Manufacturing for Sustainability, Environmental Protection, and Approaches to Waste/ Environmental Management

Dr. Akepati S. Reddy School of Energy and Environment Thapar University, Patiala 147 004

Contents
Industrial systems and sustainability End of pipe approach to EMS approach
End of the pipe approach to waste management,
multimedia approach

Waste minimization through source reduction & waste recycling and reuse
integrated approach to waste management USEPAs hierarchical waste management strategies

Pollution prevention programs EMS approach

Basic concepts of EMS approach Essential elements of an EMS

Legal requirements and environmental functions of organizations. ISO 14001, ISO 14000 series of standards, and their relevance to EMS and to the environmental performance improvement.

Industrial Systems
One of the three vital conversion systems designed, created and managed by human beings Heavily depend on technological and human resources Powered by conventional primary energy sources (fossil fuels) and electrical energy
Solar radiation is usually undesirable and considered as nuisance

Linear systems transforming input materials into finished goods (and services) and wastes
Wastes represent lost production and inefficient use of resources/input materials

Natural resources Other natural resources Solar radiation

Technological and human resources

Natural ecosystems

Harvested renewable natural resources Solar radiation and conventional energy

Agricultural systems
Wastes and residues Secondary resources - Agricultural produce

Wastes

Harvested renewable natural resources

Technological and human resources Other natural resources

Industrial systems
Industrial products
Wastes

Conventional energy

Other natural resources

Technological and human resources

Human settlements
Technological and human resources Wastes

The vital conversion systems of mankind

Interactions of industrial systems with the environment

Interacts with environment through
taking in raw materials, energy, water and chemicals (including toxic/hazardous inputs and ecologically important inputs) inputs are becoming scarce natural resource base is depleting discharging wastes (solid, liquid and gaseous wastes, GHGs, hazardous wastes, radiation and heat, noise and vibrations, etc.)

Industrial products consume valuable resources and generate wastes during use Used industrial products, after service life, are disposed off as wastes

Industrial systems and environment

Both resource consumption and wastes disposal are polluting the environment
Polluting the physical environment (land, water and air) Changing climate, stratospheric ozone layer depletion, and biodiversity loss Depleted and polluted natural resource base Shrinking and unhealthy natural ecosystems and agricultural systems Adversely affecting the finite self-cleansing and resource regenerating capacities of the environment

Polluted environment deteriorates the natural resource base of the environment

Sustainability
Meeting needs of the present without compromising on the legitimate needs of the future generations (Our Common Future Earth Summit, 1992, Rio)
Equality across the world and among the generations!

Polluted environment and depleted natural resource base are making the world unsustainable Meeting the needs (specially biological needs) of majority human populations is threatened Physical environment is becoming less habitable Human settlements are more challenged by more frequent and high intensity natural disasters/calamities Symbiotic coexistence of human settlements with the vital conversion systems (industry units!) has become less feasible

Sustainable development
Imbibing sustainability concept in all human activities needed
Extraction, storage, transportation, production/manufacturing (by industrial and agricultural systems), use and disposal

Impose limits to renewable resources use Use resources (specially non-renewables) conservatively (proper allocation) and efficiently Find substitutes and compliments to the scarce natural resources Maximize use of flow resources (convert into fund resources!) Use recycled materials in place of virgin resources

Sustainable development
Increase dependence on human and technological resources Maximize human resource use, optimize individual workers productivity, and make human work meaningful/interesting Complement (rather than replace) human work with technology
technology should support extensive use of human resources

Use technology to find new resources and expand the resource base, and to enhance the resource utility value

Manufacturing for sustainability

Key areas of concern in sustainable manufacturing
GHG emissions Material consumption (water, non-renewables, toxic chemicals and ecologically important materials) Wastes (including hazardous wastes)

Ozone layer, air quality, and health are also important Sustainable manufacturing (in the narrow sense) thus should include the technologies that transform materials without
GHG emissions Using non-renewable or toxic materials Generating wastes

Options for sustainable manufacturing

Use less material (raw materials, water and chemicals) and energy Substitute input materials
Non-toxic for toxic, renewable for non-renewable, and recycled inputs for virgin resources Substituting ecologically important inputs

Reduce unwanted outputs (avoid or reduce wastes, and encourage cleaner production and industrial symbiosis) Convert outputs to inputs (recycle and reuse wastes, and recover from wastes) Changed structures of ownership and production
Product service systems Deliver function rather than product to customer

