DMK5013

BASICS OF QUALITY MANAGEMENT

IN OIL AND FAT INDUSTRY
J A B ATA N T E K N O L O G I K I M I A D A N M A K A N A N
POLITEKNIK TUN SYED NASIR SYED ISMAIL
 TOPIC 5:
ENVIRONMENTAL
MANAGEMENT
SYSTEM
 LIST OF CONTENT

1) ENVIRONMENTAL MANAGEMENT SYSTEM (EMS).

2) CLEAN TECHNOLOGY AS AN APPROACH
TOWARDS SUSTAINABILITY.
3) LIFE CYCLE ASSESSMENT AS AN APPROACH
TOWARDS SUSTAINABILITY.

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 ENVIRONMENTAL
MANAGEMENT SYSTEM
(EMS)
 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

General definition:
An environmental management system brings together
the people, policies, plans, review mechanisms,
and procedures used to manage environmental issues
at a facility or in an organization.

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

ISO 14001:
The part of the overall management system that includes
• Organizational structure
• planning activities
• Responsibilities
• Practices
• Procedures
• Processes and resources for developing implementing achieving
• Reviewing the environmental policy

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

ISO 14001:

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

What does certify to the standard means?

▪ An organisation has established a systematic approach to protect the
environment, to prevent pollution (air, water, land, noise and nuisance), and
to improve their environmental performance.
▪ By complying with the standards helps relevant organisations to comply with
legal requirements set out by Environment Quality Act 1974 (Act 127) and the
relevant regulations.
▪ EMS also form the building block for Green Supply Chain Management
(GSCM) and by complying with EMS, organisation are complementing
GSCM.

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Standards used?
National Standards
▪ MS ISO 14001:2004 – Environmental Management Systems – Requirements
with guidance for use (FIRST REVISION)
(ISO 14001:2004, IDT)

International Standard
▪ ISO 14001:2015 – Environmental Management Systems - Requirements with
guidance for use

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Certification cycle?

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Benefit of certification
1) EMS will help you to comply with legal requirements as specified in
Environment Quality Act 1974 (Act 127) and the relevant regulations while
providing you with the benefit of fulfilling business and social responsibility
on environmental management.

2) EMS complement GSCM and complying to EMS boost the capability to

implement the relevant requirements in GSCM.
*Green Supply Chain Management

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Benefit of certification
3) With proper implementation of the systems, you will save more on :
• Product materials due to better product input processing,
substitution, and recycling of by-products and waste
• Energy consumption, costs for emissions, discharges, waste
handling, transport and disposal
• Relevant audits (Customer, supplier etc.)
• Environmental liabilities

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Benefit of certification
4) The systems promote continual improvement, which will provide your
business with the competitive edge to compete in the market place and for
those who have succeeded, to become more successful and resilient.

5) The systems also look into the needs of your human resource which will
also increase staff morale, competencies in environmental aspects and
commitment.

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Benefit of certification
6) Complying to standards provide you with the accolades for competitive
edge.

7) All of the above will increase profitability.

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Plan your EMS by:

▪ Identifying, document, implement environmental aspects. Establish
procedure on identifying environmental aspects.

▪ Identifying, document, implement legal and other requirements. Establish

procedure on identifying legal and other requirements.

▪ Establishing environmental objectives and targets and establish

programmes to achieve those targets and objectives.

228
 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Check your EMS by:

▪ Establishing procedures to monitor and measure the key operational
characteristics that could have a significant impact on the environment.

▪ Ensuring that environmental monitoring and measuring equipment are

calibrated and verified, maintained and records are retained.

▪ Establishing a procedure to periodically evaluate compliance with all

relevant legal environmental requirements.

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 ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

Check your EMS by:

▪ Establishing procedure on managing actual and potential non-
conformity and the corrective and preventive actions.

▪ Establishing record control procedure for the EMS.

▪ Establishing internal audit procedure, conduct internal audit and report

result to management.

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ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

231
CLEAN TECHNOLOGY AS
AN APPROACH TOWARDS
SUSTAINABILITY
 CLEAN TECHNOLOGY

The European Commission defined:

Clean technologies are new industrial processes or
modifications of existing ones intended to reduce the impact of
production activities on the environment, including reducing the
use of energy and raw materials.

233
 CLEAN TECHNOLOGY

Precisely formulated: 6. Disposal or recycling of

1. Conservation of raw materials.
unavoidable waste.
2. Optimization of production
7. Accident prevention.
processes.
8. Risk management to prevent
3. Rational use of raw materials.
major pollution.
4. Rational use of energy.
9. Restoring sites after cessation
5. Rational use of water. of activities.

