WASTE MINIMISATION

&
RESOURCE CONSERVATION
Bijadhar Pandey
Certified Energy Auditor (CEA)
Bureau of Energy Efficiency
Govt. of India, Delhi
 INTRODUCTION

Traditionally

Waste is viewed as an unnecessary element

arising from different activities of an Industry.
 INTRODUCTION

In Reality
• Waste is a misplaced resource, existing at a wrong place at a
wrong time.
• Waste is also the inefficient use of utilities such as electricity,
water, Air & Fuel , which are often considered unavoidable
overheads.
• If it is measured , it can be controlled.
 COST OF WASTE
The cost of these wastes are generally underestimated by all
of us , it is not only the cost of waste disposal but also other
cost such as :
– Disposal Cost
– Inefficient energy use cost
– Purchase Cost
– Production cost
– Management time spent on waste management.
– Lost revenue for what could have been a product instead of
waste.
– Potential liabilities due to waste.
 WASTE MINIMIZATION
• Systematically reducing waste at the source.

• Efficient use of raw materials and packaging.

• Efficient use of fuel, electricity , air & water.

• Improving the quality of waste generated to facilitate recycling

and/or reduce hazards

• Encouraging REUSE , RECYCLING and RECOVERY .

• Waste minimization is also known as pollution prevention, source

reduction and cleaner technology.
 WASTES & POSSIBLE RESOURCES
WASTES
• Fly ash from power plant
• Bagasse wastes from sugar
manufacturing
• Co2 release from ammonia
plant
• Lime sludge of caustisizing
plant.
• Wood dust of Chippers.
RESOURCES
• Raw materials for cement or
bricks manufacturing.
• Fuel for boiler operation
• Raw Materials for Urea
manufacturing.
• Raw materials for lime kiln
plant.
• Fuel for boiler operation.
WASTE MANAGEMENT TECHNIQUES

• Waste Reduction at the Source

• REUSE , RECYCLE & RECOVERY

• Waste Reduction by Product Modification.

 WASTE REDUCTION AT SOURCE
Good Housekeeping

• Systems to prevent leakages & spillages through preventive

maintenance schedule and routine equipment
inspections/checking.

• Well written working instructions, supervision, awareness and

regular training to workforces.
 PROCESS CHANGE
• Input material change : Substitution of input materials by eco-
friendly material preferably having longer service life.
• Better Process Control: Modification of working procedures,
machine operating instructions and process record keeping in
order to run the process at higher efficiency and lower waste
generation.
• Equipment modification: Modification of existing production
equipment by the addition of measuring and controlling devices,
in order to run the process at higher efficiency and lower waste
and emission generation.
• Technology Change : Replacement of the technology, processing
sequence in order to minimize waste and emission generation
during production.
 RECYCLING

• On site Recovery and Reuse : Reuse of wasted materials in

the same process or for another useful application within
the industry.

• Production of useful by-product : Modification of waste

generation process in order to transform the wasted
materials into a material that can be reused or recycled for
another application within or outside the company.
 PRODUCT MODIFICATION

• Characteristics of the product can be modified to minimize

the environmental impacts of its production or those of the
product itself during or after its use ( disposal).
WASTE MANAGEMENT METHOLOGY
Step-01 : Getting started

• Form a waste minimization team.

• List process steps/ unit operation.

• Identify and select wasteful process steps.

 WASTE MANAGEMENT METHOLOGY
Step-02 : Analyzing process steps.

• Prepare process flow chart.

• Make materials and Energy balance.
• Assign costs to waste stream.
– Cost of Raw Materials
– Manufacturing cost.
– Cost of product in waste.
– Cost of waste disposal
– Cost of waste transportation.
– Cost of maintaining required work environment
– Cost due to waste cess.
 WASTE MANAGEMENT METHOLOGY
Step3: Review of process

• Through the materials and Energy balances, it is possible to

carry out a root cause analysis to locate and pin point the
causes of waste generation.
 TYPICAL CAUSES OF WASTE
• Poor house keeping.

• Operational & maintenance negligence.

• Poor raw materials quality

• Poor process/ equipment design

• Poor Layout

• Bad technology

• Inadequately trained personnel

• Employees de-motivation.
 GENERATING WASTE
MINIMIZATION OPPORTINITIES
Develop waste Minimization Opportunities.

• Equipment suppliers

• Consultants.

• Consultancy Organizations

• Trade associations.

• Other person from the same or similar plant else where.

 GENERATING WASTE
MINIMIZATION OPPORTINITIES
Select workable opportunities:

• The waste minimization opportunities developed should be

screened and those , which are impractical should be
discarded.

• Unnecessary effort in doing detailed feasibility analysis of

opportunities, which are impractical , should be avoided.
 SELECTING WASTE
MINIMIZATION SOLUTIONS
Assess technical feasibility as follows.
• Availability of Equipments.
• Availability of operating skills
• Effect on production.
• Effect on production quality
• Safety aspects
• Maintenance requirement.
• Effects on operational flexibility.
• Shut down requirement for implementation.-
– Assess Economic viability
– Evaluate environmental aspects.
– Select solutions for implementation.
 IMPLEMENTING WASTE
MINIMIZATION SOLUTIONS

• Prepare for Implementation.

• Implementation Solutions.

• Monitor and Evaluate Results.

 SUSTAIN WASTE MINIMIZATION

• Monitor and review the implemented measures among

Employees.

• Communicate the benefits achieved to all the employee.

• Reward for deserving ones.

• Waste Minimization should become an integral part of the

organizations.
 TARGET

So aim for ZERO waste to maximize profits