What to manufacture?
Manufacture the products having the least life cycle environmental costs
ISO 14040 series of standards provide a systematic and standardized approach for Life Cycle Analysis/assessment

Design for Environment can be used to design products with least environmental costs Design for Dismantling can be employed in the design of products
Reversible manufacturing and modular design of products Dismantling the used products for recovering reusable and recyclable components and updating products through replacing modules become feasible

What to manufacture?
Sustainable manufacturing is possible when consumer demands eco-friendly and least environmental cost products Consumer should be environmentally conscious and environmental information on products should be made available to consumer to facilitate right decisions Eco-labeling, energy star rating etc., provide environmental information on products ISO 14020 series of standards provide a systematic and standardized approach for eco-labeling

How to produce and using what inputs?

Product design influences the manufacturing process used Manufacturing process employed influences
Input materials needed Material and energy intensities of products

For sustainability manufacturing process should

Use non-hazardous, non-toxic and environmentally acceptable inputs, and recycled materials Minimize/eliminate use of scarce non-renewable resources and ecologically important and environmentally damaging resources

Quality of input materials is also important for sustainability (minimizes reworks and waste generation) Green chemistry can provide sustainable manufacturing processes (cleaner production technologies, CDM, etc., !)

Principles of Green Chemistry

1. It is better to prevent waste than to treat or clean up waste after it is formed. 2. Synthetic methods should be designed to maximize the incorporation of all materials used in the process into the final product. 3. Wherever practicable, synthetic methodologies should be designed to use and generate substances that possess little or no toxicity to human health and the environment. 4. Chemical products should be designed to preserve efficacy of function while reducing toxicity 5. The use of auxiliary substances (e.g. solvents, separation agents, etc.) should be made unnecessary whenever possible and, innocuous when used. 6. Energy requirements should recognized for their environmental and economic impacts and should be minimized. Synthetic methods should be conducted at ambient temperature and pressure.

Principles of Green Chemistry

7. A raw material feedstock should be renewable rather than depleting whenever technically and economically practical. 8. Unnecessary derivatization (blocking group, protection/deprotection, temporary modification of physical/chemical processes) should be avoided whenever possible. 9. Catalytic reagents (as selective as possible) are superior to stoichiometric reagents. 10. Chemical products should be designed so that at the end of their function they do not persist in the environment and break down into innocuous degradation products. 11. Analytical methodologies need to be further developed to allow for real-time in-process monitoring and control prior to the formation of hazardous substances. 12. Substances and the form of a substance used in a chemical process should chosen so as to minimize the potential for chemical accidents, including releases, explosions, and fires.

How to produce and using what inputs?

Sustainable manufacturing process should ensure source reduction of wastes
Right technology, infrastructure, machinery, equipment and instruments System approach and process approach Documented procedures and management practices Total involvement of all the concerned personnel

Reduced waste generation can mean

Efficient use of input materials and resources Enhanced productivity Reduced embodied material and energy content of products

How to produce and using what inputs?

Process improvement and sustainable manufacturing can be achieved by Breakthrough approach (Technology management and R&D bring about breakthroughs) Kaizen approach for continual improvement (modern management systems using PDCA cycle can achieve this)
EnMS (ISO 50001 or BS 16001), EMS (14001), OHSMS (OSHAS 18001), QMS (ISO 9001), etc. can achieve

Lean manufacturing can support sustainable manufacturing

Can improve the process and the product quality Can minimize waste generation and reduce impacts on the environment and human health Can affect the bottom line

Housekeeping and implementation of 5S also helps

Sorting, straightening, systematic cleaning, standardizing and sustaining (safety and security are additionally added)

Lean manufacturing
Involves identification and steady elimination of 7 (+2) types of wastes
Transport (moving products that is not actually required to perform the processing) Inventory (all components, work in process and finished product not being processed) Motion (people or equipment moving or walking more than required to perform the processing) Waiting (waiting for the next production step) Overproduction (production ahead of demand) Over processing (resulting from poor tool or product design creating activity) Defects (the effort involved in inspecting for and fixing defects) Manufacturing goods or services that do not meet customer demand or specifications Waste of unused human talent

