Produksi Bersih

(Cleaner Production)
TKK 4405
2 SKS
No Learning Outcome Level Isu Pokok
1 Menjelaskan pentingnya
penerapan produksi bersih pada
kegiatan industri
2 Industri dan lingkungan
Industri Gula dan alkohol
2 Menjelaskan beberapa strategi
pengelolaan lingkungan terkait
produksi bersih, seperti green
chemistry, life cycle analysis, dan
ekologi industry
2 LCA
Green Chemistry
Ekologi Industri
3 mengidentifikasi potensi dan
faktor-faktor penyebab sumber
limbah pada unit proses, unit
pemisah, dan unit utilitas.
1 Sumber buangan :
Bahan baku,
Unit Pemisah
Unit Sintesis
Transport bahan, Penyimpan
Pengolah air, Penyedia energi
Laboratorium

4 Menjelaskan strategi pengurangan
pencemaran melalui integrasi
proses.
2 Integrasi Massa
Integrasi energi
Human Activity
INDUSTRIES
(Physical, Chemical,
Biological Processes)
RM P+Wastes
RM
Water
Energy
Product
Side Prod.
Waste
Environment

WasteNat Res
Communities
WWT?
Natural
Resources
Waste
t> P& C>
W>
NR<
Time
NR
tQB
tQCP
with CP
Without CP
Overview
Traditional enviromental thinking focuses
on what to do with wastes and emissions
after they have been created.
Cleaner production avoids or minimizes
waste and polluton even before it is
generated !
Therefore it is called pollution reduction
at source


Anatomy of Chemical Process industries
Raw
Material
RM
Preparation
Reactor
Separation
Purification
Product
Wastes
Old Paradigm
Anatomy of Chemical Process Industries
New Paradigm
Raw
Material
RM
Preparation
Reactor
Separation
Purification
Product
Waste
Overview
The key difference between pollution control
and cleaner production is one timing.
Cleaner prodction can be seen as recognition of
the need to consider the complexity of
sustainable production.
While the earlier focus on pollution control was
an after-the event, react and treat approach,
cleaner production is a proactive, anticipate
and prevent philosophy. Prevention is, as is
well known, always better than cure.
Dispersion
Pollution
control
Recycling
Pollution
prevention
Sustainable
development
Cleaner
Production
1960 1980 1990
Environmental Management History
Cleaner Production - Timeline
Late 1980s
Environmental managers in the U.S. and Europe realized the
importance of pollution prevention at the source
Stress on reducing waste and pollution at source rather than
treating waste produced
Combined effort of production, administration and
environmental specialist teams to reduce waste generation
and improve efficiency
1990s
EPA decided on Pollution Prevention (P2)
National Pollution Prevention Act passed by Congress
P2 the top priority for protecting the environment from
pollution
Established that recycling is not P2 but finding use for
something thats already waste
New P2 programs established in many states
The United Nations Environment Programme (UNEP) in Paris
made similar observations about the need for Pollution
Prevention
Cleaner Production
In Developing Countries
Weak or no regulations regarding treatment of pollution
UNEP - major resource for Environmental Policy
Decided on cost effective prevention through improved efficiency
and business management as the means to reduce industrial
pollution
UNEP called this CLEANER PRODUCTION
Cleaner Production (CP) is the international term for reducing
environmental impacts from processes, products and services by
using better management strategies, methods and tools
A global movement for improving business performance and a
profitable, cleaner, sustainable future
CP called Pollution Prevention, waste minimization, green
productivity
The US Office of Technology reported to the
Congress that :
By considering pollution prevention
separately from other manufacturing needs,
such as productivity and quality improvements,
most pollution prevention programs fail to
develop the vital synergies and working
relationships with manufacturers that are
essential to drive both pollution prevention and
manufacturing competitiveness
Cleaner Production (CP) :
Is defined as the continuous application of
an integrated preventive environmental
strategy to processes, products and services
to increase the overall efficiency and to
reduce risks to humans and environment.
In production processes, CP includes the
saving of rm and energy, the elimination of
toxic rm and the reduction in the quantities
and tocicity of wastes and emissions.
Cleaner Production (CP)
In product development and design, CP
aims at the reduction of negative impacts
throughout the life cycle of the product :
from rm extraction to ultimate disposal.
In services, CP advocates the incorporation
of environmental considerations into the
design and delivery of services.
Cleaner Production
is a Preventive Integrated Environmental Policy
applied to the entire Production and Service cycle
Products:
Reduction of waste
through better design
Use of waste for
new products
Processes:
Conservation of raw materials,
energy, water
Reduction of emission at source
Evaluation of technology option
Reduction of costs and risks
Services:
Efficient environmental
management in design
and delivery
Impacts:
Improved efficiency
Better environmental performance
Increased competitive advantage
Critical CP Factors
Management Systems
Ensures right tools are used properly
Environmental Management Systems (EMS) most common tool for CP and P2
Other Management systems such as Balanced Scorecard and Balridge Quality
Award are also in use, Proper

