, King of Prussia, Pennsylvania, 19406.
Abstract
This presentation will provide a general overview of several initiatives we are undertaking in the
area of "Design for Environment" and our efforts to determine what "Green Chemistry/Green
Technology" mean for our company. We will describe how we are using Sustainability Metrics
(Environmental), provide an in-depth review of our chemistries, and explain our use of Lifecycle
Inventory and total cost assessment (TCA) methods to answer the very difficult question of what
is really "Green." Our findings to date suggest that no single methodology in isolation will yield
the "correct" or best result; rather, each different methodology informs the other and provides
different viewpoints and potential answers to many difficult questions. A lack of standardized
approaches to using these methodologies, and differences in impact valuation, present very clear
challenges as to how best interpret data and make sustainable business decisions. Preliminary
results will be presented to show the types of learnings that we are gaining as we have developed
our sustainability metrics, pursued a detailed lifecycle inventory of a major drug product,
evaluated our chemistries,and collaboratively developed a TCA tool.
Summary of presentation
The presentation gave a brief overview of sustainable business practice at SmithKline Beecham
with focus on the Design for Environmental Tool Kit. The most effective ways to integrate
sustainable business practice are considered to be
Life Cycle Assessment
Total Cost Assessment and
Green Chemistry
How do you weave the sustainability into an every day business practice in a multinational
business? First of all, if you are not keeping score you are not acting. There a very different
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World Business Council on
Sustainable Development says it's
3i
Eco-Ejfficiency Metrics
Seven Elements of Eco-efficiency
- RcdtKi>kcncrgyiiiCeiuilyofgoodiandBnvicci
- Reducmg toxic* diipcnkm
- Enlumcfaig tntierial rccyclabflity
- Extending product durability
of foods and cervices
Figure 1. Eco-Efficiency Metrics
paradigms for measuring. One of these are set by the World business Council as shown in figure
1. However, what we stress is that sustainable metrics are not environmental performance metrics
or eco- efficiency metrics. Under the auspices of American Institute of Chemical Engineers'
Center for Waste Reduction Technologies, SmithKline Beecham together with other large
pharmaceutical companies and chemical companies has tried to define what sustainable metrics
means and what will be useful to the companies. One approach is to combine efficiency type
metrics with economic information. It is important to pick the right set of metrics. SB is working
on moving the company frprn environmental performance metrics to sustainability metrics, see
figure 2.
Sustainability Metrics
, One approach is to combine selected
efficiency type metrics with economic
information.
The economic information is a surrogate for
the social value a particular good or service
might have. This approach is demonstrated
with examples for mass and energy.
Figure 2. Sustainable Metrics
Why does SB want to design for an Environment Tool Kit? In essence, because of the nature of
our industry, it is very difficult to make substitute changes after a product is in production. The
company is highly regulated and if you make changes in the profile of i.e. a pharmaceutical
product you have to re-do clinical trials, which is very costly.
So if you want to make changes you have to do it when developing the product. We want a tool
that can be used by the chemical engineers as they are making their choices and highlighting
issues as early as possible, so you have the time to come up with appropriate solutions.
Life Cycle Assessment
Beside metrics we focus on whole idea of LCA, Total Cost Assessment and Green Chemistry.
However, the controversial issue of LCA is the evaluation of impacts. We know what the impacts
are, but how the impacts are weighted is still a controversial question. At SB we are involved
with LCA in two areas
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Packing
ซ Pharmaceutical R&D
Packing is in large part driven because of the European Packing Directive. Every new concept of
packing has to go through a life cycle assessment as part of the decision process and an easy
accessible tool is provided on the SB Intranet Site, see figure 3 and 4.
SB Intranet Sitei
Environmental Expert for Packaging
Packaging Development
Environmental Packaging reviews:
Integrated into SB NPD packaging processes,
R&D Product Development Processes, etc.
Compliance requirement in Europe
Recognized industry best practice
' ^ - Life Cycle Analysis
, Example* Oxv l)aiiv Cleanser
, packaging reduced Iy46ii
energji consumption reduced by 26%
, emissions cut by four tonnes annually
Figure 3. SB Intranet Site
Figure 4. Packaging Development
For Pharmaceuticals R&D work has been ongoing for a couple of years. The goal is to develop a
framework tool for the scientist, much like the packaging tool. The task of getting life cycle data
is quite huge. We started out by contacting our suppliers to see if data was available but only a
couple of companies were actually able to deliver data. SB is working with professor Michael
Overcash, North Carolina State University to develop a database essentially from scratch. At
present there is approx. 300 chemicals in the database whereof about 125 are SBs. A Life Cycle
Inventory-model showed that solvents in the products cause major environmental impacts, and
one of the first actions at SB was to develop a Solvent Selection Guide.
Total Cost Assessment
Another tool that is considered useful is Total Cost Assessment, which translates the impacts into
dollars. We believe that we can sell this concept easier in the business environment. People can
see dollars, whereas it is hard to see global warming or eutrophication, when they do not even
know what that means. Dollars you can understand.
A prototype tool for total cost assessment has been developed and is being tested in different
companies, but there are still a lot of gaps.
Green chemistry
With regard to Green chemistry, complex molecules, complex chemistry, and regulations
constrain pharmaceutical companies more than perhaps other industries. Up till now focus has
been on waste loads which mostly means waste minimization that is not the right driver for
sustainability. To develop green chemistry in context with sustainability, we looked at all the
chemistry that we could find in the company for the last 10 years. We ended up with over 200
examples from 35 products. These were categorized. 25 chemicals represented 80% of all the
chemicals that we use. Now we are evaluating each of these for their greenness. The goal is to
come up with metrics similar to the sustainability metrics.
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BIOLOGICAL CONTROL OF MICROBIAL GROWTH IN THE PROCESS WATEROF MOULDED PAPER
PULP PRODUCTION - AVOIDING THE USE OF BIOCIDES
Gert Holm Kristensen and Martin Andersen
DHI- Water & Environment,
Agern Alle 11, DK2970 Denmark
Abstract
Among the large water consuming industries are the paper mills, including paper mills based on
recycled paper. Recycling of the white water results in a build-up of components released from
the recycled paper and components added during the production. One of the serious problems
encountered when decreasing the water consumption through increased recycling, is caused by
the high concentrations in organics, COD, released from the paper. A major part of the COD is
easily degradable by microorganisms, which give rise to excessive microbial growth in the water
system, if not controlled. Such excessive growth of biomass in the water and production system
may lead to various problems and nuisances, like foul smell, corrosion, clogging, reduced product
quality, reduced hygienic quality of the working environment.
As part of a large Danish project on industrial water management, CEVI, various scenaria for
optimising the water management at the recycled paper factories are being evaluated, aiming at
avoiding the addition of biocides for controlling the biological growth. The most promising
scenaria are being investigated experimentally. The scenaria comprise: avoiding the biofilm
growth by addition of dispergents; aerobic removal of organics; anaerobic/aerobic removal of
organics; membrane filtration for removal of organics and subsequent anaerobic digestion of the
organics in the concentrate; The scenario evaluation activities include model simulations and
technical/economic/environmental evaluations.
Introduction
As water is getting a limiting resource water reuse has become more and more attractive in the
water consuming industries. Among the large water consuming industries are the paper mills
including paper mills using recycled paper. Recycling of the white water has already been
implemented in many mills, and the water consumption lowered significantly and even closed in
some cases. Closed water circuits have until now in most cases required large dosage of biocides
to control growth, and thereby avoid corrosion, bad odours and deterioration of the paper quality
produced.
Attempts to control the growth of microorganisms in the water system have been described in
literature. Some of these efforts have focused on optimizing the water circuit around the stock
preparation and the paper machine, while others focus on removal of the substrate and
microorganisms.
Biological treatment of the effluent wastewater from paper mills is well known and described in
the literature. Mobius and Cordes-Tolle (1994) review the existing knowledge and best available
technology and discuss the possibilities of further reuse of water in the paper industry by using
biologically treated effluent in the process.
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The most common way of controlling the microbial growth today is the addition of various
biocides. However, due to the harmful impacts of biocides on the environment, the growth
control by biocides addition is not an attractive long-term solution and new control measures are
being investigated.
To control the biological growth in the water circuit without using biocides, different strategies
can be used. In table 1 the different mechanistic ways to control the growth and possible
technologies, which can be applied, are described.
Table 1. Control of microbiological growth: Mechanisms and Technologies
Mechanism Technology
Removal of the substrate
Removal of the microorganisms
Killing of the microorganisms
Biological treatment,
Membrane filtration
Membrane filtration,
UV, Ozone, Biocides
The increased reuse of paper leads to a steadily deteriorating quality of the raw material and an
increased content of small organic molecules like volatile fatty acids. These organics are an
excellent substrate for bacterial growth, and if sufficient nutrients are present the growth will be
difficult to control. Removal of the substrate can be done by controlled biological growth in an
aerobic or anaerobic stage or by membrane filtration.
Removal of the microorganisms will solve the problems with the suspended bacteria but biofilms
will still develop in pipes and tanks and the effect will therefore be local. Killing of the bacteria
by ozone or UV has the same limitations. It will only be efficient locally, while growth still is
possible in pipes and tanks. The best solution thus seems to be removal of the growth potential
from the water through removal of the easily degradable organics.
Hartmann waste paper processing mill
Hartmann produces egg trays and other products of moulded paper from recycled newspapers.
The factory has implemented different water recycling methods to reduce the water consumption.
The white paper from the paper machines is flotated before reuse for pulp preparation and at the
paper machines, partly for adjustment of the consistency of the pulp and partly for spray water at
the machines. The spray water requires low suspended solids content. A side stream of the
flotated white water is sand filtrated and reused for special technical purposes. With the
implemented water reuse technologies, the water consumption has been reduced to around 5-10
nrVton of the product. The cleaning methods implemented until now have focused on removal of
fibres and other suspended solids leaving dissolved organics and inorganic substances unaffected.
The factory is now facing two major limits for further recycling:
- The content of dissolved organic matter has reached a level where growth in the water system
is getting difficult to control.
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- The concentration of different ions is reaching a level where precipitation in pipes and
nozzles may cause problems.
The system consists of 4 stock preparation pulping units and 10 paper machines for moulded
paper production. Part of the pulp is dewatered at a belt filter press before the paper machines to
establish water recirculation around the stock preparation and water recirculation around the
paper machines. A simplified flow sheet of the production and recirculating white paper is
presented in figure 1.
Wastewater
treatment
Raw
materials
Product
Pulper
Pulp Paper
preparation machine
Fresh
water
Drying oven
Figure. 1 Flow-scheme for production of moulded paper.
Scenaria for avoiding biocide addition to white water system
A system analysis has revealed three conceptually different scenaria for control of the biofilm
growth potential in the white water system, without the addition of biocides. The scenaria are
shown hi Figs. 1,2, and 3.
In the first scenario the growth potential in the white water system is reduced by biological
removal of the easily degradable organics in the white water.
In scenario 2, the biological growth is suppressed by removal of the organics in the white water
by membrane filtration. The organics in the concentrate are utilised by biogas formation through
anaerobic fementation.
In the third scenario the pulp is washed and two water loops are introduced: one around the
pulper and one around the paper machine. The organics are removed from the water loop around
the pulper.
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The three scenaria are subjects to technical/economic/environmental evaluations. Mathematical
simulations and experimental investigations are applied in order to identify and design the
optimal concept for bio-growth control without the addition of biocides.
Besides the above mentioned scenaria it is also being part of the study to investigate the
substitution of biocides with the addition of dispergents to the process water system. The
mechanism involved is that microbiological growth is allowed to take place, but formation of the
problem causing biofilm is avoided through the addition of components affecting the tendency of
the microorganisms to adhere to surfaces.
Wastewater
Raw
materials
Vapor
8ป Product
Pulper Pulp Paper
preparation machine
Drying oven
Fresh
water
Figure 2. Scenario 1. Removal of organics by biological treatment at white water loop.
Wastewater
Raw
materials
Puiper Pulp Paper
preparation machine
Biogas
Anaerobic _T
digestion '"^
Vapor
Sป Product
Drying oven
Fresh
water
Figure 3. Scenario 2. Removal of organics by membrane treatment at white water loop.
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INVITED PRESENTATIONS
Flotation
Wastewater
Raw
materials
Wash Pulp Paper
press preparation machine
Vapor
*j !^Product
Drying oven
Fresh
water
Fresh
water
Figure 4. Scenario 3. Removal of organics by biological (anaerobic) treatment at pulper
water loop.
Treatment and characterization of white water
Pilot plant experiments with bio-filtration at the Hartmann factory in Tender (Jepsen et al., 1996)
have shown that it is possible to remove efficiently the easily degradable organics, thereby
reducing the growth potential in the process water system. Very high loads have been applied to
the biofilter due to the favourable growth conditions: easily degradable organics and a high
process temperature. Dosing of nutrients, nitrogen and phosphorus, to the biofilter were needed.
Effective control of the nutrient dosage was essential, as excess nutrients were recycled with the
treated water, resulting in an enhanced growth potential in the water system.
Oxygen utilization rate (OUR) measurements have been used to characterize the degradability of
the COD in the white water before and after biological treatment. OUR measurements give the
basis for calculating the different fractions of the carbon; easily degradable, easily hydrolysable,
and slowly degradable (Kristensen et al., 1992). From the OUR experiments it can be calculated
that about half of the COD content in the white water can be removed in the biofilter. The rest of
the carbon will only cause minor problems with growth because it has to be hydrolyzed before
the microorganisms can utilize it.
Experiments with membrane filtration have shown, that it is feasible to apply this technology on
the white water (Knudsen et al., 1996). The experimental work was undertaken with ultra
filtration and further investigations are needed to explore the possibilities for reverse osmosis.
Before implementing new technology in the paper mill it is important to evaluate possible new
barriers for extended water reuse. At Hartmann the content of inorganic ions especially sulphate
and calcium may cause problems with precipitation. To reduce the water consumption further it
may be necessary to substitute aluminium sulphate with other chemicals in the production.
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Conclusions
From pilot plant experiments it was found that the biological filtration was an efficient way of
reducing the content of easily degradable organics; thereby reducing the growth potential in the
process water system.
Membrane filtration by reverse osmosis is another possible way of reducing the content of easily
organics in the white water. However, long-term experiments need to be undertaken if the
technical/economical/environmental evaluation points at this scenario as being attractive.
Separating the process water system into two systems; one system around the pulper and one
system around the paper machine; might be an attractive solution for removing the organics
released from the raw materials. The biological processes applied to remove the organics from
the pulper water loop are well known and process wise the scenario is considered feasible.
The mathematical simulation is considered a valuable tool for optimisation of each scenario, once
the scenario is identified.
Large scale experiments are recommended with all scenarios before full scale imlementation, in
order to evaluate/quantify the impact; i.e. the biofilm growth control; on the process water
system.
References
Jepsen S.E., G.H. Kristensen, H. Wenzel, H.H. Knudsen, A.L. Mortensen,
U. Ringbeek (1996). Control of Microbiological Growth in Recycling Water in a Waste Paper
Processing Mill. Wat. Sci.Tech. Vol 34, No. 10, pp 105-112.
Knudsen, H.H., H. Wenzel, J. Wagner, S.E. Jepsen, G.H. Kristensen, A.L. Mortensen,
U. Ringbaek (1996). Membrane separation processes in recycling paper processing mills.
Presented at 5. IAWQ Symp. on Forest Industry Waste Waters. Vancouver, Canada, 10-13 June
1996.
Kristensen, G. Holm, P. Elberg J0rgensen and M. Henze (1992). Characterization of functional
microorganism groups and substrate in activated sludge and wastewater by AUR, NUR and
OUR. Wat. Sci. Tech. Vol 25 No 6, pp 43-57.
Mobius C.H. and M. Cordes-Trolle (1994). Production Dependant Specific Data of
Paper Mill Wastewater: Information for Treatment and Reuse. Wat. Sci.Tech. Vol 30, No.3, pp
193-198.
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ENVIRONMENTAL LIFE CYCLE ASSESSMENT OF ALTERNATIVE SCENARIOS FOR BIOLOGICAL
CONTROL OF MICROBIAL GROWTH IN THE PROCESS WATER OF MOULDED PULP PRODUCTION
Henrik Wenzel1 andNilgun Kiran2
'Technical University of Denmark, Denmark, e-mail: wenzel@ipt.dtu.dk
2TUBITAK-Marmara Research Centre, e-mail: kiran@mam.gov.tr
Abstract
This paper comprises the environmental feasibility study of 7 different scenarios for biological
control of microbial growth in the process water of moulded pulp production at Brdr. Hartmann
A/S. The study is a simplified Life Cycle Assessment of the environmental consequences of each
scenario compared to the present operation as reference. The Life Cycle Assessment comprises
material and energy flows within the cradle-to-grave system of all equipment to be installed in
the scenarios in question. The assessment proves an in-line anaerobic treatment to be
environmentally preferable and shows that the energy flows in the operation of the biological
plants are key to the environmental profile of the scenario.
1. Introduction
The Danish moulded pulp producer Brdr. Hartmann A/S continuously strives to improve the
environmental performance of their processes and the environmental profile of their products.
The company produces moulded pulp products, mainly egg trays, based on waste paper. A high
degree water reuse is implemented. Like for all paper mills of this kind, control of
microorganisms in the water system is a necessity, and like other paper mills, Hartmann uses
biocides. Hartmann seeks, however, alternative ways of controlling the microbial growth in the
system in order to avoid the use of biocides, and the feasibility of biological control is being
investigated. Several scenarios for
aerobic and anaerobic in-line treatment of the process water is being studied, and their technical,
economic and environmental feasibility assessed.