Housekeeping and 5S
Sorting: Eliminate all unnecessary tools, parts, and instructions, prioritize things as per requirements and keep them in approachable places. Straightening: There should be a place for everything (clearly labeled or demarcated) and everything should be in its place. Items should be kept close to place of use, and arrange items to promotes efficient work flow. Systematic cleaning: Keep the workplace tidy and organized, clean work area, and be sure everything is restored to its place after use. Standardizing: Work practices should be consistent and standardized. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's. Sustaining: Once the previous 4 S's have been established, they should become the new way to operate. Safety*: It is sometimes added. However, it is reasonable to assume that a properly planned and executed 5S program will improve workplace safety. Security*: It is also sometimes added. Consider security as an investment rather than an expense. It identifies and addresses risks to key businesses.

End-of-pipe Approach and Limitations

Industry traditionally collected, treated and disposed wastes
to meet the prescribed emission/discharge standards to reduce the polluting potential of the wastes to make wastes compatible for disposal into environment End-of-pipe and out-of-backdoor management approaches for managing the wastes and controlling environmental pollution.

A sectarian or narrow approach was followed for the handling and management of liquid, gaseous, solid and hazardous wastes each was considered as a discrete/distinct problem
Frequently led to removal of pollutants from one medium and placing them in some other medium Treatment generated secondary wastes - treatment of gaseous emissions resulted in liquid waste problem

Involved wasteful spending of resources (capital, materials, energy, labour and time) with limited success in the environmental protection goal.

End-of-pipe Approach and Limitations

Decisions on the input materials, process selection and product design rarely take into account the concerns associated with the waste management
Wastes will continue to suffer from lack of feasible technologies Certain types of wastes (hazardous wastes!) will continue to have no feasible treatment technologies Stringent legal requirements and increasing awareness and concern of the public may transform this limitation into a serious one

Collection, treatment and disposal of wastes require labour hours, energy, materials and capital expenditure most often, with no returns on the investments and expenditure made

End-of-pipe Approach and Limitations

Expenditure or investment on waste management, and waste management are most often considered as the necessary evils (licence to do business!) Industry focuses more on, by hook or crook, compliance with the legal requirements rather than on environmental protection through proper waste management The regulator, for ensuring environmental protection, makes the legal environmental requirements increasingly stringent, of course without much success Regulator usually finds implementation of the requirements and monitoring of compliance almost impracticable and impossible

Waste Reduction Approach and Merits

In waste reduction approach, preference is to waste minimization or elimination, and to waste recycling and reuse Waste minimisation/elimination is achieved through
raw material substitution product formulation or substitution process modification equipment modernisation and maintenance good house keeping, etc., practices

Use of the end-of-pipe approach is limited only to the management unavoidable wastes
Within the end-of-pipe, emphasis is on a multi-media strategy

Waste reduction is much more than technology

requires use of innovative management practices and involves significant employee involvement.

Waste Reduction Approach and Merits

Waste reduction approach leads to efficient use of raw materials and energy and to reduced waste generation
This in turn results in cost saving (conserved raw materials and energy, avoided treatment costs and reduced regulatory and compliance costs) results in lower product cost to the consumer and enhances the industrys performance, productivity and marketability.

Waste reduction approach may prove an appropriate means to improve environmental quality beyond what can be achieved through the end-of-pipe approach
can offer better solutions to many of the presently encountered and future anticipated environmental pollution problems.

Waste Reduction Approach and Merits

Waste reduction approach makes far more economic sense (avoid generation of wastes than develop extensive treatment schemes) Waste reduction approach has many intangible benefits
can improve relations with the regulator, local communities and with own employees.

Waste reduction approach is a proactive approach

leads to the adoption of environment friendly processes and technologies

Waste reduction approach may prove an essential and key element of sustainable industrial development

Integrated approach to waste management

Appropriate for resource efficiency and waste avoidance/ reduction
Reduce, reuse and recycle, recover, treat and disposal steps are used in the same order of priority
Pretreatment of waste may be needed to increase the waste recycling and reuse potential; to recover residual materials, byproducts and resources; and to make the waste compatible for mixing with other wastes for further treatment and disposal Waste treatment can have increasing the waste recycling and reuse potential; and/or recovering residual materials, byproducts and resources as secondary objectives

