Cleaner production package
- 1. BEST ENVIRONMENTAL MANAGEMENT PRACTICES (Cleaner Production Options) Textile Industry of Pakistan
- 2. What is the methodology of best environmental management practices? “The continuous application of an integrated preventative environmental strategy applied to processes, products and services to increase eco-efficiency and to reduce risk for human and the environment”
- 3. Classification of Management Practices Options for Textile Industry Good Housekeeping Practices Resource Conservation Process/Chemical Usage Cleaner Technologies
- 4. Good Housekeeping Practices Maintenance of Equipment Prescreening of Inventory Chemical Handling Practices
- 5. Maintenance of Equipment Good Housekeeping Practices Symptoms of Problems Leakages of oil, water,chemicals,steam Improper Chemical dosing Rare Machine, equipment and vessel cleaning Actual Problems Awareness but lack of willingness Not in the list of priority Lack of proper staff Plans but no proper implementation Action Assignment of proper resources Set as first priority Implementation on continual basis Cost/Resource Requirement No direct cost is involve Performance Indicator Aesthetic improvement of industry Savings in resources Minimization of pollution load
- 6. Prescreening of Inventory Good Housekeeping Practices Symptoms High rejection Large volume of inventory Problems No Quality Control at this stage QA Department under production Fewer personnel for testing Action Periodic Quality Checks for concentration and Viscosity of Chemicals, Count and Construction/Composition of Fiber/Fabric Acquisition of MSDS from Vendors Cost/Resource Requirement No direct cost is involved Performance Indicator Less usage of raw material and chemicals Low wastages
- 7. Chemical Handling Practices Good Housekeeping Practices Problems Improper Storage, Transportation and Handling Spillage Wastage Action Proper Storage Facility Segregation of Chemicals Use of Liquid and Granular Dyes and Chemicals Labeling of Chemicals Training of Staff on Chemical Handling & Transportation Cost/Resource Requirement No direct cost is involved Development of External & Internal Training Program Performance Indicator Less usage of Dyes and Chemicals Reduction in Pollution Load Occurrence of Accidents minimized
- 8. Resource Conservation Installation of Water Flow meters Reuse of Bleach and Dye Bath Reuse and Recycling of Cooling & Condensate Water Reduction of Water Consumption in Printing Cleaning Minimization of Energy Consumption in Stenter Reduction in water consumption in washing ranges Installation of Economizer at Boiler Calculation of Boiler Efficiency
- 9. Installation of Water Flow meters Problems Not observable at early stage like cancer Action Resources can only be conserved if water consumption is optimum in the industry. Water optimization can not be achieved without water monitoring. For water monitoring and its controlled use, water flow meters of appropriate size and types will be installed at the source and at all the major water utility areas and machines Cost/Resource Requirement 10,000-15000 Rs. Saving of 10-15 % water used Performance Indicator Identification of areas of high water consumption Basis for water reduction plans
- 10. Reuse of Bleach and Dye Bath Resource Conservation Concerns Drain of Costly Chemicals and Dyes which can be reused Action Using continuous scour wash water to batch scouring Reusing scour rinses for desizing Reusing mercerization wash water for scouring Reusing bleach wash water for scouring Use of exhausted dye bath for next run Cost/Resource Requirement Cost includes piping, pump and tanks cost, which will be approximately 150,000 Rs for each recycling option Incase of dye bath reuse in addition to above shade analyzer will be required which costs 250,000 – 300,000 Local expertise and fabricators available Performance Indicator Water conservation Cost saving in terms of less amount of chemicals and dyes usage Low pollution load
- 11. Reuse and Recycling of Cooling & Condensate Water Resource Conservation Concerns Drain of hot water which comes after cooling various machineries specially jets and singeing Drain of Boiler’s Condensate Return Action Recycle of drain hot water and condensate return in various functions where hot water is required Cost/Resource Requirement Cost of cooling water reuse will be approx 100,000 Rs. Cost of reuse of condensate return will be approx 100,000 – 150,000 Rs. Pay back with in four months Local expertise and fabricators available Steam condensate Performance Indicator Water and energy conservation Reduction of wastewater
- 12. Reduction of Water Consumption in Printing Cleaning Resource Conservation Concerns Use of water for cleaning belt even when the machine is not running Waste of printing paste after each batch change over Use of fresh water for cleaning squeegees, screens and buckets Action Provision for stoppage of running water when machine stops Use of shut off valves in water hoses Manual/Mechanical removal of printing paste Reuse of cleanest part of rinsing water instead of using fresh water for cleaning. Filtering of screen wash water by chemical means and its reuse. Use of glue for blanket which do not require repeated washing Use of multi screen washers using spray nozzles. Cost/Resource Requirement Cost incurred for reuse of rinsing water will approximately be 150,000 – 200,000 Rs. Performance Indicator Water and energy conservation Reduction of wastewater Reduction of dye paste