234
 CLEAN TECHNOLOGY

Agence de l.Environnement et de la Maýtrise de l.Energie

(ADEME) define:

Clean technologies are techniques that enable

the recycling of water and waste, or which allow
pollutants to be viewed as secondary raw
materials.

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 CLEAN TECHNOLOGY

ADEME distinguish between three types of clean

technologies:
1) Optimization of the existing process, leading to an abatement in the
emission of pollutants, thanks to additional equipment and resources.
2) Process modification, corresponding to situations where the overall
process principle remains the same, and where one simply adds one or
several step(s) that enable the recovery or replacement of certain
resources.
3) Process change, this being the situation that is the most difficult in
investment and risk terms since it involves a modification of the nature of
the production process.

236
 CLEAN TECHNOLOGY
The Green Technology Master Plan (2017-2030)
▪ The GTMP creates a framework which facilitates the
mainstreaming of green technology into the planned
developments of Malaysia while encompassing the four pillars set
in the National Green Technology Policy (NGTP).

237
 CLEAN TECHNOLOGY
The Green Technology Master Plan (2017-2030)
▪ The embedding of green technology in sector below:
▪ Energy Sector
▪ Manufacturing Sector
▪ Transport Sector
▪ Building Sector
▪ Waste Sector
▪ Water Sector

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 CLEAN TECHNOLOGY
Energy Sector

239
 CLEAN TECHNOLOGY
Energy Sector

240
 CLEAN TECHNOLOGY
Manufacturing Sector

241
 CLEAN TECHNOLOGY
Transport Sector

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 CLEAN TECHNOLOGY
Transport Sector

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 CLEAN TECHNOLOGY
Building Sector

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 CLEAN TECHNOLOGY
Building Sector

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 CLEAN TECHNOLOGY
Waste Sector

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 CLEAN TECHNOLOGY
Waste Sector

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 CLEAN TECHNOLOGY
Water Sector

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 CLEAN TECHNOLOGY
Water Sector

249
CLEAN TECHNOLOGY

250
CLEAN TECHNOLOGY

251
CLEAN TECHNOLOGY

252
CLEAN TECHNOLOGY

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CLEAN TECHNOLOGY

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LIFE CYCLE ASSESSMENT
AS AN APPROACH
TOWARDS SUSTAINABILITY
Industries are faced with new consumer’s requirements:
• Increasing demand for environmentally friendly products
• “end-of-pipe” management approach is no longer acceptable
• More comprehensive means to reduce pollution should be
through prevention, by attacking the source of pollution at every
stage of the product “life-cycle” from raw material extraction to
transportation, manufacturing, product use, recycling and
disposal.

256
• LCA is an emerging environmental managing tool that
attempts to predict the overall environmental impacts of a
product, service or function.
• Although LCA is technical in nature, its applications have direct
implications on international trade such as competitiveness of
products and possible technical-barrier in terms of eco-label.

257
LCA is one of many environmental management tools that has been
used, directly and indirectly, in a variety of applications in both the
public and private sectors to influence the market by guiding
consumers toward products and processes with a reduced
environmental impact.

LCA is also known as Life Cycle Analysis or Ecobalance.

258
• Holistic approach for evaluating the environmental implications of
products and process.
• “cradle to grave” concept ⇨ giving opportunities to industries to
minimise adverse impacts.
• Overall look at use of materials & energy and environmental
impacts:
Through - raw material acquisition ⇨ manufacturing ⇨
transportation & distribution ⇨ product use & reuse-recycling
and disposal

259
• LCA is an objective process to evaluate the environmental
burdens associated with a product, process or activity by
identifying energy and materials used and wastes released
to the environment and to evaluate and implement
opportunities to affect environmental improvements.
(SETAC- Society for Environmental Toxicology and Chemistry, 1990)
Most important applications of LCA are for:
• Analysis of the contribution of the life cycle stages to the overall
environmental load, usually with the aim to prioritize
improvements on products or processes.
• Comparison between products for internal or external
communications.
From an ISO 14000 perspective:
LCA is a formal approach to define and evaluate the
overall environmental burdens associated with a product
or service by following material and energy flows
beginning from the source of raw material up to where it will
be disposed off i.e. the concept of from cradle to grave.
▪ LCA is now frequently used as decision support tool for
improving the environmental performance through reduction in
environmental burdens associated with a product or service.
▪ LCA also is the basis for environmental labeling programmes
(ecolabel), ISO 14001 and other standards.
Environmental performance is a measurable output
from an organisation’s environmental management system (EMS)
associated with control of environmental impacts due to the
organisation’s activities, products or services based on its
environmental objectives and targets.
▪ LCA is a form of environmental system analysis. EIA is another
form of environmental system analysis. However their scopes are
different.
▪ As illustrated in Figure 1, to produce a product or service, a
production system require input in the form of material and
energy. In addition to the beneficial output, at the same time it
also generates non-beneficial output in the form of emission to
water & air and solid waste.
 ENVIRONMENTAL BURDENS: EMISSION
INPUT: MATERIAL & ENERGY TO AIR AND WATER & SOLID WASTES

