PDF Integrated Waste Management in Sarawak for Industry Network

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INTEGRATED WASTE MANAGEMENT IN SARAWAK FOR INDUSTRY NETWORK

Herman Amia

Anak

Atek

TO

Bachelor of Engineering with Honours

811.5 (Mechanical Engineering and Manufacturing Systems) 8531

2004 2004

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Pusat Khidmat Makfumat

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UNlVERSlTI MALAYSIA SARAWAl{

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P.KHIDMA TMAKLUMA TAKADEMIK UIlIMAS

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INTEGRATED WASTE MANAGEMENT IN SARAWAK FOR INDUSTRY NETWORK

HERMAN AMIA ANAK ATEK

This project is submitted in partial fulfilment of

the requirements for the degree of Bachelor of Engineering with Honours (Mechanical and Manufacturing System)

Faculty of Engineering UNIVERSITI MALAYSIA SARA WAK

2004

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Borang Penyerahan Laporan Projek Tahun Akhir Universiti Malaysia Sarawak

BORANG PENYERAHAN LAPORAN PROJEK TAHUN AKHIR

Judul: INTEGRATED WASTE MANAGEMENT SYSTEM IN SARAWAK

FOR INDUSTRY NETWORK

SESI PENGAJIAN: 2003/2004

Saya HERMAN AMIA ANAK ATEK

(HURUF BESAR)

mengaku membenarkan tesis ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Hakmilik laporan adalah milik penulis dan UNIMAS.

2. Naskhah salinan di dalam bentuk kertas atau mikro hanya boleh dibuat dengan kebenaran bertulis daripada UNIMAS atau penulis.

Pusat Khidmat Maklumat Akademik, UNIMAS dibcnarkan membuat salinan untuk pengajian mereka.

4. Laporan hanya boleh diterbitkan dengan kebenaran penulis atau UNIMAS. Bayaran royalti adalah mengikut kadar yang dipersetujui kelak.

5. * Say a membenarkan/tidak membenarkan Pusat Khidmat Maklumat Akademik membuat salinan laporan ini sebagai bahan pertukaran di antara institusi pengajian tinggi.

6. .. Sila tandakan ( ., ) di mana kotak yang berkenaan

D

^SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kcpentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).

D

^TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/

badan di mana penyelidikan dijalankan).

~ TIDAK TERHAD

Disahkan oleh

(TANO'ATANGAN PENULlS)

Alamat tetap: NO 1, FLAT PUNAI, PUAN SHANTI FARIDAH SALLEH

JALAN BATU LINTANG, Nama Penyelia

93200 KUCHING, SARAW AK.

Tarikh : Tarikh:

CATATAN • Potong yang tidak berkenaan.

••

Jika laporan ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasal organisasi berkenaan dengan menyertakan sekali tempoh laporan. Ini perlu dikelaskan sebagai SULIT atau TERHAD.

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APPROVAL SHEET

This project entitled "Integrated Waste Management System in Sarawak for Industry Network" was prepared by Herman Amia anak Atek as partial fulfilment of the requirement for the degree of Bachelor of Engineering with Honours in Mechanical and Manufacturing System is hereby read and approved by:

PuJ!!iaddah Sa1!oh ^Date: is-· 0 ([ . 0

Y

(Supervisor)

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ACKNOWLEDGEMENT

First and foremost, the author would like to thank Puan Shanti Faridah Salleh for her guidance,

patience and support, which has enable the project to run smoothly. Many thanks to the staffs of Department of Environment (Sarawak Branch) and National Resource & Environmental Board, for their kind assistance and for the permissions to use their library facilities. Not forgetting, the author's friends for their advice and invaluable assistance. Last but not least, to the author's family for their love and support.

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ABSTRACT

Waste is inevitable. Industrial waste of all waste is, pose the most challenging problem to human because of its hazardousness. Sarawak, on the other hand, is an ever-improving state with an enviable richness ofraw material (petroleum, natural gas, mineral, timber etc) and vast industrial parks. Therefore, it is imperative to implement an environmentally sustainable and integrated waste management system to handle the industry's unavoidable by-product, which is waste. This study will attempt to integrate the available waste management option by using the indexing method, with respect to the types of industrial waste being generated in Sarawak.

