Case sample of a CT option

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21 Φεβ 2014 (πριν από 3 χρόνια και 7 μήνες)

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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





50

baht


(sampling skimmed latex for ammonia check)


Savings





360

baht


(Acid costs saved per sedimentation)


Investment payback after sedimentation

23

times


(calculated from 7
,000/(360
-
50
) times)

Implementation steps

Activity
March 00
April 00
Responsible party
1.
Prepare details and obtain approval
__
CT team
2.
Approve assignment
__
Management
3.
Plot titration of skimmed latex at
various
ammonia
concentrations
_
Quality Control
Dept.
4.
Obtain a handheld pH meter
_
_
Maintenance
Dept.
5.
Train employees on proper work
procedure

__
CT team
6.
Proceed and collect data for
comparison
____
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



None


Savings




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
Day 1
Day 2
Day 3
Responsible party
1.
Prepare details and obtain approval
--
CT team
2.
Approve assignment
-
Utility Manager
3
.
Train employees on proper work
procedure
---
CT team
4
.
Proceed and collect data for
comparison
---
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 : ctu@diw.go.th