1. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 From Cleaner Production to Zero Emissions at „Integrative Approaches Towards Sustainability“ Jurmala, May 11-14, 2005, Latvia Mickael Planasch Institute for Resource Efficient and Sustainable Systems Graz University of Technology

2. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Summary  Why Zero Emissions?  What is Zero Emissions?  Description of our methods and instruments to achieve Zero Emissions  EMA –Environmental Management Accounting  ZEPRA – Mass Balancing Software  Data base for Experts  Pinch Analysis for Energy Optimisation  Case Studies

3. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Why Zero Emissions? We want to strengthen companies and help them on their way to a sustainable future

4. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Emissions = Input - Product INPUT PRODUCT fluidic EMISSIONS solid EMISSIONS gaseous EMISSIONS

5. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Why reducing Emissions? 2/3 of the costs in german car manufacturing companies are material costs! To reduce theses costs means strengthening the companies, making them fit for a sustainable future and is the way to Zero Emissions! …if you want to strengthen companies?

6. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Traditional Production Emissions are unused raw materials and they cause  Material costs  Operating costs  Personnel costs  Investment costs  Public Authority Proceedings

7. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Zero Emissions Production Zero Emissions instead means  No disposal costs  Less costs for Material, Auxiliary materials, Operating materials  Less investment costs for environmental protection plants  Easier Public Authority Proceedings

8. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Methods and Instruments 1. Step: EMA Workshop EMA = Environmental Management Accounting

9. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 EMA – Environmental Management Acounting EMA combines financial and physical data and calculates the environmental costs of companies  Physical data on material and energy input, material flows, products, waste and emissions  financial data on expenditures, costs, earnings, savings related to company activities with potential environmental aspects or impacts

10. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 What are Environmental Costs? Total corporate environmental costs = Costs of wasted capital and labour + Costs of wasted material + Environmental Protection Costs (Emission Treatment and Pollution Prevention)

11. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 EMA – water related

12. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 ZEPRA – Balancing Software 1.Applicable to different companies 2.Quick calculation of variants to the existing process 3.A visual pleasing output 4.Be able to get results without the exact knowledge of chemical reactions (rules of thumb, experimental data, experience) 5.Calculation of the composition of sludge to find possibilities for further use and for closing of water cycles or for removing valuable components 6.Easily adaptable to incorporate new knowledge

13. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Data base for experts  solutions for waste water treatment  decision support system  support for consultants  sustainable solutions (avoiding end of pipe decisions)

14. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Next step: Process Synthesis Meat-and-Bone Meal Utilization

15. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 EMA - energy related

16. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Solar Energy Efficiency – Pinch Analysis

17. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Energy Efficiency – Pinch Analysis Pinchtemperature: 292,5 K Minimal heat demand: 623,86 kW Minimal cooling demand: 95,28 kW

18. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Before optimisation After optimisation (calculated) Implemented: 35% reduction of water consumption with no costs In implementation: 17% reduction of water consumption with low costs Starting in Summer: 10% reduction of water consumption with low costs Case Study: Wire manufacturing company

19. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Case Study: Wire manufacturing Optimisation of HCl-ething bath in laboratory scale: Extension from 1 week up to 3 weeks Next step: Closing water cycles with in-house equipment and implementing an effluent free production! Testing different inhibitors

20. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Anodising Company Long term reduction of water consumption in an anodising company

21. Institute for Resource Efficient and Sustainable Systems Graz University of Technology From Cleaner Production to Zero Emissions May 12, 2005 Next Steps At this time: Zero Emissions project with 7 companies We want to proof, that it is  Technically and  Economically possible to run three branches on Zero Emissions! Branches are: Textile, Metal Treatment, Food