CLEANTECH
‘Cleantech’
is a strategic enviro-management tool developed by Ashok Sharma, Former Member
Secretary, HP State Pollution Control Board, India to reduce the generation of
pollutants in a process at source, through minor process modification, material
substitution, improved manufacturing practices or low cost innovation, with a
view to achieve low or no discharge, thereby eliminating the need for
treatment. The concept is based on eco-efficiency principles and assures rapid
payback on account of material savings, elimination of treatment costs,
avoidance of liability costs and above all, improved corporate image and brand
equity.
The
concept has been implemented successfully in over 200 industries extending over
25 categories including sugar, paper, textiles, mineral processing,
electroplating, leather processing, pharmaceuticals, chemicals and food
processing amongst others, with remarkable success rate. It has been possible
to achieve zero discharge in a wide number of cases, with a rather phenomenal
payback. In a sample of thirty cases, six could actually achieve zero discharge
while the remaining could realize a 60 to 80 percent reduction in quantity of
effluent. Drastic reduction in toxicity and hazard potential could be
experienced as an added advantage. The payback for implementation in most cases
varied between six months to a year and in many cases has been, as low as
instant. In some cases, the existing effluent treatment plants were abandoned
as no longer required, while in most others, they could serve more
efficaciously, as the effluent load reduced drastically. In most case,
substantial energy savings were effected ranging from 15 to 35 percent, in an
extreme case as high as 70 percent. A good number of industries in the red
could be revived through implementation of cleanteh.
Cleantech
is based on voluntary initiative of industry, based on the principle of
environment management beyond compliance with assured profit. It lays focus on
management along the process lines instead of the conventional end of the pipe
approach. It works on clear objectives of investment viability to provide the
industry, a strategic cutting edge above the rest.
Cleantch
as a management tool has universal applicability. However, experience reveals
that the potential for implementation of cleantech in a given facility or
activity depends upon the following factor very significantly;
a.
Cleantech potential is directly proportional to the volume of the effluent:
Examples to this could include paper mills, textile dyeing and processing, food
processing industries, fast food chains and sewage handling systems.
b.
Cleantech potential is directly proportional to toxicity of materials/effluent:
No one could imagine someone wasting cyanide, as the consequences are so well
known.
c.
Cleantech potential is directly proportional to the hazard potential of
process/materials: Examples could include the harrowing MIC leak in Bhopal or a
liquid hydrogen transportation facility.
d.
Cleantech potential is directly proportional to cost of materials/wastes: Have
you ever heard of a gold smith wasting materials.
e.
Cleantech is directly proportional to energy intensity of the process: The best
example could be that of industrial drying processes in textile, paper and food
processing sectors or the glass, ceramic and steel industries in particular.
Applying
the above broad criteria and the experience of implementation, following could
be some of the industries best suited for the implementation of cleantech;
1.
Pulp and Paper industries.
2.
Textile dyeing and processing.
3.
Metal heat treatment and surface finishing.
4.
Leather processing industries.
5.
Food processing industries.
6.
Mineral processing industries.
7.
Cement, glass and ceramic industries.
8.
Chemical and petrochemical industries.
9.
Coal based industries.
10.
Drugs and pharmaceuticals.
11.
Plywood and lamination industries.
12.
Photo film industries.
13.
Breweries and Distilleries.
14.
Sugar Industries.
15.
Butcheries and meat processing.
16. Asbestos based industries.
17.
Printing and Packaging industries.
18.
Industries handling PCB’s and other chemicals of concern.
The
above list could however be best stated as illustrative and not exhaustive. It
only includes industries, where cleantech could be implemented easily and
readily reaping the low hanging fruit and to establish the usefulness of the
techniques of cleaner production so as to motivate increasing number of
facility owners and managers to adopt cleantech for pollution control at
profit. In actual practice, it could be gainfully implemented in every facility
or activity. The best examples of other than manufacturing industries could be
the public services like hospitals, transport, sewage handling & treatment
and construction. A public or private sector office could be no exception to
the above.
Technology
of Cleaner Production
Cleantech
is not just confined to manufacturing or shop floor technologies. It has a
great lot to do with the shop floor management practices, particularly the
areas like house keeping, material handling, energy efficiency and waste
handling. The entire concept is based on source segregation of wastes or
effluent streams for specialized handling, reuse, recycling or disposal of each
such stream. It would eventually lay heavy emphasis on apt deployment of
separation technologies ranging from simple decantation, floatation,
centrifugation, filtration, distillation, sublimation and evaporation to
advance techniques like membrane technology, vacuum evaporation, freeze drying
and super critical treatment.
The
concept also lays heavy emphasis on energy conservation and cleaner energy
options. The matrix includes switching over from coal to cleaner coal, from
coal to oil, from oil to electricity, from thermal electric power to
hydroelectric power. Consideration would also be paid to the forms of
electrical energy like conductive use of energy vis a vis the induction and
radiation based consumption. It would also pay attention to areas like waste to
energy and other alternative energy options like solar power, wind energy,
refuse derived power, high rate bio-methanation of wastes, along with emerging
zero emission technologies like the hydrogen fuel cells.
The
concept of cleaner production has to take into consideration emerging options
like advanced materials like carbon fiber reinforced materials,
super-conductive materials, bio-degradable plastics and cleaner solvents.
Alternatives are to be assessed in terms of ultimate cost analysis based upon
the total life cycle analysis. Substitution of hazardous materials, carcinogens
and other chemicals of concern with benign alternative are the other essential
features of cleantech.
