COMMITTEE ON EPA/625/R-03/006
THE CHALLENGES OF April 2003
MODERN SOCIETY www.nato.int/ccms
NATO/CCMS Pilot Study
Clean Products and Processes
(Phase I)
2002
ANNUAL REPORT
Number 257
NORTH ATLANTIC TREATY ORGANIZATION
-------
-------
EPA/625/R-03/006
April 2003
2002 Annual Report
NATO/CCMS Pilot Study
Clean Products and Processes
(Phase I)
Report Number 257
U. S. Environmental Protection Agency
Kaunas University of Technology
Institute of Environmental Engineering
Kaunas, Lithuania
-------
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 to the
technical community by the United States Environmental Protection Agency (U.S. EPA).
The views expressed in this Annual Report are those of the individual authors and do not
necessarily reflect the views and policies of the U.S. EPA. This report has been reviewed
in accordance with U.S. EPA's administrative review policies and approved for
publication. This document was produced as a result of a cooperative agreement with the
U.S. EPA's National Risk Management Research Laboratory (NRMRL), Cincinnati,
Ohio, under the direction of Dr. Hugh McKinnon, and the Institute of Environmental
Engineering, Kaunas University of Technology, Kaunas, Lithuania. This Annual Report
was edited and produced by Daniel J. Murray, Director of NRMRL's Technology
Transfer and Support Division and Richard Dzija, of Science Applications International
Corporation. Mention of trade names or specific applications does not imply endorsement
or acceptance by U.S. EPA or Kaunas University of Technology.
11
-------
PREFACE
The Council of the North Atlantic Treaty Organization (NATO) established the
Committee on the Challenges of Modern Society (CCMS) in 1969. CCMS was charged
with developing meaningful programs to share information among countries on
environmental and societal issues that complement other international endeavors and to
provide leadership in solving specific problems of the human environment. A
fundamental precept of CCMS involves the transfer of technological and scientific
solutions among nations facing similar environmental challenges.
The concept of sustainable development, universally accepted as the means of protecting
the environment for all mankind, demands that future manufacturing technologies must
be cleaner, yet economically sound. With continued industrialization and an improving
standard of living among nations, and with increasing globalization of markets and means
of production, all nations by and large are facing similar environmental challenges in the
manufacturing sectors. We established this pilot study on Clean Products and Processes
to create an international forum where current trends, developments, and know-how in
cleaner product design and technologies, and in tools for measuring their cleanliness, can
be discussed, debated, and shared. We hope that this pilot study, through its annual
meetings, will continue to stimulate productive interactions, cooperation and
collaboration among national experts, with the expected benefits of effective technology
transfer.
The fifth annual meeting of the pilot study, held in Vilnius, Lithuania, on May 12-16,
2002, marked the completion of Phase I of the pilot study and the initiation of Phase II.
The meeting continued the traditions established by the previous four meetings held in
Cincinnati, Ohio, United States; Belfast, Northern Ireland, United Kingdom;
Copenhagen, Denmark; and Oviedo, Spain. The meeting was hosted by Professor Jurgis
Staniskis, Institute of Environmental Engineering, Kaunas University of Technology,
Kaunas, Lithuania. Twenty nations were represented at the meeting. The meeting
included the traditional tour-de-table presentations and updates of pilot projects. The
special one-day symposium focused on industrial ecology and included technical
presentations by international experts and examples of practical applications of industrial
ecology in several Lithuanian industries. The meeting also focused on successful
cooperative relationships between universities and industry in Lithuania, Spain, the
United Kingdom and the United States.
The fifth annual meeting marked the completion of Phase I of this pilot study and the
initiation of Phase II. The meeting included with an evaluation of Phase I which
highlighted the many productive and cooperative relationships developed during Phase I.
The meeting concluded with a reaffirmation of the mission and goals of the pilot study
and a commitment by the national delegates to work together, over the next five years, to
achieve the goals of Phase II.
Subhas K. Sikdar, Pilot Study Director
Daniel J. Murray, Jr., Pilot Study Co-Director
in
-------
CONTENTS
Notice ii
Preface iii
Introduction viii
Executive Summary x
Tour de Table Presentations 1
Substance Chain Management 2
Introduction of Cleaner Production in Masna-Zlin Meat Processing Company,
Ltd 2
Cleaner Production Tools and Methods, Manuals and Samples 3
Regional Efforts for Clean Black Sea 7
Industrial Ecology Taught at the Technical University of Lodz (Poland) 11
Presentation of United States of America 12
The Importance and Implementation of Clean Processes in the Republic of
Moldova 14
Center for Prevention of Industrial Pollution 15
Best Available Techniques for Developing Countries 18
The Benefits and Drawbacks of Voluntary Environmental Agreements Relating to
Cleaner Technologies 20
Membrane Engineering for Clean Production 21
Pilot Project Updates 23
CEVI, the Danish Centre for Industrial Water Management 24
Life Cycle Assessment of Gasoline Blending Options 25
Cleaner Energy Production with Reuse of Waste Materials from the Iron and Steel
Industry in IGCC 26
Pollution Prevention Tools 34
University-Industry Cooperation 39
An Update on Government Support for Clean Products and Processes in the
United Kingdom 40
Waste Minimization, Revalorisation and Recycling of Solid Wastes in Spain 41
Presentation of Lithuanian Cleaner Production Centre 43
Programs of the US National Science Foundation Related to Clean Processing ..46
Ceramic Membrane Applications in Clean Processes in Russia 47
IV
-------
CONTENTS (Continued)
Industrial Ecology 55
Industries of the Future: Partnerships for Improving Energy Efficiency,
Environmental Performance and Productivity 56
From Pollution Control to Industrial Ecology and Sustainable Development 61
Industrial Ecology and Research Program at the Norwegian University of Science
and Technology 63
Green Concurrent Engineering: A Way To Fill ISO 14001 with Content 76
Strategies and Mechanisms To Promote Cleaner Production Financing 77
Cleaner Production Financing: Possibilities and Barriers 79
Industrial Ecology in University Curriculum: New M.Sc. Programme in
Environmental Management and Cleaner Production 81
Chemical Risk Management in Enterprises 83
Practical Implications of Industrial Ecology: JSC "Vilniaus Vingis" 86
JSC "Utenos Trikotazas" 87
Cleaner Production at Paper Mill JSC "Klaipedos Kartonas" 90
Companies Visited 93
Environmental Performance Management in JSC "Alita" 94
Environmental Performance Management in JSC "Alytaus Tekstile" 96
Environmental Performance Management in JSC "Snaige" 98
Appendix A—Annual Reports By Country A-l
Czech Republic A-2
Israel A-10
Moldova A-12
Norway A-l 5
Poland A-l 8
Portugal A-20
Republic of Slovenia A-23
Sweden A-24
Ukraine A-32
Appendix B—NATO/CCMS Phase I Summary B-l
Appendix C—NATO/CCMS Phase II C-l
Appendix D—List of Participants D-l
Appendix E—Meeting Program E-l
Appendix F—PowerPoint Presentation Links F-l
-------
VI
-------
NATO/COMMITTEE ON THE CHALLENGES OF MODERN SOCIETY
Pilot Study on Clean Products and Processes
5th Meeting
May 12-16, 2002
Vilnius, Lithuania
NATO/CCMSPilot Study Delegates at Trakai Castle
vn
-------
INTRODUCTION
During the fourth NATO/CCMS Pilot Study on Clean Products and Processes meeting
held in Oviedo, Spain on May 6-11, 2001 the delegates attending the meeting suggested
that the fifth meeting could take place in Vilnius, Lithuania.
The distinctive feature of the meeting held in Vilnius, Lithuania was discussion of the
integration of Industrial Ecology and Clean Products and Processes.
"Industrial ecology is the means by which humanity can deliberately and rationally
approach and maintain a desirable carrying capacity, given continued economic, cultural
and technological evolution. The concept requires that an industrial system be viewed not
in isolation from its surrounding systems, but in concert with them. It is a system view in
which one seeks to optimize the total materials cycle from virgin material, to finished
material, to product, to waste product, and to ultimate disposal. Factors to be optimized
include resources, energy and capital." (Industrial Ecology. T.E. Graedel and B.R.
Allenby. Prentice Hall, New Jersey, 1995.)
Industrial ecology can be considered the "production" component of sustainable
development. The most important aspect of industrial ecology is the idea of industry as a
system in which there is no waste at any step because all "waste" is a resource for another
part of the industry network. This concept is thus one of the relationships and dynamics
between companies, research and governmental institutions.
Industrial ecology is still a very new concept, and is not recognized by most industry
executives. It requires an understanding of the basic principle of ecology, which is a set
of dynamic feedback systems. It is still too early for industrial ecology to be widely used
in promoting behavior changes of industry or even in getting its attention, but the
principles of zero waste and maximum efficiency through materials exchanges will
attract the interest of executives once we have their attention through the dissemination of
concepts such as CP.
Industry has tremendous opportunities for applied industrial ecology. The unavoidable
wastes of many companies could be turned into new products by others if enough
willpower is focused. Designing products to do more with less increases the industrial
system's metabolic efficiency, as does using inputs derived from natural renewable
sources such as plant stocks instead of non-renewable resources. Increased vertical and
horizontal integration can create significant competitive advantages, as well as increase
management and product efficiencies.
Forty-six representatives from a number of countries participated in the meeting. This
new NATO/CCMS Pilot Study report reflects most of the topics presented at the meeting.
During the field trip, three Lithuanian companies in the Alytus region were visited;
practical studies of their environmental performance have been conducted.
Vlll
-------
I would like to thank the Lithuanian governmental institutions and companies that
generously supported the meeting, particularly the Lithuanian Ministry of National
Defence, the Ministry of Environment, JSC "Alytaus tekstile," JSC "Alita" and JSC
"Snaige."
I would like to express special gratitude to His Excellency, Lithuanian President Valdas
Adamkus, who kindly welcomed participants in the President's Office.
I am also grateful to colleagues from the Institute of Environmental Engineering for their
help in organising the meeting.
Jurgis Kazimieras Staniskis
Professor, Director of the Institute of Environmental Engineering
Meeting Host
IX
-------
EXECUTIVE SUMMARY
The 5th annual and concluding meeting of Phase I of the NATO CCMS Pilot Study,
Clean Products and Processes, was held in Vilnius, Lithuania, from May 12 to 16, 2002.
Although attendance was somewhat smaller this year than last year, this meeting ran well
and ended with great optimism for Phase II, the approval of which was communicated to
us by the office of Ms. Wendy Grieder, the US EPA CCMS representative. The success
of this meeting was owed largely to the able organization and leadership of Prof. Jurgis
Staniskis of Kaunas University of Technology. The meeting was sponsored by NATO
CCMS, US EPA, the Ministry of National Defense Republic of Lithuania, and the
Ministry of Environment, Republic of Lithuania. The delegates enjoyed the rare
opportunity of having a half-an-hour meeting with Mr. Valdas Adamkas, the President of
the Republic of Lithuania. In last year's meeting in Oviedo, Spain, we decided to shorten
the duration of the meeting from four and a half days to three and a half days. Thus the
Vilnius meeting was concluded on Thursday.
The Vilnius meeting began on Sunday May 12 with registration, introduction of the
delegates, some pilot project updates and tour de table presentations, and continued until
Thursday noon with technical presentations, software demonstrations, and trips to
industrial sites that practice cleaner production. It concluded with a wrap-up discussion
and planning for Phase II.
Here is a summary of the various activities:
Monday May 13
Monday May 13 was marked by a one-day conference on Industrial Ecology, which was
particularly significant because of the opening talk by Mr. Arunas Kundrotas, the
Minister of Environment, Republic of Lithuania. Monday afternoon the delegates had a
special meeting with the President of Lithuania. The titles of the symposium talks are:
• From pollution to industrial ecology and sustainable development: Prof. Lennart
Nielsen, Royal Stockholm Technical Institute (Sweden)
• Industrial ecology and eco-efficiency, introduction to the concepts: Prof. Anik
Fet, Trondheim Technical University (Norway)
• Extended producer responsibility in cleaner production: Dr. Morten Karlsson,
Lund University (Sweden)
• Strategies and mechanisms to promote cleaner production financing: Ari Huatala
(UNEP, Paris)
• Cleaner production financing: possibilities and barriers: Dr. Zaneta Stasishiene,
The Institute of Environmental Engineering (Lithuania)
-------
• Industrial ecology in university curricula: new international MSc program in
cleaner production and environmental management (Lithuania)
• Chemical risk management in enterprises: Dr. Jolita Kruopiene, The Institute of
Environmental Engineering (Lithuania)
• Practical implications of industrial ecology in Lithuanian industry:
• Electronic industry: Vaclovas Sleinota (Vilniaus Vingis)
• Textile industry: Nerijus Datekunas (Utenos trikotazas)
• Paper industry: Arunas Pasvenskas (Klaipedos kartonas)
• International implications on industrial ecology
• Utilization of cleaner production methodology on the example of dairy plant:
Frantisek Bozek (Czech Republic)
• Utilization of cleaner production on the example of poultry processing plant:
Frantisek Bozek (Czech Republic)
The computer Cafe was the last session for Monday. The Cafe included demonstrations
of software that are helpful to cleaner production.
Tuesday May 14
Tuesday May 14 was devoted to visiting three companies chosen for their exemplary
cleaner production policies and practice. We visited a refrigerator production company
"Snaige," a textile company "Alytaus tekstile," and a wine and sparkling wine production
company "Alita."
Wednesday May 15
On Wednesday we completed the tour de table presentations and updates on current and
completed projects. There were also several specialty presentations:
• Industries of the future—partnerships for improving energy efficiency,
environmental performance and productivity: Steve Weiner (USA)
• Ceramic membrane applications in clean processes in Russia: Prof. G.
Kagramanov (Russia)
XI
-------
• An update on Government support for clean products and processes in the
United Kingdom: Prof. Jim Swindall (UK)
• Waste minimization, recalorization and recycling of solid waste in Spain:
Prof. Jose Coca-Prados (Spain)
• Presentation of Lithuanian CP Center: Prof. Jurgis Staniskis (Lithuania)
• Programs of the National Science Foundation related to clean processing: Dr.
Thomas Chapman (USA)
Pilot Project Updates
The Pilot Study consisted of several projects that were sponsored by member countries,
some of which were collaborative (between countries) in nature. Several of these projects
were completed during Phase I. The following project updates were presented in Vilnius:
• Pollution prevention tools: Dan Murray (USA)—ongoing
• Reuse of waste materials of iron-steel industries and development of sorbents
from these materials for absorption of hydrogen sulfide in waste gases: Aysel
Aytimtay (Turkey)—complete
• The Danish Center for industrial water management: Henrik Wenzel
(Denmark)—complete
• Life cycle assessment of gasoline blending options: Teresa Mata (Portugal)—
complete
Closing Session Discussion
The discussion during the closing session of the meeting focused on the transition from
Phase I to Phase II. A review of the Phase II proposal that has been approved by NATO
CCMS was presented by the Pilot Study Co-Director. The proposal reaffirmed the goals
of Phase I and established the following goals for Phase II:
• To support the development of eco-efficiency and sustainability indicators and
promote consistency and harmonization of their application;
• To examine and exchange information on state-of-the-art advancements in
product design and process development in service and industrial sectors of
importance to participating nations;
• To develop a web-based portal for the dissemination of pilot study results and
improved awareness of related global developments; and
xn
-------
• To stimulate and facilitate productive collaboration among all participating
nations.
The delegates discussed how to move forward in Phase II and to work together in the
implementation areas described in the Phase II proposal. These implementation areas will
address tools for assessment of pollution prevention and sustainability and for the design
of cleaner products and processes; cleaner production techniques in priority industrial
areas; and electronic dissemination of information and knowledge of cleaner products
and processes.
A long discussion was held on the approach to be taken to implement a pilot project on
the development and application of sustainability indicators. This pilot project was
originally proposed at the fourth meeting in Oviedo, Spain, by delegates from Germany,
Hungary, Lithuania and Norway. These delegates and others called for continued support
for this pilot project. It was agreed that during the coming year, all delegates would
provide information regarding the status of sustainability indicator development and
application in their countries.
The delegate from Germany agreed to develop a framework for the provision of this
information and send it to each delegate by September 1, 2002. Each delegate, using the
information framework, would provide his or her information back to the German
delegate by December 31, 2002. The German delegate will then prepare a summary
report based on the information. At the next meeting in 2003, a "workshop" will be held
as part of the meeting. This workshop will consist mainly of facilitating discussion of the
issues raised in the summary report and recommendations for actions to be taken by the
delegates to meet the goals of this pilot project on sustainability indicators. Initial issues
raised included the need to define "sustainability" and then develop a range of indicators
to measure progress towards sustainability. It was agreed that indicators could be specific
and general. Indicators could be based on measures of eco-efficiency, energy efficiency,
or personal "carrying capacity." Also, indicators could be industry-based, economic,
environmental, or political. A final challenge will be the development of indicators with
some common units for consistent application and measurement.
The delegates also reaffirmed their interest in addressing cleaner processes and products
in priority service/industrial sectors. At the first meeting in Cincinnati in 1998, the
delegates prioritized industries for examination. The order of priority for the top five
industries was textiles, organic chemicals (including pharmaceuticals), energy
production, pulp and paper, and food. The delegates emphasized that attention to
chemical production, energy production, and food/agriculture, along with electronics
should be priority for Phase II. The delegate from Denmark emphasized continued
interest of the pilot study in product design and service sectors.
To increase information exchange among the delegates and to provide more timely and
regular updates, the delegates agreed to provide mid-year reports on progress in clean
products and processes in their respective nations. Each delegate will provide a report to
Xlll
-------
the Co-Director by December 31, 2002. US EPA will move ahead with enhancements to
the pilot study web site during the coming year.
The delegates voted to conduct the next meeting in Italy in early May of 2003. The
specific site of the meeting will be either Rome or Calabria, depending on cost and travel
factors.
Subhas Sikdar, Director
Dan Murray, Co-Director
Pilot Study on Clean Products and Processes
xiv
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Tour de Table Presentations
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
SUBSTANCE CHAIN MANAGEMENT
Dr. Horst Pohle
Federal Environmental Agency, Germany
horst.pohle@uba.de
Abstract
Substance chain management is the answer to the change in the environmental policy
paradigm, which occurred in the early 90s. There is a growing realisation that there are
limits to environmental policies which are organised in terms of the various
environmental media and which are orientated towards emissions, plants and single
substances. There is a shift of focus from single substances to entire fields of
applications, from production to products, and from production plants to product lines.
As a result, greater emphasis is placed on more systematic material flow description and
more complex product analysis, often described as "from cradle to grave." This change in
perspective goes hand in hand with a reorientation in the field of environmental
protection, involving the replacement of reactive by proactive policies. Some experiences
and results from programs and projects in Germany were presented at the meeting.
INTRODUCTION OF CLEANER PRODUCTION IN MASNA-ZLIN MEAT
PROCESSING COMPANY, LTD.
Frantisek Bozek
Military University of the Ground Forces
Faculty of State Defence Economy and Logistics
Department of Public Economy and Logistic Services
Vita Nejedleho 1,682 03
Vyskov, Czech Republic
bozek@feos.ws-pv.cz
Tel: +420507392471
Fax: +420 507 392009
Ales Komar
Military University of the Ground Forces
Faculty of State Defence Economy and Logistics
Department of Economy and Nourishment
Vita Nejedleho 1,682 03
Vyskov, Czech Republic
komar@ws-pv.cz
Tel: +420 507 392527
Fax: +420 507 392325
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Jiri Dvorak
Military University of the Ground Forces
Faculty of State Defence Economy and Logistics
Department of Languages
Vita Nejedleho 1,682 03
Vyskov, Czech Republic
dvorakji@post.cz
Tel: +420 507 392572
The project called "Introduction of Cleaner Production in Masna-Zlin Meat Processing
Company, Ltd.," was carried out within the framework of bilateral Cupertino between the
Ministry of Environment of the Czech Republic and the Netherlands.
The project was fully financed by the Netherlands from the PSO fund aimed at the
introduction of cleaner technologies into the Czech industry. The Dutch government is
represented in the process of selection of suitable projects; the SENTER Agency, the
Czech side, is represented by the Czech Centre of Cleaner Production. The total amount
of financial support of the project in Masna-Zlin, ltd. reached 450 000 guldens, of which
170 000 guldens were earmarked for new equipment proposed during the solution of the
project.
Three Dutch firms participated in the solution of the project: TNO Institute of
Environmental Sciences, Energy Research and Process Innovation, TAUW Milieu and
Nijhuis Water Technology. They were delivering equipment.
Project work was carried out from October 1998 to June 1999, including a preparatory
phase. The project was divided into the following four phases:
1st phase—stocktaking of known data. This phase was characterised by two areas of
issues: a detailed description of individual production sections, qualitative and
quantitative descriptions of pollution and also summary and elaboration of all the
available data observed during the last 4 years at Masna-Zlin, Ltd.
2nd phase—monitoring based on drafting the system of further measurements, its
implementation and evaluation of results. Monitoring focused primarily on water
consumption and both quantity and level of pollution of wastewaters being produced by
individual production sections.
3rd phase—good housekeeping, which is one of the methods of cleaner production. The
aim of the methods of good housekeeping was to reduce water consumption and the
amount and level of pollution of wastewater being generated by individual production
sections. Participation of company employees in the process, including the company
management and individual manual professions, represent an important tool for the
implementation of the method of good housekeeping.
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
So-called good housekeeping was also divided into several spheres of action. Provisions
that do not require any financial expenditures and have an instant effect were applied
almost immediately. Provisions aimed at the reduction of wasting water are thoroughly
implemented at workplaces, and solid waste being generated during the preparation and
processing of meat is raked and not splashed into sewerage. Furthermore, the provisions
requiring certain intervention in the organisation of work at individual production
sections, or technical provisions with low costs are implemented (repair of leaking water
supply valves, washing with water under pressure, substitution of meat pickling for other
technological procedures). Technical provisions requiring higher costs and substantial
changes in technology will then be implemented according to the company's financial
resources.
4th phase—transfer of information. This phase of the project was implemented both in
the course of the project when all the employees were acquainted with the aim of the
project at various meetings and also at a seminar, which concluded the project. The
seminar was organised in co-operation with the Czech Centre of Cleaner Production
under the auspices of the Municipal Council of the town of Zlin. 100% of invited
companies and representatives of state authorities attended the seminar and finished the
project in a representative way.
It is evident from the final evaluation of measures being taken within the project,
especially implementation of principles of good housekeeping, that water consumption
decreased significantly not only at the slaughterhouse (slaughtering of pigs and beef
cattle) and the manufacture of meat products, but also at other service operation premises.
Water consumption was reduced by 9% on the average, which is almost 200 000 CK.
Waste water contamination was also reduced, which was showed both by the indicators
of biological and chemical consumption of oxygen and also by the content of extractable
substances (fats).
The IFF 45 E flotation sewage treatment plant works on the principle of flocculation and
flotation. Its efficiency is 79% elimination of biological contamination (in relation to
biological consumption of oxygen) and 96% elimination of fat substances (determined as
extractable substances). Months of operation of the preliminary treatment plant saved
3 300 Euros in charges for waste water contamination.
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CLEANER PRODUCTION TOOLS AND METHODS, MANUALS AND
SAMPLES
Prof. William Zadorsky
Ukrainian Ecological Academy of Sciences
Ukrainian State University of Chemical Engineering
mailto:William@zadorsky.com
http ://www.zadorsky. com/
Abstract
The system approach prescribed is the base of a proposed strategy for systematic
reduction of environmental loads. It expects that before problems of choosing methods of
industrial waste conversion or utilization are solved, it is necessary to consider questions
for systematic reduction of environmental loads strictly at the tier of production. It's very
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 CP
algorithm is described as a sequence of following actions: DECOMPOSITION;
IDENTIFICA TION; SELECTIVITY&INTENSITY INCREASING.
Engineering techniques and methods for Cleaner Production are described:
• Transition from macro- to micro-level.
• Flexible synthesis systems and adaptive equipment to embody them.
• Process engineering for high throughput to cut processing time and reduce by-
products and wastes, and industrial symbiosis as a basis for management of
secondary materials and energy.
• 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.
• 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.
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Separative reactions organizing (synthesis and dividing processes organizing in
the same place 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 pollution or reception of
a sub-standard product.
A databank on methods of influence on systems at various hierarchical tiers for purposes
of ecologization (this Russian termini integrates CP, EM, WM, P2P, LCA) will be
available in special table. The methods included in the bank have passed industrial tests
and/or are used in industrial conditions. There should be a match between a tier in a
hierarchy and the methodology of characterization, assessment or influence used at this
tier.
Many industrial samples are described in the paper.
A wide program of mutually beneficial collaboration is offered: joint scientific research,
including participation in international scientific programs and joint developments for
industrial enterprises and other organizations, transfer of new high technologies, joint
analysis of developments in science, industry, education and social policies in the NIS
countries, joint research in permanent areas of applied chemistry, chemical processing
and chemical engineering, chemical industry, metallurgy, engineering, food-processing
and pharmaceutical industries, exchange of leading scientists and specialists, exchange of
visiting professors that deliver lectures on the chosen themes.
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
REGIONAL EFFORTS FOR CLEAN BLACK SEA
Dr. Stefka Tepavitcharova, Christo Balarew
Bulgarian Academy of Sciences
Institute of General and Inorganic Chemistry
Acad. Georgy BonchevStr., bl. 11, 1113
Sofia, Bulgaria
stepav@svr.igic.bas.bg,
Tel: (359 2) 979 39 26
Fax: (359 2) 70 50 24
Black Sea ecological degradation has been a well recognised environmental issue; the
basin is ranked among the most threatened water bodies in the world ocean. The pollution
of Black Sea waters causes changes and could have fatal effects on the Black Sea
ecosystem, as well as on a wider area of the world ocean ecosystems. Oil spills,
eutrophication, industrial wastes, sewage waters and solid waste, among others, are seen
as serious obstacles for the development of Black Sea fisheries, tourism, etc. The
ecological status of the Black Sea and the solution of its pollution problem are one of the
highest priority environmental problems of the region.
Different scientific teams and various national and international programs have been
dealing with this issue for years. Some of the international projects for complex
regional assessment, monitoring, rehabilitation and protection of Black Sea during the
last few years are as follows:
• Marine environment assessment in the Black Sea region: The project is
financed by the International Atomic Energy Agency with the participation of the
Black Sea Regional Committee of the International Oceanographic Commission
(UNESCO). The main purpose is investigation of the radioactivity of Black Sea
area as well as the sedimentation in Black Sea.
• Integrated Black Sea coastal zone modeling and management program: The
project is financed by NATO and coordinated by the Technical University of
Ankara.
• NATO science for peace—Black Sea ecosystem processes and
forecasting/operational data base management system: The project is financed
by NATO. A Regional Center for oceanographic data, established in Sevastopol,
collects all the data from the national and international expeditions.
• Global environmental ocean observing system (GOOS)—Black Sea GOOS: The
Black Sea GOOS project is a regional component of the global program. It is
coordinated by the Black Sea Regional Committee of the International
Oceanographic Commission (UNESCO) and supported by EUROGOOS.
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Black Sea Fluxes: The project is coordinated and financed by the Black Sea
Regional Committee of the International Oceanographic Commission - UNESCO.
The project focus is sedimentation processes and their influence on the sea
environment.
• Impact of waves and currents on oil and other surfactant transport in coastal
areas: The project is financed by the EC, INT AS Association. It focuses on the
development of models of oil transport in the coastal areas and their
implementation in the oil forecasting systems.
• Center for sustainable development and management of the Black Sea region,
Varna, Bulgaria: The Center is financed by the EC, Program INCO. Its main
objective is long-range sustainable development of the Black Sea region in the
context of environmental, economic and social problems for harmonisation with
the EC standards. It will be reached through increased regional and international
co-operation, providing user-friendly information media and a strategy for
sustainable development and management of Black Sea region and improved
quality of life.
The environmental objectives of the Center are:
• to improve the Black Sea scientific bases (methodologies and scientific
tools) for assessment of the Black Sea ecosystem health through regional
and international co-operation;
• to elaborate ecological criteria and standards on water and living
resources, crucial for the adoption of regional regulations for
harmonisation with the EC Environmental Policy;
• to provide feasible options for mitigation of negative impacts and co-
ordinate efficient implementation of environmental rehabilitation
measures;
• to develop a strategy for sustainable utilization of chemical, living, non-
living and recreational resources and management of Black Sea
ecosystem.
However, none of these programs has been assigned the task of the entire solution
of the problem.
Our efforts are to initiate a project "Clean Black Sea."
The aim is to organize effective scientific and technological co-operation among all the
European countries having rivers flowing into the Black Sea, as well as the countries
from the Balkan and Black Sea region, in order to establish a wide information network
8
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
on this topic. The activities are oriented towards consolidation and cooperation of the
scientific and expert potential in all these countries working under different national and
international environmental programs and networks.
The main objective is through uniting the efforts of the regional countries and attracting
other European countries to minimize the discharge of pollution into the Black Sea and
thus, by making use of the self-cleaning ability of nature, to realize the cleaning of Black
Sea.
It is envisaged to establish an information network for gathering, evaluating,
disseminating and discussing ecological data for natural waters and soils pollution in the
European countries, Balkan and Black Sea regions for the last five year period, both at a
national and regional level. It is necessary to identify and quantify the potential
environmental impacts of the different pollution sources and explain what measures
would be taken to minimize the risk of any harmful impacts and for sustainable
management of these natural sources.
The program could contain the next stages:
• Creation of the effective collaboration - activity agreement and development of
monitoring network;
• Establishment of a permanent panel of scientists and experts for solving
ecological problems linked to the natural waters and soils pollution in the Black
Sea and Balkan regions;
• Study visits for scientists for standardization of the methods and equipment used
for sampling, measurements, data processing and analysis of the different
parameters for establishing the pollution;
• Monitoring the pollution, identifying and quantifying the potential environmental
impacts of the different pollution sources along the rivers discharging their waters
into the Black Sea and the whole aqua territory of the Black Sea coast under a
general program and specified spots for taking samples;
• Collection of the monitoring data obtained in the last five years and
development of data-bases in each of the participating countries on the specifics
and pollution levels of: i) rivers; ii) soils and iii) Black Sea coastal area. The
requirements of the international standard should be applied;
• Carrying out meetings and workshops with scientists and experts from all the
participating countries for gathering and evaluating the monitoring data
concerning the water and soil pollution;
• Discussions on the ecological status of natural waters and soils in these countries
and measures for its sustainable development;
9
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Development of an interactive web site with wide spectrum of information and
including data on: i) the species and pollution level of the rivers; ii) the species
and pollution level of Black Sea; and iii) the species and pollution level of the
soils;
• Measures for minimization of the risk of any harmful impacts; and
• Elaboration of an international agreement for elimination of pollution
sources and sustainable environment development. The agreement should
envisage an eight year period during which the contractual parties are to
undertake the engagement for the liquidation the sources of pollution. The eight
year period is the estimated time for the depreciation of the chemical industry
installations. During that period the respective enterprises or organizations are to
be given the opportunity to make their choices as to whether they will build the
needed WWTP that will ensure the discharge of the waste waters within the
accepted permissible norms or they will close the activity causing the pollution.
The first attempt to organize regional discussion on the problem "Clean Black Sea" is the
Workshop "Solubility Phenomena - Application for Environmental Improvement."
It will be held in Varna, Bulgaria from 21st to 24th July 2002 in the framework of an
IUPAC International Symposium on Solubility Phenomena.
The focus is on regional ecological problems of Balkan and Black Sea countries and on
pollution level and pollution sources in the Black Sea and in the Black Sea catchment
areas.
The major purpose of the Workshop is to provide a focus for discussions of the
application of the solubility phenomena for environmental improvement.
The specific objectives of the Workshop are as follows:
• to organize a high quality forum, which should enhance the applicability of the
solubility phenomena to the solution of ecological problems;
• to demonstrate the application of solubility related chemistry in new green
technologies for solution of ecological problems;
• to provide and disseminate updated information on the ecological status of the
CEEC and NIS, the Balkan and Black Sea regions with a view to future
environmental improvement.
10
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The workshop topics are:
• Relationship Solubility Phenomena—Environmental Problems Solution
• Black Sea Fluxes—Monitoring of the Black Sea
• Pollution Level and Pollution Sources of Danube, Dnieper, Dniester, Bug and
other rivers flowing into the Black Sea
• Methods and Schemes for Environmental Improvement of Polluted Waters and
Soils
• Reinforcement of the Regional Participation in Integrative European Programmes
for Solving of Ecological Problems
These topics are of high relevance to scientific understanding of conditions in rivers,
estuaries and regional seas like the Black Sea and Baltic Sea. It will reinforce the co-
operation and consolidation of researches from CEEC and NIS, Black Sea and Balkan
regions in future EC, INT AS, international and regional joint projects for solving of
ecological problems and sustainable environmental development.
INDUSTRIAL ECOLOGY TAUGHT AT THE TECHNICAL UNIVERSITY OF
LODZ (POLAND)
Dr. Andrzej Doniec
Pollution Prevention Centre at the Technical University of Lodz
Lodz, Poland
mailto:andoniec@ck-sg.p.lodz.pl
Abstract
The Faculty of Management and Organization at the Technical University of Lodz is a
unique one because of its location in the structure of a technical academic unit. In Poland,
management faculties are usually a part of universities, which are not involved in
teaching engineering sciences. At the Faculty of M.& 0. T.U. of Lodz, students are
educated not only in management sciences; they also receive a package of engineering
knowledge in several groups of subjects called technological specialization e.g.,
machinery and electrical engineering, food processing. These subjects are intended to
educate industrial managers of high value and prepare them to understand technical
processes. Technical subjects are taught during the third year of studies.
A new specialization called eco-engineering started in October 2001. The aim of this
specialization is to teach environmentally friendly processes as a tool for promotion of
11
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
sustainable behaviour and application of sustainable development principles in an
enterprise strategy. Employees of a newly established Department of Industrial Ecology
have developed the curricula of the subjects taught within the eco-engineering
specialization, which is a part of the Institute of Management. The set of courses taught
within the confines of eco-engineering specialization encompasses subjects originated in
process engineering presented in the light of sustainable development. Industrial
processes and apparatuses, process dynamic are the fundamental technical subjects.
Engineering solutions based on environmentally sound approach are presented in the
courses: sustainable energy use, low-waste technologies, eco-design and advanced
recycling. An industrial ecology fundamental is the introductory course of the
specialization. Diploma works of the scope of industrial ecology are also supervised by
members of the I.E. Department.
PRESENTATION OF UNITED STATES OF AMERICA
Dr. Subhas K. Sikdar
United States Environmental Protection Agency
Cincinnati, OH, USA
mailto: sikdar. subhas @ epa. go v
Abstract
In the United States, sustainable development has gradually taken hold as the umbrella
concept under which all issues of clean products and processes, cleaner technologies, or
pollution prevention ideas are being discussed. The Federal Government support for
research in these areas has been growing in various Departments and Agencies. The
agencies most active in clean products and processes research are the Department of
Energy, Department of Defense, Department of Agriculture, and Environmental
Protection Agency.
