Bangladesh Water “PaCT” Partnership for Cleaner Textile

Program Overview

Textile Sector Overview Bangladesh’s key sector is a major contributor to water availability and pollution issues

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Textile Sector

Export contribution

Economic relevance

Factory concentration

Water consumption

Water pollution

Groundwater depletion

• Estimated to be a $17.9 billion industry, textiles accounts for

30% of Bangladesh’s industrial sector GDP

• Textile industry employs 3.6 million people of whom 85% are

women

• Textile and garments industry accounts for

~80% of export earnings

• Sector includes 1,700 garment washing, dyeing and finishing units, in and around the Dhaka metropolis, and

impacts the lives of 12 million + inhabitants

• Textile industry is the country’s second biggest polluter (after tanneries), significantly impacting water surface and groundwater quality

• Sector consumes 1,500 billion liters of groundwater annually for a total production of 5 million tons of fabric (300 liters per kg fabric)

• Greater Dhaka area is experiencing decline in groundwater tables at the rate of 1-2 meters/ year, with seasonal water shortages

Key features of Textile Sector

PaCT Objectives Program aims at transformation of the textile sector through positive social, environmental

and economic impact creation

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REDUCTION IN ENERGY CONSUMPTION AND GHG EMISSIONS – 150,000MT

• Lack of awareness around optimal operations and maintenance practices lead to significant energy wastage

• Estimates suggest adoption of low-cost/ no-cost cleaner production measures by the sector’s 1,700 wet processing units will result in savings of 600 thousand MWH of electricity and 1.3 billion m3 of gas

REDUCTION OF WATER USAGE – 25MCM

• Textile sector’s overall water usage is highly inefficient, using on average 300 liters of water per kg fabric

• Best practice water usage is estimated at ~50 liters of water per kg fabric

• Substantial water savings are possible through adoption of low-cost/ no-cost cleaner production measures, as well as water treatment/ reuse and new WDF technologies

REDUCTION OF WASTEWATER USE/ QUALITY IMPROVEMENT – [Target TBD]

• Textile sector is a significant contributor to surface water pollution

• Inadequate/ improper effluent treatment are contaminating agricultural land, reducing local crop yields1 and increasing costs of water treatment for potable requirements2

IMPROVEMENT TO OHS/ WASH CONDITIONS

• Lack of capacity, low attention to occupational health and safety, and limited access to sanitation facilities lead to significant health risks for workers

• Improvement of WASH facilities can avoid water-borne illnesses and worker absenteeism

Goals of PaCT Program

Investment Facilitation: US$50 million

Bangladesh PaCT

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Rationale for water-use efficiency in rice cultivation Program Overview

• Development of harmonized procurement guidelines (Target: ~15 buyers)

• Training for buyer’s international and local procurement teams on harmonized procurement guidelines (Target: ~400 staff)

• Step 1: Awareness building/ motivation for CP (Target: 500 factories)

• Step 2: Factory-specific advice on Cleaner Production (Target: 200 factories)

• Step 3: Investment in technologies (Target: 100 factories)

• Operational, multi-stakeholder Textile Sustainability Platform to raise awareness/ build alignment among firms, associations, policy makers, civil society, financial institutions, and donors

15 awareness/ consultative workshops at sector and cluster level

5 collective action plans

BUYER CAPACITY BUILDING FACTORY SUPPORT MULTI-STAKEHOLDER ENGAGEMENT

Steering Committee

• Netherlands Embassy

• Lead Sponsors • BGMEA

Program Management

• IFC Advisory Services (managerial and technical staff)

Program Partners

• Buyers • Factories • Government • Banks

Implementing Partners

• Solidaridad

• Water Footprint Network

• BGMEA

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* About 200 local companies will contribute another $1 million in cash fees, for total of $4 million private sector cash contribution

Factory Support

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Step 1: Awareness building/ motivation for CP (Target: 500 factories)P (Target: 500 factories)

Step 2: Factory-level advice on Cleaner Production (CP measures) and water footprint reduction (Target: 200 factories)

Step 3: Facilitation of investment in technologies with significant water sustainability benefits (Target: 100 factories)

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1. Textile dyeing consumes huge amounts

of softened water : 50 - 500 liter/kg fabric*.

2. Ground water is almost free in BD and

hence used without restrains or recycling.

3. Lots of salt (low cost) added to the water

ends up in the rivers : 0.4 - 0.8 kg/kg fabric*.

In Depth CP assessment

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• Good factory

• Good attitude towards improving resource efficiency

• Many good practices in place

• Many opportunities to improve

In Depth CP Assessment

Opportunities in Dye house

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• Process engineering

Shorter processes

Lower temperatures

• Increasing right first time performance

Bulk

Lab to bulk

• Reducing energy in drying

• Recycling

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High fixation dye Enzyme bleaching

Recommendations

Change of Dyeing machine

•iMaster low liquor machines

•3.7:1 liquor ratio

Water metering

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• Cold Pad Batch plus counter-flow

bleach and wash-off

• -50% Water*

• -40% Steam*

• -40% Electricity*

Cold Pad Batch

Opportunities in finishing

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• Profile moisture content of all pre-dry fabrics

• Reduce pre-dry moisture

Mangles approx 30,000 Euro

Saving approx 30% of energy requirement

• Avoid over-drying

Moisture meters on all stenters

Saving further 5% of energy requirement

• Heat recovery from stenters

Opportunities in effluent treatment, water

recycling resource recovery

• Recover chemicals and reduce salinity at

the source by regenerating bleaching

wastewater

• Recover salt and reduce salinity at the

source by regenerating dyeing

wastewater

• Replace air mixing in ETP by submersible

mixers as to improve performance and

save energy

• Improve the clarifier(s) as to boost the

ETP effluent quality for reuse

• Improve the quality of the bio-sludge as

to boost the ETP effluent quality for reuse

• Remove color and add nutrients in ETP as

to enable water recycling

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Opportunities in effluent treatment, water

recycling resource recovery

• Remove color and add

nutrients in ETP as to enable

water recycling

• Add basic water recycling

• Invest in basic ETP lab/field

equipment as to support high

ETP performance

• Invest in capacity building by

training ETP management and

operators

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Opportunities in Utilities Section

• Measure energy production & consumption in

real-time - Measuring = Knowing

• Monitor and manage energy production &

consumption

• Install economizers on all operating steam boilers

• Install an oxygen trim on all operating steam

boilers and generators

• Install a steam management control system

• Recover stack heat from all gas fired generators

• Install a electrical power management control

system

• Reduce steam consumption and increase steam

condensate return

• Tune/revamp/upgrade or replace the gas fired

generator

• Recover engine jacket, turbo and oil cooler heat

from all operating generators

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Other Opportunities: Safe drinking water

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Conclusions

• Customer use cases

• Right pricing

• Messaging to customer

• Pre and post implementation services

• Language and local office

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