As the means of studying the environmental feasibility of a scenario, Hartmann uses Life Cycle
Assessments and this was the case also for studying these water reuse scenarios. Life Cycle
Assessment is, however, a tune consuming discipline, and in this case, a simplified approach was
used, developed by Wenzel et al. (1999).
1.1 The Concept of Life Cycle Assessment
Environmental Life Cycle Assessment (LCA) is a tool for assessing the environmental impacts of
a product, or more precisely, of a product system required for providing a particular unit of
function. The term product system is taken to mean the product throughout its entire life-cycle,
from cradle to grave, in terms of all the economic processes involved. The term economic process
- employed as the converse of environmental process - refers to any kind of process producing
an economically valuable service such as e.g. a manufacturing process, a transportation or a
waste handling. LCA takes as its starting point the service provided by a product system and, in
principle, takes into account as far as possible all the environmental impacts of all the processes
needed to provide this service - from resource extraction, through materials production and
processing, consumption or use of the product, to waste processing of the disposed product.
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LCA is not one specific method, but rather a framework for a systematic and comprehensive
environmental assessment of goods and services. Traditionally, only detailed, quantitative LCAs
have been accepted as "real" Life Cycle Assessments, but both on the methodology side and in
practical applications more simple approaches are being developed and used. Three types of LCA
approaches can be identified (Christiansen ed., 1999):
(i) Life Cycle Thinking is commonly used term for qualitative discussion to identify the stages
of the life cycle and/or the potential environmental impacts of significance e.g. for use in a
design briefer in an introductory discussion of policy measures. The greatest benefit is that it
opens for a holistic view and helps addressing potentially essential implications of a given
decision in a wider scope. Life Cycle Thinking is mainly qualitative and does not support
addressing proportions.
ii) Simplified LCA is an application of the LCA methodology for a comprehensive screening
assessment, i.e. covering the whole life cycle but in an overall manner without a great degree
of detail e.g. using generic data (qualitative and/or quantitative), standard modules for
transportation or energy production - followed by a simplified assessment, i.e. focusing on
the most important environmental aspects.
iii) Detailed LCA is an application of the LCA methodology for a detailed, quantitative life
cycle inventory analysis and life cycle impact assessment of all important environmental
aspects of the product system.
1.2 Simplified Life Cycle Assessment
LCA is commonly perceived as being complex, time consuming and expensive, and many
potential users of LCA are put off as a result of that. However, a "full" LCA, if such a thing
exists, may not be required. In many cases, all that is needed is a simplified, cost effective LCA.
Simplification, however, may affect the accuracy and reliability of the results of the LCA. This
may make the LCA results of little value. What is needed is an LCA that involves less cost, time
and effort, yet provides answers/results that meet the goal of the LCA with a sufficient accuracy.
Thus, the aim of simplification must be to identify those areas within the LCA, which can be
omitted or simplified without jeopardising reliability.
A simplified LCA should cover three steps, which are iteratively linked (Christiansen ed., 1999):
i) Screening: Identifying those parts of the system or of the elementary flows that are either
important or have data gaps
ii) Simplifying: Using the findings of the screening and focusing the work on the important
parts of the system or of the elementary flows. Doing the LCA on these parts.
iii) Assessing reliability: Checking that simplifying does not significantly reduce the reliability
of the overall result.
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In all cases, an LCA study covers four interrelated phases named 1) Goal and Scope Definition,
2) Life Cycle Inventory Analysis, 3) Life Cycle Impact Assessment and 4) Life Cycle
Interpretation. The goal and scope definition should not be simplified, but the other phases can be
simplified by applying methods of screening, simplifying and assessing reliability.
Goal and Scope Definition
All LCA studies should start with a goal and scope definition. The goal and scope definition should
state unambiguously the intended application, including the reasons for carrying out the study and
the intended audience, i.e. to whom the results of the study are intended to be communicated.
Because LCA is an iterative process, the scope of the study may be altered during the study as the
insight increases and/or additional information is collected.
Inventory Analysis
In order to develop effective simplification methods, it is obvious to address the Life Cycle
Inventory Analysis, which is typically the most time consuming phase, with the greatest potential
for savings. The Life Cycle Inventory Analysis phase offers the greatest scope for simplifying
due to its data intensive nature. The majority of methods to simplify the life cycle inventory
analysis are therefore aimed at reducing the data collection requirement.
In comparative LCA studies, it is important to ensure that the system boundaries, data quality and
data sources are as similar as possible for the product systems being compared, otherwise an
incorrect result is likely to be produced. The essential topics that have to be taken into
consideration during simplification are categorised below:
i) Data Priorities: The availability of data is a common problem in LCA. One, therefore, often
has to accept data that are not highly accurate. Some methods of dealing with data gaps are given
below with a descending order of accuracy:
Use calculated/ measured data
Use best available data from a similar product or process
Make estimates, e.g. educated guesses, estimated data from design and engineering figures or
from past experience and process knowledge.
Use data from regulatory requirements/legislative limits
Use qualitative data, e.g. as often done in eco-labelling.
Since primary data that is specific to the product system under consideration is rarely available
and necessitates very extensive data collection, secondary or generic data sources can be used i.e.
from literature or databases.
The problems that arise when using secondary data sources are mainly due to the poor
transparency of the data quality i.e. on how well the data represent the process/system in
question. Also, as final results are typically published, it is difficult to determine the relative
environmental impacts of the various stages of the life cycle and the contributions made by
energy generation, transportation, waste management etc. Difficulties also occur in comparing
different secondary data sources due to variations in data quality and system boundaries. In
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addition, secondary data may not be representative of the whole industry, particularly if the data
is based on only a small sample of the industry.
ii) Use of a limited number of inputs and outputs: Ideally, data should be collected on all the
environmental inputs and outputs, i.e. energy and raw material consumption and emissions to the
air, water and land. However, it may be adequate to focus on only one area, e.g. energy
consumption, if other areas are equal for the compared systems.
Life Cycle Impact Assessment
The life cycle impact assessment phase will be simplified by regarding the choice of
environmental problem themes and issues and the calculation of theme scores and weighting
factors.
One approach is to use impact indicators like for instance 'energy use'. Several simplified LCA .
method use such an approach (Leffland et al., 1997), (Wenzel et al., 1999) using indicators for
energy related impacts, impacts related to chemicals and resource consumption.
Assessing Reliability
The aim of simplification in LCA is to derive results that are sufficiently reliable for the required
purpose, while putting in less effort than in a detailed LCA study. In order to check that a
simplified LCA achieves this, the final step in a simplified LCA needs to be the reliability
assessment.
The reliability of a simplified LCA will depend on the same factors affecting the reliability of a
detailed LCA. The factors can be briefly categorised as:
i) Data quality and relevance, which ensures that appropriate data with respect to time
period, geography and process, are used. In addition to that, the data gabs have to be
filled. This can only be done by expert judgement.
ii) Methodological choices. The overall reliability of the conclusions has to be related to the
goal and scope of the LCA study. For the overall the choice of functional unit, system
boundaries, goal definition, screening arguments are addressed.
iii) In simplified LCA, the data used may often be of lower quality/relevance than of a full
LCA. One way to check the reliability of the final result is to identify the key data (those
that most affect the final result) and then to check their level of uncertainty. This can be
done using sensitivity analysis. This analysis is performed on selected parameters.
1.3 The simplification approach used in the study
The simplified LCA method used in the study was developed by Wenzel et al. (1999). The
approach to simplification is:
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i) to limit the scope of the study by using only very rough estimates for the life cycle stages
of product manufacturing and transportation. The method guideline (Wenzel et al., 1999)
justifies this and guides through how it is done,
ii) to limit the inventory to look at inputs and, thus, use inputs as indicators of outputs. This
has been found to be adequate and often even better than to use data on measured
outputs/emissions,
iii) to base the impact assessment on impact indicators in the categories: 1) materials
consumption, 2) energy consumption, 3) chemicals consumption and 4) "other". This has
proven to be an operational way of covering relevant impact categories.
This approach saves a lot of time and effort and is sufficient for many applications. The
difference between this simplified approach to the standard for detailed LCA's (ISO, 1997) is
illustrated in table 1.
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INVITED PRESENTATIONS
Table 1. The components of a detailed LCA according to ISO 14040 compared to the used
simplification method (Wenzel et al., 1999)
LCA (ISO 14040)
GOAL DEFINITION
- Scope Definition
- Materials
- Manufacture
- Use
- Disposal
- Transport
Inventory Analysis
- Input data
- Output data
Impact Assessment
- Classification
- Characterisation
- (Normalisation)
- Valuation
Interpretation
- Decision
Simplified LCA (Wenzel et al.,
1999)
Goal Definition
- Scope Definition
- Materials
- (Manufacture)
- Use '
- Disposal
- (Transport)
- Inventory Analysis
- Input data
Impact Assessment
- Using aggregated environmental
indicators
Interpretation
- Decision
2. Life Cycle Assessment of water reuse scenarios in moulded pulp production
In pulp and paper industry, reuse of process water is in focus, and most companies strive to
achieve a high degree of recycling without compromising product quality or working
environment conditions. A high degree of recycling, however, improves conditions formicrobial
growth in the system, and to control the growth, companies most often use biocides. Other
problems may follow a high degree of recycling, and the most commonly reported are:
i) Problems related to biocides.
ii) The concentration of salts giving rise to precipitations.
iii) Corrosion of equipment.
In the effort to seek environmental improvements, Hartmann look for options to avoid the use of
biocides but still remain the same degree of water recycling or even increase this. One approach
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INVITED PRESENTATIONS
of achieving this is to remove the substrate of microbial growth instead of combating the growth.
This could be done by an in-line biological treatment the plant. The biological processes may be
aerobic or anaerobic, or a combination of these modes may be used.
2.1 Scenarios for water treatment and reuse
A number of scenarios using in-line aerobic or anaerobic treatment to remove the substrate for
microbial growth in the back-water was studied. They can be implemented in the back water at
different points, either close to the pulper or after the paper machine, see figure 1.
106
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INVITED PRESENTATIONS
There was a wish to include anaerobic treatment, because it was intuitively believed to be
potentially environmentally feasible due to the fact that energy (from methane) is produced
during the COD removal as opposed to aerobic treatment using energy for the COD removal.
Initial modelling in the PC-tool WinGEMS from the company Pacific Simulation allowed an
assessment of the steady-state conditions of the recycled water at various points of intervention of
the treatment plant in-line in the system. The following key information was available:
The water flow varies at the different points in the system. The dry matter concentration of
the pulp is highest in the pulper (4%) and lowest down stream in the paper machine (1.3%).
The water flow is, thus, highest just behind the paper machine. For the studied production
volume (which is just part of the total production), the backwater flow at this point is around
200 m3/h.
For the studied production volume, the COD load from the raw materials amounts to 24 kg/h
of which around 50% is readily degradable in a biological treatment plant. The COD load of
the added chemicals corresponds to around 12 kg/h of which 75% is judged to follow the
product into the oven while 25% stays in the backwater. This COD is judged to be readily
degradable. The load of readily degradable COD to the backwater is, thus, assessed to be
around 12+3 equal to 15 kg/h in total.
If a treatment plant is located to treat the total backwater flow and removes the readily
degradable COD, it is, thus, evident that the steady-state COD concentration in the inlet of
this plant is around 75 mg/1.
This modelling clearly shows that anaerobic treatment is not feasible at this point of intervention,
the concentration of degradable COD is much too low. For an anaerobic plant to be attractive, the
concentration of degradable COD should be at least five times higher, maybe even ten times
higher. Moreover, aluminiumsulphate is added to the system, and the sulphate concentration is
relatively high implying a high hydrogensulphide concentration in the gas.
The idea of segregating the system therefore arose, making a closed loop around the pulper,
where the water flow is much smaller and where sulphate is not yet added. The release of COD to
the water phase from the raw material was tested (Figueroa and Sanz, 2000) and found to be very
quick. After just 10 minutes, all degradable COD was released. This would allow for segregating
the system after buffer tank 1, filtering (and washing) the pulp at this point, and keeping the COD
in a closed loop around the pulper at much higher concentrations - four to five times higher, and
with only a small concentration of sulphate deriving from the raw material. If anaerobic treatment
should be technically/economically feasible at all, it should be at this point of intervention. It
might be necessary to treat the effluent from an anaerobic plant by an aerobic afterpolish in order
to remove volatile fatty acids generated in the anaerobic plant. And it still might be necessary to
have an aerobic treatment in the loop around the paper machine.
Therefore, a number of scenarios were modelled comprising a number of such combinations. One
scenario without segregation of the system in two loops comprising, thus, aerobic treatment of
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INVITED PRESENTATIONS
the backwater in one system. Plus a number of scenarios with anaerobic treatment in a pulper
loop and aerobic treatment in a paper machine loop as illustrated in figure 1. Moreover, the
implications of by-passing part of the water and treating only part of it were modelled and
included as scenarios.
In total, eight scenarios were assessed. It turned out, though, that the significant difference stood
between anaerobic treatment and aerobic treatment in general, and the comparison is, therefore,
shown here on four scenarios only.
2.2 Goal definition
The goal of the study was to compare alternative in-line biological water treatments to effectively
remove the substrate for microbial growth in the process water and, thereby, avoid the use of
biocides.
2.3 Scope definition
Only part of the total production volume at the company was studied, namely a production of
2500 kg/h of final product with a dry matter content of 95%. This is the overall service provided
by the studied system, and this service should be provided unchanged by whatever solution is
taken for the water treatment. Moreover, the service is specified to be provided for 25 years. The
period of 25 years is selected, because it corresponds to the life time of the treatment plants.
In order to effectively remove the substrate for microbial growth in the system, the treatment
plants would have to remove around 15-20 kg/h COD equivalent to around 3,300 - 4,400 tons
COD per 25 years. This removal of COD from the process water corresponds to the daily COD
addition with raw materials and chemicals and has been judged to be sufficient to avoid the use of
biocides.
All candidates for a solution should provide this service, and should, moreover, be comparable on
a number of other properties as well, see table 2.
Functional unit
Table 2 illustrates the qualitative and quantitative properties that the treatment plants used in the
scenarios have to fulfil.
Table 2. Functional unit of the studied scenarios for water treatment and reuse
Qualitative
properties
Quantitative
properties
Duration
Allow to operate the system without the use of biocides
Low manpower requirements for operation and maintenance
Not increase the amount of nutrients available for microbial growth
in the overall system
The removal of 15-20 kg/h COD continuously at the water
conditions of the system
7 days a week for 25 years
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INVITED PRESENTATIONS
The reason for specifying that the solutions should not give rise to an increase in available
nutrients is, that nutrients, especially nitrogen, has been found to be limiting to the growth. A
nutrient increase might, thus, counterweigh the COD removal to some extent.
Secondary services of in-line process water treatment plants
Besides providing the service described above, the aerobic and/or anaerobic plants in question
will lead to the secondary services through the following by-products:
Energy production from methane
Sludge as compost and/or energy recovery source
A treatment plant would, thus, not only provide the service of water treatment for which it was
intended, but also other useful services. The practical implication of the fact that these other
services are provided would be, that alternative ways of providing these services would be
substituted. In other words: if methane is produced and used, e.g. in Hartmann's own heat &
power plant, which already runs on gas, natural gas would be substituted. And if biological
sludge from the plant is being incinerated in a municipal waste- or sludge incineration plant from
which energy is utilised (which is the case for such plants in Denmark), district heating and
electricity produced by this sludge incineration will substitute conventional fuels for producing
these utilities.
Of course, such substitutions caused by the secondary services imply environmental benefits, and
it often turns out to be the most important issues in the study, because the flows related to these
secondary services are relatively large. This turns out to be the case in this study as well, just
consider the flow of 3,300 - 4,400 tons COD/25 years compared to the flow of materials for
constructing the treatment plants. In an anaerobic plant, this flow of COD is either turned into gas
or biomass (sludge) both giving rise to energy production in a subsequent incineration.
Another important flow being affected by the treatment plant is the final product:
Removing COD from the process water of course implies that less COD will follow the
product into the oven. This will lead to a slightly lighter product, as the COD is not
contributing to the product's intended properties, wherefore the weight loss will not be
compensated. As part of the product will be incinerated end-of-life in incinerators with
energy utilisation, this will imply a loss of energy production at this point, which has to be
supplied by conventional energy sources instead.
As the COD removal is specified in the functional unit, the implication of this will be the same
for all solutions. But the significance of it will have an influence on the magnitude of the
difference between the scenarios, and therefore it is included.
Impact categories
There is no difference in chemicals consumption between the scenarios. On the contrary, the
functional unit implies the same impact on use of biocides from all scenarios and other chemicals
are not judged to be affected. The main difference between the scenarios lies in the implications
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on total energy consumption. No other impact categories are believed to be significantly different
from one scenario to the other. The study is thus a comparison on energy, taken as primary
energy consumption.
2.4 Inventory Analysis
Various data sources were used:
Basically, the production data was gathered from the company, Hartmann, itself.
Data on the treatment plants were taken from a number of sources having reported data on
wastewater treatment in anaerobic and aerobic plants. The essential data are electricity
consumption by the plants and sludge and methane production. The data quality of these data
is believed to be quite good.
As earlier described, the data for characterisation of process water are calculated by using
simulation that is made in a program called WinGEMS from Pacific Simulation. The model is
based on a steady state mass balance of water, suspended solids, sulphate and COD.
Specifications are production rate, water flow constraints, sulphate addition during
production, suspended solids concentrations and the COD release from the pulp with time.
Data on materials production for the various plants and on disposal processes were taken
from the EDIP LCA database (Frees, 1996). The data quality of these is good considering that
only energy data is used in the study.