From the indexing of waste management options, it has been found out that the best waste management options are definitely the waste reduction and waste reuse. Waste recycling is also favourable and this compliment the flrst two waste management options to form the 3R practice (reduce, reuse and recycle), which are best implemented at the industry or waste makers itself. Thermal incinerator and landfill should be the final waste options because as soon as waste undergo incineration and landfill, there is lesser possibility of salvaging (recycling) the waste or in other words the waste is lost forever as in the case of landfill.

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,..

ABSTRAK

Sisa buangan (sampah) sukar dielakkan. Sisa buangan industri merupakan cabaran terhebat yang terpaksa ditangani oleh manusia kerana sifatnya yang membahayakan kesihatan man usia. Negeri Sarawak pula adalah sebuah negeri yang terkenal dengan kekayaan hasil buminya (petroleum, gas asli, mineral, balak dB) serta pelbagai kawasan perindustrian baru. Jadi, pelaksanaan satu sistem pengurusan sisa perindustrian yang bersepadu dan mampan dalam alam sekitar, adalah amat penting. Kajian ini adalah bertujuan untuk menggabungkan pelbagai pilihan pengurusan sisa buangan industri dengan menggunakan teknik indeks, berpandukan kepada jenis sisa buangan yang dihasilkan oleh pelbagai industri di Sarawak. Daripada indeks pelbagai pilihan pengurusan sisa buangan industri, pengurangan dan penggunaan semula sisa buangan industri merupakan pilihan pengurusan sisa buangan industri yang terbaik. Proses pengitaran semula juga satu alternatif yang menarik, dan ini melengkapkan amalan 3R, yang harus dipraktikkan oleh semua industri. Pembakaran sampah dan pelupusan sampah harus dijadikan pilihan pengurusan sisa buangan industri yang terakhir kerana, sebaik sahaja sisa buangan industri melalui proses-proses tersebut, tiada lagi peluang untuk mempraktikkan amalan 3R ke atas sisa buangan industri tersebut.

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Page

ii iii iv v vi 1 2 2 2 2 2 3 3 5 7 7 8 8 9 9 9 9 10 11 13 13 13

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2.3 Waste Reuse (In-Process Recycling) 15

2.4 Waste Recycling 15

2.5 Biological Treatment 17

2.5.1 Anaerobic Treatment 17

2.5.2 Composting 18

2.6 Thermal Treatment 18

2.6.1 Pyrolysis 19

2.6.2 Gasification 19

2.6.3 Incineration 20

2.7 Operating the Waste Management System 20 2.7.1 An effective Waste Management System 21

Chapter 3 Methodology 23

3.1 Overview 23

3.2 Data Collection 23

Chapler 4 Data Analysis & Recommendation 25

4.1.1 Life Cycle Analysis Revisited 25

4.1.2 Life Cycle Analysis for Integrated Waste 25 Management System

4.2 Analysis of Industrial Waste Management 26 System in Sarawak

4.2.1 Goal Definition & Scope 26 4.2.2 Types of Industry in Sarawak 26 4.2.3 Source of Industrial Waste in Sarawak 29

4.2.4 Reference Scenario 33

4.3 Discussions 36

4.3.1 Waste Reduction Potential 36

4.3.2 Waste Reuse Potential 37

4.3.3 Waste Recycling/Recovery Potential 38 4.3.4 Biological Treatment Potential 39

4.3.5 Thermal Treatment Potential 39

4.3.6 Landfill Potential 40

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4.4 Overall Impact Assessment of Sarawak's Industry 48

4.5 Timber Industrial Waste in Sarawak 49

Chapter 5 Conclusions & Recommendation 52

5.1 Conclusions 52

5.2 Recommendations 55

Bibliography Appendix

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LIST OF TABLES

Table 1-1 Types and examples of hazardous chemicals 4

Table 1-2 List of hazardous properties 4

Table 4-1 Free Industrialized Zones in Sarawak 27

Table 4-2: Indexing of waste management option according to the types of industrial 42 waste