Research in support of sustainable development in the US EPA is being funded through
the National Center for Environmental Research (NCER) through its grants programs in
technologies for sustainable environment (TSE, in collaboration with the National
Science Foundation) and comprise such concepts as industrial ecology, green chemistry
and green engineering. Nanotechnology is a new area for support in which advances in
science and engineering that produce newer processes and materials that use nanophase
structural attributes in enhancing environmental benefits. The National Risk Management
Research Laboratory in Cincinnati is engaged in in-house research in all these areas, and
this topic will be covered in the separate presentation on the project that has been
ongoing for several years. Biotechnology is the newest area of research, which is focused
primarily on environmental concerns of genetically modified crops. Particularly relevant
is resistance of pests to these crops that incorporate pesticides, such as Bacillus
12
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
thuringiencis. The effect of the pollens from these crops on non-target species is also a
concern.
Focus Areas in the US
• Industries of the Future Program—US DOE
• Advanced Technology Program—US DOC
• Technology for Sustainable Environment—NSF and US EPA
• Vision 2020—CCR, DOE, ACS, AIChE, and others
• Many industry groups have formulated programs through their industry
associations, such as the SI A
• Sustainability—various organizations
US EPA Focus Areas
• Integrated (multimedia) Environmental Management
Ecosystem protection
Watershed restoration/protection
Sustainability
• Sector-based Industrial Management
• Metal finishing, pulp and paper
• Green chemistry and engineering
• Tools and methods for pollution prevention and Sustainability
• MTBE, its effects on ground water, and ethanol as a substitute
• Nanotechnology for environmental protection
13
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
THE IMPORTANCE AND IMPLEMENTATION OF CLEAN PROCESSES IN
THE REPUBLIC OF MOLDOVA
Alexandru Stratulat
Office of the Prime Minister
Chisinau, Republic of Moldova
a stratulat@moldova.md
Abstract
The issue of the clean products and clean production processes is a long-discussed one
not only in the Republic of Moldova, but also in many other countries. Especially in the
last decades, the environmental aspect of human and economic development has become
more and more important. Not only the ecologists' organizations, but also the
governments and broad civil society are interested in the effects of particular
development processes on the environment.
The Republic of Moldova is not an exception. Much has been done in this direction in the
last years. Moldova is a member of a number of environment related conventions, and
was one of the first to ratify the Kyoto convention etc.
Ecologically sustainable development is even more important for Moldova than for other
countries as its main generator of national welfare is agriculture or agriculture related
activities. In the past, when Moldova was part of the Soviet Union, the agricultural
methods applied here were the intensive ones, meaning that in the production process a
large amount of chemical agents were used. The ecological factor was of very little
importance, or not considered at all. The natural resources, especially the good quality
soil for which Moldova was famous, were greatly depleted. The situation was the same in
industry. A large number of highly polluting plants operated without any concern for
their effects on the environment.
The situation has changed dramatically in the last decade. As a result of the break-up of
the Soviet Union, the traditional economic ties with the socialist republics have been lost
and a significant fall of the output was registered. The old, chemical-intensive methods
were dismissed due to financial constraints. Agriculture production became more
traditional and labour-intensive, due to the low cost of the labour force, and, indirectly,
more environmentally friendly. Also, as a result of the political opening of the country,
informational exchange became possible. Society is more and more aware of the
environmental effects of human activity. A number of technical assistance projects were
initiated in order to implement in the economy new clean production processes. We also
recognise that producers became interested in these processes not only because of a
concern for nature, but also for economic reasons. The demand for clean, so-called bio-
products is constantly growing, especially in the Western European countries. A number
of studies were conducted in that respect, and the results were that Moldova has a
comparative advantage in the production of the bio-products.
14
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
But it's not enough to know that you have ecologically pure products. You have to let
people know about it too. So, in the last years, efforts have been made to harmonise
Moldavian standards with international ones. The ISO 9000 standards are already
implemented. The international community also contributes to these efforts through a
number of technical assistance projects. Also, a Swiss company, SGS S.A., is working on
the implementation of the biostandards in agriculture, as well as certification of the
production processes as ecologically clean. Seminars, roundtables and workshops were
organised in order to increase public awareness of these issues.
But, having said all this, we have to admit that there is still a lot to be done. New
technologies are not available free of charge. Due to severe financial constraints the
Republic of Moldova cannot afford these technologies. All initiatives in this area are
implemented almost entirely in the framework of technical assistance projects and are in
a pilot phase. In order to implement the new technologies, you must have personnel
trained for these processes. The policy-makers, which in many cases are subject to
inertia, should understand the importance of them. Through the exchange of experience
and increased awareness, we can achieve progress in this area. And I think seminars are
one of the instruments which have to be used in this respect.
CENTER FOR PREVENTION OF INDUSTRIAL POLLUTION
http://www.iatp/md/cppi/
mailto:cppi@mail.md
Establishment
The Center for Prevention of Industrial Pollution (CPPI) was established in June 1999.
CPPI is an independent non-profit organization with the legal status of a civic
association. The organization was created by chartered engineers trained under the
Cleaner Production Program carried out by the Russian-Norwegian Center Cleaner
Production (RNCPC) in 1996-1997.
The center has know-how in the field of microbiologic processing of waste of a food-
processing industry (meat processing, fish processing, brewing process), with obtaining
of the vitamin-mineral alimentary components in a forage agricultural animal, and as well
as for usage in a cosmetics industry (perfumery). The specialists of CPPI have designed
the project: "Closed technological cycle development at a brewery by microbiological
reprocessing of rinsing water and brewing grains." The project has been endorsed and
recognized by WCPS (World Cleaner Production Society) to the conforming
international standards and is a 100 % "Cleaner Production" project.
15
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Within the framework of the program, the Center renders practical help to firms in
looking up the new technological solution in the field of environmental protection. For
some firms, the "Concepts of the projects" in the following directions were already
prepared:
• Energy Efficiency
• Decrease of consumption of water
• Waste Minimization
• Pollution prevention
Mission
The basic purposes of the organization are:
• assistance in formation of progressive economic policy in ecology through
realization of the programs which increase the professional level of industrial
enterprise managers;
• support of concrete and complex transformations in the industry sector in order to
save energy resources and to reduce harm to the environment;
• consolidation of private public organization activity in the country and abroad for
the purpose of progress of both development of ideas and "Cleaner Production"
principles;
• public activity in order to support the initiative and professional interests of
citizens in the field of environmental protection.
Services
• training of the staff;
• development and implementation of the practical demonstration projects;
• information dissemination on Cleaner Production principles;
• consulting services for the enterprises;
• assistance in political dialogue among the representatives of the industry and
policy makers on the improvement of management of the instruments of CP
stimulation;
16
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• assistance to the enterprises in creation of environment management systems
under ISO 14000 standards;
• facilitation of communication between the enterprises and financial institutions in
the country and abroad, rendering active support in financing of the CP projects
and assistance in their implementation;
• financial engineering;
• development of the business plans for the CP projects;
• advisory services on policy in CP for state bodies and local administration.
Partners
• OECD
• Norwegian Society of Chartered Engineers (NIF)
• Norwegian Energy Efficiency Group (NEEG)
• Russian-Norwegian Center "Cleaner Production" (Russia)
• Slovak Cleaner Production Center, Bratislava
• Pollution Prevention Centre , Bucharest (Romania)
• Informational Resource Center of Informational Service of Embassy of USA in
Moldova
• Scientific-production company "Biolant" (Russia) (development and
implementation of technologies for Microbiological reprocessing of environment
polluting industrial enterprises wastes).
• Biotechnical Center (Latvia)
• Ministry of Environment and Territorial Development, Republic of Moldova
• Ministry of Industry and Energy, Republic of Moldova
17
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Activities
• Since July, 1999 "Center for Prevention of Industrial Pollution" (CPPI), Ministry
of Environment and Territorial Development and Ministry of Industry and Energy
have joined efforts in order to initiate the implementation of the international
program "Cleaner Production."
• Eight Chisinau companies (Carmez, Lapte, Floare-Carpet, Fabrica de Drojdii din
or. Chisinau, Avicola Roso, Agroconservit, CET-1, Piele) initiated the
implementation of the "Cleaner Production" principles. Their representatives have
followed a training program, carried out by CPPI in cooperation with the Russian-
Norwegian Center "Cleaner Production."
• The graduates of the training programme have received a Professional
Development Certificate in Environmental Management and Cleaner Production
in Industry (WCPS).
Publications
• "Pollution Prevention pays" (Economic review, November 1999);
• "Cleaner Production in Moldova - the first steps." (brochure, November 2000).
BEST AVAILABLE TECHNIQUES FOR DEVELOPING COUNTRIES
Peter Glavic
Faculty of Chemistry and Chemical Engineering
University of Maribor
Maribor, Slovenia
mailto: glavic @ uni-mb. si
http://atom.uni-mb.si/
Abstract
According to the IPPC Directive (96/61/EC), EU member states are asked to use Best
Available Techniques (BAT) and environmental quality objectives as benchmarks for the
establishment of environmental permit conditions for certain installations. On the other
side, many technologies which do not fulfil the BAT requirements exist and are still
being installed in underdeveloped countries. A case study of waste oil treatment is
described where such an attempt was prevented in Slovenia.
18
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Several technologies are available for the treatment of waste oil. The Flemish Institute for
Technological Research (VITO) has evaluated 10 out of 11 representative treatment
systems for waste oil removal (Jacobs en R. Dijkmans, Beste Beschikbare Technieken
voor de verwerking van afgewerkte olie, Academia Press, Gent, 1999.) Their BAT
selection methodology is based on a qualitative approach associated with stepwise expert
judgment and presented in the form of simple tables. The expert judgment evaluates
technical feasibility, environmental benefit and economic feasibility. In particular, the
ability of the process to remove polluting components in waste oil, including sulphur
components, metals and potential emission of products resulting from incomplete
combustion and VOCs, is carefully assessed. A re-refining system and injection of waste
oil into a blast furnace were the preferred options found. Next BAT was: closed loop
recycling of industrial oils, co-combustion in cement kilns and use as fuel in hazardous
waste incinerator.
Most often, water and sediments are removed from the waste oil first using settling,
sedimentation, filtering and centrifuging. After this simple treatment, one of the above
options is used. Thermal cracking at 420 °C at low pressure was planned be used in
Slovenia. Subsequent distillation and stabilisation yields marketable fuel oil. All metals
present in the waste oil end up in the bottoms of the cracked section. The sulphur content
of the gasoline depends on the sulphur level of the oil feed and the stabilisation method
applied. The technology was evaluated as a non-BAT because it merely transfers sulphur
from the waste oil into the fuel polluting the environment after burning.
A company from one of the NATO countries outside Europe marketed the thermal
cracking technology, even without the pre-treatment of sediments and water. In Slovenia,
the Ministry of Environment enabling a general discussion about its impact on the
environment announces every new plant. The local population invited our Department to
take place in the evaluation. Using the Internet information system GEPnet, which was
developed in one of the joint EU and PREPARE research projects in Austria, we were
able to find information about the BAT evaluation in VITO, Belgium. We were also able
to demonstrate that the existing cement kilns are able to treat all the waste oil produced in
Slovenia. Therefore, the Government did not permit the thermal cracking technology to
be implemented so far.
19
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
THE BENEFITS AND DRAWBACKS OF VOLUNTARY ENVIRONMENTAL
AGREEMENTS RELATING TO CLEANER TECHNOLOGIES
Gyula Zilahy
Hungarian Cleaner Production Centre
Budapest, Hungary
mailto:zilahy@enviro.bke.hu
Abstract
There is growing attention in the developed world paid to voluntary instruments as they
can substitute direct and indirect environmental regulation with a more effective policy.
A reason for this change can be found in the environmental and economic efficiency
aspects of voluntary environmental regulation; however, voluntary instruments do not
always outperform other instruments. Thus, regarding efficiency, voluntary instruments
can be more efficient only under certain circumstances. To decide what kind of voluntary
instruments are useful under which circumstances, one has to:
• analyse the situation (characteristics of problem and of participants) and
• define suitability of instruments.
Doing so, the consideration of two groups with different interests is necessary: the
environmental authorities and the polluting companies. On the one hand, there are twelve
regional environmental protection inspectorates in Hungary supervised by the head
inspectorate, which is directly controlled by the Minister of Environmental Protection.
The regional agencies have the duty to control pollution and implement environmental
policy on street-level. On the other hand, there are polluting firms trying to chase their
profit interests, sometimes with the representation of industrial alliances.
After conducting a proper analysis, we can present the following results:
• Advantages and disadvantages of usage
• Clear definition of application fields for voluntary instruments
• Conditions for a proper usage (institution, information, content of regulation)
Considering these results, policy makers will be able to construct a more efficient policy
mix to ease environmental problems.
20
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
MEMBRANE ENGINEERING FOR CLEAN PRODUCTION
Alessandra Criscuoli1, Enrico Drioli1>2
Research Institute on Membranes and Modelling of Chemical Reactors
IRMERC-CNR
Via Pietro Bucci Cubo 17/C
87030 Rende (CS) Italy
Tel: +39-0984-492014
Fax: +39-0984-402103
mailto:a.criscuoli@irmerc.cs.cnr.it
1>z Department of Chemical Engineering and Materials
University of Calabria
Via Pietro Bucci Cubo 17/C
87030 Rende (CS) Italy
Tel: +39-0984-402039
Fax: +39-0984-402103
mailto: e. drioli@unical. it
Abstract
Membrane operations are applied for molecular separations, clarifications, fractionations,
concentrations, and chemical productions, practically covering all the unit operations of
chemical engineering. Their intrinsic properties such as modularity, no need of chemical
additives, easy scale-up and control, high flexibility and easy integration with
conventional operations, make them good candidates for the rationalisation of industrial
productions.
The main objective of the research works in progress at IRMERC-CNR (Italy) is to
achieve sustainable growth by following the "process intensification" strategy. At the
basis of this theory is the need for systems of production with high efficiencies and low
size/productivity ratios, energetic consumption and environmental impact. The goal is to
improve industrial cycles in order to achieve clean production and thus to reduce
treatment processes of polluted streams.
At this purpose, new membrane systems are under investigation at the Institute such as
membrane contactors and membrane crystallisers. The analysis of the potentials
achievable by the integration of different membrane operations is another line of research
in progress. Membrane contactors have been applied for coupling the water carbonation
to the water deareation in beverage industry. Compared to the traditional
deareator/saturator systems, the new membrane process presents lower size, investment
cost and carbon dioxide consumption. Membrane crystallisers are based on the use of
membrane distillation for concentrating solutions; in particular, the concentration process
21
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
is pushed up to crystal formation at the retentate side. The laminar flow inside the
membrane fibers reduces the shear stresses by favouring a uniform formation of crystals.
An integrated membrane system in which a membrane crystalliser is coupled to
nanofiltration and reverse osmosis devices has been analysed for the seawater
desalination. With respect to the only reverse osmosis unit, the integrated system
increases the fresh water production and potentially eliminates the problem of the brine
disposal by producing crystals as valuable product. Another example of integration of
membrane units is the coupling of ultrafiltration to nanofiltration for the chromium
recovery from exhausted tanning baths. The retentate of nanofiltration has a chromium
concentration which allows the reuse of this solution for the tanning phase, while the high
concentration of sodium chloride at the permeate side allows reuse of the permeate
stream for the pickling step. The cleaning treatment thus leads to the complete
reutilisation of the produced streams.
22
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Pilot Project Updates
23
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CEVI, THE DANISH CENTRE FOR INDUSTRIAL WATER MANAGEMENT
Henrik Wenzel
Technical University of Denmark
wenzel@ipl.dtu.dk
www.cevi.org
Abstract
Running now in its fourth year, the centre has made progress with both method
development and Cleaner Production implementation in industry. This pilot project
update will report the progress within the textile industry and paper industry.
Textile industry: As described in last year's update, energy and mass integration studies
were carried out identifying large potentials for heat exchange and direct water recycle—
up to around 50% savings. The direct water recycle options were successfully tested in
lab-scale and subsequently in a small full-scale unit as a pilot test. As previously
described, the process takes place as a batchwise dyeing process followed by three
subsequent rinses at different chemical and physical conditions. A solution has been
found in which the quite clean process water from the third and last rinse is used in the
second rinse, and medium polluted process water from the second rinse is used in the first
rinse, thus leading to a kind of semi counter-current flow applied to the batchwise
operation. Two tanks are installed next to each dyeing machine that allow buffering of
the two different water types necessary for this operation. These direct water recycle
options are under implementation at present. More than 50% has been implemented and
operated with success for about 3 months; the rest is under implementation. A total of
35% water savings will be achieved, as well as substantial energy savings.
Membrane filtration was tested, both nano- and reverse osmosis, in large pilot scale.
Some problems with pre-filtration of various suspended solids were experienced. At
present, membrane filtration is still under testing; it is believed to be a solution with an
overall payback of around 3 years.
Paper industry: At the moulded cardboard paper mill within the centre, about 80% of
the energy consumption is used for drying. Therefore, the centre has had a large focus on
reducing this energy consumption. One project focused on improving drying operations,
and a potential of 10-20% savings was identified—partly in adjusting oven settings,
partly in avoiding idle running during operation stops. Another project focused on new
drying technology, which has the potential of more than 50% energy savings compared to
conventional air drying. Yet another project focuses on reducing production waste. The
waste percentage equals around 20% in total. The main problem is that the product
adheres to the conveyer plate carrying it in the oven, so that it does not leave the oven
correctly at the end of drying. This causes the conveyer belt to stop after the oven. During
stops, dried products are wasted. An analysis of how to avoid/reduce adhering of the
product to the conveyer plates is ongoing.
24
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
LIFE CYCLE ASSESSMENT OF GASOLINE BLENDING OPTIONS
Teresa M. Mata*a> Carlos A.V. Costa3, Raymond L. Smithb and Douglas M. Youngb
a Laboratory of Processes, Environment and Energy Engineering
Faculty of Engineering, University of Porto
Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
*Corresponding author tel: 351 225081687
Fax: 351225081449
tmata@fe.up.pt
b National Risk Management Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
26 W. Martin Luther King Drive
Cincinnati, OH 45268 USA
Abstract
Today, most petroleum refineries are facing the challenge of producing gasoline, which
contains the desirable properties and complies with the ever-increasing environmental
regulations and health restrictions. The impact of gasoline on the environment is directly
related to its composition and properties. Reducing volatile organic compound (VOC)
evaporative and leak emissions has assumed a high priority. Measures to control the
emissions of volatile organic compounds, resulting from the storage of gasoline and its
distribution from terminals to service stations, are defined by an EU Directive
(94/63/EC). Another EU fuels Directive (98/70/EC) specified that starting in the year
2000 a much lower Reid vapour pressure (RVP) of 60 kPa maximum be in effect for the
summer period.
Gasoline refining, storage, handling, transportation and marketing involve many distinct
operations, each of which represents a potential source of evaporation losses, as
equipment leaks result in fugitive emissions. Substances emitted to the atmosphere from
gasoline activities are the cause of many current and potential environmental problems. It
is necessary to have quantitative information on these emissions and their sources to
evaluate the potential environmental impacts (PEI) and implications of different
strategies and to set explicit objectives and constraints for environmental improvement.
In this study, a life cycle assessment has been done to compare the potential
environmental impacts of various gasoline blends that meet octane and vapour pressure
limits. This study accounts for gasoline losses due to evaporation and leaks, from
petroleum refining to vehicle refuelling, and evaluates the potential environmental
impacts using the Waste Reduction (WAR) algorithm. The results indicate that the life
cycle stage with the largest contribution to the potential environmental impacts is
gasoline production at the refinery. According to the calculations, the most interesting
25
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
impact category is photochemical ozone creation, since it has the largest and the most
variable impact values. In general, blends that decrease photochemical ozone minimise
the amounts of cracked gasoline and reformate in gasoline. However, a reformer
operating at low pressure and temperature generates much lower photochemical ozone
creation values, so that relatively less reformate and more alkylate in the blend decrease
the potential environmental effects. The results also show that blends that decrease
aquatic toxicity potential, terrestrial toxicity potential, human toxicity potential by
ingestion and acidification potential minimise the amounts of alkylate.
CLEANER ENERGY PRODUCTION WITH REUSE OF WASTE MATERIALS
FROM THE IRON AND STEEL INDUSTRY IN IGCC
Aysel T. Atimtay
Middle East Technical University
Environmental Engineering Department
06531 Ankara, Turkey
Introduction
In thermal power plants based on gasification of coal (Integrated Gasification Combined
Cycle, or IGCC), the coal gas produced contains mainly H2S and other sulfurous gases as
polluting compounds. These gases need to be cleaned with a suitable and economical
sorbent. The waste slag from iron and steel industries is a potential candidate for the
removal of these sulfurous gases from coal gas. The above-mentioned waste metal oxides
can be used in the sorption of H2S, especially at high temperatures (400-600°C).
When coal is gasified with steam and oxygen, most of the sulfur present in coal is
converted into H2S due to the reducing medium in the gasifier. H2S concentration in coal
gas from a typical gasifier is about 5000 ppmv. H2S is toxic and corrosive; and has a low
odor threshold. It is possible that H2S causes acid rain formation when it is oxidized to
S02 and/or S03 in the atmosphere. Calcium, magnesium, and other particles formed
during the gasification process cause particulate matters to be deposited on the
mechanical parts of the IGCC system, especially in turbines. Alkaline metals present in
the composition of coal such as sodium and potassium result in corrosion on the metallic
surfaces of turbines at high temperatures. Therefore, H2S and particles should be removed
from coal gas. A gas turbine in the IGCC system can tolerate about 150-200 ppmv H2S
concentration. Thus, H2S concentration in coal gas should be reduced from 5000 ppmv to
150 ppmv in order to prevent metallic parts in the IGCC system from erosion and
corrosion.
Today most of the countries produce their electrical energy from conventional thermal
power plants, which have 30-35 % energy conversion efficiency (Atimtay et al., 1990).
The IGCC system is the most promising energy producing system of systems developed
26
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
to produce electricity from coal. The conversion efficiency of heat to electrical energy in
IGCC systems will be about 53% by the year 2000 (Harrison, 1995). This is a very high
efficiency for thermal power plants. It has been estimated that a 35% reduction in C02
emissions is achievable through this improved efficiency alone (Clean Coal Technology,
1989). Moreover, IGCC provides about 30% reduction in SOX and NOX emissions. The
IGCC system can be used for Turkish coals as well for electricity production.
Studies carried out up to today show that metal oxides with suitable mixture ratios are
very successful in absorbing H2S at various temperatures. Some metal oxide mixtures are
resistant to high temperatures (about 800-850°C), whereas some of them are good at
500-600°C. Nowadays this temperature interval is preferable, since coal gasification
units run more efficiently at a 500-600°C temperature interval. From this point of view,
iron and steel industry waste materials containing FeO, MnO, CaO and some other metal
oxides are the most suitable metal oxides for the sorption of H2S thermodynamically
(Westmoreland and Harrison, 1976). Therefore, iron oxide-containing waste materials are
chosen to be used as H2S sorbent in this investigation since they are abundant and
relatively cheap. Moreover, it is thought that the presence of Si02 in those waste
materials will give structural stability to the sorbent.
The objectives of the study are:
• to study the possibility of use of waste material from the iron and steel industry in
H2S clean-up
• to find out the conditions at which the best sorption capacity and regeneration
performance are obtained
The study is carried out with the waste materials procured from KARDEMIR, one of the
integrated iron and steel plants in Turkey.
Experimental
Sufficient quantities of metal oxide waste material, called steel slag, were obtained from
an iron and steel production plant. This slag was dried at 105°C and classified to particle
size ranges of 1-2 mm, 2-3 mm, and 3-4 mm. This is the "as-received" condition of the
waste materials.
Physical Characterization
The physical characterization of the sorbents includes the BET surface area analysis and
mercury intrusion porosimetry analysis. BET surface analyses were conducted using
Micromeritics ASAP 2000. Textural properties were analyzed by Micromeritics Pore
Sizer 9310 and Mercury Porosimeter. Scanning electron microscope (SEM) photographs
were taken before and after sulfidation experiments. The name of the instrument is "Jeol
27
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
JSM-6400 Scanning Microscope". The results of the mercury porosimeter analysis are
given in Table 1.
Table 1. Mercury Porosimeter Analysis of Fresh Slags
Average pore
diameter (|j,m)
Total pore volume
(cm3/g)
Total Pore Area
(m2/g)
Bulk Density
(g/cm3)
Porosity
Steel Slag
1-2 mm
1.0090
0.0082
0.0326
6.8815
0.0564
2-3 mm
0.0521
0.0340
2.6105
3.4981
0.1189
3 - 4mm
16.5125
0.0042
0.0010
7.4510
0.0313
Zinc Slag
2-3 mm
0.2403
0.6235
10.3791
1.3116
0.3152
SEM photographs of the fresh sorbents, shown in Figure 1, indicate that the porous
structure differs from sorbent to sorbent. Some pore diameters reach up to 200 urn. The
crystalline structure can easily be seen in photographs at high magnification. Some rod-
shaped and rectangular prisms shaped particles are most probably due to Calcium
compounds present in the sorbent.
Figure 1. SEM photographs of fresh sorbents
Chemical Characterization
The waste material, the steel slag, was analyzed for its metal oxide contents by X-Ray
Spectrophotometer. The results are given in Table 2. In order to detect the crystal
structure of the sorbent before sulfidation and the different phases contained by the
sorbent after sulfidation, X-Ray Diffraction analyses were performed with Philiphs X-
Ray Diffractometer. SEM analysis was also carried out after sulfidation.
28
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Table 2. Chemical Analysis of Steel Slag (% by wt.)
%
Fe
Si02
Mn
Al
Ca
Mg
3-4 mm
16.64
21.08
5.31
1.10
25.11
4.84
2-3 mm
16.80
17.72
5.04
1.13
24.02
4.65
1-2 mm
14.68
21.63
5.19
0.96
26.83
4.69
Experimental Setup
In order to evaluate the ability of metal oxide wastes for the removal of H2S, an ambient
pressure packed-bed reactor was used. The experimental setup mainly consisted of three
parts; pressurized gas cylinders, flow meters, and a reactor-furnace system. The inlet and
outlet concentrations of H2S are analyzed by GC with a PFP detector. The schematic
diagram of the experimental setup is given in Figure 2.
Sulfidation Runs with Steel Slag
The breakthrough curves for H2S obtained from the sulfidation at 400, 500, and 600°C
with 1000-ppmv inlet H2S concentration using 2-3 mm steel slag particles as sorbent are
given in Figure 3. As can be seen from the figure, as temperature increases the H2S
sorption capacity of the sorbent increases. From the same figure, it is seen that a 200-
ppmv breakthrough concentration of H2S is reached in 200 min, 210 min, and 680 min at
reaction temperatures of 400, 500, and 600°C, respectively. Although 200-ppmv
breakthrough concentrations are defined arbitrarily, one can see from Figure 3 that no
H2S concentration can be detected in the exit gas from the reactor for 200 min (more than
3 hrs) at 500°C and about 600 min at 600°C (for 10 hrs). This is an excellent capacity for
a H2S sorbent.
29
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Vent
Quartz Reactor'
Gas Flow
Cylinders controllers
H2S
By-pass Line
Figure 2. Schematic diagram of the experimental setup
Figure 4 illustrates the breakthrough curves obtained from the sulfidation of 2-3 mm
steel slag particles with 2000-ppmv inlet HzS concentration at reaction temperatures of
400, 500, and 600°C. According to this figure, the HzS sorption capacity of the sorbent
again increases with increasing reaction temperature. The breakthrough times for 200-
ppmv exit HzS concentration are about 20 min, 55 min, and 70 min at temperatures of
400, 500, 600°C, respectively when the inlet HzS concentration is 2000 ppmv. The time
during the reaction with no exit HzS concentration is on the order of 1-hr (about 60-70
min) when the inlet HzS concentration is 2000 ppmv. This is a considerable decrease as
compared to the first case with 1000 ppmv inlet H2S concentration. It requires further
investigation to explain this result.
200 400 600
time, min
1000
Figure 3. Breakthrough Curves for HzS at Figure 4. Breakthrough Curves for HzS at
Different Temperatures with 1000 ppmv Different Temperatures with 2000 ppmv
Inlet Concentration (steel slag as sorbent) Inlet Concentration (steel slag as sorbent)
30
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The sorption capacities of the steel slag found from the breakthrough curves at different
temperatures and at two different inlet H2S concentrations are summarized in Table 3. As
can be seen from the table, the H2S sorption capacity of this sorbent is the highest at
600°C (2.20 g S /100 g sorbent) with an inlet H2S concentration of 1000 ppmv.
Table 3. Sorption Capacities of Steel Slag
Sulfur capacity
gS/lOOgSorbent
Inlet Concentrations and Sulfidation Temperatures
1000 ppmv
400°C
0.80
500°C
0.88
600°C
2.20
2000 ppmv
400°C
0.17
500°C
0.51
600°C
0.93
XRD analysis was conducted on the sulfided samples. The results of the XRD analyses
showed that FeS was formed in the sorbent after the sulfidation reaction at all
temperatures. CaS was also detected in the structure after sulfidation at 600°C.
400 °C
Figure 3. SEM photographs of the steel slag after sulfidation
31
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The change in the morphology of the sorbents can be seen in Figure 3 in the SEM
photographs, which were taken at different reaction temperatures. The shape of the
crystalline structures in the sorbent becomes more spherical as the sulfidation
temperature increases.
Regeneration Runs with Steel Slag
The regeneration of the sorbents was carried out during the cyclic tests. The temperature
was held constant at 500°C during cyclic tests. 3Vfe successive cycles (1 cycle = 1
sulfidation + 1 regeneration) were performed both for steel slag. During the regeneration
process, the sulfided sorbent is reacted with air. The metal sulfide in the reacted sorbent
is oxidized with air, and according to the following reaction, MeS + 3/202 -^MeO + S02,
metal oxides are reformed. S02 is produced during the regeneration reaction, and
concentration of S02 is analyzed again by GC with a PFP detector. The breakthrough
curves for H2S during sulfidation reaction and for S02 during regeneration reaction were
plotted against reaction time.
Cyclic Tests of Steel Slag
The sorption capacity of steel slag decreases sharply after the first sulfidation. Although
the sorption capacities in the second and third sulfidation are almost the same, the
capacity decreases again in the fourth. However, the sorbent is still useful through three
successive sulfidation runs.
The effective H2S sorption capacities of the steel slag after cyclic test are given in Table
4. The effective sorbent capacity decreases with increase in sulfidation number. The main
reason for the decrease of sorbent capacity is metal sulfate formations in the presence of
oxygen rather than metal oxide formation.
Table 4. Sorbent Capacities of Steel Slag During Cyclic Test
Sulfidation number
S-l
S-2
S-3
S-4
Sorbent capacity,
gS/1 00 g Sorbent
1.18
0.19
0.17
0.10
Conclusion
In this study the possibility of reuse of waste materials from iron steel industry in the
sorption of hydrogen sulfide from waste gases was investigated and it was found that it
may be a good candidate as a low-cost sorbent for the removal of H2S in the temperature
range of 400-600°C. The results of the sulfidation experiments showed that H2S sorption
capacities increase with temperature. The highest efficiency is achieved at 600°C and at
32
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
an inlet concentration of 1000 ppmv HzS, both for steel slag. It is seen that steel slag can
reduce the 2000-ppmv H2S concentration down to 1-2 ppmv levels before breakthrough.
The cyclic performance of the steel slag was good. The regeneration results of the
sorbents showed that steel slag lost most of its sorption capacity after the third sulfidation
run. Appreciable amounts of SOz are released during the regeneration of the sorbent.
Acknowledgement
This study was supported by TUBITAK, Project Code: 99Y030. The authors extend their
thanks to TUBITAK for supporting this project.
References
Atimtay, A.T., Gasper-Galvin, L.D., Poston, J.A., "A Supported Sorbent for Hot Gas
Desulfurization", Preprints, Fuel Chemistry Division, American Chemical Society,
Vol.35, No. 1, pp. 104, 1990.
Atimtay, A.T., Gasper-Galvin, L.D., Poston, J.A., "Novel Supported Sorbent for Hot Gas
Desulfurization", Environ. Sci. Techno!., Vol. 27 (7), pp. 1295-1303, 1993.
Grindley, T., Seinfeld, G., Development and Testing of Regenerable Hot Coal-Gas
Desulfurization Sorbents, DOE/MC/16545-1125, 1981.
Harrison, D.P., "Control of Gaseous Contaminants in IGCC Processes, an Overview",
Pittsburg Coal Conference, Pittsburg, Pennsylvania, September 1995.
Mojtahedi, W., Konttinen, J., Ylitalo, M., Lehtovaara, L., "Integrated Approach to Air
Pollution Control in an IGCC System", 10th World Clean Air Congress, Espoo, Finland,
May28-June2, 1995.
Westmoreland, P.R., Gibson, J.B., Harrison, D.P., "Evaluation of Candidate Solids for
High-Temperature Reaction Between HzS and Selected Metal Oxides", Environmental
Science and Technology, Vol. 10, pp. 659, 1976.
33
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
POLLUTION PREVENTION TOOLS
Daniel J. Murray
United States Environmental Protection Agency
Office of Research and Development
National Risk Management Research Laboratory
Cincinnati, OH, USA
murray.dan@epa.gov
Abstract
The primary pollution prevention tools that this pilot project was focused on the last
several years have been:
1. Pollution Prevention Progress (P2P Mark III)
2. WAR Algorithm (Simulated version and Stand-alone)
3. PARIS II (program for the replacement of industrial solvents)
4. TRACI (tool for the reduction and assessment of chemical impacts
5. LCAccess life cycle data portal
These products have all been completed. The P2P beta test version is available and was
demonstrated at the meeting; a pre-publication manuscript is also available. Earlier we
had reported the incorporation of WAR algorithm for process design in a commercial
process simulator. Now a stand-alone version is available; CD-ROMs were distributed at
the meeting. PARIS II has been commercialized and available through TDS, Inc. of New
York City. PARIS II is for designing benign solvent or solvent mixtures. The TRACI
beta version is now available and was distributed to those interested in testing the
product. TRACI measures environmental impacts. LCAccess is already up and running.
This web-based product is planned to be continually updated as newer LCA data sources
are made available for linkage.
A new version of the EPA pollution prevention manual has been completed. "An
Organizational Guide to Pollution Prevention" expands on previous EPA guidance on
how to establish a pollution prevention program by including four different approaches to
implementing a pollution prevention program in an organization. With an accompanying
CD-ROM tool, this will provide the most comprehensive view of pollution prevention.
