Graz University of Technology

The Concept of Cleaner Production

BUP Teachers Conference on Environmental

Management
Borki-Molo, Poland, June 28th July 2nd, 2006

Mickael Planasch
Institute for Resource Efficient and Sustainable Systems
Graz University of Technology
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Disclaimer

Graz University of Technology

This series of slides is made for a class room

presentation and not for a scientific publication
Many of the figures and photos are taken from
other publications or presentations; the original
authors might not be cited completely on the
slides
This set of slides may not be cited as a source
for the material included!
For more information please contact:
planasch@tugraz.at
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Environmental protection reduced air and

water pollution
end-of-pipe treatment
recycling
reuse
incineration
save disposal

1985

2000

Institute for Resource Efficient

and Sustainable Systems

2015
The Concept of Cleaner Production
June 30, 2006

Graz University of Technology

What we have learned

Pro:

Environmental technologies lead to a significant

reduction of emissions (at least per product)

But:
Environmental technologies are expensive and need

further input of materials, energy and manpower

no economic incentives for industry in general
higher production costs
regulatory approach, industry looks for countries with
less strict regulations
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Investment/Depreciation

Investment/Depreciation

Personal Costs

Personal Costs

Maintainance

Maintainance

Product
Half-finished product

Product
Half-finished product

Raw Material

Process

Process

Process

Emissions

Emissions
Raw Material

Operating Material

Operating Material

Auxiliary Material

Auxiliary Material

Energy

Energy

+ disposal costs

+ Disposal costs

Costs for Emissions

handling

+ Disposal costs

Institute for Resource Efficient

and Sustainable Systems

Inefficiencies in all
previous processes

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Eco-efficiency, IPPC, CP

good housekeeping
waste minimization
closing cycles
energy efficiency

Cleaner Production

1985

2000

Institute for Resource Efficient

and Sustainable Systems

2015
The Concept of Cleaner Production
June 30, 2006

Graz University of Technology

Investment/Depreciation

Investment/Depreciation

Personal Costs

Personal Costs

Maintainance

Maintainance

Product
Half-finished product

Product
Half-finished product

Raw Material

Process

Process

Process

Emissions

Emissions
Raw Material

Operating Material

Operating Material

Auxiliary Material

Auxiliary Material

Energy

Energy

CP options!
+ disposal costs

Costs for Emissions

handling

+ Disposal costs
+ Disposal costs

Institute for Resource Efficient

and Sustainable Systems

Inefficiencies in all
previous processes

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Total Waste Water Costs:

Textile Company in Austria in 2005

Taking Depreciation,
Maintainance
and Personal Costs into
account: add factor 4-5!!!

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Cleaner Production

Institute for Resource Efficient

and Sustainable Systems

Graz University of Technology

The Concept of Cleaner Production

June 30, 2006

Cleaner Production

Graz University of Technology

Is the conceptual and procedural approach to

production that demands that all phases of the
life-cycle of a product or of a process should be
addressed with the objective of prevention or
minimization of short and long-term risks to
humans and to the environment

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Cleaner Production

Graz University of Technology

The goal is to improve the eco-efficiency in

companies by implementation of technical or
organisational actions
By reducing the negative effects to the
environment operating costs are reduced
Cleaner Production works with process
integrated preventive - methods instead of
End-of-Pipe solutions
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

There are some basic methods/techniques to

implement CP in companies
But
Every single company has different problems.
So there is no time the same solution for two
different problems! Every solution is unique, due
to the specific features of every company.
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

5 Basic Principles of CP
Input-Substitution
Good Housekeeping

Internal Recycling
Technological Optimisation/Change
Optimisation of the Product

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Input-Substitution

Graz University of Technology

Use of less hazardous raw-, auxiliary- or

operational materials
Use of operating materials with a longer life-time

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Good Housekeeping

Increasing the Material and Energy efficiency

with actions in the process. Try to fetch the Low
anging fruits
Reducing losses due to leakage
Training of employees

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Internal Recycling

Graz University of Technology

Closing of Material and Energy Loops (Water,

Solvents,)
Cascading of Material and Energy streams

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Technological Optimisation/Change
Implementation of new technologies
Improved process control
Redesign of processes
Change in or Substitution of hazardous
processes

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Optimisation of the Product

Increasing the life-time
Easier reparing

Easier demanufacturing, recycling or deposition

Use of non-hazardous materials

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and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Leather straps for watches

cross section
through strap

4 functions
functions:

cover leather: design

inlay: shape
base leather: strength
glue: adhesion

Institute for Resource Efficient

and Sustainable Systems

provided by 4 different
materials

product is:
durable ?
recyclable ?
repairable?
cheap ?

