Worksheets and Checklists For Cleaner Production Clubs
Worksheets and Checklists For Cleaner Production Clubs
for
Cleaner Production Clubs
ASIE/2006/122-578
Improving the living and working conditions of people in and
around industrial clusters and zones
IVAM
2008
©IVAM Research and Consultancy on Sustainability 1
List of worksheets and checklists
Nr. Checklists
1 PLANNING & ORGANISATION 20
2 PREASSESSMENT 21
3 ASSESSMENT 25
4 GENERATION & SCREENING 27
OF OPTIONS
Name
Position
Justification
2 Team member
Name
Position
Justification
3 Team member
Name
Position
Justification
4 Team member
Name
Position
Justification
Justification: What are the main reasons to include the person in the team? Or in the case of a team
leader: What are the main reasons to appoint the person as a team leader.
1 Team leader
Name
Position
Justification
2 Team member
Name
Position
Justification
3 Team member
Name
Position
Justification
4 Team member
Name
Position
Justification
5 Team member
Name
Position
Justification
Justification: What are the main reasons to include the person in the team? Or in the case of a
teamleader: What are the main reasons to appoint the person as a teamleader?
Use more worksheets for utilities (boilers, etc) and waste water treatment or in case the process is
complicated.
Step 1 Benchmarks
Use experience records and benchmarks for material and energy utilisation per unit of product to
determine if your process can be improved and waste prevented.
Selection
year losses losses
of focus
(in waste
stream)
Raw materials
(by)Products
Utilities
Air pollution
Water pollution
Electricity
Water
Auxiliaries
Costs of losses:
Material losses
Product losses
Discharge/disposal
Other
Future developments
Regulations
Other
Other aspects
Occupational health
Other
Opportunities for CP
Input
Packaging materials
Paper
Wood
Plastic
Total
INPUTS OUTPUTS
O
P
CATALYSTS QUANTITY COSTS E
R BY-PRODUCTS QUANTITY COSTS
A
T
I
ENERGY QUANTITY COSTS O RE-USE in other QUANTITY COSTS
operations
N
&source)
Where (waste stream
Where – Why – How ?
12
©IVAM Research and Consultancy on Sustainability
Worksheet 8A: Description of options and benefits
Option Description of option Benefits after implementation Cost
Nr level
Environmental Economical Other
Good operation practices; good workers skills and good production management
Product modification
Cost level: A: Low/No cost options; B: Medium/high investment; C: complex/not enough information
Auxiliary materials Quantity Unit price Costs Auxiliary materials Quantity Unit price Costs
Rp - Rp -
Rp - Rp -
Total Rp - Total Rp -
Energy cost Quantity Unit price Costs Energy cost Quantity Unit price Costs
Steam Rp - Steam Rp -
Electricity Rp - Electricity Rp -
Oil Rp - Oil Rp -
Gas Rp - Gas Rp -
Total Rp - Total Rp -
Environmental costs Quantity Unit price Costs Environmental costs Quantity Unit price Costs
Waste disposal Rp - Waste disposal Rp -
Water treatment Rp - Water treatment Rp -
Air emission abatement Rp - Air emission abatement Rp -
Total Rp - Total Rp -
Personnel costs Person-years Salary Costs Personnel costs Person-years Salary Costs
Operators Rp - Operators Rp -
Supervisors Rp - Supervisors Rp -
Total Rp - Total Rp -
Total running costs after investment per year Rp - Total running costs before investment Rp -
Fill in the data from the worksheet with the investment costs
Equipment costs
Installation costs
Engineering costs
Other costs
Fill in the data from the worksheet with the old and new running costs
Total running costs before investment
Total running costs after investment
Divide the investment cost over the annual savings, this will give you the
General points
Yes No
Is a list with the focused and non-focused assessment items
included in the report?
Concerning the obvious improvements, is the situation before
and after the implementation described and quantified?
Did you include a simple general flow chart and are the
targets described in the report?