Reduces manufacturing costs Makes cost-effective and consistent compliance with legal environmental requirements Makes zero waste production and zero effluent discharge both feasible and possible

energy raw material Industrial process product

Recycling & reuse

Wastes for Recycling & reuse secondary wastes byproducts & resources recovered

energy raw material wastes from other processes Pre-treated wastes From other units energy

Waste pretreatment

treated wastes for recycling & reuse

raw material
treated wastes for recycling & reuse

Waste treatment

secondary wastes byproducts & resources recovered

treated wastes for disposal

Integrated approach for waste management

Waste Management Hierarchy

Corner stone for most waste minimization strategies Aims to extract maximum practical benefits from products, while benefiting the environment through generating minimum of waste and orienting the manufacturing process towards sustainability Classifies various options available under the waste reduction approach and under the end-of-pipe approach into four hierarchical categories:
Source reduction (1) Recovery, recycling and reuse (2) End-of-pipe treatment (3) Final disposal (4)

Waste Hierarchy

Waste Management Hierarchy

Source reduction Raw material substitution/improving purity of raw materials Process changes or modifications
using efficient and modern/ new machinery and equipment improving maintenance of the equipment and machinery improving house keeping and other management practices practising recycling within the process

Altering the product formulation and/or product substitution Recycling and reuse Segregation and concentration of waste streams On-site and off-site use of wastes (after removing undesired contaminants!) as raw material or as fuel supplement Recovering energy and material resources from wastes

Waste Management Hierarchy

End-of-pipe treatment
Segregation and treating separately of waste streams which are incompatible for treating together Separation of polluting contaminants from the waste streams by physico-chemical and biological methods Concentrating and reducing volume of the wastes and the separated contaminants or treatment sludges Thermal, chemical and biological destruction of wastes Transformation of polluting or hazardous contaminants of waste streams into non-polluting or non-hazardous forms. Transformation and recovery of energy/material resources from wastes by physico-chemical & biological treatment

Waste Management Hierarchy

Disposal
Temporary storage for natural detoxification and stabilisation and for reuse or recovery at a later stage Sanitary landfill disposal Incineration! Land application for irrigation or soil conditioning Land disposal for filling low lying areas Disposal into surface waters Injecting into ground water or under ground mines Disposal into public sewers Disposal into marine coastal waters

Waste Management Hierarchy

Sticking to the hierarchy (for complying with legal requirements) can result in a balanced use of both waste reduction and end-of-pipe approaches
also means following an integrated and multi-media approach for waste management

Cost is a criterion used for selecting the waste management options

In certain instances, because of invisible and/or intangible benefits, cost is considered second to the hierarchy Options under each of the categories are exploited up-till that point beyond which it will prove costly (when compared to the cost of exploiting the options of next category)

For managing a specific waste stream, exploitation of a combination of options, that too from different categories may also be practised.

 PP approach emphasises implementation of waste hierarchy PP approach involves development, implementation and maintenance of facility level PP programs PP programs are dynamic and work for continuous improvement Implementation and maintenance of PP programs include:
Pre-assessment of industrial facilities for identifying and prioritizing the potential pollution prevention opportunities Detailed assessment of the prioritized list of individual PP opportunities for identifying potential options, their feasibility analysis.and selection of options for implementation Planning and implementation of selected options Measurement and assessment of the PP program success and review of the PP program

Pollution Prevention Approach

Implementation and maintenance of a PP program should be preceded by an additional program (establishment and maintenance of procedures for controlling the operations and activities with significant environmental aspects)

End-of-the pipe approach PP approach EMS approach

Environment protection and sustainability mainly requires industry
To be conservative and efficient in the use of raw materials and energy To generate the minimum possible wastes To reduce polluting potential of the wastes generated and make them compatible for the environmentally safe disposal

Industry is evolving from the traditional end-of-the-pipe approach to the environmental management system (EMS) approach (through pollution prevention approach!)
Identify significant environmental aspects and manage Achieve continual environmental performance improvement and orient manufacturing units towards sustainability Frame environmental policy, set objectives/targets consistent to policy and implement policy through achieving objectives

EMS Approach
Environmental functions of industrial facilities are not limited just to waste management and compliance with prescribed standards - have many other environmental functions
Obtaining environmental clearances, consents, authorisations, etc. facility should make necessary applications and follow them up Handling regulators visits, specially for
collecting environmental samples inspecting the premises, facilities, materials, documents and records

