Page 60 - Materials Chemistry, Second Edition

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Cleaner Production
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Process modification/better process control and proper housekeeping as cleaner
production techniques were employed to achieve the cleaner production
objectives in this case study.
Cost/benefit analysis
The cleaner production recommendation resulted in the following environ-
mental advantages:

• Sugar production yield increased by 6.5% by saving about 1,690 ton/y
of sugar from being disposed off as waste in landfill.
• Energy consumption was reduced by 2.1% thus sparing about 150ton/y
of heavy fuel oil.
• About 2,000 ton/year of beet pieces were saved from being disposed
of as waste to landfill.
• The most significant savings resulting from this case study were:
– Process optimization through increased productivity and produc-
tion yield accounting for more than 85% of savings
– Resource conservation due to reduced material and energy con-
sumption accounting for 15% of savings.

In all, the implementation of the cleaner production process led to an annual
saving of US$1,400,000 for a total investment of no more than US$35,000,
thus economically efficient.

Food sector: Recovery of cheese whey for use as an
animal feed
This case study will show that when cleaner production and pollution control
options are carefully evaluated and compared, the cleaner production options
are often more cost effective. By implementing two simple techniques, which
are on-site recycling and input material change, the cleaner production option
will generate savings through reduced costs for raw materials for the animal
farms, and reduce waste treatment cost for the factory and help it to comply
with environmental regulations.
This case study was implemented in Misr Company for Dairy and Food
in Damietta, Egypt (SEAM 1999a). The objective of the case study is to
explain the methodology of implementing the cleaner production techniques,
which starts by forming an environmental audit to identify the problem, pro-
pose solutions, test the proposed solution through laboratory and model exper-
iments, prepare a feasibility study based on the data obtained from the model
experiment, and finally assist the concerned parties in implementing the CP
techniques on a prototype scale.

Process description
Misr Company for Dairy and Food, located in Damietta, Egypt, is a public
sector factory with a workforce of 512. The factory annually processes