The mass and energy flows related to each scenario were compiled, see table 3. The table
compares four scenarios: two scenarios in which the COD removal is done aerobically on the
backwater after the paper machine (one with a by-pass), and two scenarios in which the COD
removal is done anaerobically (in two different treatment plant types) in a closed pulper loop. In
the two anaerobic scenarios, 20% of the COD is anticipated to be removed in an aerobic
afterpolish.
Ill
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INVITED PRESENTATIONS
Table 3. Reference flows per functional unit in two aerobic and two anaerobic scenarios
none. UASB - Upflow Activated Sludge Blanket, ICR = Internal Circuit Reactor
Flows
Unit
Scenario
Aerobic
Full
With by-pass
Anaerobic
Full
UASB ICR
MATERIALS
Concrete
Cast iron
Steel
Stainless Steel
Copper
Aluminium
PE
kg
kg
kg
kg
kg
kg
kg
7500
530
1000
2100
220
-
2630
3750
510
520
2100
120
110
700
21750
770
1230
2260
200
190
700
21750
770
1230
7550
200
190
700
USE
Electricity
Phosphorus
Nitrogen
Product COD incineration
CREDIT
Wastewater COD
degradation
Methane
Sludge (dry matter)
MWh
kg
kg
kg
10000
25600
128600
1700000
8000
21800
109200
1700000
2000
14800
73900
1700000
2000
14800
73900
1700000
kg
kg
kg
-2800000
-:
-1073100
-2800000
-
-908850
-2800000
-854100
-547500
-2800000
-854100
-547500
DISPOSAL
Shredding
Manual Separation
Incineration
Landfill
kg
kg
kg
kg
50
6000
2370
6270
26
4200
640
3250
44
6800
640
17360
44
11900
640
17470
REUSE/RECYCLE
Remelting
Stainless steel
Al/Silicon
Copper
Steel
Concrete
kg
kg
kg
kg
kg
2060
-
50
1530
-
2060
-
26
1520
-
2210
-
44
3870
-
7400
-
44
3870
-
CREDIT
Stainless Steel
Al/Si
Copper
Steel
PE incin. (energy credit)
Concrete
kg
kg
kg
kg
kg
kg
-2060
-
-50
-900
-2370
-
-2060
-
-26
-470
-640
-
-2210
-
-44
-1100
-640
-
-7400
-
-44
-1100
-640
-
Materials
As is evident, the anaerobic scenarios requires more materials that the aerobic, because the
needed hydraulic retention time in the anaerobic reactor is much higher than in the aerobic
reactor. This implies a material consumption of the anaerobic scenarios of around twice the
amount of the aerobic scenarios - equal to around 14 tons - primarily in concrete and steel.
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Manufacture
No significant differences are believed to lie in the manufacture of the plant, compared to
materials consumption, use and disposal of the plant, and the manufacturing stage is not included
at all.
Use
Data on electricity consumption of an aerobic biofilter in another aplication is known to be
around 2.5 kWh per kg COD removed, and this figure is used here. As seen, it amounts to 10,000
MWh for the full aerobic scenario compared to 2000 MWh for the anaerobic scenarios, being the
electricity used for aeration in the aerobic afterpolish of 20% of the COD.
Nitrogen and phosphorus addition to the water just prior to the plants are needed for optimal
COD removal, and this can be done without increasing nutrient content of the effluent of the
plants as the nutrients are fully taken up by the biomass of the plants. Evidently, the aerobic
scenarios need more nutrients than the anaerobic ones, because of the higher sludge production of
the aerobic plants.
In today's steady-state situation, COD in the circulating process water is around 3000 mg/1.
Moreover, around 40% of the water leave the system through the ovens and the rest via the
wastewater effluent. This implies that 40% of the COD follows the product, equivalent to around
1700 tons per 25 years. As a conservative estimate, this is taken as being fully incinerated in
order to see the significance of this. The flow is equal for all scenarios, but is included because it
is altered compared to today's reference and in order to see the significance of it compared to the
differences between the scenarios.
The rest of the COD leaves the system via the wastewater, where it is first let to Hartmann's own
wastewater plant and subsequently to the municipal plant further downstream. In these plants,
electricity is used to remove the COD. This flow is, of course, also equal for all scenarios,
because the COD removal is specified in the functional unit, but it is included for the same
reasons as above.
Methane production is of course only present in the anaerobic scenarios, and here in an amount of
around 850 tons per 25 years equivalent to around 1.2 mill. m3. Sludge production is highest for
the aerobic scenarios, judged to be twice as high (remember the 20% aerobic COD removal in the
anaerobic scenario), equivalent to around 1000 tons of sludge dry matter per 25 years.
Disposal
On disposal, concrete will be deposited, metals primarily recycled and plastic incinerated as
seen from table 3.
Most significant flows
As evident from table 3, already at this Inventory Analysis phase of the LCA, the flows of the
operation of the wastewater treatment plants are seen to be the significant flows. The other life
stages of the plants seem to be of no significance to the total burdens from the scenarios. The key
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is the fate of the COD in the scenarios, and the energy flows this fate gives rise to. This is
subsequently assessed in the impact assessment phase.
2.4 Impact Assessment
Data on energy consumption of the materials, energy efficiency of electricity production, energy
utilisation in waste- and sludge incinerators etc. has been available (Frees, 1996), (Wenzel et al,
1999), and the mass-and energy flows per functional unit as presented in table 3 have been
translated into consumption of primary energy. Primary energy is the energy content of the
resulting fuels entering the system, when all flows are followed to the initial extraction of raw
materials and fuels from ground.
The primary energy flows of the four compared scenarios are shown in table 4.
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Tabel 4. Primary energy flows per functional unit in two aerobic and two anaerobic
scenarios
- = none. UASB = Upflow Activated Sludge Blanket, ICR = Internal Circuit Reactor
? = no data available
Flows
Unit
Scenario
Aerobic
Full
By-pass
Anaerobic
Full
UASB
ICR
MATERIALS
Concrete
Cast iron
Steel
Stainless Steel
Copper
Aluminium
PE
MJ
MJ
MJ
MJ
MJ
MJ
MJ
15,150
30,475
35,028
181,040
20,000
-
210,000
7,496
29,440
18,284
168,080
11,000
19,000
56,000
43,500
44,160
43,050
180,720
18,000
32,000
56,000
: 43,500
44,160
43,050
604,320
18,000
32,000
56,000
USE
Electricity
Phosphorus
Nitrogen
Product COD incineration
MJ
MJ
MJ
MJ
36,000,000
9
?
30,600,000
28,800,000
?
?
30,600,000
7,200,000
9
9
, 30,600,000
. 7,200,000
?
?
30,600,000
CREDIT
Wastewater COD
degradation
Methane
Sludge
MJ
MJ
MJ
-25,200,000
.
-10,731,000
-19,000,000
-9,088,500
-25,200,000
-50,400,000
-5,475,000
-25,200,000
-50,400,000
, -5,475000
DISPOSAL
REUSE/RECYCLE
Remelting
Stainless steel
Copper
Steel
MJ
MJ
MJ
60,000
2,500
23,000
60,000
1,300
23,000
66,000
2,200
58,000
222,000
2,200
58,000
CREDIT
Stainless Steel
Copper
Steel
PE (incineration)
MJ
MJ
MJ
MJ
-60,000
-4,500
-900
-71,000
-60,000
-2,300
-470
-19,000
-66,000
-4,000
-1,107
-19,000
-22,000
-4,000
-1,106
-19,000
Z LIFE CYCLE
MJ
31,000,000
31,000,000
-43,000,000
-42,000,000
2.5 Interpretation
The significance of the use stage of the plants is now fully evident, and it is seen that the
difference between the aerobic and the anaerobic scenarios is quite significant as well. A
magnitude of 74,000,000 MJ is equivalent to almost 2000 tons of oil. In monetary terms, this
amounts to around 2.2 mill DKK or around 0.3 mill US$ with the Danish oil-price of 1,1
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INVITED PRESENTATIONS
DKK/kg of fuel oil (0.14 US$/kg). Per years, this is a quite low economic difference - around
12,000 US$/year.
Hartmann sees around the same difference, namely the difference between electricity
consumption of the plant and methane production, and this amounts to around 80,000,000 MJ/25
years, the yearly difference on operation costs, thus, being around the 12,000 US$/year.
It is, therefore, clear that the anaerobic plant should not be much more expensive than an aerobic
one, if economy is decisive. Moreover, an aerobic plant is less troublesome and time consuming
to run and gives less odour problems in the factory. Technical criteria are, therefore, in favour of
the aerobic plant.
References
Christiansen K (ed.) (1999): Simplifying LCA - Just a Cut? SETAC Europe Working Group in
Simplification of LCA, 1999.
Wenzel H, N Caspersen and A Schmidt (1999): Life Cycle Check - A Guide. Institute for
Product Development, 1999 (In Danish). An English version of 2000 exists.
Leffland K and H Kasrgaard (1997): Comparing Environmental Impact Data on Cleaner
Technologies. European Environment Agency, Technical report, no. 1, December 1997.
Figueroa M C and D Sanz (2000): Laboratory Scale Characterisation and Simulation of Pulp and
Process Water of Moulded Pulp Production. Identifying Options for Preventing Growth of Micro-
organisms by Removing their Substrate. Master Thesis, Technical University of Denmark, IPT-
098-00.
Frees N and Pedersen MA (1996): EDIP Unit Process Database. Ministry of Environment and
Energy, Danish Environmental Protection Agency. Copenhagen 1996. ISBN 87-7810-547-1
International Organisation for Standardisation, ISO (2000): Environmental management - Life
cycle assessment - Principles and framework. International standard ISO14040: 1997 (E).
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COMPUTER TOOL CAFE
INTRODUCTION TO COMPUTER TOOL CAFE
On initiative of the pilot study directors and the Danish host, participants involved with
development or working with PC-tools and databases supporting cleaner production were
invited to present and demonstrate these tools. The computer tool cafe was organized as a hands-
on demonstration event. Descriptions of the demonstrated tools are presented here.
Computer Tool Cafe
CHEMICAL LIFE CYCLE DATABASE.
Demonstrated by
Michael Overcash, USA
Description:
Extract from the abstract to Conception, J-G., Seungdo, K, and Overcash, M.R. (2000):
Methodology for Developing Gate-to-Gate Life Cycle Inventory Information. Int. J. LCA, 5
(2000)
This work presents an option to generate gata-to-gate life cycle information of chemical
substances, based on a transparent methodology of chemical engineering process design ( an ab
initio approach). In the broader concept of a life cycle inventory (LCI), the information of each
gate-to-gate module can be linked accordingly in a production chain, including the extraction of
raw materials, transportation, disposal, reuse, etc. to provide a full cradle to gate evaluation. The
methodology aims to help the LCA practitioner to obtain a fair and transparent estimate of LCI
data when the information is not readily available from industry or literature. The LCI
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COMPUTER TOOL CAFE
information from this methodology can be used more directly in exploring engineering and
chemistry changes to improve manufacturing processes.
Further information: Overcash, M. Chemical Life Cycle Inventory Library, North
Carolina State University, Raleigh, N.C. 27695-7905, 2000. E-mail: nvercash@.eos.ncsu.edu
CAPEC SOFTWARE TOOLS FOR CHEMICAL AND PROCESS SYSTEM ENGINEERING.
Demonstrated by
Peter Harper, Denmark
Description
ProCamd: Program based on computer aided molecular design that can be used for solvent
selection, search and design
ProPred: Pure component property prediction package. An easy to use program package that is
able to predict pure component properties of most organic compounds from molecular structural
information.
ICAS: An integrated computer aided system through which various problems related to a
process, product and/or operation could be investigated and solved efficiently, consistently and
reliably. Various computer aided tools such as proCamd, proPred, and design tool-box have been
integrated with databases and simulation engines within ICAS.
CAPEC database: A database of pure component and mixture properties and, solvent properties
for a very large range of compounds, including amino acids and steroids.
Further information: Rafique Gani, Deparment of Chemical Engineering, Technical University
of Denmark, e-mail: rag@pot3eve.kt.dtu.dk or www.capec.kt.dt.dk
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COMPUTER TOOL CAFE
Explaining the EDIP LCA-software needs standing argumentation
THE EDIP (ENVIRONMENTAL DESIGN OF INDUSTRIAL PRODUCTS) LIFE CYCLE ASSESSMENT
TOOL.
Demontrated by
Morten Als Pedersen, Denmark
Description
The EDIP-PC tool, betaversion 2.11 was released by the Danish Environmental Protection
Agency in June 1998. The betaversion contains the necessary functionality to support the work
process of life cycle based environmental assessment of products and systems. The betaversion
2.11 system contains three functions:
the Unit Process Database,
the Modelling Tool and
the Calculation Facilities.
The EDIP PC-tool contains the neessary functionality to fully support the work process in life
cycle based environmental assessment. The in-built Unit Process Database contains approx. 750
process cards, covering all types of systems. Approx. 200 of these are in the category
"substances" leaving over 500 unit processes, which are categorized in: materials, auxiliary
materials, transport systems, production processes, disposal systems/scenarios, energy systems,
etc. Unit processes are the basic building blocks of the EDIP Life Cycle Model. The quantitative
part of the process data is scalable, making it possible for students and other users to apply the
data in other contexts.
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COMPUTER TOOL CAFE
Env. Result - Calc.lfor OPRODUKT
Calc. for OPRODUKT
0,0000
0,5000
1,0000
1,5000
2,00^,
,01; Global warming.mPE
02: HumarrToxicity mPE
.Q3:ECO-toksicity mPE
04: Persistent tokslcity mPE
05:Bulk waste mPE,
08: Hazardous waste mPE
07:RadioActive waste mPE
08: Slag and ashes mPE
,09: Acidification mPE
10. Photochemical ozone-1 (low NOx)
mPE
11: PhotQcheraical ozbne-2 (high
NOx) mPE
12: Nutrient enrichment mPE
[Official
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Scale
\TextXExlemal environment Impacte^Working environmentXResources ^Calculation data^Parameters/
Figure: screen dump from the EDEP tool showing grachical desplay of results
The modelling process is done in a Windows file-manager-alike structure. With the calculation
facilities it is possible to calculate an inventory or to assess the environmental impacts for the
whole system or any part of this. Above figure shows a graphical display of results.
Further information: Morten Als Pedersen, Department of Manufacturing Engineering and
Institute for Product Development, map@,ipl.dtu.dk.
Danish version of software and software licence can be obtained at Danish Environmenal
Protection Agency Center for Information http://www.mem.dlc/butik/ Information on English version
can be obtained at Department of Manufacturing Engineering and Institute for Product
Development, cm@ipi.dtu.dk
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COMPUTER TOOL CAFE
PARIS II - AN ENVIRONMENTAL FRIENDLY CHEMICAL SUBSTITUTION IN INDUSTRY.
Demontrated by
Dan Murray, USA
Description
PARIS II is a solvent design software. It has been completed and transferred to the private
enterprise TDS, Inc. (New York City) for marketing. Beta testing has just started with 50
companies participating. PARIS II program designs, in the computer, solvent mixtures with
reduced environmental impact (such as toxicity and other measures) that match the property
profile of the solvent mixture being used currently.
User inputs are chemical composition of solvent, operating conditions, and the tolerance ranges
for solvent physical parameters including environmental parameters and the output of the
software analysis is a ranked list of solvents based on closeness in meeting the specified criteria
PARIS II can be used by the designer or producer of solvents or by the solvent user or decision-
maker to evaluate the effectiveness and environmental impacts of solvent substitutes or to
develop custom solvents to meet specific needs based on chemical properties and environmental
considerations.
Further information:
Point of contact at USEPA is e-mail: cabezas.heriberto@epamail.epa.gov.
PARIS II is further described in the paper dated September 16, 1999 entitled Environmental
Improvement Toolbox, published by EPA, National Risk Management Research Laboratory,
Sustainable Technology Division, Systems Analysis Branch. The toolbox contains a description
of fifteen pollution prevention/environmental analysis tools, and is continually updated as tools
are refined and new tools added. Point of contact at EPA is e-mail: hoagland.theresa@,epamal.epa.gov.
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POSTER PRESENTATION
POSTER PRESENTATION-NATO FELLOW
Application of life cycle assessment and sustainable process index to process design
Teresa M. Mata and Carlos A. V. Costa LEPdE - Laboratory of Energy, Process and
Environmental Engineering Chemical Engineering Department, Faculty of Engineering,
University of Porto Rua dos Bragas, 4050-123 Porto, Portugal
In this work a general approach for the flow and generation of potential environmental impacts
through a chemical process is introduced. Sustainable process indexes (SPI) and Life cycle
assessment (LCA) are powerful and general analytical tools. They help to identify more
sustainable solutions in the process industries and assess their potential environmental impacts
(PEI). In this work a process simulation model is presented as case study and analysed from an
environmental impact perspective. It was built using the process simulation program: PRO/IIฎ of
Simulation Sciences Inc.
Introduction
Companies facing the task of promoting sustainable development must have ways of measuring
progress towards that goal. The use of SPI is a simple way of substituting all the available
information in order to support a decision making process. It is based on the balancing of a
process over material and energy flows, i.e. an environmental input-output analysis and gives a
picture about the environmental status of an activity. LCA is widely accepted as a methodology
that enables quantification of environmental impacts and evaluation of the improvements
throughout the life cycle of a process, product or activity.
Design and retrofit of processes is a creative activity whereby we generate ideas and then
translate them into equipment and processes for producing new materials or for significantly
upgrading the value of existing materials. The purpose of design and retrofit of processes is to
find the best process flowsheet, i.e., to select the process units and interconnections among them
and estimate the optimum design conditions. There are some constraints that must be considered
during the process design including safety, environmental, operational, economic and others.