Where can we use:

recycled material
less material
.

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

recycling parts for base strap and glue

Luftemission
60.0

Verklebung
Einkauf

40.0
Produkt
Reinigung

100.0

10.0

60.0

Abfall
30.0

Luftemission
60.0
Verklebung
Einkauf

40.0
Produkt

75.0
Reinigung

10.0

60.0
Aufarbeitung
30.0

Abfall
5.0

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Internal recycling

re-utilization of materials
(solvents, ...)

reuse of materials for different purpose

(paper,

solvents for inferior use i.e. pre-cleaning...)

closing of loops (water)

multi way systems (packaging materials)
reclaiming of materials with high value

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Difference between internal and external

recycling

Internal recycling reduces the amount of

materials purchased
external recycling has no influence to amounts
of materials purchased
the use of wastes / emissions in an other
process at the same industrial site is not
considered as recycling
Institute for Resource Efficient
and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Flow of
Acetone

Luftemission
60.0
Verklebung
Einkauf

40.0
Produkt
Reinigung

100.0

10.0

60.0

Abfall
30.0

Luftemission
60.0

before

Verklebung
Einkauf

and

40.0
Produkt

75.0

after

a mass flow analysis

for internal reuse
Institute for Resource Efficient
and Sustainable Systems

Reinigung

10.0

60.0
Aufarbeitung
30.0

filter

Abfall
5.0

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Meeting
regulations

1,2

Continuous
Improvement

1
Redesign
of
processes

0,8
0,6
0,4
0,2
0
1996

1997

1998

1999

2000

2001

2002

2003

year

Heuberger eloxal
Institute for Resource Efficient
and Sustainable Systems

Source: STENUM, 2004

The Concept of Cleaner Production
June 30, 2006

Graz University of Technology

Examples for CP results

1.400.000
1.200.000

30,0

27,3

Frischwasser - Hl

25,0

prod. Hl Getrnke
Hl/Hl prod. Getr.

1.000.000

20,0

18,3
800.000
600.000

15,0

10,7
9,6

400.000

8,6

7,2

7,0

7,0

6,9

6,7

7,0

10,0

6,2

5,9

5,5 5,5
5,0

200.000
HL

0,0
1975 1977 1979 1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2000 2001

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

How to implement CP actions in companies

Get to know the process:
What are the processes units?, e.g. in electro-plating:

degreasing, etching, bondering, rinsing

Understand the process with its chemical and
physical connections
Draw a Flowsheet with all (!!!) Input and Outputstreams and all interrelationships (quantitative)
Take a closer look at the most important material
streams (qualitative and economically, m/a, EUR/a)
Look at existing cross-media effects

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

How to implement CP actions in companies

Material and Energy balance
Identify the weak points of the process: it is
easier to convince companies to take actions if
the economic benefits are clear at the start, so
Identify the low-hanging fruits

Define process optimisations

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

The future

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

The shift from continuous improvements to

redesign

1985

2000

Institute for Resource Efficient

and Sustainable Systems

2015
The Concept of Cleaner Production
June 30, 2006

Graz University of Technology

The paradigm shift in environmental

protection

Meta-system optimization
System optimization

Sub-system optimization
Fighting symptoms
1985

2000

Institute for Resource Efficient

and Sustainable Systems

2015
The Concept of Cleaner Production
June 30, 2006

Mobility

Graz University of Technology

why mobility
mix of transport technologies
3-liter car

catalyst
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and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006

Graz University of Technology

Thank you, for your attention!

Institute for Resource Efficient

and Sustainable Systems

The Concept of Cleaner Production

June 30, 2006