Assessments
To identify CP and P2 opportunities
Assessments get integrated with the management system as a continual
improvement process over time

Measurements
To obtain data on whats happening in an organization before applying CP and
P2
Performance indicators linked with the mission and strategy developed
Accounting tools used for developing the right data
CP and P2 projects evaluated financially and by risk and impact assessments
Critical CP Factors (Contd.)
Design
Product design - ultimate driver for CP and P2 process improvements
Process improvement follow proper Product Design

Purchasing
Critical for CP and P2
Green Purchasing or Environmentally Preferred Procurement creates
demand for better products that in turn creates better supply

Reporting
Public reporting of CP and P2 and social performances






CP Assessments in Industries
Cleaner Production assessment
methodology is used to
systematically identify and evaluate
the CP opportunities and facilitate
their implementation in industries

Assessment methodology is useful
in organizing the CP program in a
company and bringing together
persons to be involved with the
development, evaluation, and
implementation of Cleaner
Production measures
Phase 1: Planning & Organization
Elements important for the successful start of a Cleaner Production
program:
Management commitment
Employee involvement
Cost awareness
Organize a project team
Identify barriers and solutions
Set plant-wide goals

Effective CP Planning Process ensures
Selection & implementation of the most cost effective CP
options
Broader business planning investment analysis and decision-
making (such as capital budgeting and purchasing)
Cleaner Production objectives and activities are consistent
with those identified in the organizations broader planning
process
Phase 2: Assessment Procedure
Source Identification
material flow diagram with
associated costs made to identify
sources of waste and waste
generation
Cause Diagnosis
investigation of factors that
influence the volume and
composition of waste and
emissions generated
Option Generation
create a vision on how to
eliminate or control each of
the causes of waste and
emission generation
Option generation in turn
considers the following
elements
PROCESS
Technological
Change
Good Operating
Practices
Product
Changes
Change in
Raw Materials
Onsite Reuse
& Recycling
Phase 3: Feasibility Studies
Evaluates the technical and economic feasibility of options
Preliminary Evaluation
Options are sorted to identify additional evaluation needs for complex processes
Technical Evaluation
Availability and reliability of equipment
Effects on product quality and productivity
Expected maintenance and utility requirements
Operating and supervising skills
Economic Evaluation
Collection (regarding investments and operational costs, and benefits)
Evaluation criteria (pay back period, Net Present Value (NPV) or Internal Rate of
Return) and feasibility options
Environmental Evaluation
Determine the positive and negative impacts of the option for the environment
Selection of Feasible options
Elimination of technically non-feasible and environmentally insignificant options
Selection of the right option in case of competing options or limited funds
Phase 4: Implementation and Continuation


Evaluates the feasible prevention measures which are implemented
and provisions taken to ensure the ongoing application of CP

Results of this phase include:
Implementation of feasible CP measures
Monitoring and Evaluation of the progress achieved by the
implementation of the feasible options
Initiation of the ongoing CP activities

bb

AP+R
50% (P,T)
AP+R
80% (P,T)
AP+R
80% (P,T)
A=80
K=20
A=80
K=20
A=80
K=20
A=80
A=100
A=80
P=40
P=80
P=64
K=20
K=20
K=20
A=40
R=40
A=16
R=64
Hs1=80
Hs2=20
A=20
R=80
A=40
R=40
H=40
A=20
R=80
H=80
A=16
R=64
H=64
Statoil
(oil refinery)
Kemira
(sulfuric acid)
Asnaes (Coal-fired electric
power generating station)
Lake Tissa
(freshwater
source)
Greenhouse
District
heating
Gyproc
(gypsum
wallboard
plant)
Fish farming
Novo Nordisk
(pharmaceutical plant)
Fertilizer
Steam Gas CW WW
Steam
Cement and road
Industrial Ecosystem in Kalunborg Denmark
sulfur
sludge
water
water
water
heat
Fly ash
heat
gypsum
gas
heat
Benefits of Cleaner Production
Improved production efficiency
More efficient use of raw materials, water and
energy
Recovery of valuable by products
Less pollution
Lower costs for waste disposal and wastewater
treatment
Improved image
Improved occupational health and safety
Reduced enviromental liability
Buku Acuan
Allen, D.T. and Rosselot, K.S., 1997, Pollution Prevention for
Chemical Processes, John Wiley & Sons Inc., New York.
Allen, D.T. and Shonnard, D.R., 2002, Green Engineering :
Environmentally Concious Design of Chemical Processes,
Prentice Hall PTR, Upper Saddle River, NJ.
Anastas, P.P., and Warner, J.C., 1998, Green Chemistry :
Theory and Practice, Oxford University Pers Inc, New York.
Curran, M.A., 1996, Environmental Life-Cycle Assessment,
McGrawHill Book Company, New York.
DeVito, S.C. and Garret, R.L., 1996, Designing Safer
Chemicals, American Chemical Society, Washington.