34
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Slide 1
Pilot
Products and Pr
U.S. EPA Pollution Prevention and Cleaner Production Tools
LCAccess: Making Life Cycle Data
Available via the Internet
Portal/Web Site to provide access to life
cycle inventory data designed to:
increase awareness of existing life cycle
inventory data sources;
provide direction on how and where to
access data sources; and
document data quality
www. epa. gov/O RD/N RM RL/lcaccess
Slide 2
Pilot
Oie»«productsaild
U.S. EPA Pollution Prevention and Cleaner Production Tools
Organizational Guide to Pollution Prevention
Third Generation P2 Guide: Waste Minimization Opportunity Assessment
Manual (1988); Facility Pollution Prevention Guide (1992)
Integrates Environmental Management Systems (EMS) Thinking into P2
Provides Comprehensive Guidance on P2 Implementation Using
Traditional Approaches, EMS, and the Quality Model
Accompanying CD-ROM Provides Extensive Collection of Related
Documents and Internet Links
www.epa.gov/ttbnrmrl
35
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Slide 3
CCMS Pilot
products and
U.S. EPA Pollution Prevention and Cleaner Production Tools
IUO
Downloads
Fact sheets
Order NOW
PARISTLinks
IDS Home
Program for Assisting the Replacement of
Industrial Solvents - Version 2 (PARIS II)
Tool for Identifying Pure Chemicals or Designing Mixtures
that Can Serve as Alternative Solvents
"Greener" Solvents Have Improved Environmental
Properties with Equivalent Solvent Performance
Properties
Provides Cost-Effective Approach because New
Solvents Can Be Substituted without Equipment
Changes or Process Changes
www.tds.ee
Slide 4
CCMS Pilot
Products and P
U.S. EPA Pollution Prevention and Cleaner Production Tools
Pollution Prevention Progress - P2P
Pollutant Classification System
Includes a Database of over 5600
Chemicals
Will Classify Chemicals in 22
Environmental Impact Categories (e.g.,
Ozone Depletion, Global Warming)
bare.jane@epa.gov
36
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Slide 5
CCMS Pilot
products and
U.S. EPA Pollution Prevention and Cleaner Production Tools
Tool for the Reduction and
Assessment of Chemical and Other
Environmental Impacts - TRACI
TRACI
OpfcoA OUcnB
Impact Assessment Tool Using Nine
Chemical Impact Categories and
Three Resource Use Categories
Assesses Various Chemicals to
Assist in P2, LCA and Sustainability
Programs
bare.jane@epa.gov
Slide 6
CCMS Pilot
Products and P
U.S. EPA Pollution Prevention and Cleaner Production Tools
Chemical Process Simulation for Waste Reduction: WAR Algorithm
Design Methodology for Waste Reduction to Minimize Impacts of
Chemical Processes
Develops a Potential Environmental Impact (PEI) for Chemical
Processes
WAR Attempts to Minimize the PEI Rather than the Amount of Waste
WAR is Integrated into Chemical Process Simulator ChemCAD IV
under an Agreement with Chemstations, Inc.
WAR GUI Allows for Comparative Assessment of Different Process
Designs without Process Simulator
young.douglas@epa.gov
37
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
38
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
University-Industry Cooperation
39
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
AN UPDATE ON GOVERNMENT SUPPORT FOR CLEAN PRODUCTS AND
PROCESSES IN THE UNITED KINGDOM
Prof. Jim Swindall QBE
QUESTOR, QUILL and QUMED Centres
The Queen's University of Belfast
Northern Ireland, UK
i.swindall@qub.ac.uk
Abstract
There have been four significant funding developments: the STI (Sustainable Technology
Initiative), the MMI (Manufacturing Molecules Initiative), the new Faraday Centres and
SRIF (Science Research Investment Fund).
The STI is a programme to support collaborative research and development aimed at
improving the sustainability of UK business. It is funded by the DTI, EPSRC and ESRC
and will operate as follows:
A LINK programme, funded by DTI and EPSRC (£5M each) which provides up to 50%
funding for collaborative R&D projects between businesses and universities; DTI grants
(£5M budget) to businesses for collaborative projects; up to 50% of eligible costs;
EPSRC funding for networks (£60K) and ESRC grants to academia (£3M). The total
funding available is £18M (£10M from DTI, £5M from EPSRC and £3M from ESRC)
over five years.
For MMI £3 million of Government funding is available for a wide variety of activities:
LINK projects, general and specialist training, technology transfer, demonstrator and
pilot projects. Environmentally sound manufacturing is one criteria for a successful grant
application.
An existing initiative, called The Faraday Partnerships, named after Michael Faraday,
who maintained strong links with industry while pursuing fundamental research, has two
new Faraday Centres in the area of clean technology.
Green Technology for the Chemical and Allied Industry
The CRYSTAL Faraday Partnership seeks to improve and develop the UK Science and
technology base by providing a virtual centre of excellence in low cost, sustainable
("green") manufacturing technologies and practices. The UK's three major chemical
industry-oriented organisations, IChemE, CIA and RSC, have joined forces to form the
hub of the CRYSTAL Faraday Partnership.
40
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Remediation of the Polluted Environment
This Faraday Partnership will facilitate research, training and technology transfer for the
remediation of polluted land and water by biological as well as physical and chemical
methods, especially in the subsurface environment. The Faraday Partnership will interact
with a wide network of SMEs and larger companies, both technology providers and
problem holders (of contaminated sites).
The Research Council sponsor(s) will provide up to £1M to each Faraday Partnership on
a pump-priming basis. DTI/SE will provide additional grant funding of up to £1.2M over
3 years to each Faraday Partnership but with the possibility of a further 2 years support if
recommended after an interim evaluation.
SRIF funding of £1 billion is being made available throughout the UK during 2002-2004.
Some of this will fund clean technology projects such as the £2.4 million Environmental
Engineering and Biotechnology project at the QUESTOR Centre.
WASTE MINIMIZATION, REVALORISATION AND RECYCLING OF SOLID
WASTES IN SPAIN
Prof. Jose Coca Prados
Department of Chemical Engineering and Environmental Technology
University of Oviedo
Oviedo, Spain
jcp@sauron.quimica.uniovi.es
http ://www.uniovi. esMngenieria. quimica
Abstract
Solid wastes, including home trash, have become a serious problem that encompasses a
range of social, political, and technical issues. The first efforts in managing these wastes
were focused on avoiding the environmental and health problems derived from their
inappropriate disposal. However, in the last decades, the increasing amounts of solid
wastes have led to more complex waste management with potential economical benefits.
Regarding municipal solid wastes (MSW), the key decision is whether to dispose them by
incineration or landfill disposal. However, new trends include alternatives such as
recycling (metals, glass, paper, etc.), composting, and anaerobic digestion, along with
redesigning of conventional processes. Thus, recovery of biogas is the most important
issue in the design of a sanitary landfill, whereas heat recovery is a major issue in the
design of MSW incinerators.
41
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
New processes and the application of new tools to waste management, such as the life-
cycle assessment approach, lead to the concept of Integrated Solid Waste Management.
This concept includes three hierarchical steps: Source reduction, recycling and disposal.
Regarding the final disposal of solid wastes, the choice between the conventional
alternatives of land filling and incineration depends basically on the availability of land.
Countries like the UK or USA tend to use mainly land filling, whereas in Denmark,
Netherlands, Belgium or Germany, the choice is incineration as final treatment of MSW.
In Spain, land filling is the most common alternative. However, in the last years, in
several regions, especially the most populated ones (Madrid, Catalonia, Balearic Islands,
and partially Galicia), incineration has received a lot of attention. Leakages from the
landfill sites are collected and treated. In the region of Asturias, all the biogas produced is
recovered and valorizated (as heat/steam for its use in nearby facilities and electric power
production). More details on this latter process were presented at the meeting.
Concerning industrial wastes, the waste treatment processes are more complex. The
available alternatives in hierarchical order are: Source reduction, in-process recycling,
on-site recycling, off-site recycling, waste treatment to render the waste less hazardous or
voluminous, secure disposal, and direct release to the environment. Major efforts have
been devoted to the first alternative.
25
"
•a 20 H
o
15-
00
0
500000
400000 ^
rt
300000 >,
fe
200000 Eo
100000 ~
0
1993 1995 1997 1999
year
a. Industrial solid wastes (ISW)
1 6H
oo
ffi
4-
2-
0
4000
3000
2000
1000
0
1993 1995 1997 1999 2001
year
b. Hazardous solid wastes (HSW^
Fig. 1. Evolution of solid wastes in Spain since the Responsible Care program was
established
These practices, that in the case of Spain were developed in the framework of the
international program Responsible Care, were adopted by Spanish industries in 1993 and
have led to a decrease of both amount and hazard of the wastes, as shown in Fig. 1
42
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
PRESENTATION OF LITHUANIAN CLEANER PRODUCTION CENTRE
Prof. Jurgis K. Stanislas
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
iurgis.staniskis@apini.ktu.lt
Abstract
It is increasingly recognized that solution of the most pressing environmental problems
requires a consolidated efforts of all stakeholders, particularly industry, government and
academia. In Lithuania, these groups lack the awareness, knowledge and resources to be
fully effective in promoting and implementing cleaner production (CP). Generally,
industry and other stakeholders are not familiar with preventive approaches and the
potential benefits they can bring. The Lithuanian Cleaner Production Centre established
at the Institute of Environmental Engineering (APINI), Kaunas University of Technology
acts as a catalyst for sparking interest in CP and providing services to allow for its
implementation. In various programmes performed by the Centre, more than 150
Lithuanian companies and other organisations took part.
CP training can be offered in two ways: (i) as an integral part of the formal education
system in universities, or (ii) as continuing education courses. The former has a long-term
perspective and may serve the training needs of future specialists, while the latter has a
short term perspective and has proven to be the most efficient way of training people
currently working in industry. These two approaches complement each and both are
necessary to build national capacity in CP. In Lithuania, only the Lithuanian CP Centre at
the Institute of Environmental Engineering provides courses on CP. A new M.Sc.
Programme in Environmental Management and Cleaner Production developed by the
experts of the Centre in cooperation with technical universities in the Baltic Sea region
(BALTECH consortium) is particularly important in this regard. In terms of post-
education training, the Lithuanian CP Centre provides long-term training programmes
emphasizing on-the-job training as this is the most effective way to create domestic
professional capacities. The staff of the Centre trained more than 80 persons from
Lithuanian industrial companies in 1995-2002.
To demonstrate CP potential, i.e., the economic and environmental benefits of CP
measures, there is a need to implement demonstration projects. The demonstrations are
usually carried out in selected enterprises with the ultimate goal of catalysing interest in
CP by participating and other enterprises. To increase the value added of demonstration
projects, the Lithuanian CP Centre aims to ensure that such projects consist of more than
installing a piece of equipment: hardware is seen as a means, not an end in itself. The
methodology used in identifying and implementing CP measures is a very important part
of demonstration projects implemented by the Centre.
43
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
To achieve CP sustainability in the country, there is a need to continue training
programmes and demonstration projects while also strengthening information output. In
addition to development and dissemination of case studies, the Lithuanian CP Centre also
uses other possibilities for information dissemination, e.g., seminars and workshops,
direct contacts with enterprises, and articles in different publications.
Very often enterprises require on-site technical assistance from external parties in
increasing efficiency of their operations. The Lithuanian CP Centre provides training for
experts from industrial enterprises and leading specialists from other organisations and
technical assistance to Lithuanian industrial enterprises in the following areas related to
sustainable industrial development: cleaner production and industrial ecology; financial
engineering aimed at development of cleaner production projects for loan financing;
environmental and quality management systems and standards; and product related
measures.
One of the obstacles in conducting CP assessments in enterprises is lack of technical
information. A modern environmental laboratory specialised for research and technical
assistance programmes in enterprises established at the Lithuanian CP Centre enables
sampling and monitoring of environmental parameters related to pollution generated by
enterprises, analysis and technical evaluation of material and energy losses in production
processes, and detection of the sources and emissions of pollutants. The laboratory
includes stationary and portable devices.
The experience of the Lithuanian CP Centre shows that environmental management
systems (EMS) have quickly become an issue for companies in Lithuania, particularly for
larger exporters. However, it should be pointed out that enterprises often perceive
environmental management systems as a certificate that has to be obtained for
overcoming a new trade barrier rather than a tool to increase their efficiency and improve
environmental performance. In such cases, the potential of EMS is not being fully
utilised. The work of the Lithuania CP Centre on EMS and CP integration helps to
increase the effectiveness of environmental management systems and ensure that EMS
leads to continuous improvement in the environmental performance. To date, the Centre
in EMS implementation has consulted more than 15 companies. These companies have
been certified in accordance to the ISO 14001 standard. The Centre was also closely
involved in developing conditions and principles for the national accreditation and
certification system in Lithuania.
While the experts of Lithuanian CP Centre have implemented a number of projects in
Lithuanian companies with assistance of different foreign institutions and financial
support from several donor countries in respect to technological processes, the field of
cleaner products is generally unexplored. Product oriented approaches such as eco-
design, life-cycle assessments have yet to be analysed more deeply in Lithuania and the
ways to get the best use of these approaches are yet to be found. The Lithuanian CP
Centre recently started research activities and initiated its first projects in the area of
cleaner products. The Centre's unit in Vilnius is particularly active in this area.
44
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The key role of governmental institutions in promoting CP is to establish a policy
framework, which provides appropriate incentives for enterprises to adopt preventive
environmental management practices and to increase their efficiency. The Lithuanian CP
Centre provides government institutions with policy analysis and advice on the
instruments that are most effective for promoting CP initiatives and sustainable industrial
development. Experts of the Lithuanian CP Centre developed the National Strategy for
CP Implementation and National Programme for Sustainable Industrial Development.
The availability of financing for CP investments is in many instances a necessary
condition for implementation of CP. Ideally, enterprises should raise money themselves
to finance CP investments. However, the capacity of enterprises to do so is often
constrained by different internal and external obstacles. The Lithuanian CP Centre plays
an important role in project identification, preparation, appraisal and monitoring within a
Revolving Facility established by the Nordic Environment Finance Corporation
(NEFCO) for financing of priority CP investments. To date, more than 30 CP investment
projects have been developed and financed by NEFCO in Lithuania.
The concept of total cost assessment/environmental management accounting facilitates
self-regulation within industry by building a voluntary proactive approach to source
reduction into corporate decision-making. Unlike the command and control regulations to
ensure proper management of wastes already created, the role of authorities in promoting
prevention might therefore be more appropriately viewed as catalytic—pressing industry
to identify pollution prevention opportunities which serve both their own and the public's
interest.
As long as the material components of products are largely based on the use of virgin
resources, while energy is derived from fossil fuels, there is no way by preventive
management to reduce the output of wastes and pollutants below a certain minimum
point. Unless, the product cycle and materials cycle are (very nearly) closed, the system
as a whole will continue to be unsustainable. In this case, preventive and reactive
environmental strategies have to be used as a feed forward-feedback management
structure.
To ensure successful operation of the Centre, there is a need to ensure continuing
capacity development. The Lithuanian CP Centre co-operates with similar institutions in
other countries, a number of foreign universities, international organizations and
international financial institutions. Experts of the Centre also participate in capacity
development and experience transfer projects in developing countries.
45
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
PROGRAMS OF THE US NATIONAL SCIENCE FOUNDATION RELATED TO
CLEAN PROCESSING
Dr. Thomas W. Chapman, Acting Director
Division of Chemical and Transport Systems
National Science Foundation
Arlington, Virginia
Professor Emeritus
Chemical Engineering Department
University of Wisconsin-Madison USA
tchapman@nsf.gov
Abstract
The National Science Foundation (NSF) is the single national agency in the United States
with the sole mission of supporting basic research and education in science and
engineering. NSF does no research in-house; rather it is one of the primary sources of
funding for research in American universities. The total budget for the current fiscal year
is $4.8 billion.
The activities supported by NSF are organized around three basic themes: people, ideas,
and tools. All proposals for funding are reviewed by the peer community and evaluated
in terms of two general criteria: intellectual merit and potential impact.
Although NSF encourages unsolicited proposals for research on all appropriate areas of
science and engineering, it does identify certain priority areas and solicits proposals that
address specific problems. In this talk, the major research thrusts and program areas that
are related to clean processing were summarized briefly. The 10-year environmental-
vision document NSF is currently drafting was also discussed.
One current initiative of NSF is called "Biocomplexity in the Environment," which
includes an element called "Materials Use: Science, Engineering, and Society." An
Engineering Directorate program that is run jointly with the Environmental Protection
Agency, "Technology for a Sustainable Environment," seeks to promote research on
pollution prevention, with an emphasis on Green Chemistry and Engineering. Earlier this
spring we supported a workshop on capture of carbon dioxide as a target greenhouse gas,
and subsequent discussions with the U.S. Department of Energy may lead to a joint
grants program. It is hoped that my presentation helped to identify opportunities for
collaboration between U.S. and European researchers in this important area.
46
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CERAMIC MEMBRANE APPLICATIONS IN CLEAN PROCESSES IN RUSSIA
Gueorgui G. Kagramanov, Tatyana V. Kisseleva
Moscow Mendeleyev University of Chemical Technology of Russia
Department of Chemical Engineering
Chair of Membrane Technology
125047 Miusskayasq. 9
Moscow, Russia.
sark@muctr.edu.ru; kadri@muctr.edu.ru
Tel/Fax 978-82-60
Fax 200-42-04
Production and applications of the ceramic micro- and ultrafiltration membranes,
modules and units, based on these membranes, in spite of the economic situation in
Russia, demonstrate a stable rise. Due to the unique properties of ceramic membranes—
chemical, microbiological and thermal stabilities, mechanical strength, possibility of
regeneration (using rigorous media and back-washing), long life-time etc.,—they could
have been employed in any one of the branches of industry and life. But one of their
disadvantages (and the most important one), the relatively high price, showed the way
out—to replace the polymeric membranes in the filtration systems in food,
microbiological, pharmaceutical branches of industry, potable water treatment systems
etc., as well as in processes with rigorous technological parameters, using aggressive,
corrosive and abrasive media, i.e., in production of "clean products" by "clean
processes."
Results from the research works [1-3] reveal the influence of basic technological
parameters on quantitative characteristics of membrane separation processes, such as
filtration rate and selectivity—the technologies of milk treatment, purification of wines,
natural, recycling and waste waters (including cutting fluids), diesel fuels, natural and
technological gases have been developed and commercialized.
The corresponding technological parameters and data of combined processes, apparatus
and units realized in Russia in pilot and industrial scales are presented in the following
text.
Membranes
Ceramic membranes produced in Russia are made of aluminium oxide (supports or
substrates) coated by microfiltration (MF) and, consequently, ultrafiltration (UF)
selective layers. MF selective layers are formed either of AlzOs and ZrOz powders or of
SiC microfibers. UF membranes are produced using SiOz, TiOz, ZrOz and CeOz sols.
Some characteristics of MF and UF membranes are presented in Tables 1 and 2.
47
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Table 1. Characteristics of MF ceramic membranes of
(support) and coated by a-
or
M
1
2
3
4
Type
^LIOoo oCLUOIl/ Ol
membrane element
cylindrical
cylindrical
cylindrical
hexagonal
Number of
channels
1
1
7
19
Geometry
Length,
mm
800 - 900
800 - 900
800 - 900
800 - 900
Diameter,
mm
8x6
10x6
22
29
(spanner)
Channel
diameter, mm
6
6
4
3.8
Porosity, %
Substrate
40-45
40-45
40-45
40-45
Selective
layer
40
40
40
40
Pore diameter, mem
Substrate
3-5
4-6
5-10
10-15
Selective
layer
0.8-1.0
0.2-0.4
1.0-1.5
0.2-0.4
1.0-1.5
0.2-0.4
1.5-2.0
0.2-0.4
Distilled water
permeability,
m3/(m2-h-bar)
4.8-5.6
2.0-2.2
4.8-6.2
1.8-2.0
4.4-5.4
1.8-2.0
4.4-5.0
1.6-1.8
48
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Table 2. Characteristics of UF ceramic membranes with a-Al2Os supports. Pressure difference AP = 1 bar
Selective
layer's
material
Si02
Zr02
Ti02
Ce02
Number of
selective
layers
1
2
3
1
2
3
1
2
3
1
2
3
4
Mean pores
diameter,
mm
70
15
3
70
30
15
70
25
7
70
30
15
10
Permeability coefficient, m3/(m2-h-bar)-103
Distilled
water
145
100
50
400
250
150
610
320
55
1100
650
150
55
Si02 sol
40
25
12
50
30
15
57
35
15
60
40
23
15
PVP, molecular
massM = 40-103
58
47
32
110
78
60
90
65
35
-
Apple
pectine
29
26
19
62
33
19
-
-
Selectivity, %
Si02 sol
98.0
99.2
99.9
98.9
99.1
99.1
97.5
99.3
99.4
92.5
99.0
99.9
99.9
PVP,
M = 40-103
98.9
99.3
99.6
66.0
81.5
83.6
72.5
83.2
89.9
-
Apple
pectine
93.6
95.1
96.6
86.0
93.5
93.8
-
-
49
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The solutions tested (table 2) were:
• SiOz sol with solid phase particles of 30 nm in diameter; concentration of Si02
5 % weight;
• water solution of polyvynilpirrolidon (1 % weight) with molecular mass of 1 1 1
360 000;
• water solution of the apple pectine (2 % weight) with molecular mass 50 000
200 000.
Modules
The characteristics of modules with ceramic membranes produced in Russia are
presented in Table 3 and Figure 1.
Table 3. Basic characteristics of membrane modules, using multichanneled (19)
membranes. Construction material - stainless steel
Parameters
Quantity of membrane
elements
Filtration area, m2
Filtration rate (potable
water), not less, m3/h
Length, m
Diameter, m
Weight, kg
Type of module
FC-3
3
0.6
0.20
1.00
0.10
10
FC-7
7
1.40
0.40
1.10
0.13
20
FC-19
19
3.8
1.50
1.16
0.22
38
FC-37
(in design)
37
7.4
2.9
1.25
0.33
56
50
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Fig. 1. Modules with ceramic membranes.
51
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Table 4. Membrane MF and UF systems
Type of process
1
1 . Filtration of
biomass% in
production of
a)Bi2
b)erithromicine
c) lizine
2. Purification of
enzymes
3.
Microfiltration
of milk
4. Clarification of
beverages, fruit
extracts and
syrups
5.
Purification of
wines
6. Regeneration of
transformator
oil
7. Mineral water
purification
8. Potable water
purification
9. Waste waters
purification
Pore
diameter,
mem
2
0.2
0.2
0.2
0.2
0.2
0.8
0.2
0.2
0.2
0.2
0.2
0.02
0.2
Tempera-
ture, °C
3
110
40
50
40
55
55
70-80
10
70-80
20
20-30
20-30
Filtration
rate,
m3/m2-h
4
0.4
0.06 -
0.08
0.12 -
0.16
0.13
0.08
0.5-0.7
0.06 -
0.10
0.15 -
0.25
0.30
0.5-0.9
0.7-1.2
0.2-0.5
0.1-0.2
Filtration
area, m2
5
20
110
160
1.1
pilot
unit
0.015
1.1; 4.0
10; 20
4
2; 8
0.05 -
20
3.8 - 7.6
Notes
6
Designed
capacity
290m2
-
retention
of fats
99.9 %
(for
0.2 mem)
-
retention
of micro-
organ-
isms to
99.99 %
electrical
resistance
rise from
0 to 24.5
kV/cm
retention
of iron
compa
retention
of heavy
metals
Company
7
Biokon
Biokon
Biokon
Zvezda,
Biokon
Zvezda,
Biokon
Biokon
Zvezda,
Biokon
Zvezda
Zvezda
52
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
1
10. Cutting fluids
purification
a) coagulation and MF
b) coagulation and UF
11.
Purification of Diesel
fuel
12. Purification of natural
and technological
gases
2
0.2
0.02
0.2
0.02
0.2
3
40
40
40
40
40
4
0.08 -
0.10
0.03 -
0.05
0.17 -
0.20
0.06 -
0.07
up to
6000
5
pilot
unit,
0.1
pilot
unit,
1.4
3.8
0.3
pilot
unit,
0.15
6
retention of heavy
metals
organic components
and deemulsification
up to 68 %
up to 68 %
retention of
dispersed particles
up to 99.99 %
7
d
v z
Zvezda
The developed technologies are generally environmentally friendly, in both prevention of
pollution and in remediation of pollution.
Literature
1. Kagramanov G. G., Kocharov R. G., Dubrovin A. A. The study of water purification
from cations by ceramic microfilters // Chemical Technology. - 2001. - N 1. - P. 42
- 46 (in Russ.).
2. Kagramanov G. G. et al. Development of Technology for Utilization of
Lubrificant Cooling Liquids with the Aid of Ceramic Membranes // Chemical
Industry. - 1998. - N 5. - P. 23 - 27 (in Russ.).
3. Zyabrev A. F., Limitovsky A. B., Kunin A. I. Biokon Membrane Systems for
Ultra- and Microfiltration. Application in Various Branches of Industry //
Membranes. - 2001. - N 11. - P. 21 - 31 (in Russ.).
53
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
54
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Industrial Ecology
55
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
INDUSTRIES OF THE FUTURE: PARTNERSHIPS FOR IMPROVING ENERGY
EFFICIENCY, ENVIRONMENTAL PERFORMANCE AND PRODUCTIVITY
Steven C. Weiner
Pacific Northwest National Laboratory
Washington, DC, USA
sc.weiner@pnl.gov
Good morning. I am pleased to be here and have the opportunity to share with you the
Industries of the Future program of the U.S. Department of Energy. Several years ago,
you had the opportunity to hear from Lou Divone on a related subject. Since I can't
possibly cover it all, what I would like to do today is (1) provide an overview of the
Industries of the Future program, (2) use the chemical industry's Vision 2020 as a
specific example, and (3) provide some examples within this program that illustrate the
range of technology options from long-term research to practical, decision assessment
tools of value to manufacturing facilities.
The U.S. Department of Energy, as a mission-driven agency, is charged with helping
energy- and waste-intensive industries to improve their resource efficiency. As the
Industries of the Future program delivers energy efficiency, it also means reducing waste,
enhancing environmental performance, lowering production costs and increasing
productivity and boosting competitiveness.
The Industries of the Future strategy seeks to improve industrial energy efficiency and
productivity with two primary thrusts: (1) provide support of collaborative R&D planning
and implementation to give industry the advanced technologies it will need in the future,
and (2) help plants select and implement the best practices and technologies available
today—such as enhancing current operations through improved motor and pump systems,
for example.
In reality, Industries of the Future is: (1) a collaboration at the intersection of industry's
long-term needs and the goal of energy efficiency leading to improved environmental
performance and increased productivity, and (2) a partnership of the combined resources
of industry, academia, and government to tackle tough technical challenges, requiring
advanced science and technology options.
This continuum is another way to look at opportunities for research and development,
demonstration, and deployment of advanced industrial technologies. The lOFs (in the
industrial sectors) and crosscutting R&D programs tend to focus on projects in the mid-
to long-term stage of development, though some projects have moved to the
demonstration stage. The Emerging Technology programs focus on more near-term
applications and deployment of technologies. The Best Practices programs focus on
helping industry make better use of technologies that are available today.
56
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The key message is that the IOF process itself is an industry-led process. All parts of an
industry come together to define their current situation, identify key challenges, and
describe what they need and want to be like 20 years from now in order to be sustainably
competitive. Each industry defines its own goals (vision), creates a research agenda
(roadmap), and then forms public-private R&D partnerships. The process brings together
high-level decision makers—many of them competitors—to identify their common
technology challenges. The process underscores shared needs and lays the groundwork
for collaboration on mutually beneficial projects. Industry gains a strong voice in the
leveraged allocation of federal research dollars. In fact, state governments across the U.S.
are also using this model to develop strategies to help strengthen industries within their
states and regions.
What this means at the plant level is that you have a number of ways for technology to
provide solutions to achieve, for example, lower energy costs, increased productivity,
reduced NOx control costs and single digit NOx.
Let's turn to a specific example, the chemical industry's Vision 2020. I won't have time
to go into the specific elements of Vision 2020, but you can find the vision at
www.chemicalvision2020.org. The charter of the sponsoring organizations including the
American Institute of Chemical Engineers was three-fold:
• To provide vision and identification of technical needs critical to the chemical
industry's competitiveness.
• To strengthen cooperation among industry, government and academia, an element
that brought many participants to the visioning process.
• To provide direction for continuous improvement and step-change technology,
recognizing that incremental technology won't get one to Vision 2020.
In order to cover the chemical enterprise (even to the extent of some overlap), the
sponsors focused on these areas: New Chemical Science and Engineering Technology,
Information Systems, Supply Chain Management, and Manufacturing and Operations.
For example, areas in which needs were identified under New Chemical Science and
Engineering Technology include: new chemistries, catalyst screening, process
intensification (e.g., combining unit operations such as reaction/separation), CFD,
materials of construction, "smart" materials. Development of technology at the interface
of chemistry, biology, and physics received considerable emphasis. On the issue of the
intersection of these four areas, although I won't cover information systems in depth, it is
clear the profound impact that information systems (infrastructure, business and
enterprise management, product and process design and development, and
manufacturing) are having and can have on the future of the entire chemical enterprise.
57
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
So if we superimpose Vision 2020 and the Industries of the Future model, this is how we
might depict the program. For example, over a several year period, technology roadmaps
were developed in the following areas:
• Biocatalysis
• Computational and Combinatorial Chemistry
• Computational Fluid Dynamics
• New Process Chemistry
• Materials of Construction
• Materials Technology
• Separations
• Reaction Engineering
• Process Measurement and Control
Now, I would like to provide some examples of projects and technologies to illustrate
different aspects of the Chemical Industry of the Future program.
Computational fluid dynamic (CFD) modeling tools are proving an attractive alternative
to costly and time-consuming experimentation. However, limitations in existing
modeling tools slow broader application of the technology, e.g., model complexity, which
hinders use by operating engineers; lack of integration between models; and limited
capacity to model the reacting and multi-phase flows common in many chemical
processes.
One of the steps identified to achieve the goals of Vision 2020 is to capitalize on
information technology and computational power, both to integrate operations and
scientific computing innovations, as well as to develop molecular and fluid dynamic
modeling tools.
Vision 2020 inspired this consortium to tackle modeling of multi-phase flows, beginning
with gas-solid reactions and turbulence typical of fluid-bed reactors. By solving these
issues, gas-solid flow operating capacity could be improved.
This extensive list of participants is indicative of my earlier comment regarding
cooperation among industry, government laboratories, and academia. From an industrial
point-of-view, competitive advantage will come not from the development of these tools
(which can be expensive!), but from the application of these tools to their specific
processes.
The intelligent extruder system, targeting the extruded and molded plastics industry, will
use advanced diagnostic and control tools to reduce product variability and increase first-
pass yield, while reducing energy use and waste generation in the compounding of
polymer resin. Inferential sensors and closed-loop process controls are to be used to
adjust key process parameters when material properties are detected.
58
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Expected benefits include: improvement of first-pass yield of compounding processes,
cost and process savings of raw materials, energy savings, volatile and solid waste
reduction, and cost-effective production of smaller lots of material.
Ultrasonic tank cleaning allows industries to clean process tanks and eliminate the use of
chemical solvents. The ultrasonic resonator (developed by Telesonic, Inc.) cleans tanks
more thoroughly and quickly than solvents, uses less energy, and reduces labor and
material costs. By eliminating the need to process spent solvents, ultrasonic cleaning also
eliminates emissions of VOCs and the generation of hazardous wastes.
In 10 test applications sponsored by OIT at DuPont-Merck, cleaning time was reduced by
86 percent and 6,100 pounds of cleaning solvent were saved. The overall energy savings
can be scaled up to estimate facility wide annual savings that is equivalent of 605 barrels
of oil. For this project, the DuPont-Merck facility in Deepwater, NJ, received one of three
Technology Commercialization Awards from the U.S. Department of Energy.
How does this example fit Vision 2020? One of the identified challenges in Vision 2020
is to increase agility in manufacturing. Agility has many components. As one element,
think of manufacturing facilities planned to provide core production capabilities, rather
than specific products, that is, process equipment that can be easily reconfigured,
combined with management systems that facilitate change as an integral part of the
production capability. Cleaning tanks more rapidly can be one element of increasing the
agility of the overall operation.
Along the same lines, here's another example. A robotic tank inspection system is being
demonstrated at two BPAmoco facilities in Texas and Louisiana, and the benefits that
will be derived include: energy savings and reduced emissions in addition to lower costs
and reduced downtime.
Now let's turn to Best Practices. Best Practices is the implementation approach of
Industries of the Future, transferring energy saving products and providing energy-saving
services through energy management experts. The goal is to assist the partner industries
and their supporting industries in identifying and realizing their best energy-efficiency
and pollution prevention options from a system and life-cycle cost perspective. I am
going to focus the balance of my talk on one aspect of Best Practices—software decision
tools and databases. Best Practices software decision tools can be used to choose, apply,
and maintain electric motors and adjustable speed drives, to calculate the economic
thickness of industrial insulation, or to assess a pumping system. Databases help locate
motor manufacturers and service providers or find energy, waste, and productivity
recommendations (nearly 42,000!) that have been made to other manufacturing facilities.
Here are some of the software tools that are available. Motor Master+ 3.0 is used for
repair and/or replacement decision-making. ASD Master is used for screening adjustable
speed drive upgrades. Let's look at the Pump System Assessment Tool in more detail.
59
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The Pumping System Assessment Tool (PSAT), developed for DOE at the Oak Ridge
National Laboratory is designed to help end users, ranging from operators to engineers to:
• Assess and calculate energy and cost savings opportunities in pumping systems
• Evaluate how well suited a pump is to a particular service application
• Generate "What If assessments, following the pumping system head-capacity
curve
• Examine pumping systems, for situations where prescreening indicates that a
closer look is warranted.
The general methodology of the PSAT software treats the system as a black box. The
PSAT software estimates existing, "optimal" pump and motor efficiencies, and associated
operating costs using the motor power or current (input), the flow rate and head (output),
and nameplate information. These answers are based on average motor performance
characteristics from the MotorMaster database and using Hydraulic Institute algorithms
for achievable pump efficiency (Hydraulic Institute Standard ANSI/HI-1.3, Centrifugal
Pump Design and Application, 1994).
On the main menu and data input screens, the information in the left third of the screen is
the input data such as general nameplate-type information and field measurements of
flow rate, head, and either motor power or current. The results are shown on the right.
The Optimization Rating is like a grade—a rating of 100 is a "perfect" score—the pump
and motor combination doing as well as can be expected. A grade of 50 means that twice
as much energy is being used as would be with an optimal configuration. On the bottom
right are the calculated potential energy and cost savings of a system optimized to work
at peak efficiency, which can be used in life cycle cost or simple return on investment
calculations.
Here are some of the other tools that are also available:
• 3E Plus for insulation materials under varying operating conditions
• Air Master+ for compressed air systems
• Steam Scoping Tool for steam systems
Finally, let me say that much more detail is available on the website. Fact sheets for each
of the projects are available, as well as all aspects of the Industries of the Future program.
I hope I have given you a good, even if brief, picture of the Industries of the Future
program.
