DEVELOPING OF EXPANDABLE POLYSTYRENE INDUSTRY USING CLEAN PRODUCTION TECHNOLOGY

Abstract

In terms of the importance of clean production technology in industry for saving environment and cost, also with the importance of expandable polystyrene industry for the current development in Egypt in multi fields such as modern agriculture, construction and Building, home appliances and electrical instruments industries, the study deals with application the clean production technology on the expandable polystyrene factory. The study applied in ELaraby foam factory for backing and thermal insulation to reduce the energy consumptions and save both cost and environment. In year 2016 data was accumulated analyzed and points of weakness presented. Several scenarios and modifications were proposed and the most effective were chosen and designed, four modifications were implemented at January 2017 and the significant parameters for energy consumptions and wastes were measured again during year 2017 and the results were analyzed, evaluated and the difference between the before and after clean production application was illustrated. Total energy saving from the implemented modifications and the environmental improvements were calculated as a total benefits from clean production technology application the modifications were generated from 4R concepts which are reduce, reuse, recycle and recovery ideas and the four modifications are:- • Separate machines to two air pressures • Reusing hot air from compressors cooling • Increasing natural cooling for hot water • Heat recovery from boiler blow down process The modifications achieved technically saving in electricity by 29.45%, in natural gas by 19.03% and in water by 35% in addition to increase the production amounts by 24.54%. Environmentally, it achieved saving in CO2 emissions by 19.03% and reduction in wastewater amounts by 35% and correcting one major environmental infraction. Financially, the modifications achieved saving2,926,205 L.E this achieved with the increase of the product quantity by 24.54%.