Jeng Yuan Reclaimed Rubber Sdn Bhd

Transcription

1 For Jeng Yuan Reclaimed Rubber Sdn Bhd 22 nd October 2009 By; Energy and Process Engineering Group Environmental and Bioprocess Technology Centre SIRIM BERHAD Cleaner Technology Audit Program for Small and Medium Industry (SME) SIRIM - DOE

2 Table of Contents Executive Summary i ii 1 Introduction Cleaner Technology Audit 1 2 Process description Production process 1 3 Audit activities Data collection and measurements Material balance Occupational safety and Health 2 4 General recommendations Gross list of ideas Cleaner technology ideas and potential savings Conclusion 19 Annexes: Annex A -Process Flowchart Annex B - Material Balance

3 Executive Summary The cleaner technology audit was carried out on 22nd October 2009 at Jeng Yuan Reclaimed Rubber Sdn Bhd located in Port Klang, Selangor with the aim to enhance the profitability for the company by reducing wastes and pollution. The purpose was not limit to only waste prevention management system but also extensively to identification of any potential areas for the application of cleaner technology and energy efficiency solutions and the identification of environmental aspects associated with the operations. The audit report therefore focuses on the options for cleaner technology and energy efficiency applications, their potential savings, estimated investment and pay back periods. The following recommendations are based on the audit team s findings, observations and data information provided by the management. It is estimated that a total saving of more than RM 40,000 per annum could be achieved through the implementation of cleaner technology and energy efficiency options. No Recommended CP Option(s) Potential Saving, RM/yr Estimated Investment Payback Period 1 To re-construct the loading bay for raw material storage 38,694 50, yr

4 2 To prevent waste dust from spreading off to the environment by placing acrylic cover over the whole conveyor at Section A. 3 To improve waste dust collection method from current blowing activity to vacuum suction method yr NA 4 To install a suction hood and an odour scrubber system after the cooking process NA 5 To reform holding tray for powder collection and recycle for process. 6 To install variable speed drive (VSD) or inverter control for motor speed 8,800 5,000 <1yr 26,000 60, yr

5 1 INTRODUCTION 1.1 Cleaner technology audit Objective The aim of the cleaner technology audit is to enhance profitability for companies while reducing wastes and pollution by: identification of potential areas for the application of cleaner technology solutions and identification of environmental aspects associated with the operations Scope The scope covers an overview of the processes with base-line data collection, material balance with the sources and causes of wastes and losses and identification and recommendations of cleaner technology ideas with saving potential. All findings and recommendations will be documented in an audit report. 2 Process Description The process consumes a lot of heat and involved many other processes in making the reclaimed rubber such as raw material screening, rolling/powdering, chemical mixing, autoclave, blending, extruding, refining, cooling and packing. 2.1 Company Overview Jeng Yuan Reclaimed Rubber Sdn Bhd is one of the players in the reclaim rubber field. The company is amongst those dealing with reclaiming rubber and its product in Malaysia. They are unique in a way that it reproduces all types of defective rubber mainly from tires activity, reclaim it and send back to the industries. The raw material supply is from local and overseas.

6 3 Audit Activities 3.1 Data collection and measurements The production of reclaimed rubber was in operation during performing of the cleaner technology audit. Relevant data and information on raw materials, utilities consumption, production figures and equipment operating procedures were provided by the management. Some measurements on the necessary parameters were made to assist the audit team in identifying the possible cleaner technology options. 3.2 Material Balance The overall material balance was developed based on the data obtained from measurements and information collected during cleaner production audit. Refer to Annex B. Further audit is required to develop detail material balance diagram. 3.3 Occupational Safety & Health During the audit, it was observed that certain aspects of safety and health can be further improved which will result in positive impacts on the working environment. The following list consists of possible exposure to health hazards and some relevant improvements. Section A and Section C involved a lot of dust. Management is to ensure staffs to wear the PPE whenever carry out duty at these areas. Section B involved chemical mixing, oil and heat, in which created an odour problem. The current face mask is only to be used at dusty area and not to serve the odor problem. A proper PPE such as a face-mask attached with cartridge is more appropriate to wear when dealing with odor problem. Management is to look into this matter seriously in order to prevent any short and long term problem that associate to safety and hazards towards workers.

7 4 General Recommendations 4.1 Gross list of ideas (i) (ii) (iii) (iv) (v) (vi) To re-construct the loading bay for raw material storage. To improve waste dust collection method from current blowing activity to vacuum suction method. To prevent waste dust from spreading off to the environment by placing acrylic cover over the whole conveyor at Section A. To install a suction hood and an odour scrubber system after the cooking process To reform holding tray for powder collection and recycle for process. Energy option: To install variable speed drive (VSD) or inverter control for motor speed