PRODUCTION
SYSTEM

OUTPUT: PRODUCTS &

SERVICES

Figure 1 : Environmental system analysis

▪ EIA is “site-specific” i.e. of specific location. Its environmental
border is limited – around its production system or premise. This
can be illustrated as in Figure 2.
▪ This type of environmental system analysis does not indicate the
overall environmental burdens.
 Materials

Energy Emissions
Process

Wastes

Products

Figure 2 : Environmental Impact Assessment (EIA)

▪ Environmental LCA will try to take into account all environmental
impacts, upstream and downstream as well as the direct impact
of the production.
▪ Therefore for LCA, its system boundary will include the whole life
cycle of the material and energy flows used to produce benefits
or products.
▪ Thus the form of production system can be illustrated as in
Figure 3, which must all include the impacts of transportation.
 Raw materials

Energy Emission
Extraction &
Processing Waste
Material
Energy Emissions
Process
Waste

Energy Product
Emission
Use
Material Waste
waste
Energy
Reuse & Recycling

Emission Residue + Transportation

Figure 3: LCA
 Output
Input Raw Materials Acquisition
Water
Effluents
Manufacturing, Processing, and
Formulation Airborne
Raw Emissions
Materials Distribution and Transportation
Solid
Wastes
Use/Reuse/Maintenance
Other
Energy Environment
Recycle al releases

Usable
Waste Management Products

System boundary
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LCA Procedures – consists of FOUR phases:
I. Initiation phase – defining objectives & scopes
II. Inventory analysis – involve measurements of material and
energy used and emission produced during the whole life cycle
include during:
i. Extraction & processing of raw materials
ii. Manufacturing benefits or products
iii. Transportation
iv. Distribution
v. Use / reuse & maintenance
vi. Recycling
vii. Final disposal
III. Impact Assessment – information from phase II is used to assess the real and
expected impact to man and environmental health associated with the use of
resources (material & energy) and the related emission.
IV. Improvement evaluation or interpretation –
Information from phase III is used to implement systematically opportunities for
environmental improvements.
The objective is to identify a particular phase/phases in the system which can be
improved in order to reduce the overall environmental burden of the system or
product.
 Life cycle assessment framework

Goal and scope Direct applications:

definition
- Product
development and
improvement
Inventory Interpretation - Strategic planning
analysis - Public policy
making
- marketing
- others
Impact
assessment

ISO 14040 Life Cycle Assessment Framework

276
An example where clean technology
approach can be used:
Cleaning process/washing
Objective: To separate dirt from clothes.
The dirt = solids, oil, grease, fat etc. This is shown
in Figure 4.
 Clothes + dirt (dirty clothes)

Cleaning Process

Clean clothes Dirt

Figure 4 : Basic operation of washing

(clothes cleaning)
▪ However, the actual process performed during the cleaning process
can be illustrated by Figure 5 where dirt is dispersed in water with
the help of detergent and water (hot/cold).
▪ In this traditional cleaning process, energy and detergent are used
only once. The detergent + water are eventually discharged or
disposed off as waste.
 Clothes + Dirt
Water Detergent

Cleaning Process

Clean clothes Dirt + Water +

Detergent

Figure 5 : Traditional approach for clothes cleaning

▪ This means that a clean technology approach towards
cleaning of clothes must be focused on the function of
the dirt separation/removal from the clothes and not on
the development of a cleaner detergent.
▪ Because at the end of the cleaning process, the
detergent is just thrown away into the environment as
waste.
One approach is the use of Dry Cleaning process as
illustrated in Figure 6.
 Clothes + dirt Additional
solvent

Cleaning process Solvent

Solvent lost or
release to the
Clean clothes environment
Dirt

Figure 7 : A dry cleaning process

▪ In the Dry Cleaning process, the only environmental
burden is associated with the lost of solvent to the
environment.
▪ If this is prevented and the solvent is reused, the dry
cleaning process will be a clean process.
▪ Based on the same principle, the wet cleaning process
can be made into a cleaner process as illustrated in
Figure 8.
▪ Here the dirt is removed from waste water by means of
a filtration or membrane system, while water and
detergent are recycled back into the system. The dirt
will then be concentrated for removal/disposal later on.
Clothes + dirt Extra detergent +
water

