Preparation of Resource Efficiency Guides for Manufacturing Industry Sub-Sectors

Project Name: Preparation of Resource Efficiency Guides for Manufacturing Industry Sub-Sectors

Institutions/Organizations Supporting the Project: Directorate General of Productivity of Ministry of Science, Industry, and Technology

Project Duration: 18 months

Project Start Date: January 1, 2018

Project End Date: June 30, 2019

Brief information about the project: The subject of this project is the preparation of sector resource efficiency guides for the implementation of the identified actions in the following sub-sectors for the "preparation of sector guidance documents for dissemination of resource-efficient production technologies in the manufacturing industry" under the Tenth Development Plan's (2014-2018) "Action Plan for the Priority Transformation Program for Increasing Efficiency in Production" and also within the framework the Strategic Plan of the Ministry of Science, Industry and Technology (2013-2017) as in "3.16.5. preparation of sector implementation guides on cleaner production/eco-efficiency": 13.3 Finishing of textiles (textiles sub-sector), 23.31 Manufacture of ceramic tiles and flags (other non-metallic mineral sub-sector), 23.51 Manufacture of cement (other non-metallic mineral sub-sector), 20.15 Manufacture of chemical fertilizers and nitrogen compounds, 10.39 Other processing and preserving of fruit and vegetables (food sub-sector), 23.11 Manufacture of flat glass (other non-mineral products sub-sector), 10.82 Manufacture of cocoa, chocolate and sugar confectionery (food), Manufacture of basic iron and steel and of ferro-alloys (basic metals)

Project Work Packages:

Finishing of Textile Products (click for detailed information)

The textile sector accounts for around 16% of the Turkish manufacturing industry, and nearly 2 million people are employed in the sector. We see the use of energy comes to the forefront for different types of chemicals, high amounts of water and heat treatments especially in the finishing (dyeing, finishing, finishing, etc.) of textiles sub-sector. Based on the fieldwork and literature review in the project “Prediction of Resource Efficiency Potential in the Turkish Manufacturing Industry,” 15-79% water saving potential, 15-40% energy saving potential, 23-72% wastewater reduction potential, over 60% waste gas emission reduction potential and around 50% solid waste reduction potential were determined. These ranges were determined in quite broad terms as the operations applied in the sector vary even among enterprises. For these reasons, prevention of pollution at its source will play an effective role in achieving specified potentials. Therefore, efficiency improvements in the sector will contribute to the country's sustainable development goals.

Approximately 77% of the responses to the surveys in the sector were obtained from the "Finishing of Textiles" sub-sector. Water consumption can be reduced even in applications where energy and raw material savings are the main objectives, especially because reduced water consumption in textile, dyeing and finishing processes would lead to energy, raw material, and chemical savings. In addition, the preparation of a guide is considered a priority for the following reasons:

• This sub-sector has a very intensive chemical consumption
• Significant utilization of thermal energy in production processes
• Generation of hazardous, non-hazardous and textile waste in production processes
• The high amount of wastewater in parallel with high water consumption in the sub-sector

Manufacture of ceramic tiles and flags (click for detailed information)

53 firms are involved in the manufacture of ceramic coating sector. 2015 saw the production of ceramic construction materials worth TL 4.64 billion.

This sub-sector ranks second in its sector in terms of water savings potential after the manufacture of cement. It ranks third in terms of energy savings potential. It ranks fourth among all the sub-sectors of the minerals sector in terms of total savings. Currently, there is a BREF document prepared by the European Commission in relation to the sector. Nevertheless, the Ceramic Research Center (SAM), which has been operating in Turkey since 1998, carries out R&D activities in relevant ceramics industry areas. SAM is one of our institute’s stakeholders. In addition, the institute has carried out two projects so far regarding the sector; it has the knowledge, experience, and capacity regarding the sector. For this reason, preparation of a guide before the other sub-sectors is considered to be more urgent as the latter lack BREF documents and company diversity.

Manufacture of cement (click for detailed information)

The Turkish cement sector started production with a kiln that had 20,000 tons/year in 1991 in Darıca reaching 80 million tons of clinker and 133 million tons of cement production capacity in 2016. As of 2017, Turkey has a total of 72 plants, 54 of which are integrated and 18 are grinding plants (Turkish Cement Manufacturers’ Association, 2017a). World cement production -reached 4.6 billion tons in 2015 with China having a leading position in cement production with 2.35 billion tons. Turkey is Europe’s biggest and the world’s sixth biggest manufacturer after China, India, EU countries, US, and Brazil with 72.8 million tons of cement production (CEMBUREAU, 2016).

The sector increases its share in exports on day-to-day basis selling products to approximately 90 countries in the world. In 2016, Turkey saw cement and clinker exports of approximately 7.5 million and 3.7 million tons, respectively. At present, the sector does not have difficulty meeting the domestic demand while increasing its exports continuously becoming the biggest cement exporter in Europe.

The "manufacture of cement" sub-sector stands out clearly among all other sub-sectors, especially in terms of energy and raw material saving potential. Currently, there is a BREF document prepared by the European Commission as well as annual reports and many technical reports prepared by CEMBUREAU in relation to the sector. In addition, TCMA, a sector association in Turkey, actively carries out operations. "Manufacture of cement," a resource-intensive sector, has very high consumption amounts of energy and raw materials, in particular. The activities in this sector are quite important as it is possible to achieve huge savings with small efficiency practices. In addition, the institute has carried out two projects so far regarding the sector; it has the knowledge, experience, and capacity regarding the sector.