8 4.2 Cleaner technology ideas and potential savings i. To re-construct the loading bay for raw material storage. Observation and finding: During the audit, the team observed that all the incoming raw materials were placed on the ground outside of the plant. The material was found to be wet due to rainfall. Suggestion(s): It is recommended that the loading bay should be reconstructed by concrete the loading area at least 1ft height from the ground to release the raw material freed from inter contact with water. For this loading area, it is also recommended to build up a transparent roof in order prevent the raw material and area from getting wet. By having new loading bay: i. the raw material would remain in dry condition ii. management would able to save energy (extra energy that imposed on the rolling machines when material is wet). CP option: New loading bay with roofing and concrete ground Raw material storage on the ground

9 Calculation: The current situation is the raw material is not fully dried and might be contributed to more energy consumption in term of electricity at the sieving process. The portion of the energy consumption is estimated as follows: 1. Energy consumption with dry raw material = 10% 2. Energy consumption with wet raw material = 13% Table 1:Monthly Energy consumption MONTH USAGE RATE (kwh) USAGE RATE (RM) SEPT , , OCT , , NOV , , DEC ,710 79, JAN ,690 73, FEB ,850 95, MAR ,952 97, APR , , MAY , , JUNE , , JULY , , AUG , , Average electricity/month RM107,483.7 Savings/year (3% x RM107,483.7) x 12 month = RM38,694 By constructing transparent roof and 1 ft height floor from the ground; Investment = RM50,000 Payback period = (RM50,000/RM38,964) x 1y = 1.3yrs

10 ii. To improve waste dust collection method from current blowing activity to vacuum suction method. Findings and observations: During the audit, the team observed that air-blowing method has been applied to remove the dust from machines and the floor. However, from observation, this method had forced the dust to be blown in the air before it settled on the floor for which the worker had again to sweep and collect the waste dust before recycling it. Suggestion(s): Management should consider on replacing the current method with vacuum system. This process not only would improve the waste dust collection loss-time, but also provide better working environment to the workers. CP option: Vacuum technology is to replace current blowing technology

11 iii. To prevent waste dust from spreading off to the environment by placing acrylic cover over the whole conveyor at Section A. Findings and observations: Another part where dust spread-off badly was during transportation of product by conveyor belt. Most of the floor area and surrounding was observed to be covered by waste dust. Suggestion(s): Because of the waste dust is too tiny to be captured by naked eyes, hence collecting the dust only be done when there is accumulation of dust appeared (everywhere) after certain times. However, this practice is less efficient when the dust (on the floor) mixed with dirt, causing the quality of recycling dust reducing and downgrading. Therefore, placing a cover (preference acrylic cover) or housing at the moving conveyor is the best method in order to prevent the dust from free falling and reaching the floor. Pic showing: Waste dust spread off from conveyor down to the stacked sack and floor

12 Table 2: Renants quantity recorded May09-Oct09 Month Quantity (kg) May 263 June 788 July 929 August 1895 Sept 1567 Oct 846 Table 3: Raw materials consumption Month Quantity (kg), Rubber dust Quantity (kg), Coarse Rubber May 636,932 96,161 June 527, ,136 July 535, ,128 August 555, ,581 Sept 489, ,519 Oct 313, ,695 Source: Quoted from company information list. Assuming; 30% of renants is the wastedust; Average renant/month = 1,000kg/month 30% from renant = 300kg/month If by having cover at the conveyor, 80% of the wastedust can be recovered therefore, 80% from 300kg/month = 240kg Yearly saving = 240 x 12x RM1 = RM2880

13 1 meter of acrylic = RM 150 Say, for the whole conveyor at section A requires 30m acrylic; Therefore, Investment = RM4500 Payback period = 4500/2880 x 1yr = 1.6yr If all the wastedust collected and categorized under low grade T- mesh 40; Say, after implementation of CP option, quality is improvised from low grade T-mesh 40 to becoming reclaimed rubber product (RM2/kg); therefore, 30% of renants = 300kg/month 80% from 300kg/month = 240kg Saleable = 240 x 12 x RM2 = RM5760 Total Savings = RM ( ) = RM8,640 iv. To install a suction hood and an odour scrubber after the cooking process Findings and observations: It was observed that one of the main sources of strong and bad odour was from the cooking/steaming process especially during the transfer process of the cooked rubber into the holding pit.

14 Identified area of strong odour High concentration of strong odour Cooked rubber transfers into holding pit Transfer rubber into holding pit Holding Pit

15 Smoke and odour from cooked rubber Suggestion(s): It is advisable for the company to install a suction hood with a few units of flexible hoses close to the holding pit. However, the suitable area for the installation should also consider the crane s routes. By installing the suction hood, it is expected the concentrated and strong odour could be minimized in the building especially around the holding pit area. In addition, the company must also install a control device, an odour scrubber at the outside of the building. This device can control the strong smell from dispersing to the surrounding. Further study needs to be conducted to determine the emitted gases and the suitable type of odour scrubber. Diagrams below shows the sketch drawing of the proposed suction hood and scrubber. Flexible Hose Suction Hood Odour Scrubber Holding Pit