In conclusion, let me express my appreciation for having the U.S. Department of Energy
participate in this NATO Pilot Study meeting and my interest in your ideas as to how we
might strengthen this cooperation in the future. I also wish to thank our hosts for the
hospitality that they have shown to us. Thank you.
60
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
FROM POLLUTION CONTROL TO INDUSTRIAL ECOLOGY AND
SUSTAINABLE DEVELOPMENT
Prof. Lennart Nilson
Royal Stockholm Technical Institute
Dept of Chemical Engineering and Technology
Stockholm, Sweden
mailto:lennart@ima.kth.se
Abstract
It is increasingly evident that the current patterns of consumption and production of
society, business, and industry are not sustainable. The enormous economic and
population growth worldwide over the last four decades have together driven the impacts
that threaten the health and well-being of our communities and nations—ozone depletion,
climate change, depletion and fouling of natural resources, and extensive loss of
biodiversity and habitat.
These impacts on the environment from industry and society, made, during the first
century of industrialisation, little impact on the awareness of their ecological effects.
Comments on emissions of noxious gases from pulping industries for example were "It
smells like money..." rather than "can this be hazardous...?"
It had to take a number of serious pollution related incident and accidents before the
awareness of the dangers of the effects of emissions from industry and society on health
and environment started to result in action.
In the middle of the 20th century, efforts centered on reducing the environmental effects
by diluting the air emissions by building high chimneys and leading polluted waste water
in long pipes far from the shores into deep water, hoping that nature could assimilate and
degrade all pollutants if the concentrations could be kept low enough.
It became evident in the 60s and 70s that "the solution to pollution was NOT dilution,"
especially as it was recognized that environmental impact was not a local problem, but
that long-distance and trans-border transport of pollutants was a major contribution to the
acidification problems in many countries. To remedy this, the high chimneys and long
pipes were supplemented with pollution control equipment by which the wastewater and
the flue gases were cleaned before being released to the recipient, so called end-of-pipe
solutions.
With this strategy many of the point source problems could be reduced to acceptable
levels. However most of the cleaning processes were designed to separate the pollutants
from the primary emission streams, resulting in a waste product that had to be disposed
of.
61
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Other concerns that emerged during the 80s and 90s were emissions related to diffuse
sources and hazardous substances with the potential to accumulate in biological tissues
and with long-term effects. These problems cannot be solved by the application of end-
of-pipe technologies. The approach that developed as a response to this new challenge
was process integration, which has as its over-riding goal to avoid production and
emission of pollutants by choosing raw materials, changing processes or optimizing
process equipment in order to avoid or at least reduce the formation of polluting
emissions—pollution prevention instead of pollution control.
From this strategy the next step in the development was quite natural. From having the
focus on waste minimization through development of clean or cleaner production
processes, the environmental implications before and after the production phase became
evident. All products, services and processes have a life cycle. For products the life cycle
begins when raw materials are extracted or harvested. Raw materials then go through a
number of manufacturing steps until the product is delivered to a customer. The product
is used, disposed of or recycled. The environmental impact occurs over the entire life
cycle, not only during the production phases. In many cases the use of the product will
account for the major part of the total impact; in other cases the disposal of the used
product is the main problem. Along the entire product cycle we can see the consumption
of raw material resources and energy as well as the generation of wastes and emissions.
Therefore the concept of cleaner production expanded to a life cycle approach where
product and process design are essential elements.
In the concept of Industrial Ecology it is considered that the environmental performance
of a production process is not only governed by the design of the product and its
production process, but also by how the process integrates with other processes and
material flows. Integration with other processes can occur through exchanges of material,
through exchanges of energy and through the common use of utilities, such as cooling
and process waters. To design efficient and economic processes, designers must
systematically search out markets for byproducts; they should consider using byproducts
from other processes as raw materials; and, perhaps most significantly, expand their angle
of approach to looking for synergetic integration with other industries or with other parts
of society.
There is a growing awareness that, while these approaches are being applied, integrated
and further developed, although leading to substantial improvements for the environment
of the world, will not be sufficient in the future.
A central message conveyed by the Rio Agenda 21 document is that community and
social development and economic progress should be reconcilable with environment
protection and qualitative gains and improvements. A major task, in order to obtain a
sustainable development, is to strike the balance between the two main values and the
political objectives sustaining them. This is a continuous dilemma that has to be
addressed under shifting conditions. Leaders in business, government, academia, public-
interest organizations, and communities are responding with innovative new solutions to
sustainability issues in business and industry.
62
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
As expressed in the declaration of the Baltic 21, an initiative to develop and implement a
regional Agenda 21 for the Baltic Sea Region in order to attain sustainable development
in the region adopted by the 11 countries of the Council of the Baltic Sea States:
sustainable development for the industrial sector in the Baltic Sea Region is maintaining
continuity of economic, social, technological and environmental improvements. This
means for the industrial sector in the region:
• reaching eco-efficiency by the delivery of competitively priced goods and
services that satisfy human and social needs and bring quality of life while
progressively reducing ecological impacts and resource intensity throughout the
life cycle, to a level at least in line with the estimated carrying capacity of the
region with respect to biodiversity, ecosystems and use of natural resources;
• improved working environment and industrial safety for the work force;
• applying sustainable strategies applied to resources, processes, products and
services.
INDUSTRIAL ECOLOGY AND RESEARCH PROGRAM AT THE
NORWEGIAN UNIVERSITY OF SCIENCE AND TECHNOLOGY
Prof. Annik Magerholm Fet
Researcher Ottar Michelsen
Department of Industrial Economics and Technology Management
The Industrial Ecology Program
Norwegian University of Science and Technology
mailto:fet@iot.ntnu.no
Abstract
This paper gives a brief presentation of the Industrial Ecology study- and research
programs at the Norwegian University of Science and Technology, NTNU. These
programs have been running for a few years, and they have recently been evaluated. The
revised program will be presented. A central topic within the framework of industrial
ecology is eco-efficiency. Eco-efficiency should be a tool for measuring internal progress
as well as a tool for communicating the level of economic and environmental
performance. Some of the research projects in the NTNU-program are dealing with this
concept. Effort has been put into clarifying the terminology of eco-efficiency, the
definitions and the methodologies for selecting eco-efficiency indicators, and how they
can be used for reporting purposes and as a tool for improvement measures. The paper
presents examples of the use of indicators for eco-efficiency measures both for
production sites and for products and value chains. The paper further gives an overview
of upcoming international requirements to environmental reporting in the context of
63
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
industrial ecology. Here we find different types of reporting initiatives, e.g., that eco-
efficiency reports inform about economic performance in addition to the environmental
performance while sustainability reports encompasses social, economic and
environmental aspects, the "triple bottom line." Today we see a move from traditional
environmental reporting to eco-efficiency reporting and sustainability reporting. For
products, we see an international standardisation effort of environmental product
declarations (EPDs). Among the research activities at the industrial ecology program at
NTNU is the search for eco-efficiency indicators that can be harmonised with the product
declaration standards.
Introduction
The concept of Industrial Ecology (IE) is based on an analogy between industrial systems
and ecological systems. In nature, an ecologically sustainable system is a complex web of
organisms, where materials and waste build cycles. A society that is organised according
to the principles of IE will be similarly characterized; industry and industrial products
form value chains where energy and materials enter loops that are kept as closed as
possible. The products evolve through design, production, distribution and consumption.
When they are disposed of, their energy and material can be used in new products and
processes. By placing extended focus on the entire material and energy cycles, IE
involves disciplines that range from the humanities and the social sciences to the natural
sciences and technology.
IE is also seen as a strategy complementary to Cleaner Production (CP). While CP
focuses on individual companies, the strategy of IE focuses on a group or cluster of
companies (e.g., industrial parks).
Industrial Ecology at the Norwegian University of Science and Technology
The Industrial Ecology Programme is a multidisciplinary programme at the Norwegian
University of Science and Technology (NTNU). The program is responsible for the
coordination of NTNU's activities in education, research and communication in the area
of IE. It was started after an initiative from Norsk Hydro, and soon involved other
industrial companies as well as the Norwegian Ministry of the Environment. It receives
significant funding from the Norwegian Research Council, but also relies on business and
industry partners for its activities. Industrial project works are important in under-
graduate education and of mutual benefit to business, industry, researchers, doctoral and
master's students in their work.
Present business and industry partners include furniture companies, oil companies,
packaging companies and suppliers for the car industry, all over the world. Governmental
agencies such as the Ministry of the Environment and the Pollution Control Authority
(EPA) are supporting the program. In addition, a number of other industrial companies
64
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
are involved in the case projects within the research programme Productivity 2005, or
P2005.
The Industrial Ecology Study Programme stands out as the most important long-term
activity within its areas of responsibility. It was started in 1999, and is offered to students
in engineering, natural sciences, social sciences and the humanities from their third year
of study.
Students specialise in IE not instead of, but in addition to a discipline. Students in
chemical engineering still become chemical engineers, and political science students still
become political scientists. The Study Programme gives students an alternative way of
understanding and acting in the world; this enables them to perform their profession in a
more sustainable fashion. In this sense, IE also becomes a basis for communication and
cooperation among students, researchers and practitioners from a host of different
disciplines.
In the Study Programme curriculum, the focus is upon local, regional and global use and
flow of materials and energy in products, processes, industrial sectors and economies.
The role of industry in reducing the environmental burden and minimizing resource needs
of products in a life cycle perspective is investigated. Students are to acquire skills in
evaluating opportunities of improving products, production systems and technical
infrastructure as well as changes in societal and political conditions necessary for the
promotion of sustainable production and consumption.
The Study Programme consists of eight courses, six of them being compulsory core
courses, and two of them being optional among six alternatives. The core courses
construct a mental staircase of progressing sophistication of thought, and introduce
students to the application of theories and methods of central reference to the field. The
two optional courses give students the possibility to widen their special field or
concentrate on certain aspects of IE.
The six courses constituting the compulsory core part of the Study Programme are:
• Industrial Ecology and Systems Analysis
• Environmental Science and Occupational Hygiene
• Environmental and Resource Economy
• Environmental Systems Analysis and LCA
• Systems for Recycling and Closed Material Loops
• Strategies, Innovation and Change
In addition to the compulsory core courses, the students choose two out of six courses:
• Eco-Toxicology and Environmental Resources
• Geo-Resources
• Energy and Environmental Consequences
• Ecological Design
65
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Environment and Safety Management in Public Administration and Industry
• Environmental Politics
After having completed the Study Programme, students can choose an IE angle for their
master's thesis. The Industrial Ecology Programme will assist in supervising students in
addition to the tutoring offered to them by their home department (IndEcol 2002).
Eco-efficiency
One of the concepts of great importance within several of the courses and within several
research activities is the concept of eco-efficiency. Around 12 years ago the United
Nations Environmental Programme (UNEP) developed the CP strategy. CP was mainly
developed on the background of some waste minimization efforts in the USA and later
Pollution Prevention defined by the Pollution Prevention Act. Basically, the concepts
Waste Minimization, Pollution Prevention and CP are, for practical reasons, identical. In
time, the Organisation for Economic Co-operation and Development (OECD) in co-
operation with the World Business Council for Sustainable Development (WBSCD)
developed the concept eco-efficiency in order to accommodate the CP concept and make
it more familiar to the philosophy of the business community. Eco-efficiency is a central
topic within the framework of industrial ecology. Schmidheiny first introduced the term
in the book Changing Course (Schmidheiny 1992) that was a product of the Business
Council for Sustainable Development and presented at the Rio Earth Summit in 1992.
The purpose of eco-efficiency is very simple—to maximise value creation and minimise
environmental burdens. There are several definitions of eco-efficiency. The WBCSD
defines eco-efficiency as " the delivery of competitively priced goods and services that
satisfy human needs and bring quality of life, while progressively reducing ecological
impact and resource intensity throughout the life cycle, to a level at least in line with the
earth's estimated carrying capacity" (DeSimone and Popoff 1997). The OECD defines
eco-efficiency as " the efficiency with which environmental resources are used to meet
human needs" (OECD 1998).
The most important difference between these two definitions is that the WDCSD includes
the carrying capacity in their definitions, while the OECD looks upon eco-efficiency
more as a straightforward measure on the exploitation ratio of the resources that are
introduced into the economy.
Eco-efficiency is also viewed as a tool to promote improvements of environmental
performance. As a tool, it has a wide range of use. The two most important uses are
probably for measuring internal progress and for communicating level of economic and
environmental performance. The combination of economic and environmental
information makes the results easy to understand and interpret, and it also takes into
account fluctuations in production volume and related changes in environmental
performance.
66
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The most commonly used formula for operationalising eco-efficiency is (Verfaillie and
Bidwell2000):
~. . Product or service value
Eco - efficiency =
Environmental influence
As this formula shows, the consideration of the carrying capacity is not included when
eco-efficiency is operationalised, therefore at the time not being a part of what actually is
measured. Eco-efficiency can thus be improved through increased value creation and/or
reduced environmental influence. Using this formula, improved eco-efficiency will result
in an increased indicator value. Graphic interpretations will give upward arrows and are
thus familiar for business where upward arrows indicate a desirable development.
To measure eco-efficiency, both product or service value and environmental influence
must be quantified. Product or service value can be measured in different terms: as the
quantity of produced goods, as a monetary value (e.g., net sales) or as the fulfilment of a
need or function (e.g., the quantity of goods or services produced or provided to
customers). Applicable indicators for measuring environmental influence can be energy
consumption, materials consumption, water consumption, greenhouse gas emissions or
ozone depleting substance emissions. However, these indicators must not be regarded as
a complete list. Different companies must identify what environmental aspects are most
important for their activities and use this to develop environmental performance
indicators (EPIs) through a bottom-up approach. Based on national political goals, EPIs
can also be developed through a top-down approach. In addition, the WBCSD (see, e.g.,
DeSimone and Popoff 1997 and Lehni 2000) has developed seven guiding principles that
can help companies improve eco-efficiency:
• minimise the material intensity of goods and services
• minimise the energy intensity of goods and services
• minimise toxic dispersion
• enhance material recyclability
• maximise the use of renewable resources
• extend product durability
• increase the service intensity of goods and services
According to DeSimone and Popoff (1997) indicators should be developed to cover all
these.
The Use of Eco-efRciency in Reporting
There are several different types of reporting. While environmental reports traditionally
inform about the environmental aspects of a company, the environmental achievements
and the goals for environmental improvements, eco-efficiency reporting is about
economic performance in addition to environmental performance. The most
67
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
comprehensive is sustainability reporting that encompasses social, economic and
environmental aspects, the "triple bottom line." Today we see a move from traditional
environmental reporting to eco-efficiency reporting and sustainability reporting.
Indicators are frequently used to report the performance. Figure 1 shows the three pillars
in sustainable development as the corners in the triangle and indicates reporting at
different levels. The figure shows that indicators, both specific for each evaluation area
and cross-cutting indicators like eco-efficiency indicators, are useful for reporting
purposes. Sustainability reporting is to be used at the company level, but will also most
likely be a useful information tool for groups of companies or within a region where IE is
defined as a common strategy towards sustainable development.
Sustainability
reporting
Economic
aspects
Ecor-efficiency nd cators
Socio-economic indicators
Ecologic
aspects
Social
aspect
ocio-eco ogic indicators
Environmental
reporting
Figure 1: Sustainable development encompasses ecological, economic and social
aspects; sustainability reporting is the most comprehensive reporting.
Organisations like UNEP, the WBCSD and the OECD have a strong influence on the
requirements set to such reporting. One of the initiatives by UNEP is the Global
Reporting Initiative (GRI). GRI was established in 1997 with the mission of developing
globally applicable guidelines for reporting on economic, environmental, and social
performance. The GRI's Sustainable Reporting Guidelines (GRI 2000) represent the first
global framework for comprehensive sustainability reporting. They give guidance to
reporters on selecting generally applicable and organisation-specific indicators, as well as
integrated sustainability indicators. Forward-looking indicators such as strategy,
management indicators, trend information, and targets for future years are also included.
Today, at least 2,000 companies around the world voluntarily report information on their
economic, environmental, and social policies, practises, and performance.
68
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Environmental Product Declarations
Another way of reporting performance is to use environmental product declarations.
These are reporting mechanisms used for products. Different environmental labels are
introduced for products, among others the Nordic Swan, the German "Blauen Engel", and
the EU eco-label scheme (the "Flower"). In addition, ISO standards on environmental
product declarations are developed through the ISO 14020 series. Declarations aimed at
consumers are recommended to include a third party certification, a common format
within each product group, a full life cycle approach (in compliance with ISO 14040
series of standards on LCA) and interested party input. Environmental Labels Type I
(ISO 14024), Environmental Claims Type II (ISO 14021) and Environmental
Declarations Type III (ISO 14025), also called EPDs, should not be merged together.
However, the use of other labels or claims separately is not excluded. Type III
Environmental Declarations and non-confidential information shall be made publicly
available.
Case Studies in the Industrial Ecology Research Program
The strategy of research activities at IndEcol is to focus on collaboration in a
multidisciplinary setting, but with an emphasis on issues that are believed to have the
potential for advancing the area of IndEcol. Objectives of the research are to develop
theory and methodologies in the area of IndEcol, and to disseminate knowledge on
product, production and recycling systems in a way that the Norwegian manufacturing
industry has access to expertise and methodology that will help companies implement
more eco-effective and competitive solutions. The structure of the research activities is
presented in Figure 2.
69
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Horizontal activity #1
^ LCA methodology
Responsible cony
1C
Core project b I—
Eco-efficient,
products and
production
systems
Horizontal activity #2
> Terminology
Communicating IE-
> consequences to industry
Core project
Eco-effective
recycling
systems and
producer
responsibilit
Figure 2: Research structure at IndEcol, NTNU.
The research is structured into two core projects. The first one is Eco-efficient products
and production systems, with the research activities undertaken within two main research
strategies: "Eco-effective value chain management in industry (1C 1)" and "Factor X
development of technical systems (1C 2)." 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." The activities are directly connected to industrial cases. Three general research
subjects are 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. One of the
horizontal activities in the IndEcol program is the Life Cycle Assessment (LCA)
laboratory. LCA research and other horizontal activities are carried out in accordance
with the same principles used in the vertical core projects.
Core
companies
"CC2
~CC3
CC4
"CC5
70
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Presentation of Results from Two Research Case Studies
In two of the research projects, "Environmental performance indicators for companies
and region" and "Eco-efficient value chains," the methods for selecting the indicators
through bottom-up and top-down approaches are developed and tested in business-
specific cases. A great effort is put into the formulation of the indicators so that they can
be used to measure the progress and changes over time. The challenge is to find
performance indicators that are useful for the production site, for the value chain and for
the local community in which the production company is located. Another important
aspect is to develop and find the most appropriate formulation of the eco-efficiency
indicators that meet the stakeholders' interest for information about the companies and
their products. Effort is put into clarifying the terminology of eco-efficiency, the
definitions and the methodologies for selecting eco-efficiency indicators, and how they
can be used for reporting purposes and as a tool for improvement measures.
Site Specific Information
In the first of these projects, site-specific indicators are developed. Figure 3 shows
examples of eco-efficiency indicators, sales in proportion to emissions of climatic gases
(here, COz) and acidic components (NOX and SOz). The data for calculating the emissions
are based on fuel consumption in the company. The eco-efficiency indicator for
emissions of climatic gases shows a positive development over the past four years. For
acidic components, the result shows an improvement for the last year.
Sale per climate gas emissions (C02)
n nR -T~~~~~~~~~~~~~~~~~~~~~~~~~~^^
0 04 -
n rn -
n no
n m -
n -
+—~+
//
* V I
1997 1998 1999 2000
Sale per acidifying emissions (NOx and SO2)
n m OR _________________^^
n m OR .
n m o -
n n-i -1 ft
n m 1 R -
n m 1 d. -
n ni 1 o -
^
\ I
\ I
\ , I
~-*r I
1997 1998 1999 2000
Figure 3: Eco-efficiency indicators expressed as sale per climate gas emissions and sale
per acidifying emissions (Olivin 2001).
71
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Product or Value Chain Specific Information
The eco-efficiency in the previous example was calculated for the production site. In the
second project, Eco-efficient value chains, " the research concentrates on eco-efficiency
along the entire value chain of a furniture product. In this research, the models developed
by BASF in Germany (BASF 2002, Saling et al. 2002) are used. The main steps here are
to determine the environmental impacts from the life cycle and the life cycle costs of the
products. The environmental data are aggregated to a single score through a (for BASF)
standardised normalisation and weighting procedure. All products then received one
unique score in both an environmental and an economic dimension. See Figure 4.
BASF uses life cycle cost as a measure of value. Value creation could also be measured
as profit, but since few companies are willing to disclose their profit, the price of the
product was found to be the best alternative. In our study there is no significant difference
between life cycle costs and prices, therefore price on product delivered to customer is
used. The environmental performances are derived from LCA-studies of five different
models of the same chair. The most significant environmental performance indicators
were greenhouse gas emissions, emissions of photochemical oxidants to air, emissions of
heavy metals and acidification emissions to air (Fet et al. 2003).
Figure 4 shows the eco-efficiency indicators for each of the five product models (Mio I -
Mio IV, Mio chair). The indicators are calculated by using relative values of economic
and environmental data. The relative values are calculated by the formula
..... , (absolute indicator value i)x n
relative indicator value i = —n - - —
^ absolute indicator value j
where n is the number of products, and the relative indicator can be the indicators on
greenhouse gases, on price, etc. The values are further plotted in the diagram in Figure 4.
The relative prices are shown on the horizontal axis and the relative environmental
performance on the vertical axis. The diagram reveals the eco-efficiency of one product
compared to other products.
72
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
0.5
Relative price
1
1.5
0.5
o>
o
ra
If
t '-
fc 0.
E
8
|
2?
0)
> o
'
"T.5
O
o
Figure 4: Eco-efficiency diagram for different products.
Figure 4 shows how products with a similar function can be presented in an eco-
efficiency diagram. The eco-efficiency is lowest in the left lowest corner and highest in
the right upper corner. This model gives joint information about economic and
environmental aspects of the different products. This can be used within the company to
identify which products need to be improved, either in environmental performance or in
profitability. It is also possible to include future products in the model, thereby using this
model for strategic decisions in development of new models. Such information can also
be used in advertising and in environmental product declaration to inform purchasers who
want environmental friendly products at a reasonable price.
Discussion and Conclusion
In most research studies, eco-efficiency is only used for production sites (see, e.g., Keffer
et al. 2000). A production site (e.g., a furniture producer) is regarded as the producer of
the product. However, in the value chain of a product, several companies (or production
sites) will contribute to the final environmental performance of a product. By improving
the eco-efficiency of the production site, this can lead to a sub-optimisation in the value
chain. For instance, it is possible to outsource processes that are problematic from an
environmental point of view, such as varnishing. It is well documented that end
producers with direct contact to the market are more exposed to demand for
environmental information (i.e., Hall 2000). Moving problematic environmental
processes upstream, the value chain can thus lead to less focus on these if the overall
performance in the chain is not measured.
73
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Another problem regarding product information is that no acceptable way of measuring
the value created along the entire value chain of the product exists. Therefore, the price of
the product is believed to be an acceptable proxy. Also, environmental specific data for
each part of the product is difficult to obtain, and average data from databases must be
used. Different models of weighting significant environmental information also gives
different answers as to which indicators are most important (Fet et al. 2003).
Harmonisation of eco-efficiency indicators and the requirements set in the environmental
product declarations in accordance with the ISO 14020 series, is also to a certain extent
problematic. However, since there are no common international schemes of
environmental product declarations, there are possibilities to include eco-efficiency
diagrams for series of products with similar functions.
The objectives of these research projects have been to develop appropriate approaches to
measure and report eco-efficiency both for production sites and for products. The goals
have been to establish general frameworks that are flexible enough to be widely used and
easily interpreted in different sectors.
The UNEP's GRI goals are to develop a set of core indicators and business specific
indicators, mainly for production sites. Furthermore, this paper has shown it is possible to
use the eco-efficiency indicators to also yield products as demonstrated by the case study.
These objectives are in line with the research strategy in the Industrial Ecology program,
especially under core project #1. An additional challenge is to obtain international
agreements on how to use eco-efficiency indicators in product declarations. For this
purpose, eco-efficiency calculated for products' entire life cycle has to be included.
References
BASF, 2002: www.basf.de/en/umwelt/oekoeffizienz
DeSimone, L. D. og Popoff, F. 1997. Eco-efficiency: The Business Link to Sustainable
Development. The MIT Press, Cambridge
Fet, A. M., Dahlsrud, A. and Michelsen, 0. 2003. Eco-efficient furnitures. Report in
progress.
GRI. 2000. Sustainability reporting guidelines on economic, environmental and social
performance. Global Reporting Initiative, http://www.globalreporting.org
Hall, J. 2000. Environmental supply chain dynamics. /. Clean. Prod. 8: 455-471
IndEcol Programme 2002: http://www.bygg.ntnu.no/indecol/. P2005:
http://www.p2005.ntnu.no/
ISO 14020: Environmental labels and declarations - general principles
74
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
ISO 14021: Environmental labels and declarations - self-declared environmental claims
(Type II environmental labelling)
ISO 14024: Environmental labels and declarations - Type I environmental labelling -
principles and procedures
ISO TR 14025: Environmental labels and declarations - Type III environmental
declarations
Keffer, C., Shimp, R. & Lehni, M. 2000. Eco-efficiency indicators & reporting. Report
on the status for the Final Printed Report (updated Feb. 23rd 2000). WBCSD
Lehni, M. 2000. Eco-efficiency - creating more value with less impact. WBCSD,
http://www.wbcsd.org/newscenter/reports/2000/EEcreating.pdf
OECD. 1998. Eco-efficiency. OECD, Paris
OECD, 2001. Policies to enhance sustainable development, OECD, Paris
Olivin AS, Environmental Report 2000, Aaheim, May 2001, Norway.
Saling, P., Kicherer, A., Dittrich-Kramer, B., Wittlinger, R., Zombik, W., Scmidt, I.,
Schrott, W. and Schmidt, S. 2002. Eco-efficiency Analysis by BASF: The Method. Int. J.
LCA 7: 203-218
Schmidheiny, S. 1992. Changing Course: A Global Business Perspective on
Development and the Environment. The MIT Press, Cambridge
Verfaillie, H. A. and Bidwell, R. 2000. Measuring eco-efficiency - a guide to reporting
company performance. WBCSD,
http://www.wbcsd.org/newscenter/reports/2000/MeasuringEE.pdf
75
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
GREEN CONCURRENT ENGINEERING: A WAY TO FILL ISO 14001 WITH
CONTENT
Dr. Marten Karlsson
Lund University
Sweden
mailto:Morten.Karlsson@iiiee.lu.se
Abstract
No one could have missed the sharp increase in ISO 14001 certifications worldwide. It is
not only a phenomenon in the OECD nations but also the economies in transition show a
bold progress. The discussion is however quite intense on its success. ISO 14001 has
been named to be nothing but a paper tiger and has been accused of being a green facade.
The intention of this paper is not to contribute further to this debate but to seek a
constructive solution on how ISO 14001 can be filled with content so that it can promote
continuous improvement. One way forward is to include product development in the
environmental management system. Green Concurrent Engineering, summarized in the
paper, is a model to do so.
The first formal standards and requirements for environmental management systems
(EMS) did not cover product development very well. Consequently, arguments has been
raised by academia and NGOs that product-related environmental concerns risked being
left without attention. Green Concurrent Engineering (GCE) is a model for a DFE
management program that integrates DFE in product development in the framework of
ISO 14001. DFE and EMS act in a symbiosis and can strengthen each other. An example,
product development is a cross-functional activity. This is an advantage in environmental
management and DFE. The problem could just as well originate from consumer
behaviour or production as the product design. For example, the technical solution to
avoid voluminous packaging of say, batteries, is easy. What needs to be addressed is how
to get the same amount of information and product exposure to the consumer while
smaller packaging is used. Engineering cannot alone solve this and instead, marketing
must be engaged.
A survey conducted in the year 2000 in the Swedish manufacturing industry discovered
that DFE activities increased when industries implemented ISO 14001. The survey also
revealed a large difference in ambition level and usage of DFE tools and processes.
The current development is being judged as being primarily positive. Some signs of
weaknesses can, however, be found. Many companies seem to have placed their ambition
level on the minimum for a certification, that is, assurance of compliance with existing
legislation. The idea of continuous improvement will therefore foremost be aimed
towards the procedures of the system. The organisations will need to improve the way
they define environmental aspects and objectives and how they evaluate improvements of
76
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
the environmental performance in order to be able to achieve continuous improvements
of their products.
Tools and methods seem to be available for the organisations. The key issue will not be
to develop new tools and methods to face the challenges of DFE management programs
but to transfer and deploy knowledge on how DFE management programs may be
designed.
Environmental consultants with satisfactory knowledge of DFE and product development
as well as environmental management systems do exist. Even so, it must be the primary
recommendation that environmental consultants become a target group for education and
information on DFE and how it relates to ISO 14001.
STRATEGIES AND MECHANISMS TO PROMOTE CLEANER PRODUCTION
FINANCING
Ari Huhtala
Senior Programme Officer, United Nations Environment Programme
Division of Technology, Industry and Economics (UNEP/DTIE)
mailto:ari.huhtala@unep.fr
Abstract
Cleaner production (CP) is a recognized and proven strategy for improving the efficient
use of natural resources and minimizing wastes, pollution and risks to human health at
the source, rather than the end of the production process. CP brings tangible economic
savings by improving the overall efficiency of production and facilitating access to new
markets. Despite the advantages of this strategy, finding investment funds is a major
constraint in making CP widely practiced.
To bring preventive approaches and efficient resource management closer to the financial
community, UNEP/DTIE launched a four-year project in 1999. The project has been
implemented in five demonstration countries (Guatemala, Nicaragua, Tanzania, Vietnam
and Zimbabwe), but its conclusions and deliverables are applicable to most countries in
the world.
Some of the key conclusions include:
First—Cleaner production is frequently an investment with a return at the end. Spending
money on repairs or on environment control is a capital cost with no return. This makes
CP part of the development agenda, not an item of overhead.
77
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Second—Prevention of loss, whether materials, products or money, is a matter for
mainstream business managers, including financial controllers. Cleaner production is a
loss prevention approach which often justifies the extra expenditure by the increased
productivity and business security it creates.
Third—Cleaner production has an eye on long-term profitability. Current fiscal policy is
often needlessly short-term. CP financing is trying to overcome this barrier.
Fourth—Cleaner production is an attitude; it is behaviour. Therefore it cuts across the
entire spectrum of stakeholders from production engineers to accountants, financial
analysts and managers, government policy makers and academia.
Based on the experience accumulated during the project, UNEP/DTIE will publish the
following in June 2002 for world wide use:
• Booklet "Profiting from cleaner production—Journey to efficient resource
management" for senior and middle management in government, finance and
business
• Executive awareness slide presentations "Profiting from CP" for industry,
financiers and government
• Checklists to facilitate decision making related to CP investments
• A Trainer's Guide and generic versions of training modules of the following:
• CP1—Introduction to CP concept and practice (1-day awareness course)
• CP2—Introduction to capital budgeting and financing of capital projects (1-
day awareness course)
• CP3—Profiting from CP (2-day skill course)
• CP4—Funding CP projects (2-day skill course)
Mainstreaming preventive strategies and efficient resource management is one of the
objectives of several follow-up activities being formulated with different partners in
Africa, Asia, Latin America and Eastern Europe and NIC.
78
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CLEANER PRODUCTION FINANCING: POSSIBILITIES AND BARRIERS
Prof. Jurgis K. Stanislas, Dr. Zaneta Stasiskiene
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
jurgis.staniskis@apini.ktu.lt
zaneta.stasiskiene@apini.ktu.lt
Abstract
Cleaner Production (CP) as a concept has expanded rapidly in recent years: internally, the
adoption of CP measures is driven by pressure to reduce the costs of waste, to reduce the
costs of compliance with changing regulations, and to position the enterprise as a "green"
enterprise in the local, national or global marketplace. Externally, investors, financial
analysts, regulatory bodies, and the public at large increasingly question corporate
environmental performance. Therefore CP serves as a tool, which brings tangible
economic savings and environmental benefits by improving the overall production
efficiency and facilitates competitiveness.
Despite the above-mentioned advantages of the strategy, the financing problem is one of
the important constraints in making CP widely adopted. Companies that have identified
cost-effective and technically feasible CP options may still not be able to make the
necessary CP investment to realise the financial benefits and environmental advantages.
The obstacles to financing CP investments could be described under two major groups:
• On the demand side, enterprises have insufficient experience in preparing a real
CP project, which is systematically evaluated from environmental, economical
and technical point of view and to prepare proper applications for the project
financing. Lack of knowledge in CP assessment, evaluating the financial aspects
of the project efficiency and investments often blocks implementation of CP
projects. Even when capital exists, CP is one among a range of investment
options.
• On the supply side, there are obstacles in capital markets: there is a lack of
environmental expertise and loan rates are unattractive to enterprises. Also, costly
administrative requirements result in international financial institutions
establishing loan thresholds, which are sometimes significantly higher than costs
of CP investments; it is difficult to receive financing for small projects. Generally,
there is little experience with the implementation of economically viable CP
projects.
In this regard two processes are crucial, i.e., the selection and priority setting among
alternate investment options (the "capital budgeting" process) and the collection and
79
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
allocation of capital to finance the prioritised investment options (the "financing"
process).
Commercial banks are the main formal providers of financial services to the business
community. The banks, as usual, do not distinguish financing opportunities by project
type, e.g., CP versus pollution control or regular equipment loan. Rather the strength of
the loan application is reviewed based on conventional considerations, such as
creditworthiness of the firm and generation of sufficient cash flow to make required loan
payments.
As it was indicated many times at the different meetings, financial services alone will not
be able to ensure sustained CP development. In such cases non-financial support services
are expected to be offered by other service providers. Synergy between financial services
and business development services (BDS) can make credit schemes more effective and
can produce a more successful outcome in lending programmes (see Fig.l).
Regional Revolving (Guarantee) Facility for CP
Investments
Regional Level
(South East
Africa)
ABC Holdings Ltd
Incorporating African banking Corporation Limited
(CP Financing Facility)
Country
Level
Business development services providers
TISCO
NCPC
New organizations
Com pany
Level
Guarantee providers:
I Bank of Tanzania
I Tanzania Investment bank
*l Tanzania Postal Bank
Companies for Industrial Sectors of Tanzania
Textiles, clothing, Leather and Footwear
Wood and wooden products, Excluding furniture
Chem icals, petroleum , Rubber and Plastics
Basic Metal products
Fabricated metals, machinery and equipment
Fig. 1. Regional Revolving (Guarantee) Facility for CP investments
More has to be done by governments and communities to press the commercial banks to
recognise the importance and value of the CP business sector as an expanding clientele
for their services.