Catalysis and Bio-processing are two distinct areas of focus under
cleantech. Use of advance catalysts can not only lead to enormous energy
savings and processing time, but also help altering the operating temperature
and pressure conditions avoiding workplace hazard in many situations. The
concept has ever been in use for cost advantages in manufacturing but has not
so far been deployed for effective environmental management. Similarly putting
bio energy to use for more energy efficient and cost effective production has
very bright prospects in acquiring eco-efficiency. Examples of bio-pulping and
bio-bleaching in the pulp and paper industries are already in view as cleaner
production options. Deployment of bio-technology in disposal of organic wastes
has already acquired commendable dimensions. The fullest potential of
bacteriophages as a major tool for bio-remediation is far from fullest
exploitation. Cleantech lays focus on such emerging techniques, which could
sometimes be amazingly low cost.
Minimization
of wastes at source and ‘in-process recycling’ are the main features of
Cleantech. A great amount of in-put, therefore comprises of such technologies
and practices. These technologies, however, have to be essentially coupled with
efficient material handling systems for effective spill control and pilfer
proof recycling. Experience reveals that process control equipment like CNC and
programmable logic controls invariably lead to tremendous results. An efficient
dosing system for just the right quantity of a chemical could often ensure its
presence in the final effluent below the detectable limits or well within the
compliance norms, at the same time, ensuring phenomenal savings on cost of the
chemical apart from the probable treatment and disposal costs. Whatever said
above, the ultimate strength of cleantech lies in the strongest hidden
component of innovation. The entire concept sharply focuses itself on process
re-engineering using low cost innovation to manage effluent loading, toxicity
and hazard. The same principles shall hold good in case of emerging production
technologies, particularly the environmentally sustainable technologies or the
EST’s for future industries.
Some
Case Studies in Implementation of Cleantech
A large
number of case studies on implementation of are sifted to reproduce some of the
significant examples to amplify the broad features of cleantch as follows;
1. High Costs High Returns: The case pertains to an Indo-U.S. joint
venture producing high quality bimetal bearings for use in the automobile
industry. The industry, an ISO: 9000 company, was releasing electroplating
effluent containing lead, tin and nickel after treatment into a highly
sensitive watercourse, meeting the drinking water needs of a downstream
township. They had invested U.S.$ 500,000 to install an effluent treatment plant
and were spending another U.S. $ 40,000 annually towards its operation still
not able to satisfy the community. After a cleantech study analyzing the
material balance and the nature of effluent, many options including membrane
technology and electro-dialysis were considered. Since the nature of effluent,
which comprised of rinse water, revealed the presence of plating chemicals
only, it was decided to install a vacuum evaporation unit, subjecting the
entire effluent to vacuum evaporation. The condensate was used back as process
water and the concentrated plating chemicals were ploughed back into the
process. The savings on chemicals recovered and treatment cost avoided ensured
a pay back of one year on an investment of the order of U.S. $ 400,000, leaving
the process truly to a zero discharge. The effluent treatment plant was
dismantled to make way for a tennis court.
2. Low Cost High Returns: After serious complaints of pollution of a
nearby stream, the wastewater from an apple processing industry was analyzed to
find no harmful effluents. At the same time, it was discovered that the
industry was dumping apple pomace (solid waste after juice extraction) into the
stream, causing much trouble. After process analysis, a waste heat dryer was
installed, using the waste heat from the boiler flue, to dry the apple waste.
Dry waste was ground and sold off as ingredient for cattle feed. The total
investment involved was not in excess of U.S. $ 3000 and the savings from the
sale of the nuisance material equaled approximately 12% of the raw material
costs.
3. Negligible Cost Good Returns: After successful implementation of vacuum
evaporation plant for reuse of recovered chemicals, many tiny electroplating
industries indicated interest in finding solutions but were hesitant towards
making heavy investment because of financial limitation. With small number of
users, scattered over a larger geographical spread and lack of cooperation
amongst themselves, common effluent treatment concept could not also mature.
After detailed deliberation, a cascading system was devised involving three
successive rinse baths. It was decided to replenish freshwater only in the last
bath, replenishing the make up water for the second bath from the third one and
the first from the second one, eventually meeting the replenishment of the
plating tanks from the first bath. The low cost system costing a mere
investment of U.S. $ 1000 ensured a zero discharge, saving plating chemicals
worth up to U.S. $ 4000 and avoiding treatment costs and hassles. Some excess
wastewater problems were encountered, that were controlled by solar evaporation
and minimization practices like vibrating rinse and/or brushing while rinsing.
4. No Costs High Returns: Then came up the case of a mushroom
processor who was the victim of political attacks on the plea of pollution. He
pleaded that his effluent comprised only the biodegradable food waste and was
willing to install any equipment prescribed, to ward off the problem of smell.
A detailed analysis of his process revealed only two types of waste i.e., the
wastewater from the blancher and the mushroom fleshing arising out of breakage
of tender button mushroom. The company had installed surface aeration facility
for the wastewater treatment and was composting the solid waste. After
detailing many options, some of them highly capital intensive, an innovative
approach was finally taken. Water from the blancher was tapped at source, mixed
with the ‘waste’ mushroom, freshly collected and mashed. Just a little salt and
spice, and the soup was ready. It was just sent to the canning line instantly
to embark upon a new product. No investment and a potential for up to 24%
increase in turnover. A case of simple innovation with zero investment leading
to zero discharge with zero gestation and instant payback.
For
more success stories, free net based advice and free implementation advice
anywhere in the world, contact; Ashok Sharma, Chief Executive, Cleantech
International Foundation, 64 MIG, Sector I, Parwanoo 173220, India.
Phone:
+91 98160 77777, Fax: +91 1792 33735, email: cleantechfoundation@vsnl.net