Adaptation to Climate Change in Industry: Demonstration Projects for Water Saving Through Eco-Efficiency Approach

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2 Alkaya E, Böğürcü M, Ulutaş F, Demirer G N, Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach Alkaya E 1*, Böğürcü M 1, Ulutaş F 1, Demirer G N 2 1 Technology Development Foundation of Turkey (TTGV), Cyberpark B-Blok Kat:5-6, Bilkent, Ankara, Turkey 2 Department of Environmental Engineering, Middle East Technical University, İnönü Bulvarı, Ankara, Turkey, *ealkaya@ttgv.org.tr Abstract In order to establish the necessary strategies and enhance institutional capacity for Turkey to combat and manage the effects of climate change, a United Nations Joint Programme titled Enhancing the Capacity of Turkey to Adapt to Climate Change was carried out between Within the scope of the Joint Programme, the risks that climate change poses to industrial enterprises, mainly water scarcity, higher energy and raw material costs, etc. were emphasized through the UNIDO Eco-efficiency (Cleaner Production) Programme. In the context of the Programme which was carried out by United Nations Industrial Development Organization (UNIDO) and Technology Development Foundation of Turkey (TTGV) cleaner production demonstration projects were realized in addition to national capacity development activities. As the demonstration projects, eco-efficiency (cleaner production) applications which improves environmental and economical performance were implemented in 6 industrial facilities analyzing production processes, water consumption and wastewater generation. As a result of the applications, 784,550 m 3 of water was saved annually besides 4,947,000 kwh savings achieved in energy consumption. Thanks to energy saving, 978 tons/year of CO 2 emission was also avoided. Not only water and energy but also raw materials, chemical and manpower were saved as a result of project activities which decreased operational costs. Keywords: Adaptation to Climate Change, Cleaner Production, Eco-efficiency, Environmental Performance,

3 1. Introduction From its inception, the international climate effort has focused predominantly on mitigation. The next stage of the international effort must deal squarely with adaptation coping with those impacts that cannot be avoided (Burton et.al. 2006). In order to establish the necessary strategies and enhance institutional capacity for Turkey to combat and manage the effects of climate change, a United Nations (UN) Joint Programme titled Enhancing the Capacity of Turkey to Adapt to Climate Change was carried out between 2008 and The Joint Programme aimed at integrating the climate change adaptation into national, regional and local policies within the framework of future development targets of Turkey in terms of sustainability. The project aimed to achieve its goal through: Mainstreaming climate change adaptation in Turkey s national plans and developing a Climate Change Adaptation Strategy Developing national and regional institutional capacity in order to predict and manage risks induced by uncertainties caused by climate change and climatic conditions Implementing community-based pilot projects in the Seyhan River Basin Mainstreaming climate change adaptation into UN programming framework in Turkey Executing UN Agencies of the Joint Programme are listed below: United Nations Development Programme (UNDP) Main Implementing Agency United Nations Environment Programme (UNEP) United Nations Industrial Development Organization (UNIDO) Food and Agriculture Organization of the United Nations (FAO) 2. Adaptation of Industrial Enterprises to Climate Change Adapting to the impacts of climate change in order to minimize its human and environmental toll is a significant challenge for all sectors. While some sectors are particularly at risk, all businesses face the possibility of property damage, business interruption, and changes or delays in services provided by public and private electricity and water utilities, and transport infrastructure. A more strategic and long-term approach for managing climate change risks will be necessary for all sectors including manufacturing industry. There are many adaptation options available to reduce the vulnerability of sectors. Eco-efficiency (Cleaner Production - CP ) which is based on the concept of creating more goods and services while using fewer resources and creating less waste and pollution is one of these options that manufacturing industry can apply for adaptation purposes. Along with other resources, water is expected to become scarce directly affecting the competitiveness of industries, highly depending on it. In other words, industrial enterprises should take serious measures to decrease their resource intensity including water intensity by applying eco-efficiency methodology. Owing to this, the industry component of the Joint Programme, namely UNIDO Eco-efficiency (Cleaner Production) Programme was carried out by United Nations Industrial Development Organization (UNIDO) and Technology Development Foundation of Turkey (TTGV) with the consultancy of Prof. Dr. Göksel N. Demirer (Middle East Technical University) in the Seyhan River Basin Area (Adana, Kayseri and Niğde). The main objective of UNIDO Eco-efficiency (Cleaner Production) Programme was to foster the implementation of Eco-Efficient Production (EEP) and Environmental Sound Technologies (EST) in the Turkish manufacturing industry through national capacity building, pilot (demonstration) projects and dissemination of the results achieved in the Seyhan River Basin Area. Within the scope of the Programme 6 pilot projects, focusing mainly on water saving through recycling and reuse, were implemented in the manufacturing firms operational in food industry, beverage industry,

