Best Available Techniques in the Textile Sector€¦ · Best Available Techniques in the Textile...

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Best Available Techniques in the Textile Sector Brigitte Zietlow German Federal Environment Agency

Transcript of Best Available Techniques in the Textile Sector€¦ · Best Available Techniques in the Textile...

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Best Available Techniques in the Textile Sector

Brigitte ZietlowGerman Federal Environment Agency

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Outline

Overview over textile industry in Europe

Status of the BREF Textile Industry

Examples for Best Available Techniques

Conclusions

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Overview over the European Textile & Clothing sector

Companies(number)

Employment(1000 Pers.)

Turnover(bil. €)

Extra‐EU imports (bil. €)

Extra‐EU exports (bil. €)

Extra‐EU tradebalance (bil. €)

Man‐madefibres

78 21 9,6

textile 53.887 674 80,6 24,4 21,8 ‐2,7

clothing 127.457 1.085 75,1 65,2 20,3 ‐44,9

total 181.423 1.780 165,3 89,6 42,1 ‐47,6Quelle: Euratex

• T&C industry is among the largest industrial branches in the EU• Predominantly small and medium-sized enterprises• second world exporter in textiles and clothing (26% of global

sales)• largest world market for textile and clothing products (household

consumption of nearly 500 Billion Euro/year)

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Overview over the European Textile & Clothing sector

Quelle: Eurostat

32,5%

16,3%

9,7%6,8%4,2%

30,5%

Main textile suppliers for the EU

China

Turkey

India

Pakistan

USA

others

42,7%

13,1%13,1%

6,2%

3,2%21,7%

Main clothing suppliers for the EU

China

Bangladesh

Turkey

India

Tunisia

others

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Overview over the European Textile & Clothing sector

Italy, France, UK, Germany and Spain accounting for about three quarters of EU production of textiles and clothing

European producers are world leaders in markets for technical/industrial textiles and non-wovens (for example industrial filters or products for the automotive industry or the medical sector), as well as for high quality garments with a high design content

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Overview over the European Textile & Clothing sector

45%

14%

12%

8%

4%2% 15%

The share of the main types of fibres used in the textile finishing industry

cottonpolyesterviscosewoolacrylicsilkothers

Quelle: BREF Textile industry

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Overview over the European Textile & Clothing sector

45%

20%

18%

10%7%

The main categories of processed goods of the EU textile finishing industry

clothing textileshousehold textilestechnical textilesinterior textilesothers

Quelle: BREF Textile industry

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Status and scope of the BREF Textile Industry

The BREF Textile Industry is the major outcome of the European information exchange on BAT for the sector

The BREF provides a lot of information on available techniques

First issue of the BREF Textile Industry published in 2003

Revision is planned for 2015• In Germany information exchange has started

in 2009 already

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Status and scope of the BREF Textile Industry

• Scope: Textile finishing operations where the treatment capacity exceeds 10 tonnes per day

• Additionally included: Upstream processes with

influence on the environmental impact of finishing processes

backing of carpets

Fibre manufacturing: Natural fibres/Man-made fibresFibre manufacturing: Natural fibres/Man-made fibres

Spinning of fibres Yarn manufacturingSpinning of fibres Yarn manufacturing

weaving, knitting, non-woven technologiesCloth manufacturingweaving, knitting, non-woven technologiesCloth manufacturing

Finishing processespretreatment, dyeing, printing, coating, finishingFinishing processespretreatment, dyeing, printing, coating, finishing

Make-upcutting, sewing, assemblingMake-upcutting, sewing, assembling

TradeTrade

UseUse

DisposalDisposal

Fibre manufacturing: Natural fibres/Man-made fibres

Spinning of fibres Yarn manufacturing

weaving, knitting, non-woven technologiesCloth manufacturing

Finishing processespretreatment, dyeing, printing, coating, finishing

Make-upcutting, sewing, assembling

Trade

Use

Disposal

BREF Textile

Industry

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Environmental issues of textile finishing

Leaking Chemicals likely to enter the groundwater in a mixing station for chemicals (carpet factory in Egypt)

Ca. 7000 textile auxiliaries with approx. 400 – 600 single substances

Up to 300 m³ Water per ton finished textile

High chemical load of the waste water with non biodegradable auxiliaries

Energy consumption Air emissions Solid wastes Odours

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Environmental issues of textile finishingMain environmental loads from textile industry in Europe

Substances Environmental load (t/yr)

Salts 200 000 – 250 000

Natural fibres impurities (including biocides) and associated material (e.g. lignin, wax, etc.)

50 000 – 100 000

Sizing agents (mainly starch, starch derivatives, but also polyacrylates, polyvinylalcohol, carboxymethylcellulose and galactomannans)

80 000 – 100 000

Preparation agents (mainly mineral oils, but also ester oils) 25 000 – 30 000

Surfactants (dispersing agents, emulsifiers, detergents and wetting agents) 20 000 – 25 000

Carboxylic acids (mainly acetic acid) 15 000 – 20 000

Thickeners 5 000 – 10 000

Urea 5 000 – 10 000

Complexing agents <5 000

Organic solvents n.d.