Table 4-3: Indexing of general waste management options 44

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LIST OF FIGURES

Figure 1-1 Life Cycle Assessment of a product or function 11

the types of industrial wastes in Sarawak

for Sarawak's industry

Figure 2-1 Waste Management Hierarchy 22

Figure 4-1 Industrial parks of Sarawak 28

Figure 4-2 Source of industrial pollution by division 29

Figure 4-3 Number and types of industry 30

Figure 4-4 Quantity of scheduled waste by division 31

Figure 4-5 Disposal quantity of scheduled waste according to type of waste 32

Figure 4-6 Types of wastes and methods of waste treatment in Kuching 33

Figure 4-7 Classifications of Sarawak's main industrial waste 34

Figure 4-8 Hierarchy of available waste management options with respect to 36

Figure 4-9 Number of landfills in Sarawak 40

Figure 4-10 The stages of proposed integrated industrial waste management 41

Figure 5-1 The stages of proposed integrated industrial waste management 52

~~__^~.' t______________________________________________________________________________________^~

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Chapter 1

INTRODUCTION

The objective of this project to study the existing industrial waste management options available and try to integrate all the suitable waste management options in order to create an environmentally and economically sustainoole waste management system for industry in Sarawak.

We consider waste as something that we do not want or something that we fail to use. Waste can be produced as the unwanted by-product of a process, or something can become waste when it is no longer useful to the owner.

Waste in modern context occupies both space and time. In terms of space, its first and most obvious characteristics in global society is its ubiquitousness, waste could be found almost anywhere. Increased consumption and throw-away culture all contributed to waste. In terms of time, waste as we know it is essentially a modern problem because humanity has always produced wa teo

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1.1 Waste Classification

1.1.1 Controlled Waste

Household, industrial and commercial wastes are categorized as controlled waste.

Sewage sludge disposal to landfill and by incineration is controlled waste, but disposal of this waste at sea and spreading on agricultural land is regulated separately.

1.1.2 Uncontrolled Waste

Uncontrolled wastes are those that are not controlled, including agricultural waste and mine and quarry waste, which are subject to separate legislation.

1.3 Special Waste (Hazardous Waste)

Special waste is controlled waste of any kind that is or may be so dargerous or difficult to treat, keep or dispose of that special provision is required for dealing with it. Such waste is defiDed as containing substaoces that are dangerous to life.

Commercial & Industrial Waste

Commercial and industrial waste covers a large range of materials. Commercial waste, collected by local authorities, is referred to as municipal waste. All other waste collected from commercial properties and organizations, but not collected by the local authority, is commercial

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Commercial and industrial waste is essentially all commercial enterprises and industrial businesses not covered by municipal waste. This covers enterprises involved in transportation, manufacturing and processing of all material types, the service industry, and business services.

1.2 Types of Waste

(i) household and urban waste (ii) industrial waste

(iii) mining waste (iv) nuclear waste (v) agricultural waste

(vi) toxic and hazardous waste (chemical waste)

1.2.1 Defining industrial waste

Waste is defined as any discharge of unwanted material arising from human activity and/or industrial processes or facilities (Environmental Impact Assessment Guidelines DOE Malaysia). What about industrial waste? The Oxford English Dictionary defines industrial waste as "useless by-products of any industrial process" while Webster's New International Dictionary con iders waste as "damaged, defective or superfluous material produced during or left over from a manufacturing process or industrial operation".

Industrial waste is produced as part of a process but despite its common features, waste is distinguished by a variety of forms, and these factors have affected the treatment of the problem.

The waste process is usually framed in terms of generation, storage, treatment and disposal.