Therefore tools are needed for design decisions.
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POSTER PRESENTATION
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In the design and retrofit of processes with environmental care, some existing or new
technologies could be integrated to minimise the wastes generated by the process (e.g.,
absorption, adsorption, condensation, membrane process, a new catalyst, expert systems) or
simply by recycling and reuse some waste streams. A list of alternative solutions can be proposed
for each decision, therefore generating a list of process alternatives. In many cases, no heuristic
rules or guidelines are available to make decisions about the structure of the flowsheet and/or to
set the values of some of the design variables. Using sustainable processes indexes, the penalty
paid in the time required to screen more alternatives is not very high and thereby an increase in
efficiency could be obtained. The use of indexes or indicators are not new; several authors have
implemented them to evaluate the potential impact that chemical emissions have on the
environment.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
INTRODUCTION
Product Oriented Environmental Measures and Integrated Product Policy (IPP) in the
European Union was the special topic chosen for the Copenhagen meeting. One day of the
meeting was allocated to presentations within this subject and presentations were given by
industrial companies, academia and authorities. In the following abstracts, papers or summaries
covering the special topic presentations are given. A specially edited and supplemented version
of the full special topic theme and discussions are planed published by an international publishing
house. This publication should be available ultimo 2001/primo 2002. The abstracts presented
here are grouped under the following headings: authorities, academia and industrial companies
AUTHORITIES
A CHALLENGE FOR MODERN SOCIETY: UNCOUPLING GROWTH AND POLLUTION
Steen Gade, Director-General of the Danish EPA
Strandgade 29
DK-1401 Copenhagen K
Denmark
Phone: +45 32 66 01 00
Fax: + 45 32 66 0479
e-mail: mst@mst.dk
Abstract
Steen Gade addressed the issue of uncoupling economic growth and increased pollution. The
point of departure was the European Unions efforts to integrate environmental policy and sector
policies. Another important point was the study by European Environment Agency (EEA) on the
state of the environment and its future development. Thus having addressed the necessity for and
the political commitment to uncoupling economic growth and pollution, attention was drawn to
challenges that must be overcome in order to secure a sustainable development. Knowledge, tools
and principles that can be helpful include the concept of ecological space and the ideas behind a
Integrated Product Policy (IPP). IPP uses a number of different elements and tools that is
expected to support this goal e.g. sector integration, active involvement of relevant parties such as
companies, retailers, consumers etc., market based approach, product information, lifecycle
thinking just to mention a few of the more central elements.
Summary of the presentation
Decisions in Helsinki 1999
The EC Amsterdam Treaty states that environmental protection requirements must be integrated
into the definition and implementation of the Community policies and activities. The aim is to
promote sustainable development. In June 1998 in Cardiff the European Council initiated a
process of integration. All relevant formations of the Council were encouraged to establish
strategies for integrating environmental concerns and sustainable development in their respective
policy areas.
Special focus sectors are transport, energy, agriculture, industry and internal market development.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
In December 1999 in Helsinki, the European Council again had integration and strategies on the
agenda. One major objective is improving the eco-efficiency of production and consumption in
order to break the link between economic growth and adverse environmental effects. The succes
of integration can be measured by the extent to which the sectors de-couple their economic
activity from environmental impact.
EEA 1999
In 1999 the European Environmental Agency (EEA) made its third state of the environment
report: "Environment in the European Union at the Turn of the Century" about the state of the
environment in Europe after 25 years of EU environmental policies and the 5th Environmental
Action Plan.
In EU only air pollution parameters have attained absolute uncoupling from GDP since 1990. To
achieve sustainable development an absolute reduction in the total load on the environment is
necessary with regard to pollution parameters. And relative- or absolute decoupling are key
issues.
Environmental space
It is obvious that there are limits to amount of resources that can be consumed in Europe, if the
Europeans are to share fairly with other parts of the world. Today approx. 20% of the world's
population is responsible for approx. 80% of the resource consumption. Factors 4 and 10 have
been mentioned as the orders of magnitude needed to increase eco-efficiency and decrease
environmental pressure to obtain sustainable development. Environmental space is not yet an
instrument in regulation, but it promotes policy and useful technical analysis related to given
resources.
Sustainable development
As presented in UN's Brundtland report "Our common future" the three pillars of sustainable
development are economic development, social development and environmental protection. Since
the world-wide political commitment in 1992, sustainable development has been on the
international political agenda, and in these years before Rio+10 in 2002 it sets national agendas in
Denmarks as in many other countries.
A major challenge when dealing with products and processes is to make a balanced assessment of
social, economic and environmental impacts. The market plays a major role in achieving
sustainability. But the market will not provide sustainability by itself; Integrated Product Policy
(IPP) may well be a corner stone in getting there.
IPP and the Life Cycle approach
It is widely accepted that use of products poses a potential thread to the environment. It is also
more and more accepted that the life cycle approach is required to get a full picture of all the
potential problems connected to a specific product. It is not possible to use standards, rules, and
legislation for each product put on the market. IPP must be a voluntary process and we have to
change attitudes by putting IPP and cleaner products on the public agenda. But how do we get
from attitude to action where the manufacturer not only wants to create cleaner products, but
actually has the ability to do so. Many countries have put many resources into establishing
methods and tools for Life Cycle Assessment. In Denmark we developed a life cycle assessment
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
tool known as the EDIP methodology, PC-tool and database, but getting these tools into everyday
life of companies is a problem with no easy solutions. To provide knowledge, tools as ecolabels,
environmental product declarations and databases are necessary but traditional activities for
authorities. Another thing is actually influencing the market by stimulating sales of specific
environmentally sound products by influencing consumers and by green public procurement.
Such activities are new and challenges our public way of thinking. Nevertheless, we have to find
ways to meet the challenge and find our role not as bystanders but as actors on the market.
Dt coiipluuoFป)oซtii mil
t n\ irpoiurnfil pi tssuri
Steen Gade, Director General, Danish EPA giving a presentation on De-coupling of growth and
environmental pressure
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
THE DANISH PRODUCT ORIENTED ENVIRONMENTAL INITIATIVE - SCOPE AND CHALLENGES
Preben Kristensen, Head of division for Cleaner Products,
Danish Environmental Protection Agency
Strandgade 29
DK-1401 Copenhagen K
Denmark
Phone: +45 32 66 01 00
e-mail: mst(3>jnst.dk
Introduction
The understanding of the complexity of the sources for environmental contamination
and the development of methodologies for reducing the contamination has significantly increased
during the last decade. Few years ago an end-of-pipe approach for reducing the contamination
from point sources was one of the corner stones. Within the last 15 years cleaner technology
measures has been introduced as a source oriented approach for reducing the amount and
increasing the quality of the waste. Both cleaner technology and end-of-pipe methodologies have
significantly improved the environmental quality of point sources. To-day we have realised that a
further improvement of environmental quality necessitate a focus on all life stages of products -
from cradle to grave - in addition to the end-of-pipe and clean technology approach.
An approach which focus a prioritised improvement of the environmental quality of all stages of
the life cycle of products calls for new thinking not only by the industrial sector, but also by the
authorities. While the end-of-pipe era was governed by traditional authority regulation and
control, a holistic life cycle approach in addition call for an extended co-operation between the
authorities and all stakeholders involved, as the traditional market forces need to be addressed. Of
crucial importance for implementing this new approach is, 1) that the producers are producing
and marketing environmentally cleaner products and are passing on credible and sufficient
information regarding the environmental properties of the products to the down stream users and
2) that the down stream users request and purchase such products irrespective of the possible
higher costs (and thus set priority to environmental quality in parallel to costs and use quality).
One of the central issues of the Danish government's Nature and Environmental Policy report in
1995 /!/ was the concern about the environmental impact from production, use and disposal of
products. The report stated, that the serious environmental problems, global as well as local, call
for the environmental protection measures provided so far to be supplemented by measures
dealing with all aspects of product life-cycle. The background for this statement was, that the
various measures implemented for reduction of the environmental impact - waste treatment, clean
production processes, environmental audit systems, a.o. - would only reduce the environmental
load to a certain degree and that there in addition was a need for addressing other stages in the
life of products and to set the environmental quality of products on the agenda for both producers
and consumers in line with other quality aspects.
As a follow-up of the above report, the agency issued in 1996 a document for initiating a
discussion between all stakeholders on the objectives and means for an Intensified Product-
oriented Environmental Initiative (a "green paper") 111. The document set focus on the national
and global environmental problems, propose overall environmental goals for such an action and
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
analyse the needed framework and terms for the market and for the stakeholders. In this light the
document propose a number of new activities as well as a consolidation of present activities with
the aim to increase the production and use of environmentally cleaner products.
In February 1998 a Product Oriented Environmental Action Plan was issued (1998-2002) /3/.
The document outlines a number of initiatives for the support of an integrated product policy:
Development of pragmatic tools for Life Cycle Assessments (LCA) for the design and
improvement of cleaner products; systems for facilitating information flow within the chain of
goods from industry to the users regarding such products (e.g. eco labels, environmental product
declarations); activities for promoting green public procurement, among others by elaboration of
environmental product guidelines for public purchasers; activities for promoting market co-
operation amongst others by the development of stakeholders panels within certain product
classes; etc. The Product Oriented Environmental Initiative, which focus all major life stages of
the product, is supported by a financial support program of approx. 120 million DKK a year
(2000 budget).
Also Sweden has launched a number of initiatives with the overall goal to approach a sustainable
development and thus to reduce the environmental impact (including the use of resources) from
products in its entire life cycle. The Swedish Government proposal for promoting a sustainable
development was presented to the Parliament in may 1998 /4/. Since then Sweden has increased
its activities within this area and Sweden has this spring announced, that the Integrated Product
Policy will be one of the priorities during its Presidency of the EU in spring 2001
A Nordic co-operation in the area of product-oriented environmental policy under the Nordic
Council of Ministers was initiated in 1996. A seminar on this issue was belt in Salsobaden in
Sweden in January 1998. The objective of the seminar was to promote a common Nordic
understanding of the framework and the elements of the product-oriented environmental policy
and to discuss measures for promoting this environmental policy. Based on the recommendations
from this seminar a cross sectorial working group was formed under the Nordic Councill of
Ministers in 1999. The objective of the group is to develop a common Nordic position on
Integrated product policy (IPP) and to promote a further development. In february this year a
technical study regarding the provisions for a common Nordic IPP was presented at another
seminar at Salsobaden.
In Marts 1998 EU issued a consultant report for debate on Integrated Product Policy (IPP) 151.
Based on an analysis of national and international developments in this area, elements of a
possible EU-policy was proposed. The document was later discussed at an EU-workshop and in
May 1999 the EU Member States gave the Commission a broad mandate to initiate the process
for the elaboration of an integrated product policy in the European Union. The Commission
intends to publish a Green Paper on a strategy on IPP during 2000. Sector integration is an
important condition for the successful development of IPP. It is therefore important to note, that
not only the Nordic countries ministry for consumer, for industry and for environment is
represented in the Nordic cross sectorial group but also the EU Commissioner for Enterprise
support the idea for an Integrated product policy.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Challenges for promoting an environmental product policy
An important challenge is to move the focus from fragments of the life cycle of products ( eg.
clean production processes, waste handling technology) to a prioritised action based on an
analysis of the environmental aspects of the entire life cycle of the product: Use of raw material,
emission during production and manufacture, environmental aspects of transportation and
product use including the services linked to the use and finally waste handling, reuse/recycling
and disposal.
Another important challenge is to facilitate credible and sufficient information of the properties
and proper handling of the products to all the stakeholders involved in the product life chain. The
request for proper information will lead to a placement of an extended responsibility to producers
and manufactures for the environmental properties of the product.
A third challenge is to promote the creation of a market for cleaner products. The starting point
may be the national market but the succes will depend on the international implementation.
Although the focus most often are on private households as buyers of goods, all steps of the
supply chain comprises purchasers. It is a major challenge to increase and to maintain the
environmental issue as a quality parameter in parallel to traditional quality aspects and cost of the
product. To maintain the focus is perhaps the most difficult issue and require that the
improvement of the environmental quality is accepted to be significant by the consumers.
Finally the challenges for the authorities are to elaborate a framework for the product policy, to
provide good conditions for a green market and to promote the co-operation between
stakeholders and relevant authorities.
Initiatives in Denmark for supporting an intensified product-oriented environmental policy
The array of initiatives taken by the Danish EPA according to the Product oriented environmental
action plan are briefly outlined below.
Development of know-how and methods
The LCA method: Environmental Design of Industrial Products (EDIP) 16,11 is to be further
developed: Improvement of the Chemical assessment methodology and the assessment of the
waste aspect. An important activity will be to elaborate operational guidelines and tools for the
various stakeholders. In addition to the EDIP-method a data-base has been developed covering
data of interest for many industries in their LCA-work. This data-base will be further
supplemented amongst others by data generated in projects financed by the Agency. Also the
transfer of knowledge within this area to major stakeholders (designers, enterprises, public
purchasers a.o.) are prioritised. The Agency is presently analysing the future organisational
structure to provide a long term availability of up-dated operational LCA tools as well as high
quality LCA data to the users.
Information systems
It is the intension of the Agency to initiate the development of information systems which is
targeting the various stakeholders and taking into account the nature of the product groups.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Presently the EU-eco-label (the "flower") and the Nordic "Swan" has been implemented, partly
organized by the Danish eco-label secretariate. The eco-label is not able to cover all type of
products and the need for information by all stakeholdres. The Agency is therefore presently
considering other types of information systems and has taken the initiative to analyse frames for a
national business to business environmental product declaration system based on the provisional
ISO documents (type III) (3. Part certified system, LCA framework).
To support the green public procurement, environmental guidelines for a number of product
groups are elaborated. During a 5 year period 50 product groups are to be covered by such
guidelines. The guidelines are giving advises to purchasers (private or public) regarding the
major environmental impact of the specific product group in a life-cycle framework and
identifying the areas where producers should be able to improve the environmental quality of the
product and offer such products to the purchasers.
Creating markets
One of the major challenges of the integrated product policy is to promote the development of a
significant market for green products. Without a significant market the producers are not likely to
initiate or to increase a production of clean products. A crowbar for the opening of the market is
the public procurement. In Denmark the value of public procurement is amounting to more than
100 billion DKK a year. The use of a fraction of this sum for green goods will make a significant
difference for the market and thus be a kick starter for the product policy. At the same time, the
very attitude by the public will presumably influence also the attitude of private households.
Since 1995 a ministerial circular has obliged governmental institutions to elaborate a policy for
green procurement. Also in a number of counties and municipalities green public procurement
has been organised.
In 1998 an agreement was made between the Minister of Environment and Energy and the
municipalities and counties to set up a common framework for public procurement for the entire
public sector. The agreement also include an objective to set up overall goals for green
procurement and to develop report format and benchmark indicators for a future reporting of the
progress of the green procurement in relation to those goals. Some of the initiatives in 2000 for
promoting the entire public sector to increase the purchase of green goods will be focussed on 4
product areas: Electronics, furniture, textile detergents and textile cleaning services, cleaning
agents and cleaning services.
The success of an integrated product policy is very much dependent of the establishment of an
international market. Therefore the Danish EPA find it very important to participate actively in
the development of international policies within this area. To increase and maintain an
international green market, a number of aspects should be focused: The development of high
environmental quality CEN product standards are important for the possibility to improve the
environmental quality of products. Also the EU tender directives for public purchase should give
better possibility for taking environmental considerations into account
Stakeholder co-operation
It is important that the major stakeholders are invited for a co-operation on these issues. The
Agency therefore initiated a number of round-table discussions on the means and methods for an
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
integrated product policy. In 1998 product-panels was established for goods transportation,
textiles and electronic devices and in 2000 a new panel will be formed for "buildings". The
members of the panels are major stakeholders representing all important stages of the product
lifecycle (producers, users, waste managers, authorities). The 3 panels formed in 1998 have
elaborated action plans for promoting a green market suggesting initiatives related to the specific
product areas and have taken a number of initiatives according to these plans (Workshops,
information materials, development projects). The Textile panel has established an environmental
information centre and is planning a campaign for green products labelled with the EU ecolabel
next year. The goods transportation panel is elaborating a bench mark system and an
environmental management system.
Waste management
Reducing the amount of waste generated and increasing the reuse and recycling of the waste
generated is an important aspect in the Danish integrated product policy. The experiences
regarding the environmental problems related to reuse/recycling and disposal are very important
also for the future design of cleaner products. An action plan covering this area was issued last
year (Waste 21).
Financial subsidy scheme
To support the integrated product policy a subsidy scheme of approx. 110 mill DKK a year (2000
budget) is in operation. The Environmental Council of Cleaner Products - a council with
representatives from the major stakeholders (producers, consumers, environmental organisations,
authorities, academia a.o.) - elaborate a yearly plan of priorities for the subsidies. The Danish
Environmental Protection Agency grants specific projects within the priority plan.