Finally, access to financial services is only one ingredient for sustained enterprise
development, albeit an important one. The minimalist credit approach has clear
limitations, and for credit schemes to be effective and to have the expected impact,
complementary services are needed. Access to suitable business development services is
also important for enterprises to support the upgrading of their production techniques,
products and services, and to be able to adapt to changing market conditions, i.e., to move
into the production of goods and services that meets the demands of domestic and foreign
80
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
markets in terms of price, quality, design. In other words, to making the enterprises more
competitive, for instance, quality and environment management systems, extension of
business value of life-cycle methods in order to assure both environmental improvements
and strategic/market related benefits, environmental impact assessment, eco-design, etc.
Further details on constrains and possible strategies of CP financing are be presented in a
paper.
INDUSTRIAL ECOLOGY IN UNIVERSITY CURRICULUM: NEW M.SC.
PROGRAMME IN ENVIRONMENTAL MANAGEMENT AND CLEANER
PRODUCTION
Prof. Jurgis Stanislas, Valdas Arbaciamkas
The Institute of Environmental Engineering, Kaunas University of Technology
Kaunas, Lithuania
mailto:jurgis.staniskis@apini.ktu.lt
mailto:varba@apini.ktu.lt
Abstract
The focus of environmental work has during the last decades shifted from having dealt
entirely with the emissions and wastes of industrial production plants to include the total
environmental responsibility and performance of enterprises, where the environmental
properties of products become more and more important. The introduction and
integration of environmental management systems into the management of companies is
becoming more or less a business necessity that requires a raising of the environmental
competence on all levels within the company.
Therefore, technical universities in the Baltic Sea region in the framework of the
BALTECH consortium decided to develop and implement a new M.Sc. Programme in
Environmental Management and Cleaner Production, based on an integrated approach of
industrial ecology towards current and long term/strategic environmental issues, focusing
on technologies and concepts in environmental planning and management for a
sustainable industrial development. This will be a two-year (120 ETCS Credits)
programme suitable for graduates with qualifications in many engineering fields such as
chemical engineering, mechanical engineering, civil engineering, environmental
engineering and others. The programme will start at Kaunas University of Technology in
September 2002.
The following universities participate in the development and implementation of the
programme: Technical University of Denmark (DTU), Denmark; Tallinn Technical
University, Estonia; Helsinki University of Technology (HUT), Finland; Riga Technical
University, Latvia; Kaunas University of Technology, Lithuania; Vilnius Gediminas
81
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Technical University, Lithuanian; KTH, Royal Institute of Technology, Stockholm,
Sweden; International Institute for Industrial Environmental Economics, Lund
University, Sweden; and Linkoping University, Linkoping, Sweden.
The M.Sc. programme in Environmental Management and Cleaner Production will, on
the basis of the technical background of the student, enable graduates of the programme
to:
• integrate preventive managerial and technological tools in achieving a more
sustainable development for industry and society;
• lead and sustain the process of change in industry, academia and other
organizations;
• understand the interdependence of environmental, technical, economic and social
sciences, and to perform interdisciplinary research and development.
This will be achieved by providing the M.Sc. students with:
• skills to identify and assess the effects of human activity on the environment;
• knowledge of national and international environmental policy and legislation and
the management of environmental issues in industrial and service systems;
• knowledge of technical systems, strategies and technologies for applying the
principles of cleaner production in developing products and production systems;
• practical experience in implementing preventive environmental measures.
Programme Structure
Compulsory core courses (35-45 ECTS cr): Environmental Technology; Environmental
Assessment; Cleaner Production; Environmental Policy, Law and Economics;
Environmental Management; and Eco-Design. These compulsory courses are developed
and delivered in collaboration between the participating universities. The nature of the
collaboration can differ between the courses, but distance learning using ICT
methodology will be implemented in several (all) of the courses. The responsibility of
course leadership will rest with one of the participating universities, but with teachers and
tutors from the other universities as well. For each course there should be at least one
local tutor from universities with participating students.
82
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
In addition to the compulsory core courses the candidate shall take a selection of optional
courses (45-55 ETCS cr)in two different subject areas.
• Advanced courses in environmental and related subjects;
• Advanced courses in one engineering subject.
The contents of the programme are based on industrial ecology approach, i.e. on industry-
environment interactions to aid industry in evaluating and minimizing impacts to the
environment. The programme courses will reflect one of the most important concepts of
industrial ecology, which, like in the biological system, is rejecting the concept of waste.
The programme will cover technologies in coping with industrial residues, particularly
those technologies aimed at reuse and recycling (course in Environmental Technologies);
identifying, evaluating and implementing technical and managerial options for
improvement of environmental and economic performance (courses in Environmental
Assessment, Cleaner Production and Environmental Management); design of industrial
processes and products from dual perspectives of product competitiveness and
environmental impact (Eco-design), and development of policy framework, which
provides appropriate incentives for enterprises to adopt preventive environmental
management practices and to increase their efficiency (course Environmental Policy, Law
and Economics). Therefore, the compulsory courses of the programme will cover all
basic aspects of the industrial ecology approach.
Optional courses will be used to discuss these issues in more detail and to provide
additional knowledge which will ensure that graduates of the programme will be able to
apply industrial ecology approach, i.e., will be capable to conduct systematic analysis of
industrial activities and to find optimal solutions for many problems related to sustainable
industrial development.
CHEMICAL RISK MANAGEMENT IN ENTERPRISES
Dr. Jolita Kruopiene
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
mailto:iolita.kruopiene@apini.ktu.lt
Abstract
Several ten thousands of chemical substances are included in a large variety of chemical
products and traded and used on the European market, including Lithuania. Many of
these chemicals are hazardous; therefore working with them needs special care.
83
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Chemicals control legislation is developed and harmonized on the EU level. The majority
of it is already transposed into Lithuanian legislation. The implementation of Chemicals
control legislation is a huge task and requires corresponding capacity from industries and
state authorities.
The Institute of Environmental Engineering started to carry out a training program on
Classification, Labelling and Packaging of Chemicals in 2000. 87 participants from 54
enterprises and institutions have been trained and certified since then. The program aims:
• to provide participants with theoretical knowledge on new requirements for
chemical risk management and the corresponding implementation measures to be
taken by industry,
• to train practical classification and labelling skills,
• to develop creativity and concept in how to organise tasks with regard to chemical
risk management on enterprise level, what leads to improved worker and
consumer health and safety, environmental protection.
Chemicals stand in the cross-roads, where health, safety, environment, competitiveness
and innovation meet. When managing chemical risk, companies have to follow special
requirements for chemicals, but also think about production installation and process,
worker and environmental protection, clean products. Currently Institute of
Environmental Engineering, together with partners from Latvia, Estonia and Germany, is
assisting four Lithuanian companies (representing textile, furniture and metal processing
branches) in their chemical risk management work. Parallel work is also ongoing in
Latvia and Estonia. The following management related issues were identified as problem
areas for all three countries:
• No clear overview of chemicals, environmental, health and safety legislation;
• Roles, responsibilities and authorities are not always clearly defined and
communicated;
• Lack of information about used chemicals and their flow through the company;
• Risk assessment at working places not properly performed;
• Low priority of environmental, health and safety issues in decision-making.
The set of tools to solve the mentioned problem areas and to improve chemical risk
management at enterprises was elaborated. The set includes:
• Priority setting,
• Chemicals inventory,
• Obtaining hazard information,
84
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Input-output analysis,
• Risk assessment at working places,
• Risk reduction measures,
• Risk communication within the company,
• Product information,
• Organizational analysis,
• Legal requirements.
These tools are quite universal, and can be applied by different companies in different
countries, and even for the solution of different problems. Therefore, it is planned to
multiply the gained experience and make it accessible to other companies via workshops
and publications.
Lithuanian enterprises have mainly chosen to work on chemicals inventory, which forms
the basis for different kind of chemicals risk management work, on risk assessment,
which sets priorities for risk reduction, and on risk reduction measures themselves.
Substitution of hazardous chemicals by less hazardous alternatives stands at the top of
hierarchy of risk reduction measures. The choice of chemicals is a very important issue
for industries to deal with. Authorities use different restrictions, bans, procedures of
licensing, registration, etc., as a risk management instrument to influence the choices
made by enterprises. Attempts to avoid dangerous chemicals in products are stimulated
by market pressure as well.
Currently APINI is participating in downstream user analysis carried out in Baltic States
to identify sources, pathways and fate of certain RELCOM priority substances (like
phtalates, chlorinates paraffins, nonylphenolethoxilates, tributyltin, polycyclic aromatic
hydrocarbons, namely creosote). The RELCOM objective with regard to hazardous
substances is to prevent pollution of the Convention Area by continuously reducing
discharges, emissions and losses of these substances. In order to meet RELCOM'S
objective, it is essential for state authorities to have information on flows and use of
chemicals on the national market. At the same time, industries need to be well informed
about the composition and regulatory status of chemicals they use. The downstream user
analysis was chosen as an approach to gather data since the importers and producers have
no idea what happens with those substances after selling them to the mixtures. During
analysis, users of chemicals learn not only what chemicals they use in production, but
also about the principal alternatives.
The responsibility of Lithuanian companies with regard to chemical risk management is
increasing, together with awareness about environmental issues, market demands, and
transposition of legal EU requirements. Their achievements and problems have become
similar to those in other European countries.
85
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
PRACTICAL IMPLICATIONS OF INDUSTRIAL ECOLOGY: JSC "VILNIAUS
VINGIS"
General Director Vaclovas Sleinota
JSC "Vilniaus Vingis"
Vilnius, Lithuania
Lina Budriene
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
Abstract
JSC "Vilniaus Vingis" is one of the largest producers of electronic components in
Europe. It supplies about one-fifth of the deflection yokes used by colour tube makers in
Europe. Other products include flyback transformers for TV sets and monitors, special-
purpose equipment and tooling for the manufacture of deflection yokes, flyback
transformers and others.
JSC "Vilniaus Vingis" has been growing steadily since the early 1990s; a 14 percent rise
in sales in 2001 is a sound result amid the general slowdown in the global electronics
market. The main customers are Samsung SDI (Germany, Hungary), LG.Philips Displays
(Spain, United Kingdom), Thomson Multimedia (Poland), Ekranas (Lithuania).
Committed to stable growth and continuous modernisation, JSC "Vilniaus Vingis"
maintains close ties with a number of international companies for innovation and
supplies. The main partners are General Electric Plastics and Festo in the Netherlands,
Nichimmen Corp and Fuji Corp in Japan, LG.Philips in Poland and Burim Industrial in
South Korea.
Constant development and co-operation with partners help JSC "Vilniaus Vingis" to keep
to its determined pursuit of quality. In 1997 the company's quality system was accredited
to the ISO 9001 standard. Every newly developed item is certified according to VDE
(Germany), BSI (England) and UL (USA) security standard systems.
Continuous improvement of environmental performance of the company has been always
an important issue in the corporate agenda. Since 2001 the company was certified and
manages its activities in accordance with ISO 14001, the internationally accepted
environmental standard.
JSC "Vilniaus Vingis" was the first company in Lithuania which was successful in
preparing and implementing investment project according to requirements of Nordic
Environmental Finance Corporation Revolving Facility (NEFCO). After the
implementation of Lithuanian and Danish cleaner production project "The modernization
of waste water treatment plant in the galvanizing department" in 1997, the company
86
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
decreased water consumption by 4 times, volume of solid waste decreased by 10 t of sand
per year, volume of slime utilized after the treatment process decreased by 13%, waste
water pollution by Zn and Ni decreased by 15%. Implemented innovations allowed to
improve even the quality of coating.
In 1997, JSC "Vilniaus Vingis" in close co-operation with Lithuanian scientists prepared
and implemented a second cleaner production project "Cleaner technologies in
electroplating industry." The project improved the environmental performance further; it
helped to decrease consumption of water in department by 4 times, consumption of
chemicals by 15 %, as well as increase capacity of the department by 2,3 times.
It's planned that the third cleaner production project "The modernization of new
generation deflection system assembling process and department" will bring further
environmental improvements: savings in consumption of raw materials and energy,
reductions of emissions, including indirect environmental effects, such as improved
conditions of labour safety.
There are still challenges for the company in the environmental field; however, the case
study of JSC "Vilniaus Vingis" is a good example of how using internal human resources
as well as employing scientific partners can help in achieving continuous improvement of
environmental performance.
JSC "UTENOS TRIKOTAZAS"
Financial director Nerijus Datkunas
JSC "Utenos trikotazas"
Utena, Lithuania
Dr. Zaneta Stasiskiene
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
Abstract
JSC "Utenos trikotazas," established in 1967, has always been a stable, profitable and
consistently growing company. Since that period the company has been awarded
manufacturing prizes on several occasions, and in 1998 received the National Quality
Prize. In 1999 JSC "Utenos trikotazas" was certified in accordance with ISO 9001.
The average number of employees at "Utenos trikotazas" is 1,500, most of whom work in
the Sewing Department. From the beginning of the establishment of the company up to
87
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
today, the company's philosophy has been to encourage every employee to work well,
providing him or her with favourable conditions for promotion and wage increases.
Without waiting for favourable business decisions from the government or for better
economic conditions, JSC "Utenos trikotazas" implemented reforms that have brought
the company closer to European standards of quality. A well-qualified staff has been
recruited and trained. Effective and modern management has been applied. The company
is implementing new information, management and industrial technology and believes
that this is not only the best guarantee for today, but for the future as well.
Every person has the right to live in a healthy environment. In acknowledgement of this,
JSC "Utenos trikotazas" obtained an ISO 14000 certificate from the World Environment
Protection Agency in 2001 and promotes the company's integration into the World
Environment Protection system. By implementing and certifying the system of
environmental protection, JSC "Utenos trikotazas" proved that it is capable of managing
all aspects of its activities in order to decrease any negative impact on the environment.
In 1999 the company graduated from the Lithuanian-Norwegian Cleaner production
program and the Nordic Environment Finance Corporation provided a "soft loan" for the
CP project "Modernisation of Dyeing Department" implementation.
By introducing a production control system, JSC "Utenos trikotazas" can monitor how
various product parameters meet their standards, i.e., colour retention in dyed materials,
the shrinkage of fabrics after washing, and the pH value and formaldehyde levels in
fabrics.
The company also tries to minimise the harmful effects of various production processes
while designing new products. The company's management believes that contamination
should be prevented at its inception. During the first half of 2000, JSC "Utenos
trikotazas" invested LTL 8 million into purchasing machinery and new technology,
improving working conditions and job safety. New "Thies" dyeing equipment was
purchased, a chemical station was reconstructed, and a "Colour Service" automatic
potion system for dry and liquid chemicals was installed. Besides this, an "Orgatex"
programme for managing and controlling the dyeing process was implemented and two
additional "Thies" dyeing machines were installed.
Today the company is taking measures that enable it to use electricity and natural
resources economically, decrease the contamination of the air and water, and decrease the
risk of unforeseen accidents.
Representative of "Utenos trikotazas" participated in and were certified by the very first
training course on Classification, Labelling and Packaging of Chemicals, held at APINI
in spring 2000. As a follow-up, a lot was done in the company. Communication routines
were established with suppliers to get up-to date, good quality SDS and further
information. A systematic approach ensures internal hazard and risk management
information flow. Procedures to evaluate information on SDS, to translate SDS
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
information into instructions for safe handling of chemicals and accidental release
measures are followed. Labelling of chemicals in storage places and in places of their use
was ensured. Company specialists and workers are trained to understand labelling and
chemicals issues in general.
The market pressure for textiles that are safe with regard to chemicals is very strong.
Substitution of hazardous chemicals by less hazardous alternatives is very important in
order to have "cleaner" products. Therefore, "Utenos trikotazas" uses dyes that allow
fabrics to correspond to the OEKO-TEX 100 standard. There are also special quality
requirements for yarn (OEKO-TEX). Classification according to TEGEWA list is
required also for auxiliary chemicals. Working according to the requirements of the
OEKO-TEX standard, the company can ensure that its products have no harmful
substances and are safe to use, and that the entire production cycle has no negative impact
on the environment and on the employees. Raw materials, dyes and additional materials
used in the production process are free of hazardous substances and meet environmental
protection requirements
Risk assessment, further improvement of risk communication within the company, and
establishment and maintenance of the chemical inventory are currently on agenda.
"If you don't go forwards, you go backwards," says Nijole Dumbliauskiene, Managing
Director of JSC "Utenos trikotazas." Continuous improvement is the work concept of the
company and has been proven by the events of the last few years. In fulfilling quality
management principles, implementing new trends flexibly, making accurate prognoses
for fashion trends, improving product design and speeding up the product preparation
process, JSC "Utenos trikotazas" can offer good prices, high quality and favourable terms
to its clients today.
89
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CLEANER PRODUCTION AT PAPER MILL JSC "KLAIPEDOS KARTONAS'
General Director Arunas Pasvenskas
JSC "Klaipedos Kartonas"
Klaipeda, Lithuania
Technical Advisor Valeras Kildisas
Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
Technical Advisor Henrik Wenzel
Technical University of Denmark
Copenhagen, Denmark
Abstract
A Lithuanian-Danish co-operation project on Cleaner Production in the Lithuanian paper
industry was conducted during 2001. One of the paper mills in the project was the
corrugated cardboard producer JSC "Klaipedos Kartonas." A team of managers and
technicians of the paper mill and Lithuanian and Danish Cleaner Production experts
worked on identifying options for Cleaner Production, including savings on energy and
saving and recycling of water.
JSC "Klaipedos Kartonas" operates a sound paper machine and has a good potential for
extending production in the future. Water and energy consumptions were high compared
to European standards, mainly due to the fact that water is taken in from the nearby
lagoon and discharged to the same lagoon with costs that are lower than average
European water costs. Costs for water and energy, however, are expected to increase
greatly in the near future, and the company has an interest in reducing water and energy
consumption. Moreover, the company has an interest in meeting standards that will allow
export to European markets, where meeting certain minimum key figures on water and
energy may be a future competition parameter.
The team identified water and energy savings comprising a variety of Cleaner Production
options:
• Changes in water circuit
• Altered operation of existing spray rinses
• Exchange of the oldest spray rinses with new spray rinses
• Installing new double layer paper wire (was already decided)
90
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Improvement of existing filter or installation of flotation unit thus improving
Whitewater quality
• Increased water recycling when Whitewater quality was improved
The implementation of these options was judged to lead to improved runnability of paper
machine and thus less paper breakages and better dewatering before drying, to reduced
water consumption, and to reduced energy consumption. Energy consumption is judged
to be reduced due to better dewatering because of the higher water temperature and better
wetting profile of the paper lane. Moreover, less solids are lost to wastewater and instead
deposited on the paper lane and sold with the paper.
Total savings of around 80% on water plus substantial energy savings were judged
possible with a potential of saving 1-2 mill. Lt/year with investments having a pay-back
period of a few months.
More details of this Cleaner Production audit were be given in the presentation and the
subsequent priorities and work done by the company were also presented.
91
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
92
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Companies Visited
93
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Alytaus Tekstile
CCMS Pilot Study
Products and Pi
Field Trip
Alytus Companies
Alita Wines
Snaige Refrigerators
Siiaig'e
Patyrimas. Kokybe. Stilius
ENVIRONMENTAL PERFORMANCE MANAGEMENT IN JSC "ALITA"
Audrim Valuckas
JSC "Alita"
Alytus, Lithuania
Valeras Kildisas
Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
The company was founded in 1963 in Alytus, a lovely town of Lithuania surrounded by
pinewoods. In 1995 it was reorganized into the joint stock company "Alita." The
registered capital is about 72 million LTL. The annual turnover is about 96 million LTL.
Currently, the company has 540 employees.
The main company's activity is production of alcoholic beverages. The enterprise
produces sparkling grape wine, fruit and grape wines, brandy, bitter brandy, whisky, a
national home-made vodka "Samane," concentrated apple juice and apple aroma.
The company has steadily paid attention to the environment where relevant. In 1998 JSC
"Alita" participated in the Second Norwegian-Lithuanian Cleaner Production School. It
94
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
was a good incentive to solve environmental problems in a more systematic and efficient
way. The most important environmental responsibilities are the consistent efforts to
reduce resource consumption, e.g., energy and water, as well as discharge of wastewater
and waste from concentrated apple juice production. During the period 1998-2001, the
following cleaner production measures were introduced:
• An automatic washing system for wine storage tanks;
• Reconstruction of the water-cooling system and supply network of compressed air
and cold production;
• Installation of electric energy and water consumption meters in different
production departments;
• A warm water and condensate recycle system in the concentrated apple juice
production department;
• Installation receivers and an apple juice sediment collection system.
Capital investments of LTL 980 thousand during this period were earmarked for
improvement of the environmental situation and pollution prevention.
The largest single environmental investment of LTL 1.02 million was a reconstruction of
the JSC "Alita" boiler house in the years 1995-1996. The boiler oil system was changed
to natural gas. Total emissions to the atmosphere were reduced from 155.6 t in year 1995
to 31.0 t in 2001. The boiler oil consumption was reduced from 2210 t to 27,8 t; natural
gas consumption increased from 606 thousand m3 to 2462 thousand m3.
Increasing concern about environmental issues was an incentive for "Alita" to implement
an environmental management system in accordance with the ISO 14001 standard. The
implementation process was started at the end of 2001. The fundamental basis of the
system is consistent implementation of cleaner production, pollution prevention and
preventive risk management principles. The main goals of the preventive environmental
management system were set as efficient consumption of energy and material resources
and continuous and financially efficient improvement of environmental performance.
95
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
ENVIRONMENTAL PERFORMANCE MANAGEMENT IN JSC "ALYTAUS
TEKSTILE"
Deputy of General Director for Environment, Health and Safety
LinasJ. Palionis
JSC "Alytaus tekstile"
Alytus, Lithuania
Irina Kliopova
The Institute of Environmental Engineering
Kaunas University of Technology
Kaunas, Lithuania
JSC "Alytaus tekstile" is one of the largest producers of cotton and mixed fabrics in the
Baltic States. The enterprise was founded in 1967 and in 1993, it became a joint stock
company. The company's authorized capital - 105 462 726 Lt. About 3 600 workers are
working in the company. The company's annual production (2001) includes:
• Total production of yarn-9 812 t;
• Total production fabrics in weaving - 26,7 mil. m;
• Total production of fabrics in finishing -14,2 mil. m;
• Sewing - 7,8 mil. m
The volume of production in 2001 was 141 474 382 Lt. About 80% of this sum was for
export. As far back as 1997, management decided to implement Cleaner Production
within the company. Since 1997 JSC "Alytaus tekstile" has participated in three Cleaner
Production projects:
1. (1997-1998) Implementation of Cleaner Production Projects in Lithuanian Textile
Industry;
2. (1998-1999) The third Lithuanian-Norwegian Cleaner Production School;
3. (1999-2002) Financing of Cleaner Production projects in the Baltic States and
Western Russia.
In 1997 the company created real environmental policy, in which it pledged to improve
the environmental situation within the company and solve environmental problems by CP
methodology. During CP programs JSC "Alytaus tekstile" implemented several CP
projects:
1. Experimental optimising of one sizing machine (1998 year);
2. Recycling of cooling water from scorching machine (1998 year);
96
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
3. Heat recovery from wastewater in bleaching department (1999 year);
4. Recycling of cooling water from scorching process in bleaching line (1999 year);
5. Optimising of all sizing machines (2000 year);
6. Heat recovery from waste water from dyeing and rinsing department (2000 year)
(The company received NEFCO's loan for the implementation of this CP project
in 1999)
Environmental improvements of implemented CP projects:
1. Heat energy saving - 9 115 MWh/year. It represents 10 % of the total heat energy
consumption in the company
2. Industrial and soft water saving and therefore minimization of waste water
volume -178 560 m3/year. It represents 16 % of the total industrial and soft water
consumption in the company
Economical benefits for the company - 2 301 037 Lt/year saving. Project implementation
required 617 757 Lt of total investments.
In February 2002 JSC "Alytaus tekstile" received new NEFCO's loan proposal for the
implementation of reconstruction of the company's air conditioning system in the
production department. The implementation of this CP project will allow decreased
volume of electricity consumption by 11% (7 953 060 kWh /year); of heat energy
consumption by 116 MWh/year. Consumption of soft water will be decreased by 7 080
m3/year (1,1 %). The noise volume within production facilities will be decreased too.
Environmental fees will be decreased by 9000 Lt/year due to refuse from phreon F-12
cooling agent using in new freezing system (600 kg/year). The planning annual cost
savings -1 318 670 Lt. Total costs for the implementation - 2 081 200 Lt.
Since 2000 JSC "Alytaus tekstile" has implemented an Environmental Management
System (EMS). The company takes part in the Lithuanian-Danish program
"Implementation of EMS in Lithuanian Textile Industry." The main purposes of the
participation are to prepare several EMS managers (internal auditors) and implement a
real active Environmental Management System within project frames and certified
according to the ISO 14001 standard.
97
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
ENVIRONMENTAL PERFORMANCE MANAGEMENT IN JSC "SNAIGE'
Alvydas Rakstys, Regina Radziukyniene
JSC "Snaige"
Alytus, Lithuania
Jotita Kruopiene
Institute of Environmental Engineering
Kaunas University of Technology
JSC "Snaige" is a producer of household refrigerators and freezers. In 1963, the first
household refrigerators were produced in the production base of the Alytus machinery
factory. That established "Snaige." In 1992 "Snaige" was privatised and registered as a
joint stock company. In 1995 the company was reconstructed; it was refused from old-
fashioned equipment, and modern technologies were implemented. 1800 employees of
the company now produce about 300 thsd. refrigerators and freezers per year. About 90%
of production is exported to more than 20 countries in the world.
Environmental Management System
Environmental protection is the priority of the company "Snaige." Ecological issues are
constantly considered in the company and everything is done to produce JSC "Snaige" in
correspondence with strict environmental protection requirements. In 2001 JSC "Snaige"
received the international standard ISO 14001 certificate for its environmental protection
management system. This year, a yearly environmental protection management program
(EPMP) was formed for the achievement of environmental protection goals and
implementation of tasks.
Chemicals Management
Chemical control is an issue that has raised more attention in recent years. A
representative of JSC "Snaige" participated in and was certified by the training course on
Classification, Labelling and Packaging of Chemicals. This initiated work on obtaining
hazard information and on risk communication within the company. One of 60
environmental management system procedures (so called enterprise standards) deals
particularly with the safe handling of chemicals. It concerns obtaining and spreading
hazard information, chemicals inventory, and storage of chemicals. Recently the
procedure was amended and expanded. Currently, the company participates in the project
on Chemical Risk Management. JSC "Snaige" further works on improvement of its
chemicals inventory, which is a basis for different kind of chemicals risk management
work. It also plans to work on identification of hazards and exposure from chemical
agents at working places. Particular attention will be paid to risk reduction measures, i.e.,
98
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
comparing different solutions to prevent the open use of hazardous chemicals and
identifying and assessing possible solutions.
Product Design
Considerations of how to use raw materials more efficiently, what ecologically clean and
recyclable materials should be chosen, and what the production process should be are
integrated in product design from the very beginning. The company tries to use the
fewest mixed materials, which are difficult to recycle, as possible. In addition, low
consumption of electricity for the product usage and the lowest possible level of noise are
never forgotten. The technological process of surface covering is absolutely clean from
an ecology perspective: dry cover and drying by gas.
Use of Ozone Depleting Substances (ODSs)
Freezing Agents
The company started to use the freezing agent HFC-134a, which courses the greenhouse
effect, in 1994 instead of HFC-134a, which depletes the ozone layer. Investment for the
substitution was 170 thsd. Lt.
The use of isobutane RGOOa, which is a natural gas, gradually started in 1997. It is
planned to completely shift to its use in 2002. 495 thsd. Lt have already been invested
into substitution, and final implementation will cost 1 mlrd. Lt (investment of GEF fund).
Foaming Agents
Syspur SH4080, which has in its composition CFC-11 (foaming agent, ODS), was used
until 1994. It was substituted for Syspur SH4109/3, containing CFC-141b (foaming agent
with less OD capacity).
Further substitution for Syspur SXH2030/49 (does not contain ODS), used together with
foaming agent cyclopentane, took place. The cost was 12 mln. Lt. (Including 7 mln. Lt
from the global economical fund, or GEF. The GEF fund is a financial mechanism, which
gives grants for ecological projects related to global issues. It was established after the
announcement of the Montreal protocol.) Use of cyclopentane started in 1995. Currently
all refrigerators are filled with thermo isolation material using cyclopentane.
Use of ODSs (tonnes/year):
—
CFC-12
CFC-141b
1994
7,6
10,3
1995
8,1
104,8
1996
4,7
48,5
1997
—
45,7
1998
—
12,9
Since 1999 ODSs have not been used.
99
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
100
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix A
Annual Reports by Country
A-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CZECH REPUBLIC
UTILISATION OF CLEANER PRODUCTION METHODOLOGY AT A DAIRY
PLANT
Jana Kotovicova, Jiri Dvorak and Frantisek Bozek
Description of Company and Its Production
A cleaner production project was elaborated for the dairy MILTRA Company, Ltd., in the
Czech Republic. The company, located in a small town of Mestecko Trnavka, belongs to
smaller dairies. It processes about 130 000 litres of milk a day. Daily production of milk
is transported with the help of a so-called pick-up transport service, usually from the
nearby neighbourhood.
The dairy specialises in the production of Eidam cheese. The production of Eidam cheese
represents almost 63 % of the whole dairy production. The rest of the production includes
mostly curd cheese, delicate curd cheese and flavoured cream and curd cheese products.
Process Analysis
The case study was aimed at finding shortcomings in two spheres: water management
and waste management.
The water management effort was aimed at the reduction of the waste water pollution
load. Waste waters from dairy industry can be divided into cooling waters and rinsing
waters. Cooling waters are not usually polluted, and, after cooling, they can be
recirculated without any problem. Rinse and wash waters contain residues of milk and
disinfectants. They are heavily polluted, especially with organic substances, due to the
fact that over 1% of processed milk gets into them.
Wastes and by-products generated during the processing of milk include mainly the
following:
• separator sludge originates during the purification of raw milk. The sludge can
contain a large amount of pathogenic germs, and that is why it must not be used
as feed. It is either processed in rendering plants or burned;
• buttermilk: Due to its composition, it can be used as dietetics or it can be
processed for casein and salts of casein, which can be utilised as additives in
bakeries;
• whey, which contains under normal conditions 4,7% of lactose, 1,3% of lactic
acid, 0,9% of proteins, 0,6% of mineral substances and about 0,3% of other
organic substances, mainly citric acid, non-protein nitrogenous substances,
residues of fat, etc. More than two thirds of all the vitamins present in the
processed milk go into whey. Whey in its original state is used for drinking, as
A-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
well as in the production of drinks and as feed. It has only limited durability due
to the high water content, and that is why it is mainly processed into condensed
whey concentrate and dried whey. The above mentioned products are used in the
production of fodder as well as by food and pharmaceutical industries. Whey is
not utilised efficiently and in the whole range.
Project Objectives
Whey management was chosen as a priority objective of the project in response to the
number and significance of its environmental impacts. Whey represents over 90% of the
total amount of processed milk. Although it is the source of high-quality proteins with
high nutrition value, its processing is very problematic. In present market economy
conditions, when the supply of whey exceeds demand, the dairy is forced to offer whey to
farmers for 0,10 CK.l"1, despite its high nutrition value. Taking whey delivery is agreed to
in contracts between a firm and its customers. Only the price of whey is contracted, not
the amount being taken. Finding possibilities for further processing of whey has the
potential for direct economic profit and reduction of waste water pollution.
Measures of Cleaner Production
It was suggested to accumulate whey in storage tanks and from there to transport it to the
RF 1A rotary screen filter with the help of centrifugal pump. It is possible to eliminate
residues of coagulated proteins and cheese powder with the help of this equipment. The
casein gained can be then returned to the manufacturing process or utilised as a full-scope
raw material in melting processes during processed cheese production. The waste water
load will be reduced through significant elimination of organic matter. Whey, cleared of
proteins and cheese powder, will be pumped into storage tanks, where it will be ready
either for sale as feed or for further processing, e.g., drying.
Parameters corresponding with the implementation of newly proposed procedure are
presented below:
amount of milk processed per day: 1,35.105 litres
amount of whey produced per day: 1,25. 105 litres
capacity of rotary screen filter: 5.103 - 104 litres of whey per hour
operating hours of filter per day: 17 hours
cleaning of the equipment including conduit line: 1 hour per week
filtration efficiency per day: 210 - 250 kg of proteins with the dry
matter of 25-30%
A-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Results Achieved
The environmental and economic benefits of the proposed cleaner production measures
can be briefly summarised by a comparison of current and envisaged conditions.
current state:
whey production:
sold for feed:
1,255.10 litres per day
1,255.105 litres per day
If we count the cost of whey to be 0,10 CK.l"1, then the daily sale profit is 12 545 CK, but
only if all the production is sold. The state after the implementation of filtration is
presented here:
After filtration is implemented:
whey production:
sold for feed:
sale of obtained protein:
costs of one employee:
increased energy costs:
increased transport costs
1,255.10 litres per day
1,255.105 litres per day
210 kg per day
500 CK per day
1 600 CK per day
400 CK per day
It is possible to obtain 12 200 CK per day higher income with regard to the
above-mentioned information and to the fact that 1 kilogram of protein costs 70 CK.kg"1.
If the dairy operates non-stop 250 days a year, the income is 3,05.10+6 CK. If whey is sent
back into production, the total income will be even higher. If the investment costs are
estimated to be 1,15.106 CK (purchase of rotary screen filter - 4.105 CK; purchase of
necessary tanks - 7,5.105 CK) with 12,5% depreciation in machinery, 7% interest and
39% profit-tax, the economic benefit can be the following (Chart No 1):
year of installment
revenues [CK]
depreciation in machinery 12,5 % [CK]
interest 7 % [CK]
profit before taxation [CK]
tax 39 % [CK]
profit after taxation [CK]
credit [CK]
cash flow [CK]
1
3 050 000
143 750
80500
2 825 750
1 102 043
1 723 707
1 150000
717457
2
3 050 000
143 750
-
2 906 250
1 133438
1 772812
-
1 916562
Chart No 1. Profit and its distribution
It is clear from Chart No 1 that the cash flow CF(t=2) = 1,917.10 CK per year after the
investment is paid (t = 2).
A-4
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The investment payback period PP can be counted according to the formula written
below, where IN represents investments and CF(t+i) is cash flow of profits in the year t +
1, when the investments have already been paid:
IN 1150000
PP = = = 0,60 year
1916562
(t+D
The present worth of investment at the time of instalment PW(i) was calculated with help
of the following formula. It is 1,005. 106 CK at the interest i = 0,07.
115000°=100445CK
a+0,07)2
To the above mentioned economic benefit, it is also necessary to add the environmental
benefit, which is represented by the reduction of waste water pollution and which is
difficult to express in numbers.
Conclusion
The cleaner production project elaborated for the MTLTRA dairy in the town of Mestecko
Trnavka clearly proved considerable economic and environmental benefits. The measures
of cleaner production are based on the filtration of whey through the rotary screen filter.