Is everything going according to the planning? Is adjustment
of the planning and division of tasks needed to allow for better
results?
Have you re-evaluated the objectives of the assessment?
Would refinement of the objectives serve the cleaner
production assessment?
Have you informed management and employees about the
progress of the cleaner production assessment?
Have you adjusted the composition of the assessment team in
anticipation of the needs for the following steps?
Production data
• What are the different unit operations and main equipment?
• How is the product quality and are there variation in its quality?
• What are the major raw and subsidiary materials of production, the main products, the
consumption of energy and water in each workshop and consumption of the energy and
materials and utilities per unit product (can be annual figures)?
• What are the major material consuming operations and practices?
• What are the major energy consuming operations and practices?
Production layout
• How can de production layout be described, is it compact or are the related units
located far from each other?
• Is there much transport of materials and products?
• Are the directly related unit operations close to each other?
General points
Yes No
• Is a list with all assessment items included in the report?
• Did you include the flow chart and the material and energy
balance in the report?
• Is everything going according to the planning? Is adjustment
of the planning and division of tasks needed to allow for better
results?
• Have you re-evaluated the objectives of the assessment?
Would refinement of the objectives serve the cleaner
production assessment?
• Have you informed management and employees about the
progress of the cleaner production assessment?
• Have you adjusted the composition of the assessment team in
anticipation of the needs for the following steps?
Screening of options
Yes No
• Have you involved experts from within the company or/and
experts from outside the company in the screening of
options?
• Have you arranged all options per unit of operation and
investigated if some of the options interfere with or exclude
each other?
• Have you made estimations for the change in inputs and
outputs?
• Have you been aware of possible shift from material savings
to increased energy demands and reverse effects?
• Have you looked at the technical, organizational, economic
and environmental consequences?
• Have you divided them into the following three groups?
- Options that can be implemented directly
- Options that look promising but need extra investigation
- Options that are clearly not (yet) feasible (next timers)
Management Setting up a task force "Energy Tasks and competence’s are not
concerns" clearly defined, there are no
regulations, no monitoring of energy
concerns (e.g. energy figures for newly
bought machinery)
Energy accounts No continuous registration and
updating of energy consumption and
costs
Respecting energy key figures High specific consumption of existing
machinery, out-of-date technology
Energy supply Use of environmentally friendly High 502, dust or NOx emissions, no
fuels renewable energy sources
Installation of solar. Collectors Great demand for warm/hot water,
even in summer
Load management High performance cost, low continuous
performance
Compensation for idle current High cost for idle current
Energy cost High cost for electrical energy in
comparison to similar plants
Conversion Co-generation Great parallel need (over 6000 h) of
heat and electricity
Boilers Low combustion efficiency, high
exhaust temperature, no flue gas
register, badly adjusted burners
Adjustment of burner Heat consumption drastically changed
performance (exchange nozzles) in recent years
Control and maintenance No cleaning of heat exchangers;
refrigeration checking the temperature in the
refrigerating chamber, insufficient
aeration
Compressed air Great losses due to leakage’s,
compressor located at a warm spot, no
maintenance of filters
Distribution insulation of pipes, High energy consumption in spite of
maintenance/exchange of steam low production (e.g. at night, on
traps weekends)
Consumer - Better adjustment of heating Adjustment, no thermostatic valves ,
Space heating no adaptation of room temperature to
Warm water seasonal weather conditions, no
lowering during the night, local
overheating, radiators blocked or in
niches
Lowering transmission losses no automatic gates, doors and
windows in a bad state, air extraction
not stopped when necessary
Warm/hot water High temperatures, no checking for
water saving fittings and water
stoppers, no insulation of pipes
Air conditioning No adjustment of air input
according to need, refrigeration,
internal heat and humidity
sources existent in the area, no
sunblinds, no adjustment to
specific needs (temperature and
volume)
Optimization of process Volume stream of carrier (water, Consumer -