References
/I/Ministry of Environment and Energy, Denmark: Nature and Environmental Policy Report,
June 1995
/2/Danish Environmental Protection Agency: Intensified Product-oriented Environmental Action
- A Green Paper. Proposal from the Danish Environmental Protection Agency. November
1996 (preliminary translated edition)
/3/Danish Environmental Protection Agency:The Product-oriented Environmental Actions,
February 1998 (in Danish)
/4/Ministry of the Environment, Sweden: Swedish Environmental Quality Objectives, a summary
of the Swedish Government's Bill 1997/98: 145. Environmental Policy for a Sustainable
Sweden June 1998
151 Integrated Product Policy, Final Report to the European Commission: DG XI. Ernest &
Young, March 1998 (confidential)
/6/Wenzel, H., M. Hauschild and L. Airing: Environmental Assessment of Products. Vol. 1:
Methodology, tools and case studies in product development. Chapman & Hall 1997
/7/Hauschild, M. and H. Wenzel: Environmental Assessment of Products. Vol. 2: Scientific
background. Chapman & Hall 1998
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
ACADEMIA
THE CONCEPT OF ECO-DESIGN AND RESULTS FROM THE DUTCH ECO-DESIGN PROGRAMMES
Tom van der Horst
Sustainable Product Innovation Department
TNO, The Netherlands
Huge public programs have been undertaken in The Netherlands and a large number of products
have undergone considerations of environmental improvements. Tom van der Horst has been
involved from the beginning and is today Manager of Sustainable Product Innovation Department
at TNO.
INDECOL - NTNU's INDUSTRIAL ECOLOGY PROGRAMME
Annik Magerholm Fet
Department of Industrial Economy and Technology Management,
Norwegian University of Science and Technology (NTNU)
Introduction to Industrial Ecology
The transformation into a sustainable society does not only require an environmentally sound
technology. Industrial ecology (IndEcol) is about designing sustainable structures -
technologically, economically as well as socially and individually. There are several important
elements within IndEcol; improving the metabolic pathways, creating loop-closing,
dematerialising industrial output, patterns of energy use, balancing industrial input and output to
natural ecosystem capacity, policy to conform with long-term industrial system evolution, and
new action-co-ordinating structures, communicative linkages, and information.
Tools and methods
The future focus of environmental concerns seems to change from site specific towards the life
cycle perspective. This means that the holistic perspective must be taken into consideration when
an industry wants to improve its environmental performance. A company's environmental
performance is not only a measure of the impacts caused by the production processes, it is also a
total measure of the environmental impacts caused by the products and the activities,
idealistically viewed in a life cycle perspective. The goal must be to reduce the environmental
impact in every phase of the life cycle. To reach this goal, appropriate methods for evaluating and
improving the environmental performance must be taken into use. A model of the levels of
environmental performances is shown in figure 1. The first axis is the time axis, the product's
lifetime with its phases in planning, manufacturing, use and disposal, human lifetime and the
civilisation span. The second axis indicates the scope of the environmental concern, ranging from
a single product life cycle, to x products within one manufacturer and towards x manufacturers
and the society.
The areas in figure 1 represent environmental performance efforts at different levels;
1.Environmental Engineering, 2.Pollution Prevention, 3.Environmental Conscious Design and
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Manufacturing, 4.1ndustrial Ecology, and S.Sustainable Development. Environmental
Engineering includes here various types of engineering and production. Pollution Prevention
takes system thinking into account, and the planning process is essential. The other concepts,
Environmental Conscious Design and Manufacturing are related to product design and
improvement of products concerning the manufacturing process, the distribution, the use and
final disposal of the products. Both Sustainable Development and Industrial Ecology are concepts
for the macro (and meso) level, taking environmental, economic and social issues into
consideration. Companies may find themselves within these areas. A shift or movement from one
area to the next area represents a change towards more holistic thinking and focus on the life
cycle performance.
in Society
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i Planning Manufact. Use Disposal
Human Civilization
Life time Span
time
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Scope of Temporal Concern
Figurel: Classification of environmental performance levels. Modified after Bras (1996).
There are different tools and methods for improving the life-cycle environmental performance.
For production systems ("process oriented tools") material flow and energy analysis,
Environmental Accounting (EAc) and Cleaner Production (CP) are frequently used. These
outline procedures for conducting assessments to identify opportunities for waste reduction or
elimination. Further it describes how to use the results to develop pollution prevention options,
recycling and recovery, and how to implement those options that withstand feasibility analyses.
For product systems Life Cycle Assessment (LCA), Life Cycle Screening (LCS), Design for
Environment (DfE) and Eco-labelling are important ("product oriented tools"). The main steps in
an LCA/LCS are Goal and scope definition, Inventory analysis, Impact assessment and
Interpretation. According to goal and scope definition the application, depth and subject of the
study, the functional unit and the system boundaries must be defined. Interpretation is the phase
in which a synthesis is drawn from the findings, and they may form conclusions and
recommendations to product improvements. When the intention is to identify key issues for
further investigations, e.g. identify parts of a life cycle that needs further research, an LCS should
be carried out. An LCS is a simplification of an LCA. Based on information drawn from LCA /
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONIVIENTAL MEASURES
LCS, the traditional list of product design criteria should be supplemented with environmental
conscious design requirements. Eco-labels are used to provide information about the
environmental impact of a product.
Companies that adopt CP, LCA, DfE etc., normally improve their overall environmental
performance because of better housekeeping and better products. To achieve continuous
improvement, their management systems should build on principles of environmental
consciousness. Formal Environmental Management Systems (EMS), Environmental Auditing
(EA), or Environmental Performance Evaluation (EPE) in accordance to given standards, help
companies in this work. Environmental management systems and environmental regulations are
of great importance both for organisational and societal systems.
The presented methods are systematised into a framework similar to the one shown in figure 2.
Area 1 is related to manufacturing processes, and appropriate tools are CP (hi the narrow sense)
and EAc. The next area is related to products and their life cycles. Appropriate tools are LCS,
LCA, and DfE for the purpose of environmental conscious product development. Area 3
represents one company, EMS, EA and EPE are important here. At society and global system
level, policy programs and international regulations are drawing up the guidelines for how to
improve environmental performance in a broader term perspective.
Society
(U
I
U
13 X Manufacturers
1
a
2
o
-------
SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Study programme
An interdisciplinary study programme on IndEcol is established at NTNU. The intention of this
programme is to create an academic basis for IndEcol in close collaboration with our partners in
industry and government administration. Our activities are organised around three main focus
areas: Education, research, and outreach activities. The study programme has ten courses, all
with a focus to industrial ecology principles, see Table 1.
In addition we are also involved in a few other courses where we make use of distance learning
courses delivered over the internet. The study programme has a horizontal organisation, and
works across the structure of five faculties; the faculties of Civil and Environmental Engineering
(the host faculty); of Mechanical Engineering; of Chemistry and Biology; of Social Sciences and
Technology Management and of History and Philosophy. The organisation of IndEcol is shown
in figure 3.
Table: Courses in the IndEcol study programme 1999 - 2001
Environment and resource economy
Environmental Science
Environment & Safety
Introduction to Industrial Ecology
LCA - Methodology & Application
Environmental Politics
Energy and Industrial Ecology
Geo-Resources
Ecotoxicoloev and Environmental Resources
Material Loop Closing
Interdisciplinary Project 1
Interdisciplinary Project 2
Fall 1999
Spring 2000
Fall 2000
Spring 2001
Fall 2001
136
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
FACULTY
FACULTY
HOST
TTArTTTTV
FACULTY
FACULTY
BOARD
EXTERNAL
PARTNERS
SECRETARIAT/CENTER
Programme leader
Research coordinator
Study programme coordinator
- ' Accounting
IndEcol-FORUMu:
network of tutor
thematic groups
Figure 3: Organisation of IndEcol.
Research programme
Closely related to the study program there is a research programme called Productivity1 2005.
The main objective is to increase know-how and knowledge in alliances between Norwegian
manufacturing industry and NTNU/Sintef. It aims at high international level of strategic
competence within technology, organisation and management. Main projects are Integrated
product development (IPU), Companies in networks (BiN), Industrial Ecology (IndEcol), and
Flexible, effective, reliable production (FEPP) . Our project "P2005 Industrial ecology" is one of
the key focus areas in P2005, and gives us a long-term financial basis for the development of
theory and methodology in the area of IndEcol. The strategy of research activities at IndEcol is to
focus on collaboration in a multidisciplinary setting, but with an emphasis to issues that we
believe have potentials for advancing the area of IndEcol within our university. We want to give
a high priority to research projects at the PhD and Post-doctoral level, as well as students'
research projects at the graduate level. Objectives of P2005 Industrial ecology are to raise the
level of expertise at NTNU, and disseminate knowledge on product, production and recvclins
systems, through research and networking in such a way that the Norwegian manufacturing
industry has access to candidates, expertise and methodology that will help companies implement
more eco-effective and competitive solutions in such systems.
1 Research program supported by Norway's Research Council, 1998-2005.
137
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Horizontal activity
';>LCA" ,'"?'';""''
^Responsible
Core project
Eco-
products
production
system
Horizontal activity
> Communicating
w IE consequences to
industry
Core project
Eco-
recycling
systems
producer
responsibilit
Core
companies
Figure 4: P2005 IndEcol structure
The P2005 IndEcol is structured in two core projecst. The first one is Eco-effective products and
production systems with the research activities undertaken within two main research strategies:
Eco-effective value chain management in industry >&n&.Factor X development of technical systems
Both activities are directly connected to industrial cases. Three general research subjects will be
covered with reference to each of the research strategies: 1) Methodologies for quantification of
eco-effectiveness with regard to products, companies and networks of companies, and how to use
this information in specific industrial cases. 2) Governmental regulations and financial
instruments as promoters or barriers to development of eco-effective solutions in product and
production systems, and 3) Organisational learning and new ways of managing eco-effective
companies and networks of companies in relation to product and production development.
The second core project is Eco-effective recycling systems and producer responsibility.
The research activities hereunder will be carried out within the main research strategies
Evaluation of eco-effectiveness in recycling systems and Principles of good practice in local and
national recycling systems. They will cover the same strategies as mentioned above.
One central activity in the IndEcol program is the LCA-laboratory. This will help students and
persons employed at NTNU to get a more holistic view of the challenges we are facing. This
research is to be carried out in accordance with the same principles used in the vertical core
projects.
P2005 IndEcol Industrial case-projects in 1999 - 2000 are:
Eco-effective value chains in the food industry
Environmental Indicators and accounting methods in furniture production systems
138
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
From eco-design to factor 4/10 development in eco-effectiveness
Eco-efficiency of beverage container recycling systems
Eco-parks as strategy in Industrial ecology and local agenda 21 programmes
Principles of good practise towards loop closing
Development of information network system of Norwegian LCA databases
Responsible companies in manufacturing industry
IndEcol Partners
In addition to the companies that are directly involved in the projects, there are several important
contacts. International contacts to be mentioned are:
Massachusetts Institute of Technology - Technology, Business & Technology Programme
Yale University - Industrial Environmental Management Programme
Georgia Tech - Centre for Sustainable Technology
Delft Univ. of Technology - Industrial Design Programme; Systems Engineering & Policy
Analysis
Ecole des Mines de Paris - ISIGE
There is also a close contact to World Business Council for Sustainable Development: North Sea
Region, and to Interreg ( a co-operation between Norway and Sweden), to Cre-copernicus among
others.
Future perspectives
The study programme is running fulltime this year with approximately 35 students. They say that
"The educational program is interesting, we have skilled professors, guest professors, and we
feel that we are highly appreciated. The educational program is intimate and engaging, the
education is bases on practical training in projects groups from different departments, and
several specialists and guest professors are from industrial companies ". A few criteria to
measure the success of the IndEcol activities (both the study programme and P2005) are the
number of publications, PhD-degrees, diploma thesis, seminars and conferences during a year.
Over time it is also the intention to develop new multidisciplinary courses with an environmental
contents for other students, or that students from traditional studies can participate in IndEcol-
courses part time.
THE EUROPEAN PERSON EQUIVALENT: MEASURING THE PERSONAL ENVIRONMENTAL SPACE
Michael Hauschild and Henrik Wenzel
Department of Manufacturing Engineering and Management
Technical University of Denmark
Building 424, DK-2800 Lyngby
e-mail: mic@ipl.dtu.dk
The European person equivalent (PE) is a quantification of the environmental impact caused
annually by the activities of an average European. It comprises contributions to all the major
environmental impacts from global to local as well as our consumption of resources.
139
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Similarly, the targeted European person equivalent (PET) is a quantification of the average
person's environmental impact in a near future according to the current politically set
environmental targets. In addition to expressing the current societal priorities in pollution
reduction, the targeted PE expresses the environmental space available to all of us according to
the current environmental policy.
Table 1 European PE and PET for a number
of environmental impacts
Impact category
Global warming
Ozone depletion
Photochemical ozone
formation
Acidification
Nutrient enrichment
Chronic ecotoxicity in
water
Human toxicity via
water
Human toxicity via air
UNIT
gco2-
eq/person/yr
gCFC11-
eq/person/yr
g C2H4-
eq/person/yr
gso2-
eq/person/yr
g N03"-
eq/person/yr
^
m3
water/person/yr
m3
water/person/yr
m3 air/person/yr
European PE
(impact level
per average
European,
1994)
8.2-106
0,081
25
74
120.000
350.000
52.000
3.1-109
European PET
(politically
targeted impact
level per average
European, 2004)
7.9-106
0
20
49
85.000
290.000
35.000
2.9-109
While the PE is a measure of the current level of environmental impact from the European
society's activities, the PET is a measure that on a per capita basis expresses the level that the
European society aims to reduce its environmental impact to in the year 2004. The ratio between
the PE and the PET is a measure of the ambitions of current environmental policy for each of the
environmental problem areas. The more ambitious, the lower the PET. At the same time, the PET
is a prediction of what the average impact per person (i.e. the PE) will be in the near future
(provided that society pursues its environmental targets).
Both concepts were developed in the mid-nineties for use in life cycle impact assessment to help
comparisons across different environmental impact categories (Wenzel et al., 1997, Hauschild
and Wenzel, 1998). Since then they have shown their value as a pedagogic tool in the
presentation and interpretation of environmental impacts from all kinds of man-made activities,
technologies and systems.
An environmental assessment is performed of the possible introduction of technologies to treat
the wastewater emission from a plant. The assessment results in the environmental profiles
shown in Table 2 for the situation without and with treatment
140
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Table 2. Environmental profile for plant (per year) before and after a proposed introduction of
wastewater treatment.
Unit No treatment Treatment
kg CO2-eq /yr
kg CFC11-eq/yr
kg SOa-eq/yr
kg C2H4-eq/yr
174.000
0
868
200
461.100
0,808
2.480
720
Impact category
Global warming
Ozone depletion
Acidification
Photochemical ozone
formation
Nutrient enrichment
Human toxicity
Ecotoxicity
Land use
Volume waste
Hazardous waste
The example reveals a number of trade-offs between the two situations. The ecotoxicity and
human toxicity caused by the emissions are strongly reduced by the treatment but the reduction is
accompanied by a considerable increase in the energy-related impacts, global warming,
acidification and photochemical ozone formation. So is it a good idea to treat the discharge from
an environmental perspective?
No unambiguous answer can be given to the question but by expressing the environmental
impacts in person equivalents they are expressed at a common scale and their relative size is
displayed on the background from society's environmental overall environmental impacts as
illustrated in Figure 1.
kg NOs eq/yr
m3 air/yr
m3 water/yr
ha-yr/yr
kg/yr
kg/yr
3.576
3,40-1011
2.16-107
170
9.450
248
5.364
1.38-1011
9.60-106
50
40.500
165
141
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Global warming
Acidification
Photochemical ozone formation
Nutrient enrichment
Human toxicity
Ecotoxicity
Land use
Volume waste
Hazardous waste
A
174.000
868
200
3.576
3,40. 1011
2.16.107
170
9.450
248
B
461.100
2.480
720
5.364
1.38.1011
9,60.10s
50
40.500
165
kg CQ2-ea
kg, SOa-eg
kg C2H4-eg
kg NOs'-eg
m3 air
m3 water
ha-yr
kg
kg
Global warming
Acidification
Photochemical ozone formation
Nutrient enrichment
Human toxicity
Ecotoxicity
Land use
Volume waste
Hazardous waste
100
120
PEweu94
Figure 1. The environmental impacts are expressed in common units through translation into
person equivalents, PE.
Expressing the impacts in PE's does enlighten the user on their relative sizes. It can be seen from
Figure 1 that when compared to the societal background load, none of the impacts is completely
insignificant compared to the others for either alternative. We are, however, still not able to
answer the question whether we should treat the discharge or not. In order to do so, we must
know how important the different impact categories are relative to each other. "Is global warming
more important than acidification" and if it is, how much more important? In other words, we
must have some values introduced into the comparison. Evidently, a valuation can not be
objectively we must decide whose values should be the basis for the final comparison.
When the impacts are expressed in targeted person equivalents, PET, instead of in PE's, the
priorities of the current European environmental policy are introduced as values into the
comparison. Now, an expression of the relative importance of the different impact categories has
been introduced into the comparison. It is thus permissible to compare the impacts directly across
impact categories when they are expressed as targeted person equivalents.
142
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Qobal warning
Aadfication
Photochemical aane
Nubientenridirrert
Human taxidty
Bnotcwdty
Land use
Vdume waste
.
Hazardojs waste
^^^^
!F
!*
seas
__
i
^
j
ฃ - "" S- S?~
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fi
fo
!
j-
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if
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;
^
,-
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.-
-
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*
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s
?
B
1A
Qobal \Aarrrirg
Aadficafion
Rntocterical OZOTE
NLWertenrichTBrt
Hurrantoxidty
Bootoxidty
Lard use
VduTE waste
Hazardous v\este
c
^^^^
5"
!F
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nJ
!=,
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1
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04
-
-
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- ฐ
;
D
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"
0 3E
B
HA
B
50 100 150 200 250 300 350
PEweu94
Figure 2. Introducing the priorities of current European environmental policy as values into the
comparison by expressing the impacts in targeted person equivalents, PET
Accepting the current political reduction targets as a relevant expression of environmental
importance, it can be concluded from Figure 2 that treatment should be preferred to non-
treatment from an environmental perspective. Applying these values, the reductions in
particularly ecotoxicity and human toxicity impacts are more important than the accompanying
increases in the energy-related impacts.
