C253
- Ravensdown Fertiliser Co-op Ltd, Christchurch - Canterbury
Region
Summary
The gradual implementation of cleaner production ideas and
approaches within Ravensdown, coupled with the establishment
of an ISO 14001 environmental management system, puts the
company in a powerful position to successfully integrate the
cleaner production philosophy and approach into the core of
the company culture and systems.
Business Profile
The Ravensdown Fertisliser Co-op site at Hornby in Christchurch
is one of 3 in the Ravensdown group manufacturing phosphate
fertilisers for New Zealand’s agricultural industry.
Type of Projects
Reduced utility and chemical use
Reasons for Projects
The cleaner production approach was introduced to the
Hornby site in parallel with a programme to establish the
ISO14001 environmental management system (EMS). As a result
of this parallel implementation process, Ravensdown have recognised
the close synergy between cleaner production and the formal
EMS and are now integrating the CP principles, practices and
objectives into the ISO 14001 system.
Target Zero
Ravensdown Fertiliser has been a participant in Target
Zero, a two-year sponsored cleaner production programme involving
12 companies in Christchurch and 10 in Hawkes Bay during the
period 1997-1999. The programme was sponsored by the Sustainable
Management Fund of the Ministry for the Environment, Meridian
Energy Ltd (formerly ECNZ), and the local authority and electricity
company in each area.
The Projects
Lighting Control
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Description
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There are 770 lights around the Ravensdown site with
current operating costs of around $52,000 per annum.
There is considerable opportunity to improve their efficiency
and a target has been set to reduce their operating
costs by $10,000.
An example of the measures being introduced is the
installation of a time-clock to control some of the
road lighting. The road lighting at the side of the
sulphur store tends to be left on continuously because
staff forget to turn them off during the day (since
electricity is generated on site, the plant culture
has traditionally been to regard electricity as a free
good). The six 160 watt spotlights between them currently
cost $645/ year to operate.
By installing a mechanical clock set for 9 hours of
night time operation, the operating cost for these 6
lights was reduced by 62.5%.
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Environmental Benefit
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Reduced electricity consumption and increased bulb
life.
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Economic Benefit
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Capital cost $279
Savings $403/annum
Payback 9 months
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Minimising Waste Lithium Grease
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Description
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Lithium complex grease is supplied in 55kg drums. The
suction pump as currently used leaves around 12.3 kg
of grease in the bottom of each drum, with the result
that less than 80% of the purchased grease can be used.
In addition, because of the grease left in the drum,
the company has not been able to claim the $26.098 refundable
deposit per drum, and has been stockpiling them.
To reduce wastage and facilitate drum recycling, the
site engineers fashioned a 10mmm thick metal plate addition
to the pump. The extra weight creates a greater suction
and as a result, the grease remaining in the drum has
been reduced from 12.3 kg to 2.85 kg ie grease waste
has been reduced from 22% to 4.5 %. The drum can also
be returned and the deposit refunded.
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Environmental Benefit
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Drums can be recycled.
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Economic Benefit
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Capital cost $65
Savings $1,180/annum
Payback 3 weeks
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Recycling acid plant waste water
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Description
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Existing practice had resulted in treated acid plant
cooling waters being discharged to the ground in violation
of a general authorisation from the regional council.
In addition bore water used in the acid-plant plate
heat exchangers was stored in an open pond that developed
algae and required chemical treatment before use.
By storing the acid plant waste waters in what were
previously the bore water ponds, and installing four
new enclosed bore store water tanks meant that:
- The stored acid wastewater could be reused as make-up
water for scrubber, reducing the need to use fresh
bore water.
- Eliminating sunlight form the storage tanks significantly
reduced the need for water treatment chemicals to
treat algae.
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Environmental Benefit
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Eliminated undesirable discharge and reduced bore water
consumption and chemical use.
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Economic Benefit
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Capital cost $185,000
Savings $11,400/annum
Payback Several years
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For additional information contact:
Paul Barrett
Ravendown Fertiliser Cooperative Ltd
PO Box 16 081
Christchurch
Phone 03 349 6189
Fax 03 349 9174
psb@ravensdown.co.nz
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For further information about the Target Zero programme
see following publication:
- You too can profit from cleaner production and waste
minimisation
- Coordinating cleaner production programmes. Lessons
from Target Zero
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