Download Case sample of a CT option

Case sample of a CT option
Control of sulfuric acid use in
concentrated latex industry
Working conditions found during audit
In latex sedimentation, workers add sulfuric acid to the
latex to promote coagulation. They do this by depending
on long experience - without measuring. Then they use
a stick to stir and mix the acid with latex, and later
scoop the coagula floating on the surface. The water
remaining is drained into the rubber trap.
Suggested CT option
Ensure appropriate consumption of acid used in
coagulation, by plotting titration curve of skimmed latex at
various amount of ammonia, and add only required
amount of acid each time.
Technical feasibility study
It is an operational control measure in use.
The factory is capable of implementing.
There are no other technical limitations.
Economic feasibility study
Investment cost
7,000 baht
(handheld pH meter and cost for plotting skim latex titration)
Service cost
baht
50
(sampling skimmed latex for ammonia check)
Savings
360
baht
(Acid costs saved per sedimentation)
Investment payback after sedimentation 23
(calculated from 7,000/(360-50) times)
times
Implementation steps
Activity
1. Prepare details and obtain approval
2. Approve assignment
3. Plot titration of skimmed latex at
various ammonia concentrations
4. Obtain a handheld pH meter
5. Train employees on proper work
procedure
6. Proceed and collect data for
comparison
March 00
April 00
__
Responsible party
CT team
__
Management
_
_ _
__
Quality Control
Dept.
Maintenance
Dept.
CT team
____ Workers and CT
team
Case sample of a CT option
Proper use of a water softener
Working conditions found during assessment
Resin is rinsed off the water softener by using 100 kg. of
salt in each regenerating cycle.
Regeneration takes 15 minutes
The softener is used for eight hours before the next
regeneration
Suggested CT options
Use salt with 10% concentration for cleaning, or about 125
kg. per regenerating cycle.
Increase regeneration time to 30 minutes
Operational time is increased to 24 hours
Technical feasibility study
It is a proper resin washing method, lasting no less
than 30 minutes.
The factory is capable of implementing such
adjustments.
There are no other technical limitations.
Economic feasibility study
Investment cost
Savings
None
385 baht/24 hours
(salt cost 175 kg./day x 2.2 baht/kg., excluding cost for water, labor
and time saved)
Payback period
Immediate
Work procedure
Activity
1. Prepare details and obtain approval
2. Approve assignment
3. Train employees on proper work
procedure
4. Proceed and collect data for
comparison
Day 1 Day 2 Day 3
--
Responsible party
CT team
-
Utility Manager
---
CT team
---
Operators and CT
team
Samples of different CT options
When cleaning factory floors, sweep off dirt and
scraps before hosing down with water
Check for leaks in various connections, e.g., pipes for
raw, soft and cold water, and repair immediately if
leaks are found
Ensure that float valves are properly functioning
Where possible, use high-pressure nozzle on water
hoses
Avoid cleaning by overflow system; counter-flow system
is preferable
Plan production process so that minimal washing is
required
Product change should not take place too often
Check quality of water used and use appropriate type of
water
Insulate hot and cold water pipes and repair the
insulation if damaged
Consider returning condensate
Avoid using steam directly by using indirect heat
transfer where applicable
Water used to cool machines should be reused
Acid and alkaline should not be dumped after only one
use; try to re-use by adding acid or alkaline to obtain
required concentration
For light, fluffy materials, trap systems should be
utilized to prevent loss
Install water meter at key points so that loss and
production efficiency will be known
Avoid using hazardous chemicals
Prepare work manuals and have them available for
use
Maintain machines in good working condition
Check condition of boilers regularly
If production is much lower than production capacity,
production process should be revised to minimize loss
Air conditioner should be set at an appropriate
temperature
Lights should be turned off when not in use; use
spot lighting where possible
Light switches should be positioned throughout
different work areas. Replace spent bulbs with
energy saving bulbs.
Clean light bulbs and reflectors regularly
Summary CT benefits
Increased production efficiency
Reduced production cost
Reduced environmental
problems at source
Good image
Good relations with local
community
Summary Factors crucial for sustaining CT
Management support
Team work
Determination
Communication
Training
Incentives
Summary Management role in CT implementation
Continuous support for CT
activities
Involve everyone in the
organization in CT activities
Incorporate CT into
management plan (marketing,
production, finance, accounting,
personnel and information
system
For additional information, contact:
Cleaner Technology Unit
Tel. 281-2010
Fax 281-7287
e-mail : [email protected]