The "environmental latitude" or "ecological space" is used to define the environmental impact
that each person can cause in a sustainable society. In the same way, the PET is the
"environmental policy target latitude" for the target year, i.e. the impact which we on average
may cause for each of the impact categories if the targets for reductions are to be fulfilled.
143
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
The size of the environmental policy target latitude will gradually approach the size of the
environmental latitude as the environmental policy targets approach the targets for sustainability.
Table 3 shows a comparison between current political targets for 2004 and an approximate
estimate of the needed reductions for sustainability.
Table 3 Current political reduction targets and sustainability reduction targets for a number of
environmental impact categories
Impact category
Global warmina
Ozone depletion
Photochemical ozone formation
Acidification
Nutrient enrichment
Chronic ecotoxlcitv in water
Reduction for
2004
%
4
100
20
34
29
17
Reduction for
sustainability
%*
65
<100
50
90
90
85
' highly approximative, sustainabilitv targets ambiguous
In conclusion, the targeted person equivalent has properties which makes it suitable as a yardstick
for industry's environmental performance:
- It is centrally determined, indirectly derived from actual emission levels and current political
reduction targets, and it is common to all
- It is reflecting society's priorities and the most probable development in environmental
impacts
- It is providing an estimate of the personal environmental space in the near future
- It is suitable as a yardstick for industry's communication of environmental performance
- hi green accounting
- in system and process optimisations
- in product documentation
References
Wenzel H, Hauschild M and Alting L (1997): Environmental Assessment of Products. Volume 1:
Methodology, tools and case studies in product development. Kluwer Academic Publishers,
second printing 2000, ISBN 0-412-80800-5 (hardbound), ISBN 0-7923-7859-8 (paperback).
Hauschild M and Wenzel H (1998): Environmental Asssessment of Products. Volume 2:
Scientific Background Chapman & Hall 1998. Distributed by Kluwer Academic Publishers,
ISBN 0412808102 (hardbound)
144
-------
SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Associate professor Michael Hauschildfrom Department of Manufacturing Engineering,
Technical University of Denmark explaining the European Person-Equivalent
INDUSTRIAL COMPANIES
DESIGN FOR ENVIRONMENT AT DANISH A/V PRODUCER BANG & OLUFSEN -
CASE : COOL POWER, NEW AMPLIFIER TECHNOLOGY WITH 80-90% ENERGY REDUCTION
Jesper Olesen
Senior consultant, Bang & Olufsen a/s
Peter Bangs Vej 15, DK-7600 Struer
e-mail: jpo@bang-olufsen. dk
phone: +45 96 84 10 75, fax: +45 9684 11 44
Abstract
The lecture focused on the following questions: Who is Bang & Olufsen and what is
"environmental concerns" at Bang & Olufsen ? What is the company's Environmental focus ?
How do Bang & Olufsen handle environmental issues during product development ?
Case: The ICE-power amplifier
145
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
ENVIRONMENTAL IMPACT ASSESSMENT (LCA) ENERGY AND RE-CYCLING FOR A
CIRCULATOR
Nils Thonip, Senior Engineer
Grundfos A/S,
Research department,
DK-8850 Bjerringbro
Abstract
The use of LCA in the product development process points out two clear areas of improvement of
the environmental impact of a Circulator. Most of the energy used in the whole life cycle, from
cradle to grave, is used in the use phase of the circulator, with the end user of the product.
Typically, 99% of the whole life cycle energy is consumed in this phase.
All other phases like raw material productions-, transport- and the disposal phase consume 1%.
The main environmental improvement will therefore be development of highly efficient pumps,
and secure the right dimensions of the pump to the system were in it has to operate.
An other important environmental improvement of the pumps environmental performance, is to
make sure, that the resources, bound in the product, can be recycled on disposal. The most
important material in a typical Circulator is the Copper. Therefore, the Circulator should be
constructed in a way, that the copper can be recycled in the disposal stage.
The conclusion from the LCA of the circulator is valid for almost all types of pumps, which run
daily during the use phase. Only "special" pumps like "pumps in fire fighting equipment" have a
different environmental impact profile.
At Grundfos we use the Danish LCA-tool EDEP (Environmental Design of Industrial Products) to
secure that the environmental performances are documented in the product development process.
PRODUCT ORIENTED ENVIRONMENTAL MEASURES AT VOLVO
Tomas Rydberg
Volvo Technological Development Corporation
Dept 6700, PVH38
40508 Goteborg, Sweden
phone:+46 31 59 52 27
fax: +4631546188
email: tu. tomasr@memo. volvo. se
Abstract
This presentation aims to show a variety of product oriented environmental measures that have
been and are taken within Volvo Companies, including Cars, Trucks, Buses, Construction
Equipment, Marine powertrains and Aerospace products. Some examples from the past up to now
will be covered in the presentation, and also some aspects on present work which will contribute
to reduced impact in the future, relating to for example:
- Fuel consumption
146
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Alternative fuels
Alternative powertrains
Lightweight materials
Emissions
- Tools and working methods for environmental care in product development
Volvo (AB Volvo & Volvo Car) has been a forerunner and a major driving force in the
development and use of Product oriented environmental measures in Swedish companies,
especially from the late 1980's and onward. Volvo Car was also the first company to publish a
third-party certified Environmental product declaration, in connection with the launch of the
sedan S80 in may 1998. Volvo Technological Development Corporation is a corporate, task
driven, R&D unit
operationally integrated in Volvo's different business areas.
FACTOR 2 PROJECT ON TELECOMMUNICATION AT ERICSSON ENTERPRISE SYSTEMS AB
Lars Lenell, Ericsson Enterprise Systems AB
Ulf Ostennark, Chalmers Industriteknik
An extensive Life Cycle Assessment project at the Enterprise Systems has been concluded
during year 1999. About ten persons from Enterprise Systems have together with Flextronics
International Inc. and Chalmers Industriteknik, collected a large amount of inventory data at a
detailed level. Almost everything. Raw material extraction, component manufacturing, the
product production at the Flextronics factory, the Ericsson "office parts" (design process,
marketing, sales, distribution, service, installation and maintaining), the use stage and the end-of-
life treatment were included in the study.
The purpose of the project was to create a "base platform" for the future system design goals and
work of the Private Branch Exchange MD110. The study resulted in concrete design guidelines,
which are important to focus on in future product development, and has given a large material-
and inventory database for the Business Unit.
A new (BC10) and an old (BC8) model of the private branch exchange MD 110, produced and
sold by Ericsson Enterprise Systems, in this case for the EU market, has been compared. The Life
Cycle Assessment (LCA) is a technique for assessing the environmental aspects and potential
impact, associated with a product's whole life cycle from the "cradle to the grave".
This study meets the requirements of the international standards EN ISO 14040:1997 E, ISO
14041:1998 E and the draft standard ISO/DIS 14042 and 14043 from the International
Organisation for Standardisation. A third party reviewer has also critically reviewed the study.
The modelling of the system includes manufacturing (hardware and Ericsson's organisation), use
stage (electricity consumption), end-of life (recycling processes) and transports. Electronic
devices are modelled in depth (16 groups of components) and data from over 40 suppliers have
been collected. Ericsson's organisation (development, marketing&sales, supply, installation,
service and sustaining) is modelled for use of offices and business travelling.
147
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
The comparison between the two generations of the system showed that the technical
development towards reduced electricity consumption and more compact design resulted in a
reduction of the environmental impacts.
The following mam conclusions of the project are based on results for potential contributions to
the environmental impact categories acidification, global warming and eutrophication, which
were chosen to be the most relevant. The results predominantly reflect energy use, whereas
toxicological aspects needs separate attention (could not be reliably assessed due to lack of data
and reliable methods). The technology improvements shown for BC10 compared to BC8 do only
describe design improvements made by Ericsson, and does not take into account potential
technology production improvements made by suppliers.
The following main conclusions are illustrated with results for global warming. The unit is grams
of carbon dioxide equivalents per functional unit (one extension line during use in 15 years).
As illustrated in the diagram below, the use stage and the manufacturing stage are the most
important stages of the products' life cycle.
The end-of-life stage appears to be of low or moderate importance for the energy-related
impacts, but may be of large importance for toxicological impacts not reliably covered in this
study.
(g CO,-
oqv.)/F.u.
20000 -
Global Warming Potential (100)
,v. -,
jr "'''''"' ':
,|
fi*r
K-fS,.
'ซ- i
r - <
Maniifar-li.rinn Use End nf Life
BC10H Total
In the manufacturing stage, the hardware production is dominating and Ericsson's
organisation is secondly most important.
(g COi-
eqv.)/F.u.
40000
35000
Global Warming Potential (100)
Production
Ericsson's organisation
BC10H Manufacturing
Transport of MD
148
-------
SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
organisation is secondly most important.
Production of integrated circuits (1C) appears to be the individually most significant issue of
the hardware production (approximately 20-40%). Printed circuit boards (PCB) contribute
approximately 10% of the total score for hardware production.
g COa-eqv./ Global Warming Potential (100)
f.u.
onnn
ofinn
ynon -
finnn -
cnnn _
^nnn
onon
1 nnn
I i
Ov^ ^5^" / ^v ^>^ **& /^^ ^-* *& fy x^ /"^? V* ^ ^\^ J^* ^^ V* &~ &) ^^
BC10H 5 year group
The environmental impact improvements of the new model compared to the old are
approximately 10%, and the uncertainty of the results is judged to be smaller than the
difference between the systems.
(g Cฐ2~ Greenhouse Warming Potential (100)
eqv.)/F.u.
\ onnnn
1 60000
1 j.nnnn
i onnnn -
mnnnn _
onnnn -
cnnnn -
4nnnn -
onnnn -
n -
* '-V-.
$-r*
" f* *
,
-
'
.-
-
BC8L Total BC10L Total BC8H Total BC10H Total
All systems
The conclusions lead to the following design guidelines:
For existing MD 110 system, focus on decreasing the electricity consumption during the use
stage.
149
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
When possible, reduce the total area of silicon and the total size of capsules for ICs by
substitution of standard ICs with application specific integrated circuits (ASICs).
In future product development, the largest possibilities for the hardware appears to lie on a
conceptual level (system design level). It appears to be difficult to reduce environmental
impact significantly only by component substitution or detail construction adjustments.
In future product development it is also recommended to include organisational development
as a possibility for decreased environmental impact.
PRACTICAL EXPERIENCES IN THE FIELD OF PRODUCT-ORIENTED ENVIRONMENTAL
MANAGEMENT IN THE TEXTILE INDUSTRY .
LeifN0rgaard, Novotex,
Green-Cotton,
Ellehammervej 6, 7430 Ikast, Denmark
ln(5):green-cotton. dk
Novotex, a traditional Danish garment maker began as early as 1986 to consider the
environment as an important part of a garment. From the beginning very simple ideas - but
despite this the first life-cycle assessment was mad as early as 1988.
Novotex began as one of the first companies in the world growing their own certified organic
cotton ( beg. in Turkey in 1988). We realized that Novotex is not a farm-company - and the idea
costs a lot of money. When the first ideas about environmental management were introduced
Novotex was again in front and introduced - supported by the Danish EPA - the BS 7750 . Later
up-grated to EMAS and to ISO 14.001.
The strategy of ECO-labeling fitted Novotex well - and I was a member of the working group
from the very beginning. To day the strategy of Novotex is to use ISO 14.001 (EMAS) on very
product-level to prove the impact on the environment. By using the environmental management-
system one can prove the fulfillment of the criteria in the eco-labeling - and thus integrating the
two systems.
The VISION is to add working conditions to the requirements in ISO 14.001 (has happened).
Social responsibility is another important question which can be delt with by talking the rules of
ILO and add those to the ISO 14.001.
Culture and commitment is necessary not to forget - but difficult to quantify
Where no ISO 14.001 is available - by some smaller suppliers - a questionnaire of
"Environmental impact assessment" is used. The above strategy - documentation - is used to
prove the 4th marketing-tool: Environment
150
-------
SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
For 100 years three marketing tools only have been used in textile.
1. Price
2. Quality
3. Design - now adding the fourth
4. environment
All build on existing tools. Just simple coordinated into a integrated approach for textiles.
The only problem: A strategy to inform the consumer, to convince the consumer, to educate the
consumer.
THE STEP MODEL - THE ENVIRONMENTAL MANAGEMENT TOOL IN HARTMANN, INCLUDING
LIFE CYCLE MANAGEMENT
Anna Lise Mortensen,
Corporate Environmental Manager at Hartmann A/S,
Klampenborgvej 203, DK-2800 Lyngby, +45 45 87 50 30,
environment@hartmann. dk.
Summary
Hartmann was founded in 1917 and has specialized in the production of moulded pulp packaging
based on recycled paper. Hartmann has approx. 2000 employees. The products include egg and
fruit packaging and also customized packaging for large industrial customers.
The STEP model describes the environmental demands put on the different production sites in
the Hartmann Group. Or even before, since it is included in the work right from the initial
considerations and examinations in connection with the acquisition of a new company.
Hartmann developed the STEP-model in 1997. STEP stands for Systematic Tool for
Environmental Progress and it is a all-in-one management model.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Activities within the STEP
Tools STEP 1
Network
Environmental Risk analysis, prclimi-
managcmcnt nary investigations,
soil examinations, etc.
Cleaner
technology
U'fecycle
management
Communication
In-service
training
I^IHARTMAIW
model
STEP 2
Appointment of
responsible person
Preliminary
environmental
review
Overall targets for
cleaner technology
efforts
Internal
environmental
reporr
Education kit:
Why do environ-
mental work?
STEP 3
Project groups
are established
Building-up of an
environmental
management system
Cleaner technology
projects to be
carried through
Generation of data
from subsuppliers
External
environmental
report
Education kit:
Why do systematic
environmental
work?
STEP 4
Audit-teams
are established
Certification of the
environmental manage-
ment system in
ISO 14001, EMAS
More cleaner
technology projects
to be carried through
Preparation of basic
lifecycle assessments
External
environmental
report, EMAS
Education kit:
Why do holistic
environmental
work?
STEPS
Audit-teams
arc improved
Continuous
improvements
and audits
More cleaner
technology projects
to be carried through
Implementation
of lifecycle
management
External
environmental
report, EMAS
Education kit:
lifecycle
management
Figure 1. the STEP-model
The STEP model operates with a horizontal development dimension (STEP 1-5, from basic to
advanced) and a vertical tool dimension. The vertical tool dimension is built upon six
environmental tools, which are all considered necessary in order to achieve a sustainable
development: Network, environmental management, cleaner technology, lifecycle management,
communication and in-service training
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Policy & stategy
based on the LC koncept
Design for
environment
&JIHARTMAN4
Figure 2. Life Cycle based environmental management system
The corporate environmental department has developed a number of implementation tools for the
production sites. These tools range from report guidelines to advanced life cycle based
management tools, which support and facilitate the implementation of the STEP model.
SPECIAL TOPIC DAY CONCLUSION
By Henrik Wenzel, Associate Professor, Technical University of Denmark, wenzel(a),ipl. dtu. dk
On this special topic day, we have learned about environmental achievements of a number of
Nordic companies. Environmental improvement in the order of 50% in one step, and even more
over a limited period of time, have been presented for us for products like pumps and egg trays.
Yesterday, we learned that electronics' stand-by energy could be reduced by a factor of 10 or
maybe even 20, and we met ICEpowerฎ, the newly developed amplifier using only 10% of the
energy of conventional amplifiers.
Environmental product improvements of this magnitude have come through in a very short time
period of say 4-5 years. It is our experience from doing a large number of Life Cycle
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
Assessments and Eco-design initiatives of industrial products that very large improvement
potentials exist for most products.
Products are produced to fulfil human needs. And human needs are increasing. With increasing
population and increasing material standards of life, the need of products and services of human
beings seem to increase by a factor of 5 or more over 50 years. The task is, thus, to increase the
environmental- and resource efficiency of the way in which we fulfil these needs, i.e. to reduce
the resource consumption and environmental impacts per service provided/need fulfilled. This
task can be solved by measures on different level. Figure 1 illustrates these levels:
Demand
Product
Production
Design for Environment
Life Cycle Assessment
Process Integration
Process
Emission
Cleaner Production
Treatment
Risk Assessment
Figure 1. Levels of environmental improvement measures. A demand and supply chain
The figure shows a cause/effect chain - or one might say a demand/supply chain:
The human need is the demand of the product. If this need could be reduced, less products would
be produced in the world. Unfortunately, it seems that this need will increase, as mentioned
above.
The product is the supply fulfilling the need. At the same time, however, the product is the
demand of the production. Productions throughout the world only take place, because they as part
of a supply chain contribute to final end-user products fulfilling end-user needs somewhere. If the
product were intelligently re-engineered/re-developed, using e.g. life cycle assessment and eco-
design techniques, the demand for production volumes and/or hazardous production types might
decrease. Cf. the development of a new amplifier implying a demand of electricity production of
only 10% of the conventional amplifiers during use. A lot of effort goes into reducing
environmental impacts from electricity production like we have learned from Dr. Atimtay on
Tuesday. Improvement measures on products will reduce the effort needed on productions.