- 13. Minimization of Energy Consumption in Stenter Resource Conservation Concerns Wastage of hot exhaust gases Use of low efficiency burners Use of low efficiency heating systems Action Installation of heat exchangers and optimization of exhaust air flow Controlling moisture content of feed fabric High efficiency burners to be used Use of indirect gas firing systems Proper encasement of stenters Cost/Resource Requirement Cost incurred for heat exchangers will be approximately 100,000 – 150,000 Cost for encasement of stenters will be dependable on condition of insulation Performance Indicator Energy conservation
- 14. Reduction in water consumption in washing ranges Concerns Use of a large quantity of high temperature water at washing Action The consumption can be brought down by adjustments in the process parameters. For this purpose, interactive software can be used to determine specific water usages at different sets of such parameters before being applied in practical. Cost/Resource Requirement Only testing equipment for conductivity measurement is required to get washing efficiency. Performance Indicator Water and energy conservation Reduction of wastewater Resource Conservation
- 15. Installation of Economizer at Boiler Concerns Loss of waste heat from boilers stacks Action Flue gas thermal energy can be used to heat boiler feed water by the installation of an economizer Cost/Resource Requirement 650,000 Rs. Performance Indicator energy conservation Resource Conservation
- 16. Calculation of Boiler Efficiency Resource Conservation Concerns Boilers are mostly old enough to have good efficiency. Action Actual efficiency to be calculated for making the further decisions Cost/Resource Requirement No cost is involved except for a gas meter at the boiler to get the consumption. Performance Indicator energy conservation
- 17. Process and Chemical usage Process Modification Chemical Substitution Better Process Control Process Control Laboratory Process Modification and Chemical Substitution is mainly related with Buyers requirement, Quality Control and Costing. It is observed that this issue is already hotly being pursued by management to remain competitive and is a priority issue. Process and Chemical Usage
- 18. Better Process Control Concerns High rejection, low quality, production breakdowns Action Standardization and dissemination of process parameters Maintenance and calibration of gauges and equipment Regular Logging and documentation of controls variables On floor testing and measurements of key variable Cost/Resource Requirement No direct cost is involved except for few equipment of nominal costs. Performance Indicator Identification of bottlenecks Increase in A-Quality products Process and Chemical Usage
- 19. Process and Quality Control Laboratory Concerns Production often overshadows Quality Laboratory is generally considered as non value adding entity Action Independent laboratory be established Quality assurance at every level Providing Assistance to production and not hurdle Cost/Resource Requirement Costs depends upon the type of industry Performance Indicator Increase in market share Market appreciation Process and Chemical Usage
- 20. Cleaner Technologies Caustic Recovery from Mercerization Recovery of Printing Paste from Supply System Using Counter Current Washing Methods
- 21. Caustic Recovery from Mercerization Cleaner Technologies Concerns Discharge of high concentrated caustic in effluent after mercerization process Action Recovery of caustic in three stage evaporation process Through caustic recovery plant the 5Be weak lye can be concentrated up to 25Be solution Cost/Resource Requirement Cost incurred for caustic recovery plant will be approx 3 – 3.5 Million Rs. Local expertise and fabricators available Performance Indicator Approximately 50% saving of caustic soda Reduction of caustic soda loading in effluent
- 22. Caustic Recovery from Mercerization Cleaner Technologies
- 23. Recovery of Printing Paste from Supply System Cleaner Technologies Concerns Wastage of dye paste after each batch run Action Use of paste dispensing system with provision of balls in the supply system After finishing a print run the ball is pressed back by air pressure which pumps the paste back into the drum for reuse Use of minimum lengths of piping. Use of online washing systems Cost/Resource Requirement Dependent on the type of systems Performance Indicator Approximately 50% - 75% wastage is reduced Reduction of dye paste in effluent
- 24. Recovery of Printing Paste from Supply System Cleaner Technologies
- 25. Using Counter Current Washing Methods Cleaner Technologies Concerns Wastage of rinse water Action Horizontal or vertical washers can be used in principal of counter flow with respect to flow of fabric Cost/Resource Requirement 25,000 to 35,000 Rs. Pay back with in days Performance Indicator Reduction in consumption of water and energy
- 26. Using Vertical Washing Methods Cleaner Technologies
- 27. References Identification and reduction of pollution sources in textile wet processing by Brent Smith Integrated pollution prevention and control, reference document on Bet available techniques for the textile industry by European Commission Identification and evaluation of Best available technologies economically achievable (BATEA) for textile mill effluents by Merbek Consultants Canada Pollution prevention studies in the textile wet processing industry by Department of Civil Engg., VPI &SU, Virginia Best management Practices for pollution prevention in the textile industry by EPA (Manual)