4 Alkaya E, Böğürcü M, Ulutaş F, Demirer G N, Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach metalworking industry, surface finishing/coating industry, chemicals industry and textile industry. The eco-efficiency (cleaner production) implementations in related industries/firms were presented below: 2.1. Food Industry The firm is operational in food industry producing marinated, smoked and frozen seafood products. Before the eco-efficiency (cleaner production) applications firm was responsible for consuming of 75,000 m 3 of groundwater annually. Since one of the major products of the firm is anchovy fillet, processing of anchovy is the major source of water consumption. Anchovy processing is carried out in two steps in the firm: First, anchovies which are stored in cold store is thawed by the help of fresh water. Second, thawed anchovies are gutted (filleted) manually by workers using continuous supply of fresh water serving for simultaneous cleaning of anchovies. Before applications, it was calculated that annual groundwater consumption of the firm was 22,000 m 3 /year in the thawing step alone. In addition to that firm was consuming 36,000 m 3 /year of water in the gutting (filleting) step. In other words, 77% of total water consumption of the firm was recorded in the anchovy processing. Improvements in the production processes and some technology changes enabled major water savings in both thawing and gutting (filleting) steps of anchovy fillet production. In thawing step a new water spraying system which increases the heat exchange rate between frozen anchovy and water was designed and implemented. In the thawing step water recirculation was also introduced to increase the contact time between water and frozen anchovies. These measures increased the thawing capacity of the firm fourfold meanwhile decreasing water consumption by 45.8%. As it was given in Table 1 specific water consumption (m 3 water/ unit production) was decreased from 28.4 m 3 /ton of anchovy to 15.4 m 3 /ton. Since heat transfer during thawing step was optimized quality of product was also affected positively. In other words achieved temperature increase rate prevented deformations in the outer skin of anchovies, as it was the case before applications. Moreover a water reuse system consisting of filtering, sedimentation/floatation, ozonation and recycle technologies was introduced in gutting (filleting) step. As a result of this applications specific water consumption was decreased from 46,5 m 3 /ton to 16.4 m 3 /ton which corresponds to a water saving of 64.7% in gutting (filleting) step. As described above, CP applications in these two production processes resulted in 33,400 m 3 of water saving in total. Table 1: Specific water consumption in the firm before and after CP applications Reference Values * (m 3 /ton anchovy) (m 3 /ton anchovy) (m 3 /ton anchovy) Anchovy Thawing Anchovy Gutting TOTAL * (Jespersen et. al, 2000; European Commision, 2006) 2.2. Beverage Industry The firm produces beverages including fruit juice and carbonated drinks. applications 851,000 m 3 of water was being consumed in fruit processing and soft drink production processes, which are most water intensive processes in the firm. In the fruit processing step fruits are washed, pre-processed (crushing, evaporation etc.) and pasteurized before being sent to fruit juice production. In fruit processing step 346,000 m 3 /year cooling water (once-through cooling) was being consumed before CP applications.