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SPECIAL TOPIC - PRODUCT ORIENTED ENVIRONMENTAL MEASURES
The production is the supply providing the product through the supply chain. At the same time,
however, it is the demand of the individual process. Processes in the company only take place,
because they as part of the chain/network of processes at the production site contribute to the
final output from the production. If the production were intelligently re-engineered/re-designed,
using e.g. process integration techniques like the ones we learned of last year in Belfast, the
demand for process volumes and/or hazardous processes might decrease. The Industrial
Symbiosis in the city of Kalundborg, that we saw yesterday, is an example of process integration
reducing the needed volume of the individual processes in the symbiotic industrial network.
Improvement measures on productions will reduce the effort needed on the individual process.
The process is the supply providing the output from the production site through the
chain/network of processes on the site. At the same time, however, the individual process is the
demand for the resulting input from nature (resource consumption) and the cause of the final
output to nature (emission). Inputs and outputs only take place, because they are the precondition
of the process providing its service. If the process were intelligently re-engineered/re-designed,
using cleaner production techniques, like we saw in electroplating two years ago in Cincinnati,
the demand for resources and the emissions would decrease. And with it the need for treatment
measures.
Measures are possible at all levels of this demand-supply chain, and very large improvement
potentials exist at all levels. There are no overlaps between measures at the different levels and
they truly supplement each other.
Working on one level without the other is a misunderstanding and will never be cost-effective.
Why struggle and fight on the production level with reducing the negative impacts of electricity
production if it were much more cost-effective to reduce the demand for electricity on the product
level? Measures on the product level taken by Nordic companies have been presented on this
special topic day. The product focus is, however, very new in environmental policy, and Nordic
companies are among the world leaders. There are still many lessons to be learned still in this
area, and still very large perspectives in working in it.
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TECHNICAL TOUR
INTRODUCTION TO TECHNICAL TOUR
The field trip schedule included a visit to three institutes at the Technical University of Denmark
and to the industrial symbiosis in Kalundborg. Between the technical venues, the group visited
the Viking ship museum in Roskilde, and after a very long day, the group relaxed over dinner i
picturesque but haunted old Danish castle.
in a
Although in the homeland of the Vikings, astonishment at the
means of transportation provided for the field trip
The NATO/CCMS group in life jackets going out
to sea
And as the day passed the
means of transportation got
even quainter.
The NATO/CCMS Pilot Study
group waving to the
photographer
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TECHNICAL TOUR
FIELD TRIP PRESENTATIONS
The Technical University of Denmark - DTU
As a modern technological university, DTU, the Technical University of Denmark, operates at a
high international level in a wide array of activities in fields such as biotechnology,
communications technology, nanotechnology and development of technologies for
sustainable production and renewable energy. The University's research and teaching is provided
by 32 institutes, a number of major independent centers established as joint ventures between
DTU and companies and research institutes in the region. Like all modern universities, DTU also
operates a number of transient and dynamic centers in which the driving force resides in
collaboration across different fields of research and organizations.
DTU's physical presence in the north of Copenhagen gives it a natural part to play in fostering the
0resund region as anew "powerhouse" for research, the development of production facilities and
educational provisions. The platform for this drive is made up of the region's 11 universities, 5
science parks and a heavy concentration of both old and new companies. For DTU, the most
essential task is to secure and maintain the best possible framework for national and international
cooperation in both State-funded and private research. This is the Alpha and Omega in the
creation and communication of new knowledge for contributing sustainable added-value to
society. The task is achieved in collaboration with R&D divisions in private companies, through
patenting, the establishment of new enterprises and through the University's Bachelor and
Masters courses, and training of new young researchers.
The University embraces most of the engineering disciplines, and trains engineers to Bachelor,
Masters and PhD level. In addition, the University offers a comprehensive continuing education
program, with a number of courses taught in English. The University has 6000 students preparing
for Bachelor and Masters degrees, 600 PhD students and takes 400 foreign students per year on
English-taught courses. DTU also has a permanent 400 of its Danish students away on varying
length courses at foreign universities.
INSTITUTE PRESENTATIONS - TECHNICAL UNIVERSITY OF DENMARK
New technology for gasification of biomass.
Ulrik Henriksen, Biomass Gasification group
The Biomass Gasification group at ET, DTU have more than 15 years of experience within R&D
and design of pyrolysis and gasification processes. The group is the Danish knowledge centre of
biomass gasification. We are doing fundamental research, mathematical modelling and process
design and optimisation. The two stage gasification process was developed here.
The two-stage gasification process
In the two-stage gasification process, the pyrolysis and the gasification process are separated into
two different zones. In between the pyrolysis and the gasification zones, the volatiles from the
pyrolysis are partially oxidised. Hereby, most of the tars are decomposed into harmless gas
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TECHNICAL TOUR
molecules. To enable high energy efficiency, the thermal energy in the gasification gas and the
exhaust gas is being used for drying, air preheating and for pyrolysis.
For small gasification plants (up to about 6 MW thermal), the traditional two-stage gasification
process is well known. For larger gasification plants, a new way of integrating drying, pyrolysis,
gasification and combustion unit is developed where the advantages of the traditional two-stage
gasifier are maintained.
The most important advantages of the two-stage gasification process are:
High gasifier and overall energy efficiency (above 90% cold gas efficiency).
Low tar content in the produced gas (below 25 mg/Nm3).The two-stage gasification process is a
combination of well-known technologies.
Uncomplicated gas cleaning system.
Good process for fuels with high moisture content (up to 55% moist on wet basis).
Low particle content in produced gas when the fuel has a high moisture content.
Flexible choice of fuels (successful tests on straw, briquettes and woodchips).
High temperatures limited to a minor, fully temperature controlled zone.
Can be built in sizes of 0,5-100 MW (thermal input).
Low emissions from thermal conversion unit and clean condensate when product gas is cooled.
Small-scale power production based on Stirling engines
Henrik Carlsen,
One of the activities in a large research and development program in Denmark concentrating on
the development of decentralised combined heat and power (CHP) systems for biomass is the
development of Stirling engines. The Stirling engine has external combustion, which makes it
very attractive for this purpose.
Up to this point two different sizes of engines are considered. A Stirling engine designed for an
electric power output of 35 kW has been built and tested using wood chips as fuel, and two 9 kW
engines have been built and tested using natural gas and biogas as fuel.
After the 35 kWei engine was tested in the laboratory for more than 600 hours it was mounted on
a wood chip combustion system specially developed for this purpose. Currently this plant has run
.'.for more than 1400 hours using wood chips with very satisfactory results, and the field test is
now continued. The plant is fully automated and it has been running unmanned most of the time.
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TECHNICAL TOUR
Only minor problems with thermocouples and the wood chip feed have resulted in unplanned
stops.
A new and improved 35 kW Stirling engine is now tested in the laboratory with natural gas as
fuel. The test results so far has been very satisfactory, but a few changes have to be made. This
engine is expected to be ready for field test in August 2000.
The 9 kWei engines have been performing very well. They have been tested for more than 250
hours respectively, and they have showed, that they can produce a maximum output of 10.5 kWei.
The Stirling engine development projects are funded by the Danish Energy Agency and it is
carried out as a co-operation between Department of Energy Engineering, Technical University
of Denmark, and several industrial companies.
ICEpowerฎ - Switch-mode audio power amplifiers.
Associate Professor Michael Andersen
A research co-operation with the Danish audio/video manufacturer Bang & Olufsen has resulted
in a break-through in amplifier technology. Project results shows that switch-mode (class D)
techniques can now be used to realise high quality audio power amplifiers with an efficiency at
full output power at -94% and an energy efficiency in a normal user situation of-30%
(compared to a class B power amplifier with respectively -60% and -1%). This implies energy
savings during operation of around 80%. The different parts of a switch-mode audio power
amplifier with either an analogue or a digital input will be presented, and there will be focused on
the techniques that has enabled these results. Moreover, there will be a short demonstration.
Low energy stand-by function
Associate Professor Michael Andersen and PhD Nils Nielsen
Stand-by lamps and power supply for electrical equipment uses a large part of the total electricity
production world wide. This means, that even when the equipment is switched off, there is major
electricity consumption. A solution to this problem has come closer with the development of a
prototype stand-by power supply with losses as low as 0.025W-0.2W - a significant reduction
when acknowledging that 3-5 W in e.g. televisions is considered low.
Newest developments in cleaner surface technology and micro technology.
Per M0ller, Department of Manufacturing Engineering,
Materials technology and environment is becoming more and more integrated factors. In the
future, material science will be the key for solving environmental problems in several industries.
Therefore research in improvement of both process technology and products has to be an
important area. The type of problems to be solved will be minimizing of material resources by
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TECHNICAL TOUR
producing of products with improved lifetime by intelligent material selection and surface
engineering, minimizing of the material consumption by miniaturizing of components (micro
technology) and development of new processes and methods for reduction of waste and at the
same time.
In this short introduction, some cases will be shown:
Case 1. Improvement of the efficiency for big power generators for power production by
selecting of new materials for slip rings.
Case 2. Some examples of minimizing of material resources by application of micro technology.
Case 3. Design of a new multiflexible electroplating equipment for plating zinc and zinc/iron
combined with 4 different conversion coatings, 3 different sealer systems and heat treatment to
eliminate hydrogen embrittlement. The new equipment, with a capacity of 4000 metric ton/y is
able to produce more than twenty useable combinations of zinc coating, conversion-coating and
sealer. Furthermore the equipment is designed for waste minimization.
The cases show the philosophy behind the multidisciplinary way of thinking, when the goal is to
obtain a holistic concept in the improvement of product quality and flexibility and at the same
time reduce or eliminate the environmental problems. In many cases, there do not need to be a
conflict between better quality and better environment.
INDUSTRY PRESENTATIONS
The Industrial Symbiosis at Kalundborg
Valdemar Christensen, Asnces Power Station
In the industrial symbiosis of Kalundborg, several enterprises utilise each other's residual
products in a network: Asnass Power Station, Gyproc - a plasterboard manufacturer, the
pharmaceutical and biotechnology group Novo Nordic, the Statoil Refinery, and the Municipality
of Kalundborg. This mutual use of residues saves resources and reduces the burden on the
environment significantly in an area with many heavy process industries. Moreover, it offers
economic advantages to the parties involved, because all contracts within the symbiosis are based
on commercial principles.
Asnaes Power Station
Valdemar Christensen, Asnces Power Station
Asnaes Power Station is owned by SK Power, Denmark and is the country's largest power station,
employing 500 people. The station is coal fired and covers about half of the demand for
electricity on Zealand. Since 1980, Asnaes Power Station has supplied district heat to the town of
Kalundborg and process steam to the Statoil Refinery and Novo Nordic.
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TECHNICAL TOUR
Co-generation of heat and electricity means better fuel utilisation and cheaper heat than the
customers can produce themselves, and the amount of heat wasted with the cooling water
discharge to Kalundborg Fjord is reduced too. Some of the residual heat is used in a fish farm '
producing 200 tons of trout a year. The fish grow more rapidly in the warm cooling water, sludge
from the fish farm's water treatment plant is used as fertiliser on nearby fields.
The desulphurisation unit at Asnass Power Station, which has been in operation since the middle
of 1993, produces about 100,000 tons of gypsum a year. The gypsum is sold to Gyproc, which
makes plasterboard products for building industry.
Earlier, all water for steam production was ground water. Now water for steam has been replaced
by surface water from Lake Tiss0 and by cooling water from the Statoil Refinery. The power
station, then, returns some of the reused water to the refinery as steam.
The NATO/CCMS Pilot Study Group at Asnces Power Station
Novo Nordisk
Anders Brinck Larsen, Novo Nordisk A/S
Novo Nordisk makes insulin and industrial enzymes. Its Kalundborg plant has about 1,200
employees. Novo Nordisk buys process steam from Asnees Power Station and surface water from
Lake Tiss0. The company's enzyme production, which involves fermentatioon of raw materials
such as potato flour and corn starch, produces large quantities of biomass containing nitrogen, the
biomass is piped or transported by tanker to farms in West Zealand, where it is spread on the
fields, replacing commercial fertiliser. Surplus yeast from the insulin production is now used as
fodder.
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MINI TUTORIAL ON UNIVERSITY-INDUSTRY CO-OPERATION CENTERS
INTRODUCTION
In 1989, Queens University in Belfast and a number of industrial companies established a centre
for co-operation on environmental issues, the Queens University Environmental Science and
Technology Research Centre, QUESTOR. At the 2nd meeting of this pilot study held in Belfast in
1999 the centre concept, history and activities were presented. The interest among the meeting
delegates was great, and it was decided to plan a more in depth tutorial in 2000 for delegates,
who would like'to have a do-it-yourself guidance. Professor Jim Swindall of QUESTOR was
invited to and kindly accepted to give this tutorial at the Copenhagen meeting.
INDUSTRY/UNIVERSITY CO-OPERATIVE RESEARCH
A powerful mechanism for involving industry in basic research in co-operation with universities
was developed by the US National Science Foundation (NSF) in the seventies. This concept was
called Industry/University Co-operative Research Centre (IUCRC) and it has been continuously
refined until there are now 53 Centres throughout the USA. A feature of almost all of these
Centres in their interdisciplinarity and the areas addressed by them range from Applied Polymer
Research to Web Handling.
Surprisingly, the concept has been little copied outside the USA except for two centres in
Queen's University in Northern Ireland, one called QUESTOR, for environmental research
founded in 1989 and a second one called QUILL, for ionic liquid research founded in 1999. A
third one called QUMED, for medical device research is in the planning phase.
The concept provides a win-win-win scenario,
1. The university gains funding from industry in the form of membership subscriptions,
these typically range from $30,000 to $50,000 per annum and as an average centre
membership is 15 companies the funding is significant. Additionally, hard cash from
industry in support of basic research assists the participating university staff with
grant applications to Government because it demonstrates the relevance of the
proposed research. The research staff and students working in the Centre gain
valuable feedback from the industry partners on their research and their frequent
contact with senior industrialists gives them valuable contacts and confidence when
seeking jobs.
2. The industry members gain from the leverage effect whereby their subscriptions are
added to those of all the other members. In addition the industry members will have
first sight of the results of research supported by government grants secured by the
centre. A close relationship develops with the University and this can lead to
additional contacts. The members also have the opportunity to appraise the research
staff and students during their time with the centre and make an informed decision on
their recruitment.
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MINI TUTORIAL ON UNIVERSITY-INDUSTRY CO-OPERATION CENTERS
3. Government wins by the increased industry input into, and involvement in, basic
research and this inevitably leads to increased technology transfer. Government
funding is also leveraged by the industry subscriptions.
Setting up an IUCRC is a major task that requires a lot of time commitment. If this is to be done
by a senior academic with a reputation in the chosen field then he/she will need a manager with
the freedom to devote the required time to visiting companies and drumming up support,
organising a planning meeting, encouraging academic colleagues to participate in the planning
meeting etc. When the centre is set up a sound management structure needs to be put in place
with a manager charged with fostering the relationship between the centre and the industry
members. It is not possible for a Senior Academic, with academic duties, which will always take
priority, to both lead and manage a centre.
The benefits of an IUCRC to a university can be illustrated by the following: in 11 years the
QUESTOR Centre attracted funding of over ฃ15m from industry, government and the EU. The
QUILL Centre, developed from it, has attracted ฃ 1.7m in two years and is growing rapidly. In
the USA the IUCRC programme attracts an annual sum of $75m for industry relevant basic
research of which the NSF contribution is only $5m.
That two centres, following the IUCRC concept, have been successfully set up in a tiny region
such as Northern Ireland demonstrates in the most positive way that the concept is fully
transferable. Furthermore, of the 18 members of the QUILL Centre, six are located in the USA,
two in Germany, one in Holland and one in South Africa, demonstrating also that such a centre
has sufficient relevance to industry needs to attract Members internationally.
The mechanisms for setting up and running an IUCRC are set out in great detail in a 322 page
book by S. George Walters and Denis O. Gray entitled 'Managing the Industry/University
Cooperative Research Centre: A Guide for Directors and Other Stakeholders' published in 1998
by the Battelle Press of Columbus, Ohio. ISBN 1-57477-053-5. A careful reading of this book
will pay handsome dividends for anyone contemplating setting up an IUCRC and emulating the
success of the US centres.
Professor Jim Swindall OBE
22nd March 2001
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OPEN FORUM ON CLEAN PRODUCTS AND PROCESSES
OPEN FORUM ON CLEAN PRODUCTS AND PROCESSES AND FUTURE DIRECTION
OF THE PILOT STUDY
Subhas Sikdar and Dan Murray
Summary
The pilot study director, Dr. Subhas Sikdar opened the discussion by reviewing the concept
behind this pilot study: there is a definite mission behind CCMS pilot programs, namely to
facilitate a cross national dialogue and support cross national collaboration. Moreover, we are not
here due to our own professional interest only, we are approved delegates speaking for the
countries we represent. This makes the pilot study a very unique experience.
To satisfy the goal, the pilot study should stimulate discussions among nations and catalyse
collaborative work, also through other auspices. Such spin-offs have already happened. Subhas
Sikdar encouraged everyone to keep possibilities of collaboration in mind. The pilot study web-
site could'be one good catalyst for this.
Another aim of the study is to facilitate assistance CP nations - former European east block
countries. Speaking of environmental performance of technology, NATO countries are perceived
to be somewhat ahead, and an aim of the NATO CCMS is, that the study should be a helping
hand to those countries in need. Therefore, collaboration between NATO countries and CP
countries is desirable.
During the meeting it was mentioned that funding opportunities are available in e.g. NATO's
science for peace program and various EU programs.
Dr. Sikdar urged delegates to go back and get in touch with their country representative of CCMS
- or for CP nations ministry contacts or environmental protection agency contacts - and supply
them with a summary report and maybe a copy of the meeting agenda. The purpose being to
explain the benefit of the pilot to the people supporting the study and thereby prepare the land for
future participation. Some NATO countries had for this meeting stated their interest in
participating, but had not been able to raise funding. It is in-excusable for advanced countries like
Netherlands, France etc. not being able to find the money to support a delegate. The country
CCMS representative has an obligation to support the pilot study and the delegate.