Cleaning process Water + detergent

Clean clothes
Dirt (+ residual
detergent)

Figure 8 : Cleaner technology for cleaning clothes

An example on the use of LCA to
evaluate
the global warming potential of
two types of electricity
generation
 Example: Coal Fired Power Plant
(Greenhouse Gases only, per kWh)
Global Warming
Potential
Coal Mining Fugitive CH4 (4g) CO2(43g), N2O(1g)
from diesel equipment CO2(11g) from
Processing 448

CO2(2g) from diesel fuel 2

Transport by Barge

Burning in Power Plant CO2(300g) 300

Transport of Ash to Landfill CO2(0.02g) from diesel fuel 0.02

750.02 287
 Combined Cycle Gas Fired Power Plant
(Greenhouse Gases only)
Global Warming
Potential CO2
equiv.g
Fugitive CH4 (1g) CO2(2.5g) from
Gas Extraction diesel equipment CO2(2.5g) from 26
Processing

Fugitive CH4 (2g) CO2(1.5g) from

Transport by Pipeline diesel fuel 43.5

Burning in Power Plant CO2(95g) N2O(0.5g) 250

319.5
288
Another example on the use of
LCA to evaluate a product
Aluminum can
• Americans use 102.2 BILLION
aluminum cans/ year (368 per
capita/year)
• We throw away 49.6% of these
cans (50.7 billion!)
• Biggest environmental impact of
this disposal is “upstream” from
the consumer
• Had these cans been recycled
enough energy would have been
saved to supply gasoline to over 1
million cars for an entire year
Aluminum Can Production:
Step 1 – Bauxite Mining
• Most bauxite “ore” from open pit
or strip mines in Australia,
Jamaica and Brazil (99% of US
needs is imported)
• Bauxite mining results in land
clearance, acid mine drainage,
pollution of streams and erosion
• 5 tons of mine “tailings” (waste)
produced per ton of bauxite ore
removed
• Significant fossil fuel energy
consumed in mining and
transporting bauxite ore
 Land
Degradation
from mining
Aluminum Can Production:
Step 2 – Alumina Refining
• Bauxite ore is mixed with caustic
soda, lime and steam to produce
a sodium aluminate slurry
• “Alumina” is extracted from this
slurry, purified and shipped to
smelters
• Leftover “slag” waste contains a
variety of toxic minerals and
chemical compounds
• Alumina refining process is also
fossil fuel energy intensive
 Refined
alumina

Alumina Refining
Facilities
Aluminum Can Production:
Step 3 – Smelting
• Powdered alumina is heated
(smelted) in order to form aluminum
alloy ingots
• Aluminum smelting uses massive
amounts of electricity (usually from
coal)
• One ton of aluminum production
requires energy equivalent of 5
barrels of oil (210 gallons of gasoline)
• Aluminum smelting also produces 7.4
tons of air pollutants (particulate
matter, sulfur oxides, VOCs) for every
1 ton of aluminum produced
 Aluminum Ingots

Aluminum Smelter
Aluminum Can Production:
Step 4 – Tertiary Processing

• Aluminum ingots are

melted (requiring
more energy) and are
extruded as sheets
• Finishing process for
rolled sheets involves
several chemicals
(strong acids and
bases) that are toxic
Aluminum Can Production:
Step 5 – Finishing/Assembly
• Aluminum sheet is fed into extrusion
tubes and cut into shallow cups
• Cups are fed into ironing press where
successive rings redraw and iron the
cup. This reduces sidewall thickness,
making a full length can
• The bottom is “domed” for strength
• Cans are necked in at the top and
flanged to accept the end
• Little chemical pollution at this stage,
just electricity use
Aluminum Can Production:
Step 6 – Filling/Distribution
• Cans are shipped without end
portion to beverage company
• Beverage is injected under pressure
– outward force strengthens the can
• After filling, can is labeled and
packaged
• Cardboard and plastic is used, some
toxic waste from making paint and
ink used for labels
• Finally, product in the can is trucked
(diesel fuel use) to a
wholesaler/distributor and then to
retailer (multiple trips)
 Life Cycle Analysis of an Aluminum Can

• Mining/Extraction of Bauxite – Ship to processing plants

• Primary Processing – Convert bauxite to alumina
• Secondary Processing – Convert alumina to aluminum ingots (smelting)
• Tertiary Processing – Convert aluminum ingots into aluminum sheets
• Finishing/Assembly – Convert aluminum sheets into aluminum cans
• Filling/Distribution – Fill cans with beverage, transport to distributor/final
consumers
• ALL OF THESE STAGES use significant amounts of fossil fuel energy.
MOST OF THESE STAGES generate large quantities of hazardous and
toxic waste products