INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

CASE STUDY #39 1. Headline: Saving energy and raw materials in the chemical industry 2. Background: Beijing Chemical Factory No. 3 (BCF 3) participated in the preparation phase of the Cleaner Production Project in China funded by the World Bank. During 1993, representatives from BCF 3, six other companies and institutions such as the National Environmental Protection Authority (NEPA), the Chinese Research Academy for Environmental Sciences (CRAES) and the Beijing Environmental Protection Bureau (BEPB) were trained in Cleaner production by consultants from UNEP/IE and IVAM Environmental Research (Amsterdam University). Part of the training included carrying out cleaner production assessments in the participating companies. Beijing Chemical Factory No 3 (BCF 3) is one of the key enterprises of the Beijing Chemical Industries Corporation. Since its foundation in 1965, BCF 3 specializes in the production of additives for the processing of high polymer materials. 3. Cleaner Production Principle: Process modification 4. Description of Cleaner Production Application: In 1993, a cleaner production assessment took place at BCF 3's penta- erythritol (PE) plant which accounted for more than 40 per cent of the chemical oxygen demand (COD) in the wastewater discharged by the entire factory. The PE plant operations include: synthesis, first evaporation, second evaporation, crystallization, washing and drying. A total of 20 cleaner production options were identified and evaluated during the project. Nine were implemented within six months. The feasibility of a further six was also established within the first six months. Enabling technology: Four options required substantial investments: - installing a microcomputer to control the quantity and the speed of addition of one of the raw materials; - improvement and expansion of the refrigeration system; - replacement of the centrifuges by new ones with better separation characteristics; and - installation of vacuum pumps to allow the recovery of product previously lost with wastewater during the crystallization process. It was also decided that BCF 3 should install an end-of- pipe wastewater treatment facility to meet the new wastewater discharge standards. The investment for the treatment plant was originally estimated at 8 million RMB; the annual operating cost was projected to be about 600 000 RMB. The implementation of the cleaner production options will allow the capital and operating costs of this treatment plant to be significantly reduced. 5. Economics: The economics of the cleaner production options proved very favorable. The investment needed for the first batch of nine options was less then 10 000 RMB (about US$1200). The cost savings due to increases in efficiency and reduced use of materials and water amounted to 240 000 RMB annually (about US$30 000). The economic indicators for the four high cost options are summarized below. The figures have been calculated with a depreciation time of 12 years, an interest rate of 12 per cent and corporate tax of 11 per cent. Economic indicators for high cost cleaner production options: Option investment extra cash flow payback (RMB) (RMB/year) (years) changing programme control system 152 000 305 000 0.5 improving refrigeration system 910 000 621 000 1.5 replacing centrifuges 3 382 000 867 000 3.9 changing pumps 1 105 000 387 000 2.9 6. Advantages: - increased production - reduced operating costs for treatment - savings in raw materials and energy use. 7. Constraints: N/A 8. Contacts:Dr Ning Duan Director Institute of Environmental Management Chinese Research Academy of Environmental Sciences Beijing 100012 The Peolpe's Republic of China Tel: +86 1 423 2255 ext 233 Fax: +86 1 423 1308 9.0 Keywords: China, chemical, polymer, process modification, good housekeeping, pentaerythritol, COD 10. Reviewer comments: This case study was originally published in the UNEP IE document "Cleaner Production in the ASIA and Pacific Economic Coorporation (APEC) Region. In the process of preparing the document the case study underwent a technical review.