This way casein is removed from whey. Casein is then assumed to be utilised either back
into production, or as a full-value raw material in melting processes during the processed
cheese production. It was estimated that in case of investment amounting to 1,15.106 CK
(purchase of rotary screen filter for processing the whey and tanks for storing the final
liquid filtration product), it is possible to gain a total annual profit amounting to almost
2.106 CK after the investment has been paid. Payback period is approximately 0,6 year.
At the same time, positive environmental benefits will be gained by reducing organic
matter in wastewaters. Another potential for the reduction of environmental load is in
implementing recycling of the rinsing and cleaning waters.
Lack of financial resources for investments is a typical problem, which imposes restraints
on quick implementation of the results in practice.
A-5
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
UTILIZATION OF CLEANER PRODUCTION AT A POULTRY PROCESSING
PLANT
Jana Kotovicova, Frantisek Bozek and Ales Komar
Description of Company and Its Production
A cleaner production project was implemented in the poultry slaughterhouse UKAMO
Ltd., Modrice in the Czech Republic. Capacity of the company is about 6 000 pieces of
poultry per hour, of which 82% is the chicken broiler. Layers are occasionally processed
too. In addition to operating the slaughterhouse, the company has also meat production
represented by a portioning plant and smoked meat production. Breast and thigh muscles
are divided on fully automated machines in the portioning plant. Cutlets and other semi-
manufactured products, representing a higher level of preparation, are prepared there as
well. Smoked meat production includes the processing of meat, fat, offal, auxiliary
materials and meat production additives.
The poultry slaughterhouse line consists of a hanging plant, two slaughtering circuits,
a scalding tank, a plucking machine, a drawing line, two cooling circuits, a packing room
and a technology for freezing the poultry and poultry products. Cooling of drawn poultry
was carried out in continually operating fume equipment with the help of cooled water.
Poultry was moved with a worm conveyer in tanks. Poultry absorbs about 3,0 % of water
from outside during this type of cooling. Equipment for the pre-treatment of wastewaters
and trapping of the waste is a part of the line as well.
Input-Output Analysis
Real values of material and energetic losses in the production flow were identified
through detailed analyses and measurements. The methodology was based on the
implementation of operational-economic and methodological-technical procedures. After
detailed identification of the problems, the real costs of waste disposal were clarified, as
well as the costs relating to the price of input raw material, power costs, overhead
expenses and other economic elements of the manufacturing process. The result of the
analysis was surprising, as the economic loss exceeded the professional estimate provided
by technical staff.
Project Objectives
About 25% of waste is originated in relation to the input raw material during poultry
processing. The above mentioned waste makes 95% of all the solid waste in the
company. Most wastes are transported to a rendering plant. A significant level of
recycling cannot be expected here. The company has extra costs for disposal.
There are three types of wastewater: slaughterhouse waste water, meat production waste
water and sink water. Their chemical compositions vary considerably. The
slaughterhouse waste water is polluted by considerable amounts of sedimenting
substances, floating substances and mainly by blood. Meat production wastewater
A-6
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
contains only a small amount of sedimenting substances, but it has a high volume of
emulsified fat and proteins, both dissolved and dispersed. The sink water is polluted the
least. Wastewater treatment costs represent over 80% of the resources determined for the
waste treatment.
Energy and water costs represent 4% of material inputs. Parts of the slaughterhouse
line, where it is necessary to reduce the inputs, were chosen on the basis of material and
energetic balance.
Measurements of Cleaner Production
Four measures were suggested for implementation on the basis of input-output analysis.
The measures are stated below and prioritised from a) to d):
a) losses reduction during the poultry entrails processing by exchanging the
obsolete machine cleaning the maws for new equipment with the aim of
increasing efficiency;
b) reduction of energy demand and water consumption during scalding the
poultry by exchanging the scalding tank for a modern type with a closed circuit
and a compressor;
c) reduction of harmful substances in waste waters by reconstructing rough waste
water pre-treatment and implementing vacuum transport of soft wastes, heads and
feet;
d) improvement of the technological flow of production by introducing the air-
cooling of drawn poultry. The measure is based on the purchase of new
technology, which will substitute for the obsolete water cooling of poultry. The
aim of the measure was to reduce Salmonella health risks for the consumers of
fresh poultry and to remain competitive on the market with fresh poultry.
The change of cooling technology is the most costly of all the suggested measures. That
is why it was originally assumed that this measure will be implemented last and that the
company will gain the necessary financial resources for the purchase of the technology
by implementing the previous, less costly measures. However, legal amendments made
the implementation of this measure the number one priority, as the company wanted to
remain on the market with fresh poultry.
Benefits Achieved
At present a cooling tunnel is installed in the company and the cooling of drawn poultry
is carried out in a counter flow by air cooled in exchangers with ammonia. Investment
costs amounting to 2,5.107 CK were caused by necessary technological changes in other
parts of the line. Results of preliminary analyses showed that annual production income
should be about 8.106 CK. It was found that in reality the annual income amounts even to
1,06.107CK.
A-7
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
year of installment
revenues
machinery depreciation
[6,2 % first year, 13,4 % next]
construction depreciation [1%]
interest [7 %]
gross profit
profit tax [39%]
tax after taxation
machinery depreciation
construction depreciation
payment of credit
cash flow
1
10600
1 550
250
1 750
7050
2 749,5
4 300,5
1 550
250
5000
1 100,5
2
10600
3 350
250
1 400
5600
2 184
3416
3 350
250
5000
2016
3
10600
3350
250
1 050
5950
2320
3 629,5
3350
250
5000
2 229,5
4
10600
3350
250
700
6300
2457
3 843
3350
250
5000
2443
5
10600
3 350
250
350
6650
2593
4 056,5
3 350
250
5000
2 656,5
6
10600
3 350
250
-
7000
2730
4270
3 350
250
-
7870
Chart No 1. Creation and distribution of profit (all the values are in thousands of CK)
This chart demonstrates the company's profit and its distribution after the implementation
of the investment. The assumption is that machinery depreciation from the investment
costs are 6,2% in the first year and 13,4% in the following years. Profit tax is calculated
to be 39% and interest on the Phare funds is 7%. Construction depreciations are
calculated to be 1% of the investment costs.
Cash flow after the payment of investment is 7,87.106 CK per year. Payback period (PP)
can be calculated according to this formula, where IN represents the amount of
investments and CF(t+i) is the cash flow of profits in the year in which the investments are
paid.
PP = .
IN
CF
(t+D
25000000
- =
7870000
year
The present worth of investment PW(5) = 1,67.107 CK at the time the investment is paid.
Its value was counted on the assumption that the credit is 7% and payment of credit
represents 5.106 CK per year.
PW (t) = •
IN
25000000
a+0,07)E
=1665855 CK
It is possible to find that the investment is profitable in the ninth year of operation by the
amount of 8,61.105 CK. The method of present value of net benefits was used at the
internal discount rate K; = 8 % for the calculation. The calculation was done according to
the formula written below, where PNVB(t) is a cumulated present value of net benefits in
the year t at the internal discount rate K;, PVCF(t) is a cumulated present value of cash
flow in the year t at the internal discount rate K;, CF(t) represents cash flow from the
investment in the year t, and IN is the amount of investment.
PVCF (t) =
CF
-IN
A-8
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The amount of cumulated present value of net benefits PVNB(t) for the individual years
of investment, accompanied with other necessary data, is clear from this chart.
It should also be mentioned that the implementation of the above mentioned technology
had a positive impact on the reduction of wastewater pollution and increases occupational
hygiene in the manufacturing process.
year
0
1
2
3
4
5
6
7
8
9
investment
costs
[CK]
25 000 000
-
-
-
-
-
-
-
-
-
profits
[CK]
-
1 100 500
2016000
2 229 500
2 443 000
2 656 500
7 870 000
7 870 000
7 870 000
7 870 000
(1+KO1
1,000
1,080
1,166
1,260
1,360
1,469
1,587
1,714
1,851
1,999
present value
CF(t)
[CK]
- 25 000 000
1 018981
1 728 395
1 769 849
1 795 678
1 807 969
4959435
4 592 069
4251 916
3 936 959
Cumulated
present value of
net benefits [CK]
- 25 000 000
-23981 019
- 22 252 624
- 20 482 775
- 18687097
- 16879 128
- 11 919693
- 7327624
- 3 075 708
861251
Chart No 2
investment
Cumulated present value of net benefits for the individual years of
Conclusion
The applicability of cleaner production methodology in a food industry was clearly
proved by the example of a poultry processing plant. Weak points in the production were
identified on the basis of input-output analysis, and the measures of cleaner production
were proposed and prioritised. As the company wanted to remain competitive on the
market with fresh poultry, the most costly measure was prioritised. The obsolete system
of counter flow water cooling of drawn poultry was substituted for the air cooling system.
The change of technology required investment costs amounting to 2,5.107 CK. Based on
the company performance, the payback period of the investment was assessed to be about
3,2 year, and the company annual profit is almost 8.106 CK after the investment is paid.
Under these conditions and at the internal discount rate of 8%, the investment will be
profitable in its ninth year.
Environmental benefits were also achieved by the implementation of the measures. They
are represented by the significant reduction of Salmonella health risks for the consumers
of fresh poultry as well as the reduction of waste water pollution by organic matter.
Further potential for the reduction of the environmental load is seen in exchanging the
obsolete maws cleaning machine for new equipment to achieve higher efficiency.
A-9
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
ISRAEL
HIGHLIGHTS OF ACTIVITIES IN ISRAEL
Water Desalination
Due to the lack of sufficient water resources in Israel, it was decided to rely on sea water
desalination as an additional source of potable water. The plants in consideration are very
large—in the range of 50 million cubic meters of water per year per plant. While the
technologies involved are available in Israel due to extensive R&D of these technologies,
the problems that are now dealt with are related to the environmental aspects. These refer
to the effect of salty water on aquifers, which has to be avoided, and the effect of highly
salted reject of the desalination plant on the environment of the sea area where it is
introduced. The design of the plants takes into account these problems as well as the
location of the plant, which in itself is a problem to be considered.
Water Treatment
Recently a ministerial order of the Ministry of the Environment was issued stating that
industrial waste, especially from the petrochemical industry in the Haifa Bay, could not
be sent to the river without pretreatment of the streams to the level at which they could be
released to the environment. In fact several options were considered for disposal, and it
was concluded that even the treated waste water could not be returned to the river and
instead should be sent by a pipe deep into the sea. Some companies have already spent
the necessary funds in order to comply with the demand, and others are in the process of
implementing the above mentioned order. We hope that the next step will be to adapt the
processes and indeed change the processes so as to take into account their environmental
impacts.
Oil Spill Cleaning
Oil tankers and pumping stations of the neighboring countries Israel and Jordan use the
gulf of Eilat and Akaba to transport oil to their respective countries. In order to preserve
the environment and its rich marine life, a ship was acquired in order to clean oil from the
water whenever necessary. The ship was built by a Norwegian company and is now
operating in the gulf. The ship has the necessary equipment to fulfil the required tasks.
Rotem Amphert
Rotem Amphert is a large chemical industrial complex located in the Negev desert
specializing mainly in the production of phosphate fertilizers and phosphoric acid.
Recently they developed a new process to convert "green" phosphoric acid to "white"
(pure) phosphoric acid. The novelty of the process is that it has no waste stream at all
and is less expensive than the one formerly used. It is a good example, showing that it is
possible to improve processes in the chemical industry so they are environmentally more
friendly and at the same time economically attractive.
A-10
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Ramat Chovav
Ramat Chovav is a large industrial park in the Negev desert about 10 kilometers from
Beer-Sheva, where polluting chemical industries are concentrated. The national site for
hazardous wastes is located here, too. A couple of years ago, a centralized system for
industrial waste disposal was erected. In the last year a novel biological treatment plant
was introduced to treat most of the industrial waste of the complex.
A-ll
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
MOLDOVA
CLEANER PRODUCTION IN THE REPUBLIC OF MOLDOVA
The issue of clean products and clean production processes has been discussed for some
time not only in the Republic of Moldova, but also in many countries. Especially in the
last decades the environmental aspect of human and economic development has become
more and more important. It is not only the ecologists' organizations, but also
governments and broad civil society which are interested in the effects of particular
development processes on the environment.
The Republic of Moldova is not an exception. Much has been done in this direction in
recent years. Moldova is a member of a number of environment-related conventions and
was one of the first countries to ratify the Kyoto convention, for example.
Ecologically sustainable development is even more important for Moldova than for other
countries as its main generator of national welfare is agriculture or agriculture-related
activities. In the past, when Moldova was part of the Soviet Union, the agricultural
methods applied here were intensive, meaning that in the production process, many
chemical agents were used. The ecological factor was of very little importance, or not
considered at all. The natural resources, especially the good quality soil for which
Moldova was famous, were greatly depleted. The same situation applied to industry.
Many highly polluting plants operated without any concern about their effects on the
environment.
The situation has changed dramatically in the last decade. As a result of the break-up of
the Soviet Union, the traditional economic ties with the socialist republics have been lost
and a significant fall of the output was registered. The old, chemical-intensive methods
were dismissed due to financial constraints. Agriculture production became more
traditional and labour-intensive due to the low cost of the labour force, and became,
indirectly, more environment friendly. Also, as a result of the political opening of the
country, informational exchange became possible. Society is more and more aware of the
environmental effects of human activity. A number of technical assistance projects were
initiated in order to implement in the economy new clean production processes. We also
recognise that producers became interested in these processes not only because of the
concern for nature, but also for economic reasons. The demand for clean, so-called
bioproducts is constantly growing, especially in the Western European countries. A
number of studies were conducted in that respect, and the results were that Moldova has a
comparative advantage in the production of bioproducts.
But knowing that you have ecologically pure products is not enough. You have to let
people know about it too. So, in recent years, efforts were made to harmonise Moldovan
standards with international ones. ISO 9000 standards are already implemented. The
international community also contributes to these efforts through a number of technical
assistance projects. Also, a Swiss company, SGS S.A., is working on the implementation
of the biostandards in agriculture, as well as certification of the production processes as
ecologically clean. Seminars, roundtables and workshops were organised in order to
increase the public awareness of these issues.
A-12
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The main obstacles in the way of cleaner production processes in Moldova are:
• Human conservatism;
• Limited awareness and understanding of the cleaner processes;
• Financial constraints;
• Long decision-making process;
• Lack of the promotion of the cleaner production ideas and technologies.
Cleaner production in Moldova started to be developed after the signature in 1999 of the
International Declaration on Cleaner Production (UNEP). From that date, cleaner
production in Moldova started to gain ground: the principle of cleaner production was
introduced in the Government's Action Plan and in the Concept of the Environment
Protection. Also, a Centre for Prevention of Industrial Pollution (CPPI) was established.
Since July 1999, CPPI, the Ministry of Environment, Construction and Territorial
Development and Ministry of Industry and Energy have joined efforts in order to initiate
the implementation of the international program "Cleaner Production."
In 2000, eight companies based in Chisinau, the capital of the Republic of Moldova
(Carmez, Lapte, Floare-Carpet, Fabrica de Drojdii din or. Chisinau, Avicola Roso,
Agroconservit, CET-1, Piele S.A.), initiated the implementation of the "Cleaner
Production" principles. Their representatives have followed a training program carried
out by CPPI and the Russian-Norwegian Centre "Cleaner Production." In all, 113
projects were implemented in 2000. In 2001, another 11 enterprises from Chisinau
(Franzeluta, Bucuria, Carmez, Vitanta, Hidropompa, CET-2, Aroma, Termocom,
Universitatea Tehnica, Parcul de Troleibuse, Tutun) and eight enterprises from Bali
(Rada, Floutex, Combinatul de produse alimentare, CET-NORD, REUT, APA-CANAL,
Lactis, Incmlac) joined the programme.
Implementation of these projects in 2001-2002 has resulted in the following benefits:
• Energy savings - 7622 968 kWh/year
• Decrease of water consumption -124 501 M3/year
• Toxic substance in air emissions -1.02 t/year
• Toxic substance in sewages - 2 t/year
• Heat consumption - 74.5 Gcal/year
As we can see, the above mentioned projects are focused on the industrial sector. But
Moldova's main production is agricultural. And in response to the growing demand for
organic produce on the international market, Moldovan agriculture was inclined to
become more organic. In 2000 a National Concept was launched to implement Moldovan
aspirations in regard to organic farming, which identified the need for inspection and
control models and procedures. In this respect, in 2002 a study on "Strengthening Policy
and Regulatory Capacity in Organic Agriculture, Moldova" was conducted by the World
Bank "Agriculture Pollution Control Project." One of the components of this project is
promotion of the cleaner production processes in agriculture. And there are also a number
of measures provisioned for 2003, with the aim of promoting cleaner production in the
Moldovan agricultural sector.
A-13
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Enterprises are not the only ones interested in cleaner production. Through the
implementation of cleaner production processes, the Government tries to achieve a series
of goals:
• Pollution control and reduction of the social costs of the environment's
degradation;
• Sustainable development of the industrial sector and society through cleaner
production;
• Implementation of the National Strategy for Sustainable Development.
And in order to achieve these goals and to implement the principles of cleaner
production, the Ministry of Environment, Construction and Territorial Development will
take the following steps:
• Implementation of the National Declaration on Cleaner Production (about to be
approved);
• Promotion of cleaner production in all sectors of the Moldovan economy;
• Coordination of the Cleaner Production projects, implemented in different sectors;
• Investment attraction for the implementation of the Cleaner Production projects.
But having said that, we have to admit that a lot still has to be done. New technologies
are not available free of charge. Due to severe financial constraints, the Republic of
Moldova cannot afford these technologies. All initiatives in this area are implemented
almost entirely in the framework of technical assistance projects and are in pilot phases.
In order to implement the new technologies, you must have personnel trained for these
processes. The policy-makers, who in many cases are subject to inertia, should
understand the importance of it. And through the exchange of experience and increased
awareness, we can achieve progress in this area.
A-14
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
NORWAY
OVERVIEW OF WORLD CLEANER PRODUCTION ACTIVITIES WORLD
WIDE, DECEMBER 2002
The first cleaner production projects Norwegian consultants were involved in outside
Norway were organised in Poland in 1990. They were organised as a co-operation
between the Norwegian Confederation of Chartered Engineers and their Polish
counterpart, NOT.
The principles for the projects were in-plant training and learning by doing. One
important objective was to transfer Norwegian competence and experience to the Polish
colleagues based on train-the-trainer principles.
The Polish programme quite soon became a success, and similar programmes were
organised in Czechoslovakia in 1992. The Czech and Slovak programmes subsequently
formed the basis for the UNEP-UNIDO National Cleaner Production Centres.
OECD made in 1994 an evaluation of the ongoing CP programmes in CEE/NIS-countries
and nominated the Norwegian approach as the most cost effective.
Based on this, Norwegian consultants developed the OECD publication "Best Practices
Guide for Cleaner Production Programmes in Central and Eastern Europe."
The CP programmes are organised in four plenary sessions and three intermediate
sessions in between the plenary sessions with project work and visits by the instructors as
described below:
1st plenary session.
• Introduction to the CP principles
• The assessment procedure
• How to organise the assessment
• Setting objectives
• Mass-energy-cost balances
• Developing options
• Brainstorming techniques
2nd plenary session.
• Reports from the companies
• Screening of improvement options
• Introduction to strategic planning methods
• Feasibility analysis (economic, technical, environmental)
• Calculations on payback, internal rate of return, net present value
A-15
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
3rd plenary session.
• Reports from the companies
• The relations between EMS and CP assessment
• What do the banks ask for?
• Criteria for 2-year action plans
4th plenary session.
• Reports from the companies
Each plenary session takes 3-4 days (4 days for the first session) and 2 days for the last
session. At the last session we normally try to organise a high level meeting with
government officials and industry representatives to provide a platform for dissemination
of results achieved and policy development in order to develop a demand for the CP
strategy.
The typical time period for a complete programme is 7 months. Normally we work with
a mix of different companies. In addition to 1-2 participants from the participating
companies, other representatives from universities, government agencies and industry
associations are taking part in the training.
After the first three successful programmes in the period 1990-1995, similar programmes
were organised in the period 1995-2000 for:
• Russia north west (Murmansk, Arkangelsk and Karelia oblast) (ongoing). A
report from this most comprehensive programme is enclosed. Norway is still
supporting the Russian - Norwegian Cleaner Production Centre located in
Moscow.
• Lithuania.
• Kaliningrad.
• China (two programmes in Beijing).
• China (Hnan Province, Zhouzhou City).
• Zambia.
• Tunisia.
The latest programmes were organised for Indonesia and Pakistan. The Pakistani
programme (2000-2001) is the only industrial sector programme where 20 tanneries took
part. A CP centre was established with Norwegian support in Sialkot in the Punjab
province, where there is a comprehensive cluster of tanneries.
In Tanzania in 1999 a 5-year programme supported by NORAD was established. The
programme was evaluated (mid term evaluation) in April 2002 with excellent results. The
A-16
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
centre will from the beginning of 2003 make some modifications to the 1999 plan in
order to better ensure sustainability of the Centre after the programme has finished.
In 2002 new programmes were launched in Croatia (3-year programme) and Lithuania
(2-year programme).
The Croatian programme has the following main elements:
• CP assessments for three groups of companies (mix of companies, food
production companies and service sector companies).
• Financial engineering training and loan applications.
• Preparation of selected companies for preparing EMS certification.
• Policy development.
The first group of eight companies presented their results in October 2002.
The Lithuanian programme, which was kicked off in September 2002, plans to integrate
CP and bank loan applications to the NEFCO CP revolving fund with EMS preparation,
environmental reporting and benchmarking activities. In addition there will be a close co-
operation with the municipality of Klaipeda in order to develop reporting procedures
between the companies and the municipality and between the municipality and the
public. All of the eight participating companies are located in Klaipeda. The programme
is planned as a series of 10 plenary sessions
A-17
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
POLAND
THE NATO CCMS PILOT STUDY ANNUAL REPORT 2002
Dr. Sc. Andrzej Doniec
Pollution Prevention Center
Technical University of Lodz
There is the potential for implementing the idea of clean products and processes in
Poland. Poland is one of the countries invited to become European Union members. The
accession process required adjustment national regulations to EU standards. Thus Polish
environmental law was changed with accordance to EU environmental regulations. As a
result, some requirements affecting products and processes that arise from EU Directives
already exist in Polish or will be in force in couple of years.
Today implementation of principles of environmentally friendly processes and products
understood as new "green" solutions is not common. The Cleaner Production/Waste
Minimization concept is fairly well known and utilized in some companies. Producer
responsibilities that will come into being as a result of environmental regulations will
force companies to rethink their policies in the area of green products and processes to
gain a competitive advantage. The market for ecoproducts (green products) is rather
shallow because of the pretty narrow awareness of sustainability and because of our
citizens' buying criterion, which is price rather than environmental friendliness; this is of
course caused by weak purchasing ability.
The idea of clean products and processes is present to some extent in Polish university
curricula as well as in research. The courses (subjects) offered are most often aimed at
cleaner production and sustainable energy use: membrane techniques and applications,
process integration (optimization of heat exchanger networks), water management and
some energy and material efficient technologies. The Technical University of Lodz is a
good example of the approach mentioned above. Courses on low-waste technologies are
included in education process by two faculties: Process and Environmental Engineering
and Management and Organization. The latter recently started a technological
specialization named Ecotechnology, which means environmentally friendly engineering.
Industrial ecology, sustainable energy use, ecodesign and low-waste technologies are the
main subjects taught in the specialization. The specialization is conducted by the
Department of Industrial Ecology established a year ago.
The mission of the Department is to promote industrial ecology fundamentals as essential
measures on the way to sustainability. In response, a postgraduate, two-semester course
entitled Sustainable Development in an Industrial Enterprise has been developed; it
started last fall.
A-18
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Research activities at the Technical University of Lodz are manifold and include
investigating problems related to clean products and processes. Beneath are listed some
achievements in this area:
• A porous, concrete-like material for heavy metal ion removal from industrial
waste waters has been developed at the Pollution Prevention Center. Waste
industrial dusts and fly ashes are the main components of the material.
• At the Faculty of Marketing and Engineering of Textiles, a new, totally clean
technology of cellulose fibers production has been developed.
• A new construction of a very efficient ultra fast, vacuum DC switch for electric
traction. This is a series of durable, emission-less, service-free switches
constructed at the Electrical and Electronic Engineering Faculty.
• Research on anthropogenic ecosystems for cleaning of wastewater is going on at
the Department of Industrial Ecology. The aim of the project is to study the
suitability of the idea for cleaning of food processing industry wastewater, as well
as to develop a simple design procedure for such a type of treatment plant.
To facilitate exchange of information on clean products and processes between a variety
of parties, PPC at the Technical University of Lodz and the Chair of Energy Utilization
Problems of University of Mining and Metallurgy in Cracov are jointly planning to
launch in 2003 a Poland-wide seminar series on environmentally friendly technology.
A-19
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
PORTUGAL
DESIGNING EFFICIENT, ECONOMIC AND ENVIRONMENTALLY
FRIENDLY CHEMICAL PROCESSES
Teresa M. Mata
Laboratory of Processes, Environment and Energy Engineering
Faculty of Engineering
University of Porto
Rua Dr. Roberto Frias 4200-465
Porto, Portugal
tmata@fe.up.pt
This research project was developed in collaboration with US EPA in Cincinnati as part
fulfillment of Teresa Mata's PhD in Chemical Engineering from the University of Porto.
The main objective of this research project is the design and improvement of chemical
processes integrating environmental and economic considerations. This work analyses
opportunities to reduce or eliminate waste in chemical processes and through the life
cycle of products to minimise their environmental impacts. A process simulator was used
to create detailed process flowsheet and to help analysing rigorously the processes under
study. Process simulators help to analyse different design alternatives, predict the
performance of a process, locate malfunctions and solve specific problems that arise from
the original design problem. Process economics and environmental models are needed to
define the optimum for products and processes. Design and improvement of chemical
processes can be very challenging and require a balance of safety, reliability, economics,
quality, robustness and an acceptable impact on the environment and society. The
abstracts of the publications generated with this research project and the related
bibliographic references are presented below.
Designing Environmental, Economic and Energy Efficient Chemical Processes:
Heat Exchange Networks. The design and improvement of chemical processes can be
very challenging. The earlier energy conservation, process economics and environmental
aspects are incorporated into the process development, the easier and less expensive it is
to alter the process design. In this work different process design alternatives with
increasing levels of energy integration are considered in combination with evaluations of
the process economics and potential environmental impacts. The example studied is the
hydrodealkylation (HDA) of toluene to produce benzene. This study examines the
possible fugitive and open emissions from the HDA process, evaluates the potential
environmental impacts and the process economics considering different process design
alternatives. Results of this work show that there are tradeoffs in the evaluation of
potential environmental impacts. As the level of energy integration increases, process
fugitive emissions increase while energy generation impacts decrease. Similar tradeoffs
occur for economic evaluations, where the capital and operating costs associated with
heat integration could be optimised [1].
Environmental Comparison of Gasoline Blending Options Using Life Cycle
Assessment. A life cycle assessment has been done on various gasoline blends. The
purpose of this study is to compare several gasoline blends of 95 and 98 octane that meet
the vapour pressure upper limit requirement of 60kPa. This study accounts for the
A-20
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
gasoline losses due to evaporation and leaks, from petroleum refining to vehicle
refuelling, and evaluates the potential environmental impacts using the Waste Reduction
(WAR) algorithm. The results indicate that for lower PEI, it is better to use less reformate
in gasoline, due to its high contribution to the photochemical ozone creation potential.
This study also shows that the life cycle stage with the largest contribution to the PEI is
gasoline production at the refinery [2].
Environmental Analysis of Gasoline Blending Components Through Their Life
Cycle. The purpose of this study is to assess the contribution of three major gasoline
blending components (reformate, alkylate and cracked gasoline) to the potential
environmental impacts. This study estimates losses of the gasoline blending components
due to evaporation and leaks through their life cycle, from petroleum refining to vehicle
refuelling. A sensitivity analysis was performed using different weighting factors for each
potential environmental impact category in order to assess the effect of each blending
component on the total potential environmental impacts. The results indicate that
reformate and cracked gasoline mainly contribute to photochemical oxidation followed
by aquatic toxicity, terrestrial toxicity and human toxicity by ingestion. On the other
hand, alkylate contributes mostly to aquatic toxicity, but very little to photochemical
oxidation. From the sensitivity analysis, a high weighting on the impact categories for
aquatic toxicity, terrestrial toxicity and human toxicity by ingestion lead to alkylate
having the largest potential impacts of the three blending components, whereas other
combinations of weighting factors indicate that alkylate has the lowest potential impacts
[3].
Designing Environmentally Friendly Chemical Processes with Fugitive and Open
Emissions. Fugitive or open emissions can dominate the potential environmental impacts
of a chemical process. In this work the design and simulation calculations of a process
provide an opportunity to visualise relationships between economic potentials and
potential environmental impacts. The analysis of the economic and environmental effects
of process alternatives is completed quickly and easily using order-of-magnitude costing
techniques and the WAste Reduction (WAR) algorithm for environmental evaluation. In
the example studied, the hydrodealkylation of toluene, both the economic and
environmental results point towards the alternative of recycling biphenyl to extinction,
which is a form of pollution prevention by source reduction. As open emissions are
eliminated, the importance of fugitive emissions is shown to increase. Finally, results
show where economic optimum and minimal environmental impact designs occur, and
therefore one can see tradeoffs between these designs [4].
Designing Efficient, Economic and Environmentally Friendly Chemical Processes. A
catalytic reforming process has been studied using hierarchical design and simulation
calculations. Approximations for the fugitive emissions indicate which streams allow the
most value to be lost and which have the highest potential environmental impact. One can
use this information to focus attention on these high value and/or high potential
environmental impact streams. It was also found that increased recycling leads to a higher
potential environmental impact. The effect of larger recycle flows is an increase in
fugitive emissions, which leads to larger impacts [5].
Simulation of Ecologically Conscious Chemical Processes: Fugitive Emissions versus
Operating Conditions. Catalytic reforming is an important refinery process for the
conversion of low-octane naphtha (mostly paraffins) into high-octane motor fuels
A-21
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
(isoparaffins, naphthenes and aromatics), light gases and hydrogen. In this study the
catalytic reforming process is analyzed under different operating conditions to calculate
the octane number and amount of fugitive emissions. The fugitive emissions are
accounted for by considering the existing methods in the literature, and the potential
environmental impact leaving the process is evaluated using the WAR algorithm. By
examining a range of operating conditions and performing environmental analyses with
WAR, the most environmentally friendly process conditions are elucidated. The process
conditions considered here, the reactor temperature and pressure, affect the products in
terms of reformate and hydrogen yields, research octane number and reformate
composition. The results indicate that more recycling is not always a better solution for
waste minimization. In this case study increased recycling means more process
equipment and larger stream flowrates through almost the entire process, which increases
fugitive emissions and their potential environmental impacts [6].
References
[1] Mata T. M., Smith R. L., Young D. M., Costa C. A. V. Designing Environmental,
Economic and Energy Efficient Chemical Processes: Heat Exchanger Networks.
In: NATO ARW Technological Choices for Sustainability, Maribor (Slovenia),
12-18 October 2002.
[2] Mata T. M., Smith R. L., Young D. M., Costa C. A. V. Environmental
Comparison of Gasoline Blending Options Using Life Cycle Analysis. In: R'02 -
Recovery, Recycling and Re-integration, Proceedings of the 6th World Congress
on the Integrated Resources Management, Geneva (Switzerland), 12-15 February
2002, Paper 192.
[3] Mata T. M., Smith R. L., Young D. M., Costa C. A. V. Environmental Analysis of
Gasoline Blending Components Through Their Life Cycle. In: CHISA 2002,
Proceedings of the 15l International Congress of Chemical and Process
Engineering, Praha (Czech Republic), 25-29 August 2002.
[4] Smith R. L., Mata T. M., Young D. M., Cabezas H., Costa C. A. V. Designing
Environmentally Friendly Chemical Processes with Fugitive and Open Emissions.
Process Integration. In: PRES'OJ, Proceedings of the 4th Conference on Process
Integration, Modelling and Optimisation for Energy Saving and Pollution
Reduction, Florence (Italy), 20-23 May 2001, 129-134.
[5] Smith R. L., Mata T. M., Young D. M., Cabezas H., Costa C. A. V. Designing
Efficient, Economic and Environmentally Friendly Chemical Processes. In:
Jorgensen S., Gani R., editors. Computer-Aided Chemical Engineering 9,
Proceedings of ESCAPE: 11th European Symposium on Computer Aided Process
Engineering, Kolding (Denmark), 27-30 May 2001, 1165-1170.
[6] Mata T. M., Smith R. L., Young D. M., Costa C. A. V. Simulation of Ecological
Conscious Chemical Processes: Fugitive Emissions versus Operating Conditions.
In: Ramoa Ribeiro F., Cruz Pinto, J. J. C., editors. CHEMPOR'Ol, Proceedings of
the 8th International Conference of Chemical Engineering, Aveiro (Portugal), 12-
14 September 2001, 907-913.
A-22
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
REPUBLIC OF SLOVENIA
ANNUAL REPORT ON CLEANER PRODUCTS AND PROCESSES
Peter Glavic
Slovenia has recognized Sustainable Development as one of the key issues in the further
development of the country and signed the Kyoto protocol last year. In the Strategic
Development of its economic development, all three components of Sustainable
Development (economic, social and environmental) are taking place. Slovenia has been
ranked 14th of the 26 European countries and 23rd of the 124 countries in the world. The
social development component is lagging behind but the environmental and economic
components are advancing.
Most of the companies have accepted voluntary environmental protection schemes. ISO
14000 certification has been acquired by many companies, the Slovenian average being
not far from the European Union (EU) one. Most of the chemical companies have
adopted the Responsible Care Programme. The price and tax for the water usage, air and
soil pollution have been raised dramatically, causing most of the companies to reduce
pollution levels and reduce utilities usage by approaching cleaner products and processes.
The Integrated Pollution Prevention and Control initiative is going to be adopted by
medium and large companies until 2010. The Slovenian government has decided to take
an active part in the adoption of the EU directive.
On the other hand, the energy intensity is still double the EU one. The fraction of export
by "dirty industries" is still reaching 20%. Last year the first non-BAT (Best Available
Technology) was banned as a green field investment and the government permit declined.
Slovenia established the first National Cleaner Production Center on a private basis last
year. The EPA modification of the Waste Minimization Opportunity Assessment Manual
was translated 10 years ago, and several courses were conducted to disseminate the tools.
Other tools (EMAS, Ecodesign, Life Cycle Analysis, Recycling, Energy Integration,
Renewable resources) are being developed besides the Cleaner Production method.
Graduate and postgraduate studies in this field are being increased substantially.