16 v. To reform holding tray for powder collection and recycle for process. Observation/findings: During the audit, the team found there is no holding tray to collect the chemical powder or calcium carbonate dropped from the conveyer along the production line. This condition has made the floor dirty and working area dusty. The workers clean the area by sweeping the floor and from our observation it makes the area dusty and not healthy for human body. Conveyor line to transfer the product to another process

17 Suggestion The team was suggested to the management to install a holding tray along the conveyor line to avoid the powder from falling on to the floor and if possible to reused the powder again in the process line. It was recommended to vacuum the floor to avoid the dust from accumulate in the area. If 20% of the powder from the process line can be use again the company can make saving up to 20% from their cost of powder. The holding tray is recommended to have a sliding position around 25 0 to ensure the powder dropping on it and enter the collector basket which is put at the end of the holding tray. Calculation: Holding tray which is put under conveyer line Powder consumption per month: 10,000kg Assumption 20% of the recovery Saving of powder consumption per month = 2000kg Saving in RM = 2000kg x RM0.37 = RM 740 per month Estimation fabrication Cost of tray: RM 5000 Nett saving = RM 740 per month Yearly saving = RM740 X 12 = RM8,880 Payback Period = RM 5000 /RM 8880 = 6 Month

18 vi. Energy option To install variable speed drive (VSD) or inverter control for motor speed Observation/findings: The average electricity consumption at Jeng Yuan Reclaimed rubber Sdn. Bhd is 383,437 kwh or RM 105,000 per month. The main equipments that use major electricity consumption in the factory were motors. An average they have around 20 units of big motors with the capacity of 150hp per unit. Table 4.0 below shows the monthly electricity consumption of Jeng Yuan Reclaimable rubber Sdn. Bhd. Table 4.0: Monthly Electricity Bill MONTH USAGE RATE (kwh) USAGE RATE (RM) JAN ,690 73, FEB ,850 95, MAR ,952 97, APR , , MAY , , JUNE , , JULY , , AUG , , AVERAGE 383, ,924.24

19 Calculation

20 By estimation: At section C: 6 unit of VSD are installed with motor capacity are 150hp or 110kW per unit. Inverter cost (estimated RM10, 000 per unit) = RM 60,000 Average monthly electricity bills for Jeng Yuan = 383,437 kwh Or RM 105, Section C From data logger ; Electricity consumption for section C are = 161,064 kwh per month Therefore Section C Consume = 161,064 kwh/ 383,437 x 100% from total electricity Consumption = 42% If translate into money it would be = 42% x RM 105, = RM 44,488.6 per month Installation of inverter would save the electricity consumption from 5% to 30% (note: this depends on the load characteristics). Generally, detail study need to be carried out to confirm the percentage saving. Normally on site test which is before and after installation must been done if management were interested with this option. But In this case the lowest percentage saving were taken as a reference; For a saving of 5%; Monthly Saving = RM44,488.6 x 5/100 = RM2, per month Yearly Saving = RM2, x 12 = RM 26, per year Payback period = Cost of inverter (RM) = RM60,000 Saving per year (RM) RM26, = 2.25 Years

21 vii. Motor cleaning Observation/Finding Cleaning of dirt on motors is important as dirt can be abrasive to moving parts, contaminate bearing, coat windings and can combine with water to result in corrosive mixture. This will result in an increase in energy consumption by the motor. Cleaning will also ensure adequate ventilation of the motors. Suggestion It is suggest doing the regular maintenance on the cleanliness of the motors from the dirt especially at section C and Section A due to heavy dust from the process. It also recommends not to sweep but to vacuum all the dust or dirt on the floor or at the motors area. Dirt and dust attached to the motor and parts Example of inverter motor controller in the market

22 5. Conclusion The cleaner technology ideas recommended are varies from short term to long term effect with maximum potential savings and positive environmental impacts. The cleaner technology idea on waste dust prevention should be implemented immediately as the impact on the savings is significant to the company profits as this method would optimize company resources. Cleaner technology idea such as construction of a loading bay and suction hood for odor trapped system is of high costs in terms of investment, on the contrary give a significant impact to the company as the loading bay associates to the fuel consumption in which reflect on the company losses and scrubber system would assist on the odor problem. The implementation of VSD is equally important as this is one of the best solutions to reduce the electricity consumption in the company with a great savings. These recommendations are for better improvement and the most is to maximize the company's product quality and productivity. The management is also recommended to take the necessary precautions against the risks to occupational safety and health. With the information provided, it is hoped that the management is aware and is committed to make the necessary improvements for the productivity and profitability of the company and working environment for every employee in the premises. Strategies and technologies deliver promises, the most valuable asset, people, delivers results.

23 ANNEXES

24 Simplified Process Flowchart Annex A Raw mtrl screening Refining Screening (Tmesh 80 or 40) Mixing Autoclave Milling Blending Refining Extruding Cooling RECLAIMED RUBBER

25 Annex B Material Balance Raw material, Rubber Dust = 500,000kg Coarse Rubber= 170kg Others (Chemical & Oil)- unidentified value Process Products; Reclaimed = 800,000kg Crumb = 50,000kg Granule =20,000kg Renant 1000kg Basis: Monthly