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Table 1-1 Types and examples of hazardous chemicals (UK Waste Guide)

Classification Examples

Combustible liquid Ammonium sulphite, dimethylsulphoxide, pump oil

Corrosive Acids and bases, corrosive solids, mercury

Dangerous when wet I Lithium aluminium hydride, potassium ingot, sodium metal

Explosive Gunpowder

Flammable gas Hydrogen

Flammable liquid Solvents, alcohols

Flammable solid Camphor, magnesium metal, red

phosphorus

Non-flammable gas Argon

Oxidizer Ammonium nitrate, potassium chlorate,

potassium permanganate

Poison Arsenic trioxide, mercury mixtures, phenol

Poisonous gas Chlorine, methylbromide

Spontaneously combustible Activated charcoal

Table 1-2: List of hazardous properties (UK Waste Guide)

Hazards Criteria

Explosive Substances capable of exploding under the

effect of flame or which are sensitive to shocks or friction

Oxidizing Substances exhibiting highly exothermic

reactions when in contact with other substances, particularly flammable substances

Highly flammable Substances capable of heating and catching fire in contact with air at ambient

temperatures and without any application of energy

Irritant Non-corrosive substances that are capable

of causing inflammation through

immediate, prolonged or repeated contact with the skin

Harmful Substances which may involve limited

health risks

Toxic Substances which may involve serious,

acute or chronic health risks and even death

Carcinogenic

L

Substances causing or increasing the

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incidence of cancer

Corrosive Substances capable of destroying living

tissue on contact

Infectious Substances containing micro-organisms or

toxins which cause disease in men or other living organisms

Teratogenic Substances capable of inducing hereditary

congenital genetic defects or increasing their incidence

Mutagenic Substances which may induce hereditary

genetic defects or increase their incidence

Ecotoxic Substances presenting immediate or

delayed risks for the environment

1.3 Waste treatment methods

Treatment can reduce the volume and toxicity of a waste. Reducing a waste's volume and toxicity prior to final disposal can result in long-term cost savings. There are a considerable number of levels and types of treatment from which to choose. Selecting the right treatment option can help simplify disposal options and limit future liability.

Treatment can also make a waste amenable for reuse or recycling. For example, treatment might be incorporated to address volatile organic compound (VOC) emissions from a waste management unit, or a facility might elect to treat a waste so that a less stringent waste management system design could be used. Treatment involves changing a waste's physical, chemical or biological character or composition through designed techniques or processes.

There are three primary categories of treatment namely physical, chemical, and

biological. Physical treatment involves changing the waste's physical properties such as its size,

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shape, density or state. Physical treatment does not change a waste's chemical composition. One form of physicallreatment, immobilization, involves encapsulating waste in other materials, such as plastic, resin, or cement, to prevent constituents from volatilizing or leaching. Listed below are few example of physical treatment:

(i) Immobilization (ii) Carbon absorption (iii) Distillation

(iv) Filtration

(v) Evaporation/volatilization (vi) Grinding

(vii) Shredding (viii) Compacting

(ix) Solidification/addition of absorbent material

Chemical treatment involves altering a waste's chemical composition, structure, and properties through chemical reactions. Chemical treatment can consist of mixing the waste with other materials (reagents), heating the waste to high temperatures, or a combination of both.

Through chemical treatment, waste constituents can be recovered or destroyed. Listed below are few examples of chemical treatment:

(i) Neutralization (ii) Oxidation (iii) Reduction (iv) Precipitation (v) Acid leaching (vi) Ion exchange (vii) Incineration

(viii) Thermal desorption (ix) Stabilization

(x) Vitrification (xi) Extraction

(xii) High temperature metal recovery

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Biological treatment can be divided into two categories-aerobic and anaerobic. Aerobic biological treatment uses oxygen-requiring microorganisms to decompose organic and non

metallic constituents into carbon dioxide, water, nitrates, sulfates, simpler organic products and cellular biomass. Anaerobic biological treatment uses microorganisms, in the absence of oxygen, to transform organic constituents and nitrogen-containing compounds into oxygen and methane.

Anaerobic biological treatment typically is performed in an enclosed digester unit. Listed below are few examples of biological treatment:

(i) Aerobic digestion (ii) Anaerobic digestion

1.4 Waste minimization methods

1.4.1 Recycle and Reuse

The most popular waste minimization method nowadays is the recycle and reuse method.

A variety of industrial wastes can be recycled for use as products. There are three ways in which industrial waste recycling occurs: at the facility itself (on-site recycling), at commercial facilities

that gather waste streams from several companies (off-site recycling), and at a company that process the waste products of another company (inter-industry exchange).