5 In the fruit juice production step 173,000 m 3 /year cooling water was being consumed for cooling purposes as a similar case to fruit processing step (once-through cooling). As part of the CP pilot applications two separate recycle and reuse systems (closed-loop water cooling) were introduced in the production facility of the firm. Both closed-loop water cooling systems consisted of the following equipments with different operational parameters: cooling tower, stainless steel water pumps, stainless steel pipes/fittings, inverter and control panel. As a result of taken CP measures annual cooling water consumption of the firm was decreased from 519,000 m 3 to 46,000 m 3 which corresponds to 91.2% of water saving (Table 2). Table 2: consumption in the firm before and after CP applications Fruit ing Cooling es Soft Drink Production Cooling es Total Cooling es Total Consumption of the Firm 346,000 18, ,000 28, ,000 46, , , Specific water consumption of the firm was evaluated before and after CP applications through environmental benchmarking. As it is indicated in Table 3, m 3 of water is consumed in soft drink industry in order to produce 1 m 3 of product. Implemented CP measures decreased the specific water consumption of the firm from 23.6 m 3 to 10.6 m 3. Table 3: Specific water consumption in the firm before and after CP applications 2.3. Metalworking Industry Specific Reference Values Consumption (m 3 / m 3 drink) Binnie, Gumbo et.al., Hsine et.al., Environment Report, IFC, ETBPP, Firm values 23.6 Firm values 10.6 Third project was implemented in a company producing metal parts for automotive industry. The company uses fresh groundwater in production processes and most water intensive process was determined as heat treatment where cooling process requires 20,200 m 3 /year of water. applications cooling was performed by means of continuous supply of groundwater without reuse/recycle in heat treatment process. Since no major contamination was determined in cooling water it was possible to recirculate it to the main water tank, used for process water supply of the whole factory. In addition to the heat treatment process, major CP measures were taken in the surface coating process in which 3,717

6 Alkaya E, Böğürcü M, Ulutaş F, Demirer G N, Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach m 3 of annual water consumption was recorded. The following CP applications were implemented in the surface coating process which composed of step-wise batch reactors: Increase/optimize the rinsing period of the metal parts. Increase drag out time after dibbing. Increase the retention time of the parts in the tanks. To mimic countercurrent rinsing by dividing rinsing tanks into two. To implement drain boards in order to avoid water and chemical losses during transfer of the parts from one tank to another. To optimize drum filter operation period for effective drainage of the water from the surface of the metal parts back to the tanks. CP applications implemented in the heat treatment process resulted in 100% of cooling water saving (Table 4). On the other hand 79% of water was saved in the surface coating process. In total 23,150 m 3 of water was saved in the firm. Moreover CP measures taken in the surface coating process increased chemical usage efficiency and 29% of chemicals were saved in this process (Table 5). Energy was also saved due to decreased water supply rate in groundwater wells supplying water to the firm. So 31,000 kwh of electricity was saved which corresponds to 18.3 tons of annual CO 2 emission. Table 4: consumption in the firm before and after CP applications Heat Treatment 20, % Surface Coating 3, % Total Consumption of the Firm 64, % Table 5: Chemical consumption in the firm before and after CP applications (kg/year) (kg/year) Chemical (kg/year) Chemical Surface Coating 5,716 4, % 2.4. Chemicals Industry The firm is active in the field of chemical products sector manufacturing polyester fibers, filament and various polymers including specialty polymers and chemicals thermoplastic polyester elastomers (TPE) and dimethyl terephthalate (DMT). Total annual water consumption of the firm is around 2,295,000 m 3. Out of this amount, 835,640 m 3 /year of water is processed and softened by means of an ion exchange system before being used as permutit water in various processes. applications, 324,300 m 3 /year of permutit water was being used for cooling of the heat transfer pumps in order to prevent the pumps fail as a result of excessive heating (Table 6). Within the scope of the CP project, a group of water-cooled heat transfer pumps were replaced by aircooled heat transfer pumps. This implementation led to the elimination of permutit water consumption in the corresponding production lines. In addition to the water saving of 93,000 m 3 /year, 121,000 kwh/year of energy was saved (Table 7). This amount of energy saving was the sum of net electricity savings in the pumping (through higher efficiency pumps) and cooling of permutit water. 121,000 kwh/year of energy saving also resulted in the reduction of 71.5 tons/year CO 2 emission. Due to some other cost savings

