cleaner production package

BEST ENVIRONMENTAL MANAGEMENT PRACTICES

(Cleaner Production Options)

Textile Industry of Pakistan

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”

Classification of Management Practices Options for Textile Industry

Good Housekeeping Practices Resource Conservation Process/Chemical Usage Cleaner Technologies

Good Housekeeping Practices

Maintenance of Equipment Prescreening of Inventory Chemical Handling Practices

Maintenance of Equipment


Symptoms of Problems Leakages of oil, water,chemicals,steamImproper Chemical dosingRare Machine, equipment and vessel cleaning

Actual Problems Awareness but lack of willingness Not in the list of priorityLack of proper staffPlans but no proper implementation

Action Assignment of proper resourcesSet as first priorityImplementation on continual basis

Cost/Resource Requirement No direct cost is involve

Performance Indicator Aesthetic improvement of industrySavings in resourcesMinimization of pollution load

Prescreening of Inventory


Symptoms High rejectionLarge volume of inventory

Problems No Quality Control at this stageQA Department under productionFewer 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 chemicalsLow wastages

Chemical Handling Practices


Problems Improper Storage, Transportation and HandlingSpillageWastage

Action Proper Storage FacilitySegregation of ChemicalsUse of Liquid and Granular Dyes and ChemicalsLabeling of ChemicalsTraining of Staff on Chemical Handling & Transportation

Cost/Resource Requirement No direct cost is involvedDevelopment of External & Internal Training Program

Performance Indicator Less usage of Dyes and ChemicalsReduction in Pollution LoadOccurrence of Accidents minimized

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

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 consumptionBasis for water reduction plans

Reuse of Bleach and Dye Bath


Concerns Drain of Costly Chemicals and Dyes which can be reused

Action Using continuous scour wash water to batch scouringReusing scour rinses for desizingReusing mercerization wash water for scouringReusing bleach wash water for scouringUse 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 optionIncase of dye bath reuse in addition to above shade analyzer will be required which costs 250,000 – 300,000Local expertise and fabricators available

Performance Indicator Water conservationCost saving in terms of less amount of chemicals and dyes usageLow pollution load

Reuse and Recycling of Cooling & Condensate Water


Concerns Drain of hot water which comes after cooling various machineries specially jets and singeingDrain 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 monthsLocal expertise and fabricators availableSteam condensate

Performance Indicator Water and energy conservationReduction of wastewater

Reduction of Water Consumption in Printing Cleaning


Concerns Use of water for cleaning belt even when the machine is not runningWaste of printing paste after each batch change overUse of fresh water for cleaning squeegees, screens and buckets

Action Provision for stoppage of running water when machine stopsUse of shut off valves in water hosesManual/Mechanical removal of printing pasteReuse 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 washingUse 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 conservationReduction of wastewaterReduction of dye paste

Minimization of Energy Consumption in Stenter


Concerns Wastage of hot exhaust gases Use of low efficiency burnersUse of low efficiency heating systems

Action Installation of heat exchangers and optimization of exhaust air flowControlling moisture content of feed fabricHigh efficiency burners to be usedUse of indirect gas firing systemsProper encasement of stenters

Cost/Resource Requirement Cost incurred for heat exchangers will be approximately 100,000 – 150,000Cost for encasement of stenters will be dependable on condition of insulation

Performance Indicator Energy conservation

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 conservationReduction of wastewater


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


Calculation of Boiler Efficiency


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

Process and Chemical usage

Process ModificationChemical SubstitutionBetter Process ControlProcess Control LaboratoryProcess 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

Better Process Control

Concerns High rejection, low quality, production breakdowns

Action Standardization and dissemination of process parametersMaintenance and calibration of gauges and equipmentRegular Logging and documentation of controls variablesOn 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 bottlenecksIncrease in A-Quality products


Process and Quality Control Laboratory

Concerns Production often overshadows QualityLaboratory is generally considered as non value adding entity

Action Independent laboratory be establishedQuality assurance at every levelProviding Assistance to production and not hurdle

Cost/Resource Requirement Costs depends upon the type of industry

Performance Indicator Increase in market shareMarket appreciation


Cleaner Technologies

Caustic Recovery from Mercerization

Recovery of Printing Paste from Supply System

Using Counter Current Washing Methods



Concerns Discharge of high concentrated caustic in effluent after mercerization process

Action Recovery of caustic in three stage evaporation processThrough caustic recovery plant the 5Be weak lye can be concentrated up to 25Be solution


Cost incurred for caustic recovery plant will be approx 3 – 3.5 Million Rs. Local expertise and fabricators available


Approximately 50% saving of caustic sodaReduction of caustic soda loading in effluent



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 reuseUse of minimum lengths of piping.Use of online washing systems


Dependent on the type of systems


Approximately 50% - 75% wastage is reducedReduction of dye paste in effluent

Using Counter Current Washing Methods


Concerns Wastage of rinse water

Action Horizontal or vertical washers can be used in principal of counter flow with respect to flow of fabric


25,000 to 35,000 Rs.Pay back with in days


Reduction in consumption of water and energy

Using Vertical Washing Methods


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)

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