Creation and maintenance of documents and (mandatory!) records pertaining to environmental functions and performance Providing information to the regulator, on the facilitys environmental management and environmental performance Communicating with employees, local communities, local authorities and other stakeholders relating to the facilitys environmental information on its operations and activities Taking-up environmental improvement and pollution mitigation programs in the impacted region

EMS Approach
EMS Approach is supposed to help industrial facility in performing all its environmental functions in a systematic, structured and cost-effective manner Implementation and maintenance of an EMS can mean the following to the industry:
exploring environmental concerns of every aspect of the industrial operations co-ordination and organisation of the disparate elements of industrial facilitys environmental responsibilities continuous improvement and pollution prevention simple and organised environmental documentation, reporting, etc., functions. Integration of environmental issues into businesses

EMS Approach
ISO-14000 standards (ISO-14001) provide essential elements of an effective third party certifiable EMS EMS (specified by ISO 14001: 2004) is based on the dynamic PDCA (plan, DO/implement, check & Act/Review) cycle EMS includes 17 elements
The EMS elements are not independent entities, instead they are interdependent and interacting The EMS elements are grouped under the plan, implement, check and review processes of the system

The EMS developed, implemented and maintained should be functional and should work towards the following objectives:
To comply with applicable legal and other requirements To minimise the cost of compliance with the requirements, and the cost of performing the environmental functions To meet expectations of the stakeholders (interested parties) To ensure continual improvement and prevention of pollution To work towards sustainability

Key elements of an EMS

1. Environmental policy Develop a statement of your organizations commitment to the environment. Use this policy as a framework for planning and action. 2. Environmental aspects Identify environmental attributes of your products, activities and services. Determine those that could have significant impacts on the environment.

3. Legal and other requirements Identify and ensure access to relevant laws and regulations, as well as other requirements to which your organization adheres.
4. Objectives and targets Establish environmental goals for your organization, in line with your policy, environmental impacts, the views of interested parties and other factors. 5. Environmental management program Plan actions necessary to achieve your objectives and targets.

6. Structure and responsibility Establish roles and responsibilities for environmental management and provide appropriate resources.

Key elements of an EMS

7. Training, awareness and competence Ensure that your employees are trained and capable of carrying out their environmental responsibilities. 8. Communication Establish processes for internal and external communications on environmental management issues. 9. EMS documentation Maintain information on your EMS and related documents. 10. Document control Ensure effective management of procedures and other system documents. 11. Operational control Identify, plan and manage your operations and activities in line with your policy, objectives and targets. 12. Emergency preparedness and response Identify potential emergencies and develop procedures for preventing and responding to them.

Key elements of an EMS

13. Monitoring and measurement Monitor key activities and track performance. Conduct periodic assessments of compliance with legal requirements. 14. Non-conformance and corrective and preventive action Identify and correct problems and prevent their recurrence. 15. Records Maintain and manage records of EMS performance.

16. EMS audit Periodically verify that your EMS is operating as intended.
17. Management review Periodically review your EMS with an eye to continual improvement.

EMS model

EMS Approach
EMS involves
industrial facility formulating its own environmental policy and setting objectives and targets Meeting the objectives and targets and complying with the environmental policy planning and implementing a multitude of programs and procedures for meeting the targets and objectives
Each of the programs have their own objectives and targets

Proper planning, implementing and reviewing the EMS and the programs should be supported by
organisational structure documents and records, and their control system communication system training program

EMS Approach
Following standards are relevant and of immense help in the development, implementation and maintenance of EMS
ISO-14004: 2004 Environmental management systems- general guidelines on principles, systems and support techniques ISO-19011: 2011 guidelines for auditing management systems ISO-14031: 1999, Environmental management Environmental performance evaluation Guidelines and ISO/TR 14032, Environmental management Examples of environmental performance evaluation (EPE) ISO/TR 10013, Guidelines for quality management system documentation

Following sets of standards may also be relevant for the EMS

ISO 14020 series, Environmental labels and declarations (ISO 14020, ISO 14021, ISO 14024 and ISO/TR 14025) ISO 14040 series, Environmental management Life cycle assessment (ISO 14040, ISO 14041, ISO 14042, ISO 14043, ISO/TR 14047, ISO/TS 14048 and ISO/TR 14049) ISO/TR 14062, Environmental management Integrating environmental aspects into product design and development