7 (decreased maintenance and accessory need etc) total implementation cost of the project (76,124 TL) was paid back in approximately in 8 months. Table 6: consumption in the firm before and after CP applications Pumping Systems for Heat Transfer Oils (Soft ) 324, , Total Soft Consumption 835, , Table 7: Achieved environmental benefits and economic gains after CP applications Type Energy Energy Others Benefit/Gain Increased energy efficiency due to replacement of low efficiency motors Increased energy efficiency in cooling towers due to decreased cooling need Soft (permutit) water saving Decreased maintenance and accessory (seal etc.) need Quantity/ Value 44,170 kwh/year Electricity 77,000 kwh/ year Electricity 93,000 m 3 / year 21,743 TL/ year Total Annual Cost 7,014 TL 12,228 TL 74,470 TL 21,743 TL 115,455 TL 2.5. Textile Industry Being an SME, the firm produces various fabrics (polyester, cotton and lycra based) for womens wear with a monthly production capacity of 1,500,000 meters. The firm which has wet processes such as dyeing and finishing had a water consumption of 300,000 m 3 /year before CP applications % of total water consumption was recorded in dyeing and finishing processes. Therefore, the focus of CP applications was on dyeing and finishing processes which were responsible for 260,000 m 3 /year water consumption. The following CP measures were implemented in order to decrease water consumption in the respective processes: Adjustment of water consumption in fabric washing, washing after dyeing units according to adequate amounts Renovation of valves in the cooling line of dyeing machines Elimination of overflow washing practices Reuse of tumbler dryer cooling water in the system Adjustment of water consumption in tumbler dryer cooling water in the system Reuse of nap trimming cooling water in the system Renovation of water softening device Above-listed applications led to 54% of water saving which corresponds 162,000 m 3 /year (Table 8). Specific water consumption was also monitored before and after CP applications. Results indicate that specific water consumption of the firm was decreased from 111,8 L/kg fabric to, 50,88 L/kg fabric. Since water is used at around o C for dyeing and washing purposes in the firm, water saving increased energy efficiency and 22% of energy was saved accordingly. Annual energy saving of 4,780,000 kwh

8 Alkaya E, Böğürcü M, Ulutaş F, Demirer G N, Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach (natural gas + electricity) brought about significant decrease in the CO 2 emissions (879,6 tons/year). Total implementation cost of the project (34,659 TL) was paid back in less than 2 months when other economic gains including 192 tons of NaCl saving was taken into account. Table 8: consumption in the firm before and after CP applications Textile dyeing and finishing processes Total Consumption of the Firm , , Metal Coating and Painting Industry The firm is an SME and specialized in coating and painting of metal parts/accessories for various sectors like automotive, defense etc. applications two different methods were applied for surface finishing purposes. In the first method, surface of the materials were cleaned with thinner prior to painting process. Approximately 7,650 kg of thinner was used annually for surface finishing purposes, accounting for 85 % of thinner consumption in the company. In the second method, some portion of the materials outsourced for Cadmium plating in which the CdO (cadmium oxide) NaCN (sodium cynanide) are used as chemicals. implementations, thinner and cadmium plating systems were replaced by the Oxsilan process. When used on clean metal surfaces, the silane-based Oxsilan forms a thin layer (60 nm), which together with paint improves the adhesiveness and corrosion protection of the paint, depending on the material. Summary of environmental and economic gains of this application are given in Table 9. Type Consumption Chemical Consumption Energy Consumption Table 9: Operational costs before and after CP applications Operational Cost of Thinner System ( ) Operational Cost of New System ( ) Amount Cost Amount Cost 400 m TL 400 m TL (Distilled water) kg TL kg TL + m 3 Oxilan 60,000 kwh kwh + LPG + Natural TL LPG + Natural TL Gas Gas Workforce 252 man-hour TL 99 man-hour TL Outsourced services 36,000 pieces TL 36,000 pieces - Total TL TL + Oxilan 3. Conclusion In the context of UNIDO Eco-efficiency (Cleaner Production) Programme which was carried out by United Nations Industrial Development Organization (UNIDO) and Technology Development Foundation of Turkey (TTGV) with the consultancy of Prof. Dr. Göksel N. Demirer (Middle East