The Department of Chemistry and Chemical Engineering at the University of Maribor
has been researching some further Cleaner Processes: sugar beet production, methanol
process integration and optimization, and cleaner food production. Pinch technology
using Extended Grand Composite Curves and other thermodynamic methods has been
used for the purpose of reducing green house effects. Mixed Integer Nonlinear
Programming has been applied as an optimization tool for further reduction of waste
production and debottlenecking of the processes. The most interesting results have been
published in scientific journals and in the proceedings of international scientific
symposia.
A national meeting of chemists and chemical engineers is taking place at the University
of Maribor each year with a special section devoted to environmental protection. We also
organized a NATO ARW Workshop on "Technological Choices for Sustainability" held
in Maribor in October 2002.
A-23
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
SWEDEN
RESEARCH AND PHD EDUCATION AT IIIEE
Dr. Marten Karlsson
International Institute for Industrial Environmental Economics
Lund University, Sweden
As present trends in economic and population growth continue, the natural environment
is increasingly put under stress. For a considerable time, the International Institute for
Industrial Environmental Economics (IIIEE) has been involved in projects that minimise
environmental impacts from production sites. Subsequently, it has been shown that the
environmental impact of some products is largest during the use phase, and that
efficiency gains in production are often offset by the pace and scale of environmental
impacts associated with consumption. It is often stated that trends towards environmental
degradation can be slowed if new, more sustainable patterns of production and
consumption can be suggested and disseminated.
As of 2001, approximately 30 research staff (senior researchers and PhD candidates) are
engaged in research activities at the IIIEE. Complementary to these activities is the
research contributed by the MSc student thesis work. Having the common characteristics
of promoting preventative environmental strategy, taking a multidisciplinary approach
and seeking practical application, the research area ranges both in terms of area of society
targeted (e.g., industrial activities, regional cooperation, governmental policy) and focus
area (e.g., tourism, complex products, information and communication technology,
textile, financial institutions). Some of the main research activities are summarized
below.
Policies and Instruments for Cleaner Production
The IIIEE has a long record of activity within the area of policies, strategies and
instruments to promote cleaner production. The area is probably best described as the
starting point from which the other research areas at the Institute have either emerged or
have been centred around. Most activities at the IIIEE are such that they contribute to an
improved understanding of the issue, either by examining the measures as such or by
investigating the industrial setting that they are intended to affect.
Recognising this, there were a number of activities conducted at the IIIEE in 2001, with
particular relevance to the classic area of policies and instruments to promote cleaner
production including:
• The 7th Roundtable for Cleaner Production organised in Lund in May 2001.
• A review of DANCED Cleaner Production Activities in Thailand, Malaysia and
South Africa during the period 1996-2001.
• A PhD course on Law and Economics in co-operation with Maastricht University.
A-24
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• A revision and update of the UNEP publication on Government Strategies and
Policies to Promote Cleaner Production.
• A number of MSc theses produced in 2001 relate to the area of cleaner
production. For example, one student's thesis examined the potential inclusion of
Polycyclic Aromatic Hydrocarbons (PAH) in the Persistent Organic Pollutants
(POPs) convention, concluding among other things, that classic cleaner
production measures constitute a significant part of the actions that would be
necessary.
Product Service Systems
The IIIEE has been developing a new concept of product-service systems (PSS) that aims
at minimising environmental impacts of both production and consumption. The Institute
defines a product-service system as a system of products, services, supporting networks
and infrastructure that is designed to be competitive, satisfy customer needs and have a
lower environmental impact than traditional business models.
The goal of the PSS concept is to provide a system of products and services that would be
able to fulfil customer needs as efficiently as possible from both an economic and
environmental point of view. In some circumstances PSSs will have to be closed loop
systems. The general idea behind the PSS is the assumption that customers need the
product's function or value that the product provides, not the material products per se,
and thus a function provider may generate profit not from selling as many material
products as possible, but from providing a function and/or additional value of the
product.
The development of the PSS concept at the IIIEE follows several paths:
• Theoretical development of the PSS concept based on system approaches,
ecodesign techniques and consumer studies.
• Methodological development of product service systems, based on functional
arrangements in business-to-business and business-to-customer areas.
• Compilation of existing cases of functional arrangements and investigation of
possibility to upgrade them to product service systems.
• Evaluation of environmental and economic potential of PSSs.
• Evaluation of existing political frameworks and suggestions for how the
incorporation of functional thinking can be encouraged.
A-25
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Projects Finalised in 2001 and On-going
During 2001, three major projects were finalised in the area of product service systems.
• "Reaching Sustainable Consumption through the Concept of a Product-Service
System (PSS)" was funded by the Nordic Council of Ministers and completed in
2001. The project focused on the consumption and consumer side of developing
product service systems.
• "Introducing and Developing a Product-Service System (PSS) Concept in
Sweden," funded by NUTEK, investigated how well the PSS concept is known in
Swedish companies, what the barriers and success factors for implementing
functional arrangements are, and what kind of benefits the concept implies for
manufacturing companies.
• "Functional Thinking. The role of Functional Sales and Product Service Systems
for a function-based society. Functional thinking for IPP," funded by Swedish
EPA, analysed the concept of functional thinking and investigated the potential
role of PSS and functional sales in shifting towards a more function-based
society. The project also evaluated potential roles of existing policies, strategies,
instruments and tools in promoting this potential shift.
Since the early part of 2002, the IIIEE has been conducting a project, funded by Swedish
EPA, that has the goal of investigating how needs for specific functions in society can be
met by more sustainable combinations of products and services. A specific task is to look
at possibilities to incorporate functional thinking into Integrated Product Policy and
suggest how authorities can stimulate functional thinking at the societal level to secure
environmental improvements.
New Emphasis on Energy Research
Energy generation and use are central to a number of environmental issues, including
urban air pollution, acidification, and climate change. Increased levels of energy services
are a necessary element of the world's economic development. Major changes are
required in the world's energy systems and their development to address these
challenges. This will involve efforts to bring to the market new technologies for more
efficient use of energy and increased utilization of renewable sources of energy, as well
as the next generation of technologies to use fossil fuels. Policies for energy for
sustainable development represent a key area. The various aspects of energy for
sustainable development are receiving enhanced attention at the IIIEE with the
appointment of the new Director, Thomas B Johansson, Professor of Energy Systems
Analysis.
A-26
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
External Cooperation
IIIEE representatives are involved in several international research networks in the area
of product service systems and sustainable consumption:
• UNEP expert Network on Product Service Systems.
• PREPARE Network, Sustainable Service Systems group.
• Swedish 3F Network on Funktionsforsaljning.
• Research Network on sustainable consumption at the Centre for Consumer
Research, Goteborg.
Product Policy
The product related research at the IIIEE focuses on the policies and instruments that are
part of preventative environmental strategies in the product field that lead to
environmentally conscious product development. Extensive research around different
product-oriented policies and instruments, such as the principle of extended producer
responsibility (EPR), integrated product policy (IPP), eco-labelling, environmental
product declaration and supply chain management has been conducted.
Some of the research activities conducted in 2001 include:
• Analysis of effectiveness and socio-economic consequences of Swedish EPR
programmes for end-of-life vehicles.
• Organising a forum for stakeholder dialogue to further develop IPP in conjunction
with the 7th European Round-table for Cleaner Production.
• Analysis of plastic waste management policy in India.
• A study of environmental product information flow in the information and
communication technology sector.
• A series of product related reports commissioned by the Swedish EPA to support
their overall analysis of different policy instruments for IPP, looking at different
issues such as the role of different actors in relation to the greening of products,
and the role of legislation as a driver for green product development, service and
the environment.
• An evaluation of the role of Nordic Swan Eco-labelling scheme in relation to
other environmental information systems and EMS commissioned by the Nordic
Council of Ministers.
A-27
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
A study of institutional and structural factors affecting EPR programme
implementation, commissioned by the OECD for a seminar on EPR programme
implementation and assessment.
Distributed Economies—A New Research Embryo at the Institute
At the Institute, the development of a new research concept is currently underway. It
promises to open up interesting research opportunities and opportunities to cooperate
with colleagues on a broad international level. The concept has been given the
provisional name of Distributed Economies (DE), reflecting the need to switch the focus
of economic evaluation to the local and regional level in order to ensure a sustained
quality of life for communities. The idea was first proposed by Prof. Allan Johansson and
has been expanded in a number of internal seminars and discussion groups and in
forming the DE group, which consists of both seniors and PhD students from a range of
backgrounds who are interested in this field.
A final definition of a Distributed Economy cannot be given, but what is being looked at
are new ways of decentralizing systems of provision and consumption. Examples being
looked at for the moment by the DE group are energy production and the food production
chain.
In cooperation with chosen regions, the IIIEE would like to demonstrate that
decentralisation and downsizing of the traditional economics of scale model can be
economically, socially and environmentally viable. The DE Group is also developing a
strategy for industrial symbiosis to promote The International Institute for Industrial
Environmental Economics at Lund University synergy of different industries in the
region. They are in the process of constructing case study research involving different
regions in Europe. An initial study on the Island of Lesvos, Greece began in the spring of
2002. However, regions in Italy, Sweden, Finland, Norway and the UK have also
expressed interest in participating.
Tourism Research
Tourism has emerged over the last decade as a very significant sector to address from a
sustainability point of view. It is one of the fastest growing industries in the world,
creating a flow of capital and generating new businesses and jobs in local economies. At
the same time, tourism has the potential of being a seed of self-destruction. It can lead to
excessive water use, groundwater contamination from untreated raw sewage, waste
generation, emissions from transportation, decreased bio-diversity, pollution of beaches,
erosion, noise and congestion, etc. Local culture, beliefs, traditions, architecture, customs,
and ways of thinking may suffer from unsustainable tourism expansion. These social and
environmental impacts may eventually result in economic deterioration at the destination.
Another problem associated with tourism development resides in the question of how the
benefits generated by the tourism activities are distributed and at what cost. Often, the
revenue produced by tourism does not benefit local communities.
A-28
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Transitions for Sustainable Tourism
The goal of this initiative is to contribute to the transition of today's tourism, including
leisure activities, into a sustainable system (economically, environmentally and socially-
culturally-wise) by:
• Acquiring knowledge that describes, analyses, explains, prevents or predicts
problems related to the unsustainability of tourism.
• Designing and testing preventative, potential transition concepts in tourism
practice, following the reflective practice approach.
• Integrating a variety of relevant theories and models from different perspectives
(communication, technology dynamics, network, innovation, learning,
organizational change, economics, sociology, policy sciences etc.) into an
appropriate environmental sciences approach.
• Investigating possibilities of change in existing institutions, policies, strategies,
and instruments, leading to unsustainable tourism development.
The ambition of the tourism group is to create, based upon the outcomes of its
programme, a school of sustainable tourism innovation, recognized both for its scientific
quality and for its societal relevance.
Cooperation Within the IIIEE
The potential for strong links with several other research groups, activities and concepts
within the IIIEE exist and will be further developed, including:
• The ongoing research and findings on Extended Producer Responsibility (EPR),
Integrated Product Policy (IPP) and Product-Services-Systems (PSS) Design.
Sustainable Tourism as an object of study can both profit and contribute
(particularly as PSS) to this area of research.
• The concept of Distributed Economies, in which systems of production and
consumption are foreseen to be decentralized and sustainable, based on the
integration of societal infrastructure systems and technology development.
• The potential role of new technologies, i.e., Information and Communication
Technology (ICT), for the design of sustainable tourism systems.
Long Term External Cooperation
External cooperation is being developed with the following organisations and research
institutes:
• World Tourism Organization - Socially Responsible Tourism
A-29
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• European Environment Agency - Tourism Award Schemes
• Swedish Tourist Authority - Performance Evaluation/ Indicators/Ecotourism
• TU Delft, The Netherlands - Sustainable Innovation for SMEs in Tourism
• Prepare-Eureka Network - European Best Practices in Sustainable Tourism
• University of the Aegean, Greece - Islands Developments
• University of Ireland, Cork - Sustainability Management in Tourism Industry
• Randa Group, Spain - Networking for Sustainability
• Ramb011, Denmark - Nordic Tourism Development
ICT and the Environment
The emerging Information and Communication Technologies (ICT) have a number of
important environmental implications. One such implication is that they enable us to
telework and to have virtual meetings—collaborating without a face-to-face meeting.
This influences the need for commuting and business travel. The large environmental
impact of transportation makes the potential for travel substitution interesting, both from
a macro and a micro perspective. The possibility to influence the effects of telework and
virtual meetings on travel in organisations was studied in research projects and Master's
theses at Telia AB, Skanska, and Lund Municipality during 2001.
Another research area is oriented towards applying the Product Service System (PSS)
framework as a business strategy in the ICT sector. The goal is to explore the potential of
using the framework to create innovative ICT business models that would allow for
reduced product life cycle environmental impacts, provide new business opportunities,
maintain and enhance consumer value and contribute to sustainable economic growth.
The practical research is focused on exploring the existing Application Service Provider
(ASP) service models. The ASPs have several promising environmental and business
opportunities and the goal is to identify the conditions under which both opportunities are
utilised in an optimal way.
Management and Organisation
Collaboration with industry has been a core element of the work at the IIIEE, and
represents an opportunity for researchers, PhD and Master's candidates to develop
applied "solutions-oriented" activities. In particular, within the area of Management and
Organisation, research has been developed in a unique way. Since 1999, Swedish
corporations of various sizes and industrial sectors have participated in the Reference-
Companies programme (RC). Within the management-related courses of Industry and
Organisations and Strategic Environmental Management, education and research are
A-30
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
brought together for developing theoretical and empirical approaches to manage
environmental issues in industry.
Based on a unique methodological approach the environmental education has been
centred on finding practical solutions for organisations. An initial organisational analysis
(Micro-Review), developed in the Industry and Organisations course, provides students
with the basic knowledge about the organisation and the sector in which it operates.
Based on this initial review, students develop corporate environmental strategies,
environmental management systems, performance indicators, and communication by
directly interacting with the RC. Recommendations are brought to the RC via final
reports, which are normally used by the RC in the process of implementing preventative
environmental management.
A-31
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
UKRAINE
SUSTAINABLE DEVELOPMENT AND CLEANER PRODUCTION TOOLS AND
METHODS FOR NIS COUNTRIES
Prof. William Zadorsky
Ukrainian Ecological Academy of Sciences
Ukrainian State University of Chemical Engineering
ecofond@ecofond.dp.ua
http://www.zadorsky.com
A significant problem for Transitional Economy Countries is the division of economic,
social and ecological factors within the framework of systems of acceptance of the
decisions at levels of policy, planning and management. It has a significant influence on
realization of the concept of sustainable development for the country. The Ukraine needs
environmentally sustainable economic and social development. Only mutually balanced,
simultaneous, and comprehensive tackling of the three tasks (economic growth with
simultaneous improvement of ecological conditions and decision of social problems) will
allow realization of a progressive CP strategy.
A lot of scientists are suggesting that an economic-environmental-social model can be
elaborated and employed for the purposes of the country's sustainable development. This
approach is not usable at this time of industrial restructuring, privatization and other
involved processes occurring in a collapsed national economy. An alternative approach is
use systems approach and decision theory techniques. The SD and CP algorithm will look
at the following sequence of actions:
System decomposition and hierarchy level (tier) determination (for example,
manufacture — plant item — installation — apparatus or machine — contact device —
molecular level),
Identification of an initial level(s). Herewith reasonable move on the hierarchical
stairway from top to bottom and use methods of expert evaluations,
Selectivity and intensity increase at a limiting level of hierarchy. Choice from the
database of methods depending on the limiting level scale (defining size) corresponding
with parameters of influence method to the system.
Basic assumptions underlying the cleaner economy concept for transfer economy
countries:
• At this time of a deep economic crisis, the economic and environmental
challenges must be met simultaneously with one cleaner economy strategy.
• A development towards a cleaner economy must focus not on consumption but on
actual or potential polluters.
A-32
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• The success of a cleaner economy policy will be determined by the availability of
professionals well trained and expert in the theory and practice of EM, CP, SD.
• No cleaner economy will be possible without creation of an ecological market.
These strategic principles determine some tactical measures to any industry:
• no waste due to improved selectivity,
• neutralizing wastes directly at the origin, rather than at the exit,
• flexible technologies,
• recycling materials and energy,
• conservation of resources,
• waste treatment, etc.
These tactics must be combined with certain design and process engineering
techniques:
• providing a considerable excess of the least hazardous agent,
• minimizing dwell times,
• concurrent reactions and product separation,
• introduction of heterogeneous systems,
• adaptive processes and apparatuses,
• increasing throughputs,
• multifunctional environmental facilities, etc.
The macroeconomic transformations rely on changes in the structure of production
and consumption. Restructuring is to be based on:
• developing a socially oriented market economy that would guarantee a proper life
standard for the population, setting limits to raw material and semi-finished
product industries, stepwise reduction of exports from primary and other material-
and energy-intensive industries,
• cleaner production, minimizing environmental loads, material conservation,
adoption of new types of activity grounded on environmentally safe technologies,
• making a more balanced economy by shifting from production of means of
production to consumer goods, a more pronounced social orientation of industry
to increase the relative importance of light and food-processing industries, and
• environmental impact assessment and auditing for all economic projects.
A-33
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The system approach is demonstrated in the following table :
N
1
2
3
4
5
6
7
Tier of system
Man-nature-
technology
Consumption
sector
Manufacturing
Plant
Plant item
Apparatus or
machine
Work
assembly
Frequency
order
0.1
yr-1
1 month"1
to 1 yr"1
0.001-0.01
s"1
0.01-0.1 s"1
0.1-1 s"1
1-10V
i-ioV
Dimension
order, m
107
104
102
10
1
1
10"3...
10"6
Concepts and
methodologies
SD
SD, LCA, MM,
FCA, ST, WM
SD, EM, MM,
FCA, ST, LCA,
P2, ES, WM
SD, WFT, MM,
ST, P2, ES
MM, P2
MM
MM
Tools and methods
for Cleaner
Production
Systematic
approach
Recycling of the
goods as raw
materials
Industrial symbiosis
as a basis for
management of
secondary materials
and energy
Flexible synthesis
systems and
adaptive equipment
to embody them
Process engineering
for high throughput
to cut processing
time and reduce
byproducts and
wastes.
Local neutralization
of pollution
Block-modules
equipment.
Multifunctionality
Recycling flow of
the least hazardous
agent taken in
excess over its
stoichiometric value.
Flexible synthesis
systems and
adaptive equipment
to embody them.
Contacting phases
controlled
heterogenizati on .
Chemi cal - separative
A-34
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
N
8
Tier of system
Molecular level
Frequency
order
105...
108
-1
s
Dimension
order, m
io-9...
io-12
Concepts and
methodologies
Physics,
chemistry
Tools and methods
for Cleaner
Production
reactions: removal
of reaction products
at the moment of
their formation.
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
Multipleness of
resources and
energy use
Excess of nontoxic
reagent over its
stoichiometric value.
Minimizing of the
process time
Selectivity
increasing with a
change of the
phy si ci st-chemi cal
parameters.
EM - environmental management, WM - waste management, FCA - function-cost analysis, LCA - life
cycle assessment, MM - mathematical modeling, SD - sustainable development, ST - solutions theory,
WFT - waste-free technologies, P2 - pollution prevention, ES - energy saving.
The regional program of adaptation and rehabilitation of the population is developed
for the first time in the Ukraine. Main sections of the program include:
1. Organization of a system ecological education and training
2. System engineering of diagnostic, adaptation,
3. Fulfillment of scientific researches on new non-medicine methods of
healthbuilding and adaptation of the person to technogenous effects
A-35
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
4. Creation adaptogenous, immunogenous and other medicines for resistance against
acting of harmful substances
5. Development and introduction of new food products on the basis use natural
bioaddings with adaptogenous and immunogenous properties
6. Development and organization of manufacture of an ecological engineering and
surviving means.
A complex of measures by valuation of consequences of the decisions in economic,
social and ecological spheres is necessary
K0-K
PW = ----------- , (i)
K0-Kb
where: K0 - accepted worst value, Kb = best possible value, K - Real-Value of the given
characteristic.
Integrated parameter S of sustainability:
S= aE x bR x cK, (2)
where: a, b, c - "weights" contributions of appropriate parameters, R, K - parameters,
reflecting, accordingly, social and economic efficiency of transformations, determined by
expert way, E- parameter of a system's ecologization, which expediently to define,
proceeding from following reasons.
Multiplicational ecologization coefficient:
k
J = IlJi , (3)
where: J; are the main characterizations of technological process connected with resulting
measure of production purity such as: Ji - flexibility of the production; J2 -
intensiveability of the technique; Js - efficiency of the technology, etc.
Any of the measures may be defined similarly to:
Pii -Pa
ji = ------------ , (4)
where PH, ?2i, Pmaxi -are respectively the final, initial and maximum measures.
A-36
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
The value P; n
Pi = SKjPiJ5 (5)
where Kj is significance of the j-th indice (estimated expertly and changing within the
limits of O to 1).
New engineering techniques and methods for SD and CP:
• 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.
• 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.
• 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 reducing 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 pollution or reception of
a sub-standard product.
A-37
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
A-38
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix B
NATO/CCMS Phase I Summary
B-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
NATO/CCMS PILOT STUDY ON CLEAN PRODUCTS AND PROCESSES
PHASE I
Executive Summary
Clean Products and Processes (CPP)-Phase I was an attempt to lay the foundation of an
effective pilot study in which the state of the art information on cleaner manufacturing
processes and tools for designing and assessing them were exchanged. The pilot started
with 14 countries and at the concluding meeting at Vilnius, Lithuania, stood at 27
member nations participating. CPP-Phase I was a success as evidenced by widespread
interest in a Phase II (already approved) by the members of Phase I and the willingness of
several other European countries to join. CPP-Phase I was the first step towards a
scientific and technological approach to sustainable development from the perspective of
manufacturing sectors. For the explicit purpose of exploring the product and process
options that offer minimizing environmental impacts at the lowest possible cost,
throughout the last five years we have examined scientific tools and methods that can be
universally used to assess and design products and assessment tools and methods for
processes.
The inaugural meeting of Phase I was hosted by the US Environmental Protection
Agency in Cincinnati, Ohio in 1998, and the subsequent annual meetings were held in
Belfast, Northern Ireland (UK), Copenhagen (Denmark), Oviedo (Spain), and Vilnius
(Lithuania), with support from the host institutions and countries. Working collectively
we selected the dominant industries in need of cleaner approaches and discussed how the
state of the art knowledge can make a difference. We also explored the specific problems
afflicting each member nation, and invited experts to educate us all on selected industry
sectors (such as textiles) and specific approaches (such as industrial ecology). The
measure of success of CPP-Phase I was thought to be the effective dissemination of
research products for use by participating countries and the creation of productive
collaboration projects among experts from participating countries. Many such beneficial
products and collaborations were achieved, only some of which are mentioned below:
• Several of the pollution prevention and assessment tools developed by the US
EPA are made available through the EPA website, accessible through the NATO
CCMS website. These tools are widely used among the pilot member countries.
Some of the more recently developed tools are in demand and will be made
available soon.
• Phase I has completed one assessment of pollution prevention practices (and
barriers to it) in member countries in textiles, and the report is available in the
EPA website. Data for two other assessments on metal finishing and
food/agricultural sectors have been collected from the CPP members and the
reports are in preparation.
• Denmark has a successful collaboration with Solutia (USA) on industrial water
use reduction and water recycling. The results have facilitated another
B-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
collaboration between Denmark and Lithuania, and a third between Denmark and
Turkey.
• UK (Queen's University, Belfast) and USA (University of Arizona) have
launched a collaboration in biofilm characterization and reduction for ultrapure
water used in the electronics industry.
• The concept of the establishment of NSF's Industry-University Cooperative
research Center was discussed in the pilot. Prof. Jim Swindall of the QUESTOR
Center (Belfast) made a separate invited presentation in Israel. The establishment
of these centers is being explored in several countries with help from this pilot.
• Mrs. Teresa Mata (Portugal) acquired a Fullbright fellowship to work with US
EPA in Cincinnati on cleaner design techniques as part fulfillment of her Ph.D in
chemical engineering from University of Porto.
• Several multi-country collaborative projects have just been formed involving such
countries as Czech Republic, Israel, Turkey, Poland, Hungary, Denmark, Spain,
Russia, Italy, Germany, Norway, Greece, Lithuania, and the USA. The industry
sectors that have been targeted for cleaner practices are hospitals, industrial park
management, use of membranes in milk, olive oil and chemicals, agricultural
ecology, and sustainability indicators for benchmarking.
Introduction
The concept of sustainable development, universally accepted as the means of protecting
the environment for all mankind, demands that future manufacturing technologies must
be cleaner, yet economically sound. The goal of sustainable development will, in the
manufacturing sectors, be achieved by a combination of several methods. One method is
improved housekeeping in process plants leading to large reductions of emissions and
discharges of pollutants. Another method is significant modifications of existing process
technologies through the application of sound science and advanced technologies. Yet
another method is totally new process designs that are environmentally preferable, made
possible by using tools for life cycle assessment (LCA) and environmental impacts. An
effective pilot study will have far-reaching influence on future developments in NATO
and the partnership countries, in fact throughout the world. Such a pilot study needs to
put together, for the benefit of all nations, exemplary developments in three important
areas. First, we must address the issue of measuring cleanliness through devising
environmental or sustainability indicators (called analytical tools or computer software).
Second, we must examine cleaner techniques for achieving specific goals in selected
industry sectors, such as power generation, textile, pulp and paper, leather tanning, metal
finishing, and mining. Third, we must examine advanced techniques for cleaner product
designs. Additionally an effective web-based dissemination method needs to be
established to share the knowledge among academia, Government agencies, and
industries of all nations.
B-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CPP-Phase I was an attempt to lay the foundation of such an effective pilot study. This
pilot first met in Cincinnati in 1998 with 14 members in attendance. The second, third,
and the fourth annual meetings were held in Belfast, Northern Ireland, UK, Copenhagen,
Denmark, and in Oviedo, Spain, respectively, while the membership increased to 27
currently. The fifth and concluding meeting of Phase I took place in May, 2002, in
Vilnius, Lithuania.
Our initial goal of creating an effective forum for exchanging new ideas, knowledge, and
methods for achieving cleaner products and processes has been achieved. The Phase I
was launched at a time when the environmental impacts of industry and its products, and
the depletion of natural resources were just beginning to be appreciated. Additionally, in
the span of the last five years, only a few technology sectors could be examined. The
need for keeping this forum alive for free exchange of ideas for continued sharing among
the member nations is clear. Phase II is needed to conduct the unfinished business of
dealing with the exploding developments in cleaner technologies and methods and to
address some of the more important industry sectors.
Phase I Activities
Activities conducted as part of CPP-Phase I centered around five annual meetings and
follow-up communications, information sharing, and collaborations among the
participating countries.
Annual Meetings
Each annual meeting followed the same basic format which included formal plenary
sessions; updates on the progress of cleaner products and processes in each country;
overviews of special projects; presentations from special guest experts; field visits to
universities where clean product and process research is being conducted and to industrial
sites where clean production and processing is being applied; special topic seminars; and
an open forum on cleaner production and processing.
Cincinnati, Ohio, USA—1998
The first annual meeting of CPP-Phase I was held in Cincinnati, Ohio, USA, in March of
1998, and was hosted by the US Environmental Protection Agency. As the "kickoff"
meeting for CPP-Phase I, a major focus of the meeting was to formulate a direction for
the 5-year pilot study. In addition to "tour de table" presentations from each of the 14
attending countries, special guest presentations included:
• European Cleaner Technology Research
B-4
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• U.S. DOE - Industries of the Future: Creating a Sustainable Technology Edge
• Environmentally Benign Semiconductor Manufacturing
• Cleaner Technology and Production Islands in Economies in Transition
• Software Tools for Cleaner Production
• Environmental Design of Industrial Products
• Economical Cryogenic Machining
Meeting participants visited several locations to observe ongoing technology
demonstrations and research activities being conducted in the Cincinnati area. Tours of
the Institute of Advanced Manufacturing Sciences and the University of Cincinnati's
College of Engineering were conducted to familiarize attendees with several projects
related to clean manufacturing and clean products. In addition, meeting participants were
given the opportunity to enjoy Cincinnati's Museum of Fine Arts, which displays a wide
range of art from ancient times to the modern era.
Belfast, Northern Ireland, UK—1999
The second annual meeting was held in Belfast, Northern Ireland, United Kingdom, in
March of 1999 and was hosted by Queen's University in Belfast. The meeting drew
participants from 18 countries. The meeting followed the format established by the
Cincinnati meeting. The scope of the special topic presentation was expanded and
included clean product and process experts from several countries. Technical topics
included:
• Process Integration Technology for Clean Processes
• Ionic Liquids: Neoteric Solvent Research and Industrial Applications
• Industrial Energy Efficiency: Focus on Metal Casting
• Use of Supercritical Carbon Dioxide in Clean Production
• Liquid Effluent Treatment Research and Development at British Nuclear Fuels
• Help for Sustainable Waste Management through Waste Reduction and Clean
Technology
Meeting participants visited locations in Northern Ireland to observe ongoing technology
applications and practices and research activities. A tour of the Queen's University
B-5
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Environmental Science and Technology Research Center (QUESTOR) provided an
opportunity to view research facilities and projects being conducted as part of
QUESTOR's unique industry-university partnership program. In addition, attendees
visited the Old Bushmills Distillery and the DuPont Maydown Plant to familiarize
themselves with clean production activities being applied in the area. Meeting
participants also toured the scenic Antrim Coast and visited the Giant's Causeway, a
World Heritage Site, to view this impressive and awe-inspiring geologic formation.
Copenhagen, Denmark - 2000
The third meeting of CPP-Phase I was held in Copenhagen, Denmark, in May of 2000
and was hosted by the Technical University of Denmark. This meeting initiated the
inclusion of a special topic seminar and computer tool cafe in the CPP-Phase I annual
meetings. The traditional special invited presentations continued with the following
topics being addressed:
• Engineering for Sustainable Development—An Obligatory Skill of the Future
Engineer
• Membranes in Process Intensification and Cleaner Production
• Approaches to Cleaner Production in Economies in Transition—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 Practices: The "Design for the
Environment" Tool Kit
• Biological Control of Microbial Growth in the Process Water of Molded Paper
Pulp Production—Avoiding the Use of Biocides
As mentioned above, two new "features" were added to the CCP-Phase I annual meeting
format at the meeting in Copenhagen. First, in order to provide an opportunity for
meeting participants to demonstrate and use computer-based software tools, a "Computer
Tools Cafe" was set up. Several participants were able to provide "hands-on"
demonstrations of the tools being developed in their countries. Demonstrated at this
meeting were a chemical life cycle database, tools for chemical and process system
engineering, a life cycle assessment tool for the environmental design of industrial
products, and a tool for identifying environmentally friendly chemical substitutions for
industrial processes.
Second, a special topic seminar titled, "Product Oriented Environmental Measures" was
presented. The seminar included eleven presentations which highlighted innovative
B-6
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
product design applications and programs, with special emphasis on product design being
conducted in the Scandinavian countries. The seminar presented product design
initiatives at the government level and actual product design programs and applications at
several companies.
Meeting participants visited the Technical University of Denmark (DTU) to become
familiar with DTU's research facilities and ongoing research projects relating to clean
products and processes. Participants also visited Kalundborg where industrial symbiosis
is practiced among the Asnaes Power Station, Gyproc (plasterboard manufacturer), Novo
Nordic (pharmaceutical and biotechnology), Statoil Refinery, and the Municipality of
Kalundborg. Meeting participants also visited the Viking Museum in Roskilde and a
haunted Danish castle.
Oviedo, Spain—2001
The fourth annual meeting of CPP-Phase I was held in Oviedo, Spain, in May of 2001,
and was hosted by the University of Oviedo. The meeting included participants from 21
countries. As in the previous meetings, updates on clean production activities in each
country were presented, along with briefings on pilot projects being conducted by
participating countries. In addition, several specially invited experts presented
information on relevant topics.
The precedent set in Copenhagen was continued with the presentation of a special topic
seminar, "Environmental Challenges in the Processes Industries." Many speakers from
throughout Spain addressed several important policy and technical issues, including:
• Advances in the Environmental Aspects of Desalination: The Canary Island
Experience
• Lignosulphonates: Environmental Friendly Products from a Waste Stream
• Hydrogen Economy and Fuel Cells
• The Use of Membrane Technology in the Pulp and Paper Industry
• Treatment of Oil-Containing Wastewaters Using Clean Technologies
• Non-Ferrous Metallurgical Wastes: Future Requirements
• Making Carbochemistry Compatible with the Environment
• Treatment of Phenolic Wastewaters in the Salicylic Acid Manufacturing Process
• Principality of Asturias Environmental Policy
B-7
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Supporting Companies and Businesses to Improve Their Relationship with the
Environment in Catalonia
• New Legislation on Environmental Quality and Clean Production in Spain
Meeting participants visited the Department of Chemical Engineering at the University of
Oviedo and toured several laboratories and the department's pilot plant facility. The field
trip continued with a visit to the DuPont Company's Asturias plant. At the plant, the
participants were able to tour the NOMEX production facility. In addition, the tour
include a very interesting visit to the site's ecosystem restoration projects. Finally, the
participants visited a cider production plant in Villaviciosa.
Vilnius, Lithuania—2002
The fifth and final meeting of CPP-Phase I was held in Vilnius, Lithuania, in May of
2002 and was hosted by the Institute of Environmental Engineering at Kaunas University
of Technology. This meeting was highlighted with a special visit to Lithuania's
Presidential Palace and a meeting with President Valdas Adamkus. The topic for this
meeting's special seminar was industrial ecology, which included presentations
addressing:
• Industrial Ecology and Eco-Efficiency
• From Pollution to Industrial Ecology and Sustainable Development
• Green Concurrent Engineering: Filling ISO 14001 with Content
• Strategies and Mechanisms to Promote Cleaner Production Financing
• Cleaner Production Financing: Possibilities and Barriers
• Industrial Ecology in University Curricula
• Chemicals Risk Management in Enterprises
• Practical Implications of Industrial Ecology in Lithuania
• International Implications of Industrial Ecology
The traditional field trip included visits to three Lithuanian industrial sites to view cleaner
production and processes. First, the participants toured the refrigerator production
company, Snaige. The next tour was conducted at the textile company, Alytaus Tekstile.
The final tour of the field trip was of the wine and sparkling wine production company,
Alita.
The discussion during the closing session of the meeting focused on the transition from
CPP-Phase I to CPP-Phase II. A review of the Phase II proposal that has been approved
by NATO CCMS was presented by the Pilot Study Co-Director. The proposal reaffirmed
the goals of Phase I and established the following goals for Phase II:
• To support the development of eco-efficiency and sustainability indicators and
promote consistency and harmonization of their application;
B-8
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• To examine and exchange information on state-of-the-art advancements in
product design and process development in service and industrial sectors of
importance to participating nations;
• To develop a web-based portal for the dissemination of pilot study results and
improved awareness of related global developments; and
• To stimulate and facilitate productive collaboration among all participating
nations.
