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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]