Dr. Sikdar thanked the Copenhagen meeting hosts and complimented the meeting agenda. The
special topic day provided very fruitful discussions. The question of how to proceed along the
lines of such a special topic day was raised.
This year, a special focus on textiles was given by Professor Michael Overcash who had
compiled inputs on Cleaner Production in textile industry from all participating countries . A
discussion on how to proceed was -opened ending with the conclusion to continue this project
with metal finishing industry and food & agriculture.
Between meetings there had been established bi-national collaboration already, one example
being, that Dr. Russell Dunn, who was invited speaker last year at the Belfast meeting had been
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OPEN FORUM ON CLEAN PRODUCTS AND PROCESSES
invited as guest professor at the Technical University of Denmark and was going to come back
there one more time in August 2000.
Dissemination of the meeting report was discussed, and various options were mentioned. One
option is to have NATO CCMS print special booklets on elected topics, like e.g.a publication on
the special topic day. Another option is to have the full report available on the pilot study web-
site.
A discussion on the duration and structure of the next meeting concluded to follow much the
same concept as known from previous meetings.
The issue of special topics was raised and a number of suggestions were put forward and
discussed: Simplified methods and tools (e.g.LCA, Env. Management, etc.), the Military sector,
Water reclamation and reuse a special topic? Cleaner Products and Processes in University
Curriculum.
It was pointed out that the special topic to some extent would depend on the meeting location.
It was mentioned that the idea of having a Computer Cafe was good and should be continued.
Finally, as location of next years meeting: Spain was unanimously agreed on.
SUMMING UP
The pilot study director, Dr. Subhas Sikdar finalised the meeting by summing up and thanking
organisers and sponsors: NATO CCMS, Danish EPA, US EPA, the Technical University of
Denmark and the Danish Research Councils.
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APPENDIX 1
List of Delegates and Participants
Bulgaria: Dr. Stefka Tepavitcharova
Bulgarian Academy of Sciences
Institute of General and Inorganic Chemistry
Acad. Georgy Bontchev Str., bl. 11
1040 Sofia
Bulgaria
Telephone: 359-2-979-39-26
Fax: 359-2-705-024
E-mail: balarew@ipchp.ipc.bas.bg
Czech Republic:
Ms. Dagmar Sucharovova
Head of Unit for Strategy and Sectorial Policy
Department of Strategies and Environmental Statistics
Ministry of the Environment
Vrsovicka 65 100 10 Prague 10
Czech Republic
Telephone: 420-2-730-746 or 420-2-6712-2784
Fax:420-2-6731-0340
E-mail: sucharovovadagmar(a),env.cz
Mr. Vladimir Dobes
Czech Cleaner Production Centre
Botieska 4
12800Praha2
Czech Republic
Telephone: 42-02-24-91-91-48
Fax: 42-02-24-92-01-28
E-mail: dobes@,cpc.cz or VDobes@,lu-imi.iiiee.lu.se
Denmark: Associate Prof. Henrik Wenzel
Manager, Cleaner Production Group
Institute for Product Development
Technical University of Denmark
Building 424
Lyngby
Denmark
DK 2800
Telephone: 45-4525-4663
Fax: 45-4593-5556
E-mail: wenzel@,ipt.dtu.dk
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Greece: Dr. George Gallios
Aristotle University of Thessaloniki
Department of Chemistry
Thessaloniki GR-540 06
Greece
Telephone: 30-31-99-77-16
Fax:30-31-99-77-59
E-mail: gallios@chem.auth.gr
Israel: Professor Chaim Forgacs
Environmental Engineering Unit
Ben-Gurion University of the Negev
P.O. Box 653
Beer-Sheva, 84105
Israel
Telephone: 972-7-6477064
Fax: 972-7-6472969
E-mail: forgacs@bgumail.bgu.ac.il
Prof. David Wolf
Ben-Gurion University of the Negev
P.O. Box 1025
Beer-Sheva, 84110
Israel
Telephone: 972-7-130446
Fax: 972-7-271612
E-mail: dwolf@bgurnail.bgu.ac.il
Italy: Professor Enrico Drioli
Department of Chemical and Materials Engineering
University of Calabria, National Research Council
Via P. Bucci, I,
87030 Rende (CS)
Italy
Telephone: 39-0984-402706 or 492039 or 492025
Fax: 39-0984-402103 or 492058
E-mail: e.drioli@unical.it
Moldova: Sergiu Galitchii
Operative Information Systems and Actions in Extreme Situations
Department of Environmental Protection
The State Ecological Inspection
73, Stefan eel Mare
MD2060 Chishinau
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Moldova
Telephone: 373-2-226951
Fax: 373-2-769130
E-mail: sergio@medium. gov.md
Poland: Dr. Andrzej Doniec
Pollution Prevention Center at the Technical University of Lodz
ul. Stefanowskiego 4/10
90-924 Lodz
Poland
Telephone: 048 (42) 631-37-03
Fax: 048 (42) 636-52-85
E-mail: adoniec@,ck-sg.p.lodz.pl
Portugal: Professor Susete Dias
Institute Superior Tecnico
Centre de Engenharia Biol gica e Quomica
Av Rovisco Pais
1049-001 Lisboa
Portugal
Telephone: 351-1-8419074
Fax: 351-1-8419062
E-mail: pcsdias@,alfa.ist.utl.pt
Romania: Mr. Viorel Harceag
Ministry of Waters, Forest and Environmental Protection
Research and Engineering Institute for Environment
Splaiul Independentei nr. 294
Sector 6, Cod 77703
Bucharest 78
Romania
Telephone: 40-1-637-30-60
Fax:40-1-312-13-93
E-mail: viorelH@,k.ro
Slovak Republic:
Mr. Lubomir Kusnir
Ministry of Defense of the Slovak Republic
Department of the Environment
Kutuzovova 8
83247 Braitislava
Slovak Republic
Telephone: 421-7-44250-320
Fax: 421-7-4437-3204
E-mail: kusnirl@mod.gov.sk
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Spain: Dr. Jose Coca-Prados
Dept. of Chemical Engineering
University of Oviedo
C/o Julian Claveria s/n
33071 Oviedo
Spain
Telephone: 34-9-85-103443
Fax: 34-9-85-237850
E-mail: jcp@sauron.quimica.uniovi.es
Turkey: Mr. 'Akin Geveci
Marmara Research Centre
PK. 21 Gebze 41470
Kocaeli
Turkey
Telephone: 90-262-641-2300 ext 3950
Fax: 90-262-642-3554
E-mail: geveci(g),mam. gov.tr
Dr. Aysel T. Atimtay
Middle East Technical University
Environmental Engineering Department
Inonu Bulvari
06531 Ankara
Turkey
Telephone: 90-312-210-5879
Fax: 90-312-210-1260
E-mail: aatimtay@rorqual.cc.metu.edu.tr or aatimtay@metu.edu.tr
Dr. Nilgun Kiran
Marmara Reseach Centre
PK. 21 Gebze 41470
Kocaeli
Turkey
Telephone: 90-262-641-2300 ext 3958
Fax: 90-262-642-3554
E-mail: kiran@mam. gov.tr
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Ukraine: Professor William M. Zadorsky
Ukrainian State University of Chemical Engineering
Pridneprovie Cleaner Production Center
Pridneprovie Ecological Foundation
P.O. Box 4159
Dnepropetrovsk-2, 320002
Ukraine
Telephone: 380-562-416550
Fax: 380-562-416590
E-mail: ecofond@,ecofond.dp.ua
United Kingdom:
Professor Jim Swindall OBE
QUESTOR Centre
Queen's University
David Keir Building
Stranmillis Road
Belfast BT9 SAG
United Kingdom
Telephone: 44-1232-335577
Fax: 44-1232-661462
E-mail: j.swindall@qub.ac.uk
WWW: http://questor.qub.ac.uk
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United States:
Dr. Subhas K. Sikdar, Director
Sustainable Technology Division
National Risk Management Research Laboratory
U.S. Environmental Protection Agency
26 West Martin Luther King Drive
Cincinnati, Ohio 45268
Telephone: 513-569-7528
Fax: 513-569-7787
E-mail: sikdar.subhas@epamail.epa.gov
Mr. Daniel J. Murray, Jr., P.E., Director
Technology Transfer and Support Division
National Risk Management Research Laboratory
U.S. Environmental Protection Agency
26 West Martin Luther King Drive
Cincinnati, Ohio 45268
Telephone: 513-569-7522
Fax: 513-569-7585
E-mail: murray.dan@.epamail.epa. gov
Dr. Farhang Shadman
Environmental Research Center
University of Arizona
Tucson, AZ 65721
Telephone: 520-621-6052
Fax: 520-621-6048
E-mail: shadman(g),erc.arizona.edu
Prof. Michael Overcash
North Carolina State University
Department of Chemical Engineering
HSRiddick
P.O. Box 7905
Raleigh, NC 27695
Telephone: 919-515-2325
Fax: 919-515-3465
E-mail: overcash@eos.ncsu.edu
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APPENDIX II: PROGRAM FOR THE MEETING IN COPENHAGEN 2000
SUNDAY. MAY 7. 2000
18:00
Delegates/participants gather in the Komfort Hotel, Copenhagen
18:30-21:00
Reception, registration and get-together at Danish Design Centre,
H C Andersens Boulevard 27 (5 min. walk from Komfort Hotel)
Welcome:
Dr. Subhas Sikdar, Pilot Study Director
U.S. Environmental Protection Agency
National Risk Management Research Laboratory
Cincinnati, Ohio, USA
Associate Professor Henrik Wenzel
Institute of Product Development/
Department of Manufacturing Engineering
Technical University of Denmark, Lyngby, Denmark
MONDAY. MAY 8.2000
08:30
Arrival, Coffee/Tea - Association of Danish Engineers' Conference Centre
08:45
Welcome - Dr. Subhas Sikdar, Pilot Study Director
09:00
Introduction round of country delegates and participants
09:30
Overview of Meeting Agenda, Field Visits and Events. Daniel Murray, Pilot Study Co-
Director
09:45 , .,
Break - Coffee/Tea
MORNING SESSION ORIENTATION: ENGINEERING SKILLS, TECHNIQUES AND TOOLS
10:00
Engineering for Sustainable Development - an Obligatory Skill of the FutureEngineer.
Invited speaker: Dr. Leo Alting, director of Institute for Product Development, and professor at
the Department of Manufacturing Engineering, Technical University of Denmark.
10:30
Pilot Project Updates (20 minutes each)
Pollution Prevention Tools, Subhas Sikdar, USA
Water conservation and recycling in Semiconductor Industry: Control of Organic
Contamination and Biofouling in Ultra Pure Water systems, Farhang Shadman, USA, Mike
Larkin and Jim Swindall, UK
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11.10
Membranes in Process Intensification and Cleaner Productions. Invited speaker: Dr. Enrico
Drioli, Professor at Department of Chemical and Material Engineering, University of Calabria,
Italy
11:40
Departure for lunch at the City Hall of Copenhagen (walking distance of conference centre)
12:00
Copenhagen City Hall. Welcome by Copenhagen Major of the Environment, Mr. Bo Asmus
Kjeldgaard. Lunch buffet followed by a tour of the City Hall.
13:10
Departure for the conference centre
13:30
Tour-de-Table presentations (15 minutes each)
Spain, Greece, United Kingdom, Denmark
14:30
Break - Coffee/Tea
AFTERNOON SESSION ORIENTATION: CLEANER PRODUCTION DISSEMINATION
15:00
Approaches to Cleaner Production in economies in transition - the results and perspectives
of the Cleaner Production Centres. Invited Speaker: Vladimir Dobes, Czech Cleaner
Production Centre, Czech Republic
15:30
Tour-de-Table presentations
Poland, Czech Republic, Slovak Republic, Moldova
16:30
Technology dissemination - discussion. Moderator: Vladimir Dobes
POSTER- AND COMPUTER TOOL CAFE
17:00
Coffee/Tea and sandwiches. Beers and soft drinks will be for sale.
Chemical Life Cycle Database
Michael Overcash, USA
CAPEC software tools for chemical and process system engineering
Peter Harper, Denmark
FIBRESAVE Integrated Environmental Information System
Joao Dias, Portugal
The EDIPLCA tool
Morten Als Pedersen, Denmark
Paris II - environmnetally friendly chemical substitution in industry
Dan Murray, USA
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Application of Life Cycle Assessment and Sustainable Process Index to Process Design.
Teresa M. Mata and Carlos A. V. Costa, Portugal
19:00
Adjourn
TUESDAY. MAY 9. 2000
08:30
Arrival, Coffee/Tea - Association of Danish Engineers' Conference Centre
09:00
Computer Aided Molecular Design Problem Formulation and Solution: Solvent Selection
and Substitution. Invited speakers: Rafiqul Gani and Peter Harper, Department of Chemical
Engineering, Techn. University of Denmark
09:30
Tour-de-Table presentations
Israel, Italy, Turkey, Portugal
10:30
Break - Coffee/Tea
10:45
Pilot Project Updates
Nato/CCMS Project Members Evaluation of Cleaner Production,
Michael Overcash, USA
Clean Processes in the Turkish Textile Industry, Nilgun Kiran, Turkey
Energy efficiency in Moldova, Sergiu Galitchii, Moldova
11:45
Tour-de-Table presentations
Bulgaria, Ukraine, Romania, USA
12:45
Lunch
14:00
The first Step Towards Sustainable Business Practice: The SB (SmithKline Beecham)
Design for Environment Tool Kit. Invited Presentation: Virginia L. Cunningham, SmithKline
Beecham, USA
14:30
Pilot Project Updates
Cleaner Energy Production with Combined Cycle Systems, Aysel T. Atimtay, Turkey
CEVI, The Danish Centre for Industrial Water Management, Henrik Wenzel, Denmark
15:10
Break - Coffee/Tea
15:40
Biological Control of Microbial Growth in the Process Water of Moulded Pulp Production
- Avoiding the Use of Biocides. Invited speaker: Gert Holm Kristensen, DHI - Water and
Environment, Denmark
16:10
Environmental Life Cycle Assessment of Alternative Scenarios for Biological Control of
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09:30
Design for Environment at Danish A/V producer Bang & Olufsen
Case: IcePovverฎ, new amplifier technology with 80-90% energy reduction. Jesper Olesen, Bang
& Olufsen A/S, Denmark
10:00
Product Oriented Environmental Measures at Danish pump producer Grundfos. Case: new
generation circulator with 40% energy reduction. Nils Thorup, Grundfos A/S, Denmark
10:30
Break - Coffee/Tea
11:00
Product Oriented Environmental Measures at Volvo A/B. Tomas Rydberg, Volvo A/B,
Sweden
11:30
Factor 2 project on telecommunication at Ericsson A/B. Lars Lenell, Ericsson A/B, Sweden
and UlfOstermark, Chalmers Industriteknik, Sweden
12:00
Industrial Ecology programme at Technical University of Trondheim, Norway, Annik
Magerholm Fet, NTNU, Norway
12:30
Lunch
13:45
A challenge for modern society: uncoupling growth and pollution. Steen Gade, Director-
General of the Danish EPA, former Member of Parliament, Denmark
14:15
Green Cottonฎ - Selling Environmental Success. LeifN0rgaard, Novotex A/S,
Denmark
14:45
Environmental Life Cycle Management at Danish moulded pulp producer Hartmann A/S.
Anna Lise Mortensen, Hartmann A/S, Denmark
15:15
Break - Coffee/Tea
15:45
The European Person Equivalent: Measuring the personal environmental space.
Michael Hauschild and Henrik Wenzel, Technical University of Denmark
16:15
The Danish product oriented environmental initiative and the international development,
Preben Kristensen, Head of Division for Cleaner Products, Danish EPA, Denmark
17:00
Summing up/discussion, moderator Henrik Wenzel
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17:15
Sightseeing and picnic on the old Copenhagen canals. Departure by boat
directly from the Harbour front of the conference centre. The first course of
this evening's dinner will be served on the boat
18:15
Return to conference centre's restaurant and continued dinner. Adjourn.
FRIDAY. MAY 12. 2000
SESSION ORIENTATION: INTERNATIONAL INFORMATION EXCHANGE
08:30
Arrival, Coffee/Tea - Association of Danish Engineers' Conference Center
09:00
New Pilot Projects
International Exchange and Dissemination of Clean Products and Processes
Information: Within the Pilot Study and to Industry and the Public, Dan Murray, USA
09:30
Discussion. Moderator: Dan Murray
10.00
Break - Coffee/Tea
10:30
Open Forum on Clean Products and Processes - Subhas Sikdar
11:30
Discussion of Future Directions for the Pilot Study - Dan Murray
Themes and Focus for Next Meeting
Host Country, Location, and Dates for 2001 Meeting
12.15
Summing up and Meeting Wrap Up - Subhas Sikdar
12:30
Adjourn and Lunch
INVITATION FOR ACCOMPANYING PERSONS
Accompanying persons are invited to participate in the following events:
May 7, 18:00-21:00Reception
May 8, 11:45 - 13:30 Lunch at City Hall. Departure from the conference centre
May 9, 19:00 - onwards Dinner at Tivoli Gardens, restaurant Nimb
May 10, all day Field trip
May 11, 17:15 - onwards Copenhagen canal sightseeing, picnic and dinner
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United States
Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
Official Business
Penalty for Private Use
$300
EPA/625/R-01/002
PRESORTED STANDARD
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
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