9 Technical University) cleaner production demonstration projects were implemented in the Seyhan River Basin Area (Adana, Kayseri and Niğde) in addition to national capacity development activities. As the demonstration projects, eco-efficiency (cleaner production) applications which improves environmental and economical performance were implemented in 6 industrial facilities analyzing production processes, water consumption and wastewater generation. As a result of the applications, 784,550 m 3 of water was saved annually besides 4,947,000 kwh savings achieved in energy consumption. 978 tons/year of CO 2 emmision was also avoided. Not only water and energy but also raw materials, chemical and manpower was saved as a result of project activities which decreased associated costs (Table 10). Table 10: Achievements of the pilot (demonstration) projects 784,550 m 3 /year (22%) Chemical 192 tons/year NaCl 7.7 tons/year Tinner 5.2 tons/year Sodyum Cyanide (NaCN) 1.2 tons/year Cadmiyum Oxide (CdO) 1.7 tons/year Others Energy 4,681,000 kwh/year Natural Gas ( Nm 3 ) 265,970 kwh/year Electric Reduction of CO tons/year CO 2 Other Gains Improvements in production processes and products Decrease in production time Manpower saving Decrease in maintenance and operation cost Decrease in transport cost Decrease in wastewater treatment cost etc. Amount of Investment UNIDO Contribution : 139,800 $ Firms Contribution : 125,000 $ Total : 264,800 $ Annual Cost 1,357,792 $ Payback Period Approximately 3 months Acknowledgement UNIDO Eco-efficiency Programme was carried out as a sub project of MDG-F 1680: Enhancing the Capacity of Turkey to Adapt to Climate Change financed by Millennium Development Goals Fund (MDGF). References Ait Hsine, E., Benhammou, A., Pons, M.N., Resources Management in Soft Drink Industry- Use and Wastewater Generation, Environmental Technology 26 (12), Australian Food and Grocery Council, Environment Report Binnie, and wastewater management in the soft drink industry. Report no. NATSURV 3 prepared for the Research Commission by Binnie and Partners Consulting Engineers, Pretoria COWI Consulting Engineers and Planners A.S., Cleaner Production Assessment in Fish ing (for UNEP and Danish Environmental Protection Agency).

10 Alkaya E, Böğürcü M, Ulutaş F, Demirer G N, Adaptation to Climate Change in Industry: Demonstration Projects for Through Eco-Efficiency Approach Environment Report, Australian Food and Grocery Council, Environmental Technology Best Practice Programme use in the soft drinks industry, (ETBPP) EG 126 Guide. European Commision (2006). Integrated pollution prevention and control (IPPC) reference document on best available techniques in the food, drink and milk industries. Seville, Spain Gumbo, B., Mlilio, S., Broome, J. Lumbroso, D Industrial water demand management and cleaner production: a case of three industries in Bulawayo, Physics and Chemistry of the Earth 28, Ian Burton, I., Diringer, E., Smith, J., Adaptation to Climate Change: International Policy Options. PEW Center on Global Climate Change, Arlington, VA, USA. International Finance Corporation (IFC)-World Bank Group, Environmental, Health, and Safety Guidelines for Food and Beverage ing. Jespersen C., Christiansen K., Berendsen S Cleaner Production Assessment in Fish ing, COWI Consulting Engineers and Planners AS for UNEP and Danish Environmental Protection Agency. Pacific Institute for Studies in Development, Environment, and Security, Waste Not, Want Not: The Potential for Urban Conservation in California, Appendix F, Details of Industrial Use and Potential s, by Sector. Kanber R., Kapur B., Ünlü M., Tekin S., Koç D.L İklim Değişiminin Tarımsal Üretim Sistemleri Üzerine Et ile Tarım İlişkisinin Araştırılmasında Yeni Bir Yaklaşım: ICCAP Projesi. The UNEP Working Group for Cleaner Production in the Food Industry, Australian Industry Group, Eco-efficiency Toolkit for the Queensland Food ing Industry UNDP, Uyum Politika Çerçevesi.