Off-site recycling of some hazardous materials is difficult because of the dangerous nature of the chemicals themselves. In addition, industries' fears of accidents and spills during transportation or recycling operations and the resulting liability can sometimes present an

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obstacle to the recycling of hazardous materials off site. Other types of waste minimization methods are mentioned below.

1.4.2 Source reduction

The best mean of getting rid of waste is to reduce the amount generated at the source while waste minimization activities such as reusing and recycling, seek to return the waste stream into a production process or alternative use, thus leading to both economic and

environmental benefits. Source reduction is a process of reducing the amount of any hazardous or non-hazardous substance entering any waste stream or released into the environment prior to recycling, treatment, or disposal.

1.4.3 Incineration

Incineration reduces and eliminates hazardous characteristics of waste in some cases. In the case of waste-to-energy facilities, it may also provide energy for use in other production processes. However, the burning of hazardous waste in incinerators, boilers, and industria furnaces, increases the amount of toxics released to the air. In addition, the ash produced by burning hazardous waste may still be a threat to human health and the environment because it contains such compounds as lead, uranium, and arsenic. Finally, tre variety of waste streams received at commercial incineration facilities makes it harder to control the burning process, leading to problems with explosions.

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1.4.4 Source separation

It is a process that separates hazardous waste from non-hazardous waste, to prevent the overall waste from being managed as hazardous waste.

1.4.5 Substitution of raw materials

It is a process of replacing the raw material that results in hazardous waste with one that results in Ie hazardous waste or none at all.

1.4.6 Manufacturing process changes

It is a method that consists of either eliminating a process that produces waste or changing the process so that a waste is no longer produced.

1.5 Life Cycle Analysis (LeA)

Life cycle analysis is a concept of conducting a detailed examination of the life cycle of a product or a process, which emerged in response to increased environmental awareness on the part of the general public, industry and governments. Two main stages are involved which are the collection of data and the interpretation of that data.

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1.51 Defining Life Cycle Analysis

Life cycle analysis involves making detailed measurements during the manufacture of the product, from the mining of the raw materials used in its production and distribution, through to its use, possible re-use or recycling, and its eventual disposal.

Life cycle analysis provides a methodology for considering each stage of the product's life from extraction of the raw materials, through manufacture and construction, use and

disposal. The analysis should consider the positive social and economic benefits of each activity though in practice this is too comp1icated and the method usually concentrates on quantifying negative impacts for comparison.

The key elements are identifying and quantifying the environmental loads involved for example the energy and raw materials being consumed, the emissions and wastes being generated. Evaluation can then be made on the potential environmental impacts of these loads followed by the assessments of available options for reducing these environmental impacts.

Recycling ability of the wastes may be an environmental advantage in terms of prolonging the life of depleting resources as well as avoiding or reducing the energy and pollution caused by manufacture from raw materials.

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whi

eXtraction and processing of raw materials eventual recycling or

disposal as waste at

the end of it; useful life manufacturing

use, re-use and packaging

maintenanceof the product

Figure 1-1: Life Cycle Assessment of a product or function (http://www.agrifood-forum.net)

1.5.2 Objectives of Life Cycle Analysis

Life cycle analysis is a process of evaluating the effects that a product has onthe environment over the entire period of its life thereby increasing resource-use efficiency and decreasing liabilities. It can be used to study the environmental impact of either a product or the function of the product is designed to perform.

Life cycle analysis is conducted in industry sector to enable it to identify areas where improvements can be made, in environmental terms. The analysis is intended to provide environmental data for the public or for the government.

All products have some impact on the environment. Since some products use more urces, cause more pollution or generate more waste than others, the aim is to identify those

are most harmful.

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Even for those products whose environmental burdens are relatively low, the analysis hould help to identify the stages in production processes which will cause or have the potential to cause pollution, and those which have a heavy material or energy demand.

Breaking down the manufacturing process into such fine detail can also be an aid to identifying the use of scarce resources, showing where a more sustainable product could be substituted.

Life cycle analysis is a powerful tool which can assist in formulating environmental legislation, help manufacturers analyze their processes and improve their products, and perhaps enable consumers to make more informed choices.

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