The first annual meeting of CPP-Phase II will be held in Calabria, Italy in May 2003 and
will be hosted by the University of Calabria. A special focus of the meeting will be on
clean production and processes in the food production and agriculture industry.
In addition to annual meetings, pilot projects were selected and implemented by delegates
from participating countries. Pilot projects are intended to foster international
collaboration on special clean product and process endeavors which usually apply a tool,
methodology, or technology. These pilot projects are usually multi-year efforts with
annual progress reports presented at the annual meeting. In CPP-Phase I, the following
pilot projects were implemented:
• Product Oriented Environmental Measures in the Textile Industry—Denmark
• Pollution Prevention Tools—United States
• Energy Efficiency—Moldova
• Water Conservation and Recycling in the Semiconductor Industry—United
Kingdom and United States
• Research and Development Aimed at Developing Cleaner Production
Technologies to Assist the Textile Industry—Turkey
• Pollution Prevention Development and Utilization—United States
• Cleaner Energy Production with Combined Systems—Turkey
• Environmental Impact of Hydrocarbon Emissions in Life Cycle Analysis of
Gasoline Blending Options—Portugal
• Pilot Study Web Site—United States
• Cleaner Production Approaches in Industrial Parks/Industrial Symbiosis/Industrial
Ecology—Denmark, Hungary, Israel, Poland, and Turkey
B-9
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Hybrid Membrane Applications for Cleaner Production—Denmark, Italy, Poland,
Russia, and Spain
• Sustainable Indicators/Bench Marking—Germany, Hungary, Lithuania, and
Norway
Summary
As indicated by the participation of 27 countries in CPP-Phase I and the high level of
interaction and information sharing, CPP-Phase I has been an overwhelming success.
This pilot study has initiated several collaborative projects that have been mutually
beneficial to those countries that have participated. In addition, through comprehensive
information sharing, this pilot study has provided participating countries and others with
access to valuable technical information to assist in the implementation of clean product
design, clean production, and clean processes in industries around the world.
The CPP-Phase I website, located at:
www.epa.gov/ORD/NRMRL/nato
provides participating countries and others with a portal to clean product and processes
information and updates on activities conducted and planned for this pilot study. Each
annual report is available on-line and information on the next annual meeting is available.
In addition, each participating country is identified with links to related websites
provided. CPP-Phase I strived to continually improve this website to serve as the main
communication tool for this pilot study and this goal will continue in CPP-Phase II.
Despite the success of CPP-Phase I, the leaders of this pilot study want to expand on the
level of participation during CPP-Phase II. This report clearly provides the
documentation of the value and usefulness of participation in this pilot study. Other
countries are urged to participate; they should contact:
Dr. Subhas Sikdar, Pilot Study Director
U.S. Environmental Protection Agency
26 W. Martin Luther King Drive (MS-497)
Cincinnati, Ohio 45268
USA
Telephone: +1-513-569-7528
FAX: +1-513-569-7787
mailto :sikdar .subhas @ epa. gov
B-10
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Mr. Daniel J. Murray, Jr., P.E., Pilot Study Co-Director
U.S. Environmental Protection Agency
26 W. Martin Luther King Drive (MS-G75)
Cincinnati, Ohio 45268
USA
Telephone: +1-513-569-7522
FAX: +1-513-569-7585
murray.dan@epa.gov
B-ll
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
B-12
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix C
NATO/CCMS Phase II
C-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
CLEAN PRODUCTS AND PROCESSES - PHASE II
Background to Proposed Study
The concept of sustainable development is universally accepted as the means of
protecting the environment for all mankind and demands that future manufacturing
technologies must be cleaner, yet economically sound. The goal of sustainable
development will, in the manufacturing sectors, be achieved by a combination of several
methods. One method is improved housekeeping in process plants, which leads to large
reductions of emissions and discharges of pollutants. Another method is significant
modifications of existing process technologies through the application of sound science
and advanced technologies. Yet another method is totally new process designs that are
environmentally preferable, made possible by using tools for life cycle assessment (LCA)
and environmental impacts.
An effective pilot study will have a far-reaching influence on future developments in
NATO and the partnership countries, in fact throughout the world. Such a pilot study
needs to put together, for the benefit of all nations, exemplary developments in three
important areas. First, we must address the issue of measuring cleanliness through
devising environmental or sustainability indicators (called analytical tools or computer
software). Second, we must examine cleaner techniques for achieving specific goals in
selected industry sectors, such as power generation, textile, pulp and paper, leather
tanning, metal finishing, and mining. Third, we must examine advanced techniques for
cleaner product designs. Additionally, an effective web-based dissemination method
needs to be established to share the knowledge among academia, government agencies,
and industries of all nations.
Clean Products and Processes-Phase I was an attempt to lay the foundation of such an
effective pilot study. This pilot first met in Cincinnati in 1998 with 13 members in
attendance. The second, third, and the fourth annual meetings were held in Belfast,
Northern Ireland, UK, Copenhagen, Denmark, and in Oviedo, Spain, respectively, while
the membership increased to 27 currently. The fifth and concluding meeting of Phase I
took place in May 2002 in Vilnius, Lithuania.
Our initial goal of creating an effective forum for exchanging new ideas, knowledge, and
methods for achieving cleaner products and processes has been achieved. Phase I was
launched at a time when the environmental impacts of industry and its products and the
depletion of natural resources were just beginning to be appreciated. Additionally, in the
span of the last five years, only a few technology sectors could be examined. The need
for keeping this forum alive for free exchange of ideas for continued sharing among the
member nations is clear. Phase II is needed to conduct the unfinished business of dealing
with the exploding developments in cleaner technologies and methods and to address
some of the more important industry sectors.
C-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Success Record of Phase I
The success and popularity of this pilot study is evident in the gradual increase in the
number of NATO and partnership countries joining in the last four years. An expression
of support for Phase II study from the pilot members is presented in a following section.
Outside Europe, even countries such as Japan, Israel, and Egypt have joined in this study.
The number and nature of products and spin-off activities that this study has engendered
is a clear sign of the impact the pilot has achieved. Some of these products and spin-off
effects are listed below:
• Several of the pollution prevention and assessment tools developed by the US
EPA are made available through the EPA website, accessible through the NATO
CCMS website. These tools are widely used among the pilot member countries.
Some of the more recently developed tools are in demand and will be made
available soon.
• Phase I has completed one assessment of pollution prevention practices (and
barriers to it) in member countries in textiles, and the report is available in the
EPA website. Data for two other assessments on metal finishing and
food/agricultural sectors have been collected from the CPP members and the
reports are in preparation.
• Denmark has a successful collaboration with Solutia (USA) on industrial water
use reduction and water recycling. The results have facilitated another
collaboration between Denmark and Lithuania, and a third between Denmark and
Poland is being planned.
• UK (Queen's University, Belfast) and USA (University of Arizona) have
launched a collaboration in biofilm characterization and reduction for ultrapure
water used in the electronic industry.
• The concept of the establishment of NSF's Industry-University Cooperative
research Center was discussed in the pilot. Prof. Jim Swindall of the QUESTOR
Center (Belfast) made a separate invited presentation in Israel. The establishment
of these centers is being explored in several countries with help from this pilot.
• Mrs. Teresa Mata (Portugal) acquired a Fullbright fellowship to work with US
EPA in Cincinnati on cleaner design techniques as part fulfillment of her Ph.D. in
chemical engineering from University of Porto.
• Several multi-country collaborative projects have just been formed involving such
countries as Czech Republic, Israel, Turkey, Poland, Hungary, Denmark, Spain,
Russia, Italy, Germany, Norway, Greece, Lithuania, and the USA. The industry
sectors that have been targeted for cleaner practices are hospitals; industrial park
management; use of membranes in milk, olive oil and chemicals; agricultural
ecology; and sustainability indicators for benchmarking.
C-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Purpose and Objectives of the Proposed Phase II of the Pilot Study
Now that the infrastructure for the pilot study network has been established, we can use it
to build a truly effective means of fostering collaboration among countries and facilitate
dissemination of results pertaining to cleaner production. Phase II will continue on the
course charted by Phase I with special emphasis on the following items:
• We will focus on exchanging and developing the best science to support the ideas
of eco-efficiency and sustainability indicators. These yardsticks will be used in
the near future throughout the world to identify technologies and products that are
environmentally friendly. We want to use this pilot to promote harmonization of
the indicators for universal use.
• We will focus on the state-of-the-art developments in several industrial sectors.
These will be chosen from the sectors already identified by the members as most
urgent.
• We will construct a dissemination mechanism for the results of the pilot activities
and related developments achieved elsewhere. Such a comprehensive database
would be very useful for those around the world in cleaner production standards.
US EPA has already pledged to develop a web-based portal and link it to the
NATO CCMS home page.
• We will stimulate collaboration among the countries in solving common
problems. To a great extent, care will be taken to see that in each collaboration, at
least one partnership country is involved.
Estimated Duration
November 2002 (when the Phase I expires) to October 2007 (includes time for
completion of the final report for Phase II).
Methodology and Scope of Work
Phase II of the Pilot Study will be comprised of three areas. These are: a) tools for
assessment of pollution prevention, sustainability, and cleaner products and processes, b)
cleaner production methods in selected industry sectors, c) electronic dissemination of
cleaner production knowledge, products, and processes (with tutorials and examples).
a) Decision tools: Decision making tools for pollution prevention, sustainable
practices, and product designs is a continuing focus. These tools are important
because they integrate environmental solutions, life cycle concepts, process
engineering, economics, product design methods, and new assessment and
measurement methods. Most of these tools are computer-based and amenable to
C-4
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
dissemination through the web. Particular concepts that underlie these tools are
life cycle assessment (LCA), sustainability metrics, eco-efficiency indicators,
process simulation and design, material substitution, and environmental impact
assessment.
b) Specific industry sectors: The pilot members have already identified the industry
sectors of importance. In each year we will focus on one of these for in-depth
discussion and assessment. The priority sectors are metal finishing,
food/agricultural, pulp and paper, leather tanning, printing, and electronic
industries.
c) Information dissemination: An electronic portal will be created by EPA and
linked to the NATO CCMS website. This portal will host reports of ongoing work
of the pilot, as well as by individual members. We will also use it to electronically
discuss issues of importance. This method will be particularly useful in
stimulating the exchange of ideas in between annual meetings.
Non-NATO participation
This pilot currently has several non-NATO members. Because clean products and
processes is a global concern, we have opened it to other countries such as Japan and
Israel and Egypt from the Mediterranean partnership zone. The current member nations
are: Bulgaria, Canada, Czech Republic, Denmark, Egypt, Germany, France, Greece,
Hungary, Israel, Italy, Japan, Lithuania, Moldova, Netherlands, Norway, Poland,
Portugal, Romania, Russia, Slovak Republic, Slovenia, Spain, Turkey, Ukraine, UK, and
the USA.
Request for Pilot Study Phase II
It is requested of the Committee on the Challenges of Modern Society that they approve
Phase II of Clean Products and Processes. The United States participation will comprise
the US Environmental Protection Agency, National Science Foundation, and Department
of Energy.
Pilot Country: United States of America
Lead Organization: United States Environmental Protection Agency
Office of Research and Development
National Risk Management Research Laboratory
Cincinnati, Ohio 45268
C-5
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Study Director: Dr. Subhas K. Sikdar, Director
Sustainable Technology Division
National Risk Management Research Laboratory
26 W. M.L. King DR.
Cincinnati, OH 45268
513-569-7528/fax: 513-569-77877 E-mail: sikdar.subhas@epa.gov
Study Co-Director: Mr. Daniel Murray, Director
Technology Transfer & Support Division
National Risk Management Research Laboratory
26 W. M.L. King Dr.
Cincinnati, OH 45268
513-569-7522/fax: 513-569-7585/E-mail: murrav.dan@epa.gov
Funding Support
US EPA will provide funding to enable a host country to defray a part of the cost
incurred in holding the annual meeting. NATO CCMS provides support for the
attendance of the partnership countries.
Support of the Representatives of Member Nations
Annik Magerholm Fet, Norway
NTNU, represented by Professor Annik Magerholm Fet, has participated in the NATO
CCMS Pilot Program since the Copenhagen meeting in May 2000. Environmental
aspects and concerns normally address people and companies across country borders. To
reach the goal of sustainable development, cooperation across country borders is
essential. Through the NATO CCMS Pilot Project, contacts have been established and
new initiatives on cooperation have been developed. Among the results from our
meetings, there is a new project under development between Norway and East European
countries. The benefits of such cooperation go both ways; the experiences from
Norwegian results from environmental work in industry and research are being
transferred to East European countries. Similarly, knowledge about the situations in those
countries is important for the development of curricula and methodologies in Norway and
to determine how to overcome barriers in the involvement of different industries. In
addition to establishing new contacts and networking, the topics presented at the
meetings are in most cases very interesting.
Topics to Be Included in Future Meetings / Phase II
In the future meetings, I believe that there should be a stronger focus on Eco-efficiency
instead of Cleaner Production. Very often the meaning of the concept Cleaner Production
C-6
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
is the same as Eco-efficiency, but the signals of using Eco-efficiency (and Industrial
Ecology) are more proactive. Another topic is to focus on how to involve industry so the
network does not become of interest only to academia. The challenge is to get the ideas
implemented in industry and leading companies. Another focus could be on corporate
reporting of environmental performance (and further on may be on Corporate Social
Responsibility, or CSR, and how to get companies committed to that). This could be a
way to get industry more involved.
Michael Overcash, USA
I suggest we take a more focused effort than our current country reporting and host a day
of science; take two topics on cleaner production per meeting and ask everyone to report
on specific aspects that are underway in their countries. In Oviedo, we sort of stumbled
on this, as there were six or seven talks on membranes. If we did this with a rotating set
of topics, then the representatives could do a bit more work and get the information from
their countries. This seems to have worked in the questionnaires I have sent out—these
people consulted with others and submitted results. Then the host could focus (in part) on
the same topic, maybe lead or summarize the various country responses, and we can see
if there is some interest in further work. Without critical mass of focus on a topic it is
very hard to see the follow-on activities happening consistently.
Enrico Drioli, Italy
I am in favor of applying for Phase II of our NATO CCMS Pilot Project on Clean
Products and Processes. The work done during Phase I might greatly contribute to
solutions to the problems related to Clean Products and Processes or, more generally, to
sustainable growth. My suggestions, as already discussed, are on trying to focus future
activities on a critical identification of real solutions to identified problems; a second
recommendation is related to the implementation of mechanisms for the diffusion of the
results of the work done and of the Phase II activities and results to a larger public
audience. An increase of the visibility of the results reached in the Pilot Project might be
useful.
Teresa Mata, Portugal
I would like to express my interest in seeing the NATO CCMS Pilot Study on Clean
Products and Processes go to Phase II. As a Portuguese fellow, I benefited greatly from
being associated with this pilot study.
Phase I was a great success. I learnt a lot with the exchange of ideas and experiences
among the participants, through presentations, discussions and publications. I think we
already captured the ideas to explore on the existing projects and on the proposed new
ones. So, it would be of much interest to continue with Phase II of this pilot study.
C-7
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Stefka Sucharova, Bulgaria
The theme of clean products and processes stays in the base and is of special significance
for a large number of chemical industrial processes, environmental chemistry and
agriculture. It is also important in respect to the many problems of human health.
The NATO CCMS Pilot Project, due to the mobility grants, promotes the mobility of
scientists and experts from different countries of the world working in the field of clean
products and processes. The Pilot Project regularly organizes high-level international
scientific meetings, which enhance the knowledge of clean products and processes and
facilitate communication and exchange of scientific experience and ideas. The Pilot
Project provides and disseminates recent advances, and excellent knowledge, updated
information and results in the development of clean products and process studies and
their application to the solution of different problems. The scientists and experts have an
opportunity to collaborate for transfer of knowledge and technologies, exploitation of
research results, and for joint research to improve quality and sustainable environmental
development. The meetings are especially important for the scientists and experts from
Eastern European countries (Bulgaria is one of them) during the transitional period of
their economies who often lack the necessary financial support for travel and attendance
in these type of forums.
What New Things Should Be Focused On?
The experience from the Phase I of the NATO CCMS Pilot Project on Clean Products
and Processes shows it stimulates the exchange of information and experience.
In my opinion, in Phase II much more additional effort should be done to stimulate co-
operation in research and the creation of networks with a view to future participation in
joint projects under different NATO, EC and National RTD Programs for solving of
common problems dealing with clean products and processes.
HorstPohle, Federal Environmental Agency, Berlin
From the German point of view, the information exchange on Programs, Methods and
Instruments of Cleaner Products and Processes in different countries was very fruitful.
Numerous suggestions were taken up and integrated in our own work. The focusing on
the countries in which the meetings were held was therefore of special importance.
Germany is very interested in resuming the initiated transfer of technology in a Phase II.
In Phase II of the project however, ways should be found to improve information
exchange between the representatives involved and between the meetings. This could
contribute to improved quality of the compiled results.
C-8
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Jurgis Stanislas, Lithuania
As all nations move toward a true global economy and as demands for sustainable
development grow, Lithuania is faced with the challenges of creating cleaner and
economically sound manufacturing sectors. In this context, the NATO CCMS Pilot
Study was interesting and useful because it created an international forum where current
trends, developments and experience in the application of cleaner production and creation
of cleaner products are discussed, debated and shared. There is no doubt that there is a
need for the second phase, where clean products and processes could be discussed in
more systematic way in the context of ecological engineering and tools for preventive
environmental management.
George Gallios, Greece
I am very pleased that I had the chance to participate in the Phase I of the NATO CCMS
Pilot Study "Clean Products and Processes" as the Greek representative. I believe that this
study was very valuable for me and opened up new research horizons. During the
meetings of the committee (all excellently organized), I learned a lot. I met people from
many different countries (27 in last meeting) and discussed environmental problems and
tools and methods for their solution with them. In order to collect information for the
study, I made new contacts in Greece and learned a great deal about the environmental
effects of the Greek industries and measures taken (or planned) to resolve them. I hope
that the study will continue in Phase II and that I '11 have the chance to participate in it.
The topics covered by the study were all very interesting and well selected. An important
topic for Greece is the small olive oil producing factories that have a significant
environmental effect. Perhaps this topic could be included as the subject of a study for
proposing cleaner methods that are economically viable for small factories. Another topic
that could be covered is the use of simulation modeling in pollution prevention.
Viorel Harceag, Romania
In all countries on the world, there is a great deal of interest in Sustainable Development
and numerous efforts have been made to achieve it, but important barriers remain, mainly
in technical, economic, regulatory, legal, informational, and organizational categories. On
the global level, Sustainable Development still remains a very complex matter. There are
rich (developed) and poor (developing) countries, and they have different capacities to
act in this field. Waste disposal (which has become a regional or global problem as
regulations, rising costs, and public opposition has forced industries and government
officials in the rich countries to search for more distant places to dispose of wastes) is an
good example of an issue involving these complexities. The poorer countries of the world
have become suppliers of raw materials to the rest of the world, as well as the recipients
of wastes produced in wealthier countries.
C-9
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Pollution prevention (P2) is a well-developed field of environmental management that
focuses particularly on the design of industrial processes within plants, leading to
development of many strategies, assessment methods and a wide range of "clean
technologies" that often improve both environmental and economic performance. For this
reason, P2 is a very important tool for economic development of the poor countries and
an opportunity for East European countries to cross the transition period.
The NATO CCMS Pilot Study on Clean Products and Processes helps us, the developing
country representatives, to meet the developed country representatives, to learn the
simplest ways of managing industrial processes, to develop clean processes and
technologies, and to overcome the existing barriers to Sustainable Development in our
countries.
Susette Dias, Portugal
The Portuguese participation in the pilot study "Clean Products and Processes" has been
an excellent means of discussing the best approach to clean technology dissemination and
implementation. Reporting the diversity of experiences is a very powerful tool. As the
increased number of participating countries shows, there is no doubt that we can learn
more from each other and simultaneously help our countries into accomplishing the
environmental challenges of the next decades.
I think we could focus on the evaluation of the priorities for each country, taking into
account the need for best industrial practices, but a survey of the remediation or treatment
technologies in use and their impact in each country should also be analyzed.
Dissemination strategies for conclusions should also be discussed.
Henrik Wenzel, Denmark
The first phase of the pilot study has proven highly valuable at all levels: to Denmark, to
our Technical University of Denmark and to my own professional activities. The pilot has
catalyzed and initiated many activities and bilateral co-operation projects. Some concrete
examples are:
• Co-operation on Life Cycle Assessment (LCA) with the QUESTOR Centre at
Queen's University in Belfast, including mutual visits and seminars;
• Co-operation on LCA with TUBITAK, Marmara research centre in Turkey,
including a 9-month postdoctoral educational professorship at the Technical
University of Denmark for one of their co-workers;
• Co-operation on LCA with North Carolina State University on LCA databases;
C-10
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
• Co-operation on Process Integration with the company Solutia, Ltd., in USA
including a 1-month guest professorship at the Technical University of Denmark,
establishment and conduction of a PhD course, and an internal course for the
Danish Centre for Industrial Water Management. One further spin-off from this
has been the establishment of an undergraduate course at the Technical University
of Denmark on tools for industry's environmental work.
• Co-operation on Cleaner Production with the Cleaner Production Centre in
Kaunas, Lithuania in a joint project on improving environmental performance in
the Lithuanian paper industry, and last but not least;
• Hosting the pilot study meeting in Copenhagen in 2000 and having there the
opportunity to expose and receive valuable feedback on the Danish initiatives on
Clean Products and Processes for Danish environmental authorities, companies
and academia.
These activities are all a direct spin-off from the pilot study. The first phase of the pilot
has, thus, given very substantial input to activities on Clean Products and Processes in
Denmark and in our co-operation with other NATO and CP countries. Due to the network
established by the pilot study, the spin-off activities are steadily increasing as the network
consolidates. One example is that we will aim at establishing a university-industry co-
operative research center in Denmark similar to the one established at Queen's University
in Belfast, UK. This will take in-depth co-operation between Queen's University and the
Technical University of Denmark over the next year or two.
I therefore strongly support the continuation of the pilot study in a second phase. A
suggestion for a focus area is that we take the opportunity to elaborate further concrete
possibilities of support and technology transfer to Eastern European economies in
transition.
Aysel Atimtay, Turkey
I am sure that you have received many opinions from the other participants. Nevertheless,
I fully support your application for the second phase, and I am sure that with the
participation of several countries in the project, it is going to be a successful one.
Andrzej Doniec, Poland
I am convinced the NATO CCMS Pilot Project should be continued to Phase II. There
are two reasons: Such types of activities serve as a primary source of information
exchange on a very broad set of problems related to cleaner industrial processes and
products in the technical as well as the management aspects. These, in conjunction with
very specific state-of-the-art technical novelties delivered by excellent experts, have a
C-ll
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
stimulating effect, with participants transferring the experience (knowledge) to their
countries, universities, institutes etc. Personal contacts are also of great importance.
In the planned Phase II, each of the presented and discussed topics should refer to (be
composed in) a more general topic, e.g., industrial ecology or industrial symbiosis. Some
sort of cooperative or joint projects (e.g., with UNIDO?) would also be nice.
G.G. Kagramanov, Russia
To my mind, this Pilot (i.e., Phase I as well as Phase II) is very interesting and, during
our discussions in Oviedo, I realized how scientific cooperation in my field of interest
really works.
It seems to me that the ideas we discussed in Oviedo are very fruitful ones and the current
focus is OK. I would like to emphasize the critical role of membrane technologies in
clean processes however.
C-12
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix D
List of Participants
D-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
NATO/CCMS PILOT STUDY ON CLEANER PRODUCTS AND PROCESSES
Hotel Europa (Ausros vartu str. 6, Vilnius)
Vilnius, Lithuania
May 12-16, 2002
List of Participants
Country
Bulgaria
Czech
Republic
Denmark
France
Germany
Hungary
Italy
Lithuania
Name
Stefka
Tepavitcharova
Frantisek Bozek
Henryk Wenzel
Ari Huhtala
HorstPohle
Gyula Zilahy
Alessandra
Criscuoli
Valdas
Arbaciauskas
Una Budriene
Nerijus Datkunas
Valeras Kildisas
Jolita Kruopiene
Arunas Kundrotas
Unas Linkevicius
Vytautas
Ostasevicius
Darius Pamakstys
Arunas
Pasvenskas
Inga
Silvestraviciute
Vaclovas Sleinota
Jurgis Staniskis
Zaneta
Stasiskiene
Organisation
Dr., Bulgarian Academy of Science
Military University of the Ground Forces, Vyskov
Dr., Technical University of Denmark
UNEP, Strategies and Mechanisms to Promote CP
Financing
Dr., Federal Environmental Agency, Germany
Managing Director, Hungarian Cleaner Production
Centre
University of Calabria
The Institute of Environmental Engineering, Kaunas
University of Technology
The Institute of Environmental Engineering, Kaunas
University of Technology
Director of Finance, JSC "Utenos trikotazas"
The Institute of Environmental Engineering, Kaunas
University of Technology
Dr., The Institute of Environmental Engineering,
Kaunas University of Technology
Minister, Lithuanian Ministry of Environment
Minister, Lithuanian Ministry of Defence
Professor, Vice Rector, Kaunas University of
Technology
The Institute of Environmental Engineering, Kaunas
University of Technology
Director General, JSC "Klaipedos kartonas"
The Institute of Environmental Engineering, Kaunas
University of Technology
Director General, JSC "Vilniaus Vingis"
Professor, Director of The Institute of Environmental
Engineering, Kaunas University of Technology
Dr., The Institute of Environmental Engineering,
Kaunas University of Technology
D-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Country
Moldova
Norway
Poland
Portugal
Russia
Slovenia
Spain
Sweden
Turkey
UK
Ukraine
USA
Name
Alexandra
Stratulat
Abrahamsen Uno
Anike Fet
Andrzej Doniec
Andrzej Wasiak
Teresa Mata
Georgij
Kagramanov
Peter Glavic
Jose Coca
Morten Karlsson
Lennart Nielsen
Aysel Atimtay
Jim Swindall
QBE
William Zadorsky
Thomas Chapman
Dan Murray
Subhas Sikdar
Steve Weiner
Organisation
Prime Minister's Office
Norwegian Technological Institute, Oslo
Professor, Trondheim Technical University
Dr., Technical University of Lodz, Pollution
Prevention Centre
Professor, Bialystoc Polytechnic Institute
University of Porto, Porto
Professor, D. Mendeleev University of Chemical
Technology of Russia
Professor, University of Maribor
Professor, Chairman of Department of Chemical and
Environmental Engineering at the University of
Oviedo
Dr., Lund University
Professor, Royal Stockholm Technical Institute
Dr., Middle East Technical University
Professor, Queen's University-Belfast, QUESTOR
Centre
Professor, Ukrainian State University of Chemical
engineering
Ph.D., Acting Director, Division of Chemical and
Transport Systems, National Science Foundation
Director, Technology Transfer and Support Division,
NRMRL/USEPA
Director, Sustainable Technology Division,
NRMRL/USEPA
Dr., Chair, Laboratory Coordinating Council, Pacific
Northwest National Laboratory
D-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
D-4
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix E
Meeting Program
E-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
NATO/CCMS PILOT STUDY ON CLEANER PRODUCTS AND PROCESSES
HOTEL EUROPA (Ausros vartu str. 6, Vilnius)
Vilnius, Lithuania
May 12-16, 2002
Programme
Sunday, May 12, 2002
14:30 Delegates/Participants registration in Hotel Europa
15:00 Welcome
Dr. Subhas Sikdar, Pilot Study Director (USA)
Linas Linkevicius, Minister of National Defence Republic of Lithuania
Professor Jurgis Staniskis, The Institute of Environmental Engineering,
Kaunas University of Technology (Lithuania)
15:15 Introduction round of country delegates and participants
15:45 Overview of Meeting Agenda, Field Visits and Events
Daniel Murray, Pilot Study Co-Director (USA)
16:00 Pilot Project Updates
"Pollution Prevention Tools," Daniel Murray (USA)
"Life Cycle Assessment of Gasoline Blending Options," Teresa M. Mata
(Portugal)
16:30 Break - Coffee/Tea
17:00 Tour de Table Presentations
Germany, Czech Republic, Ukraine, Bulgaria, Poland, Italy
18:50 End of Session
Monday, May 13, 2002 One day conference on Industrial Ecology
9:00 Arunas Kundrotas, Minister of Environment Republic of Lithuania
9:30 "From Pollution to Industrial Ecology and Sustainable Development,"
Professor Lennart Nielsen, Royal Stockholm Technical Institute (Sweden)
10:00 "Industrial Ecology and Eco-Efficiency. Introduction to the Concepts,"
Professor Anike Fet, Trondheim Technical University (Norway)
E-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
10:30 "Green Concurrent Engineering: A way to fill ISO 14001 with content,"
Dr. Morten Karlsson, Lund University (Sweden)
11:00 Break - Coffee/Tea
11:30 "Strategies and Mechanisms to Promote Cleaner Production Financing,"
Ari Huhtala (UNEP, Paris)
12:00 "Cleaner Production Financing: Possibilities and Barriers," Dr. Zaneta
Stasiskiene, The Institute of Environmental Engineering (Lithuania)
12:20 Lunch
14:00 -14:30 Meeting with the President of the Republic of Lithuania
Valdas Adamkus at the Presidential Palace
15:00 "Industrial Ecology in University Curricula: New International MSc
Programme in Cleaner Production and Environmental Management,"
Valdas Arbaciauskas, The Institute of Environmental Engineering
(Lithuania)
15:20 "Chemicals Risk Management in Enterprises," Dr. Jolita Kruopiene, The
Institute of Environmental Engineering (Lithuania)
15:40 Break - Coffee/Tea
16:15 Practical Implications of Industrial Ecology in Lithuanian Industry:
Electronic Industry, JSC "Vilniaus Vingis," Vaclovas Sleinota, General
director
Textile industry, JSC "Utenos trikotazas," Nerijus Datkunas, Financial
director
Paper industry, JSC "Klaipedos kartonas," Arunas Pasvenskas, General
director
17:00 International Implications on Industrial Ecology
"Utilisation of Cleaner Production Methodology on the Example of Dairy
Plant"
"Utilization of Cleaner Production on the Example of Poultry Processing
Plant," Ales Komar (Czech Republic)
17:30 End of Session
17:30 - 19:00 Computer Cafe
E-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Tuesday, May 14, 2002, Field Trip - Afytus Companies
Visit to refrigerator production company "Snaige"
Visit to textile company "Alytaus tekstile"
Visit to wine and sparkling wine production company "Alita'
Wednesday, May 15, 2002
9:00 Professor Vytautas Ostasevicius, Vice-rector for research, Kaunas
University of Technology
9.20 "Industries of The Future - Partnerships for Improving Energy Efficiency,
Environmental Performance and Productivity," Steven Weiner (USA)
9:40 "Ceramic Membranes Applications in Clean Processes in Russia,"
Professor G. Kagramanov (Russia)
10:00 University - Industry Co-operation
"An Update on Government Support for Clean Products and Processes in
The United Kingdom," Professor Jim Swindall (UK)
"Waste Minimisation, Revalorisation and Recycling of Solid Waste in
Spain," Professor Jose Coca-Prados (Spain)
"Presentation of Lithuanian CP Centre," Professor Jurgis Staniskis
(Lithuania)
"Programs of the U.S. National Science Foundation Related to Clean
Processing," Dr. Thomas W. Chapman (USA)
11:15 Break - Coffee/Tea
11:45 Tour de Table presentations
USA, Moldova, Slovenia, Hungary
12:40 Pilot Project Updates
"The Danish Centre for Industrial Water Management," Henrik Wenzel
(Denmark)
"Reuse of waste materials of iron-steel industries and development of
sorbents from these materials for absorption of hydrogen sulfide in waste
gases," Aysel T. Atimtay (Turkey)
13:30 Lunch
E-4
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Thursday, May 16, 2002
9:00 Evaluation of five year programme on Clean Products and Processes
Dr. Subhas Sikdar, Dan Murray (USA)
10:00 Discussion
Moderator Dan Murray (USA)
11:00 Break - Coffee/Tea
11:30 Discussion of Future Directions for the Pilot Study, Dan Murray (USA)
• Topics and Focus for Next Meeting
• Host Country Location, and dates for 2003 Meeting
12:30 Meeting Wrap Up
Dr. Subhas Sikdar (USA)
E-5
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
E-6
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Appendix F
PowerPoint Presentation Links
F-l
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Presentation Name
Executive Summary
Tour de Table Presentations
Introduction of Cleaner Production in Masna-Zlin Meat
Processing Company, Ltd.
Cleaner Production Tools and Methods, Manuals and
Samples
Industrial Ecology Taught at the Technical University of
Lodz (Poland)
Presentation of United States of America
The Importance and Implementation of Clean Processes in
the Republic of Moldova
The Benefits and Drawbacks of Voluntary Environmental
Agreements Relating to Cleaner Technologies
Pilot Project Updates
Cleaner Energy Production with Reuse of Waste Materials
from the Iron and Steel Industry in IGCC
Pollution Prevention Tools
University-Industry Cooperation
An Update on Government Support for Clean Products and
Processes in the United Kingdom
Waste Minimization, Revalorisation and Recycling of
Solid Wastes in Spain
Presentation of Lithuanian Cleaner Production Centre
Industrial Ecology
Industries of the Future: Partnerships for Improving
Energy Efficiency, Environmental Performance and
Productivity
Industrial Ecology and Research Program at the
Norwegian University of Science and Technology
Green Concurrent Engineering: A Way To Fill ISO 14001
with Content
Strategies and Mechanisms To Promote Cleaner
Production Financing
Cleaner Production Financing: Possibilities and Barriers
Industrial Ecology in University Curriculum: New M.Sc.
Programme in Environmental Management and Cleaner
Production
Practical Implications of Industrial Ecology: JSC "Vilniaus
Vingis"
JSC "Utenos Trikotazas"
Cleaner Production at Paper Mill JSC "Klaipedos
Kartonas"
PowerPoint
ESI
TDT1
TDT2
TDT3;
TDT4
TDT5
TDT6
TDT7
PPU1
PPU2
n
UICJ.;
UIC2:
UIC3
UIC4
UIC5;
UIC6
IE1
IE2
IE3
IE4
IE5
IE6
IE7
IE8
IE9
Acrobat
ESI
TDT1
TDT2
TDT3;
TDT4
TDT5
TDT6
TDT7
PPU1
PPU2
UICI;
UIC2;
UIC3
UIC4
UIC5;
UIC6
—
IE2
IE3
IE4
IE5
IE6
IE7
IE8
IE9
F-2
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
Presentation Name
PowerPoint
Acrobat
Appendix A — Annual Reports By Country
Czech Republic
Appendix B— NATO/CCMS Phase I Summary
Appendix C— NATO/CCMS Phase II
APPA1
APPB1;
APPB2
APPC1
APPA1
APPB1;
APPB2
APPC1
F-3
-------
NATO/CCMS Pilot Study on Clean Products and Processes (Phase 1)
F-4
------- |