Manufacture of chemical fertilizers and nitrogen compounds (click for detailed information)

The products in this sector have a homogeneous structure going through similar processes. Almost all (95%) of the materials (natural gas, phosphate rock, potassium, and the like) required for the chemical fertilizer production in Turkey are imported and converted into fertilizers by 6-7 main producers.

In addition, around 350 companies of different sizes and capacities in the sector are involved in the production with various mixtures and formulations through direct imports. The external dependency of the sector makes it vulnerable to market conditions and exchange rate changes.

Preparation of a guide is considered to be beneficial in this sector as it was examined under the “Prediction of Resource Efficiency Potential in the Turkish Manufacturing Industry.” Also, it has the BREF document as well as case studies across the world. Furthermore, it ranks first in terms of water savings.

Processing and Storage of Fruits and Vegetables N.E.C (click for detailed information)

In the food sector, 10.3 processing and preserving of fruit and vegetable sub-sector covers 3 further sub-sectors.

• 10.31 Processing and preserving of potatoes
• 10.32 Manufacture of fruit and vegetable juice
• 10.39 Other processing and preserving of fruit and vegetables

Consisting of SMEs throughout the country, the sector develops continuously thanks to especially the incentives and grants of the Ministry of Food, Agriculture and Livestock. Linked to agriculture and agricultural products, this sector has a medium added value but a huge water footprint. It is also important in terms of raw material efficiency and secondary raw material output. The "Resource Efficiency Guide on the Processing and Preserving of Fruit and Vegetables" document will provide applicable and useful results for SMEs.

Manufacture of flat glass (click for detailed information)

The criteria for the selection of the sector for guide preparation are as follows;

• It is an energy-intensive sector and consumes 7% of the energy (694,000 toe) in the mineral sector according to the MENR’s 2015 Energy Balance Table.

• It has a significance for the national economy as one of the basic manufacturing fields providing input to many sectors and households such as construction, automotive, energy, white goods, food, beverages, soft drinks, medicine, cosmetics, tourism (including restaurants, catering).

• The Turkish glass sector has an important position in the world with a production capacity of 4.7 million tons/year in Turkey and abroad (MSIT, 2014).

• Şişecam ranks second in Europe and third in the world in household glassware, second in Europe and fifth in the world in flat glass (five manufacturing plants), fourth in Europe and the world in glass packaging (four manufacturing plants). (Şişecam, 2015).

• Flat gas, glass packaging, household glassware account for 50%, 32% and 16% of the domestic production capacity, whereas the remaining 2% is related to the glass fiber. (MSIT, 2014).

• The results of the Project “Prediction of Resource Efficiency Potential in the Turkish Manufacturing Industry,” shows that “23.11: Manufacture of flat glass” is among the sectors with the highest energy savings potential in the minerals sector.

• Şişecam is Turkey’s biggest glass manufacturer accounting for almost 90% of the production capacity (MSIT, 2014). There are also enterprises with different scales such as Düzcam, Güral Cam, İzocam and Marmara Cam. However, the planned handbook can also directly address Şişecam because the company accounts a large part of the capacity and production volume.

Currently, there is a BREF document prepared by the European Commission in relation to the sector. In addition, the institute has carried out one project so far regarding the sector; it has the knowledge, experience, and capacity regarding the sector.

Manufacture of Cocoa, Chocolate and Confectionery (click for detailed information)

In the main manufacture of food products, 10.8 manufacture of other food products sub-sector consists of the following seven sub-sectors:

10.81 Manufacture of sugar

• 10.82 Manufacture of cocoa, chocolate and confectionery
• 10.83 Processing of tea and coffee
• 10.84 Manufacture of condiments and seasonings
• 10.85 Manufacture of prepared meals and dishes
• 10.86 Manufacture of homogenized food preparations and dietetic food
• 10.89 Manufacture of other food products n.e.c

Even through its resource potential seems to be high, the creation of a sector guide (for the manufacturing of other food products) does not seem feasible as it is composed of many sub-sectors. Working on "Sector Guide to Resource Efficiency” with a focus on on the product and/or specific sub-sector would be the feasible action.

Therefore, 10.82 Manufacture of cocoa, chocolate and confectionery sub-sector is convenient as opposed to 10.81, which stands together with the former in the 10.8 Manufacture of other food products sector. The sector has a relatively homogeneous structure consisting of SMEs and large-scale enterprises nationwide. Such a "Resource Efficiency Guide to Manufacture of cocoa, chocolate and confectionery" will be useful for the sector. 10.81 (Manufacture of sugar) sector is important, but there are 25 public and a few private sugar enterprises throughout the country. Hence, such a "Sugar Production Resource Efficiency Guide" will remain theoretical. Public institutions take actions very slowly compared to the private sector in terms of improvement/process optimization and/or efficiency enhancement. Therefore, the preparation of the guide for the 10.81 sub-sector is not a priority for applicability.

Manufacture of basic iron and steel and of ferro-alloys (click for detailed information

The 24.10 sub-sector represents approximately 80% of the potential of the basic metals sector and has the highest resource efficiency potential among all the sub-sectors examined. A detailed BREF document is available for this sector. However, our institute has conducted three national R&D projects in the last five years about the best techniques in this sector while examining the BREF documents in detail. For this reason, preparing guides in this sub-sector will be useful to consolidate existing information and addressing the vast majority of the sector.

Click to access BREF Documents http://eippcb.jrc.ec.europa.eu/reference/

Please click for detailed opinions, questions, partnership requests and information about the project: sonmez.dagli@tubitak.gov.tr; tuba.budak@tubitak.gov.tr;emrah.s@tubitak.gov.tr)