Special auxiliaries with more or less ecotoxicological properties <5 000Source: Euratex

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Environmental issues of textile finishing Waste water in textile finishing mills

Up to 1 kg chemicals/kg textiles are used in textile finishing mills

More than 90 % of the organic chemicals and auxiliaries in pretreatment and dyeing operations does not stay on the fibre, but mainly ends up in the waste water

The wastewater load includes:• fibre by-products (e.g. fibre monomers like

caprolactam, fibre solvents and catalysts)• preparation agents applied in down-stream

processes• sizing agents applied in down-stream

weaving mills• non-fixed basic chemicals, textile auxiliaries,

and dyestuffs (including their by-products and impurities)

Process COD contentin mg O2/l

desizing 3.000 to 80.000 

bleaching 3.000 to10.000 

Scouring 2.000 bis 6.000 

Exhausted dye liquoresreaktive dyeing

400 to 2.000 

Exhausted dye liquoresdispersing dyes or vat dyes

5.000 to10.000 

Residual dyeing liquors 10.000 to100.000 

Residual finishing paddingbaths

5.000 to 200.000 

Residual printing pastes 50.000 to 300.000 

COD content of residual liquors of processes in the textile mill:

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

EXAMPLES FOR BAT

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Generic BAT for whole textile industry (I)Management und good housekeping

implementation of a monitoring system for process input and output precondition for identifying

priority areas and options for improving environmental performance

Input/output stream inventories can be drawn up on different levels (site level, process level)

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Generic BAT for whole textile industry (II)Management and good housekeeping

Equipment maintenance• Maintain machinery, pumps

and piping thoroughly and check for leaks

• Draw up maintenance plans that foresee regular maintenance and document all work activities

• Check and clean filters regularly

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Generic BAT for whole textile industry (III)Selection and use of chemicals

In general the overall strategy for the minimisation/optimisation of the chemicals used should consider the following steps:

1. where it is possible to achieve the desired process result without the use of chemicals, then avoid their use altogether

2. where this is not possible, select and use chemicals in a way that ensures the lowest overall risk.

Selection of auxiliaries and chemicals with a high degree of biodegradability/ bioeliminability, low human and ecological toxicity, low volatility and low smell intensity

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Cotton processing – recovery of sizing material

Sizing agents are the main source of COD in waste water

Water-soluble synthetic sizing agents such as polyvinyl alcohol, carboxymethyl cellulose and polyacrylates can be recovered by ultrafiltration

After ultrafiltration the concentrate can be re-used for sizing

The permeate can be recycled and re-used as water in the washing machine

Recycling of sizing agents is only technically and economically reasonable for integrated finishers with weaving and finishing near by

Recovery rates for sizing agents 80-85 %COD load is reduced by 40 – 70 %

BREF Textile Industry Chapter 4.5.1

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Cotton processing – Recover and re-use alkali from mercerising

Mercerising: main source of alkaline load of waste water

rinsing water from mercerising(weak lye: 40 - 50 g NaOH/l) is concentrated by evaporation for re-use in mercerisation.

Recycling degree up to 80%

alkaline load of waste water is reduced drastically

Pay-off time less than 1 year

Scheme of the caustic soda recovery process

BREF Textile Industry Chapter 4.5.7

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Process improvements for dyeing (I)Automated preparation and dispensing of chemicals

Microprocessor-controlled dosing systems meter chemicals automatically.

Usually the frequently used colourants (highest consumption) are selected for automation.

commonly applied in many companies in the textile industry (Examples of plants with production capacity ranging from 70 t/day to 5 t/day)

Benefits:• improved right-first-time perfomance minimising

corrective measures (e.g. reworks, redyes)• significant reduction of waste water pollution and

wasted chemicals thanks to the minimisation/ avoidance of liquor residues

BREF Textile Industry Chapter 4.1.3

Data from a textile dyehouse(production capacity 5500 t/year):17% reduction of reworks11% reduction of costs for chemicals10% reduction of costs for labour5 % increased dye machine efficiency

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Process improvements for dyeing (II)Carrier-free dyeing techniques or use of optimised carriers

Carriers include substances with human and aquatic toxicity, high volatility and high odour intensity (e.g chlorinated aromaticcompounds. o-phenylphenol, biphenyl and other aromatichydrocarbons, phthalates)

Carrier-free dyeing at high temperature using HT-dyeing equipment can be applied to all pure polyesters and wool-free PES blends

When dyeing polyester blends with fibres wich are sensitive to high temperatures (e.g.polyester/wool blends) chlorine-free carriers with improved toxicological and environmental characteristics can be used.

The optimised carriers are based on: • benzylbenzoate• aromatic carboxylic acid esters• N-alkylphthalimide.

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Process improvements for dyeing (III)Use of high-fixation polyfunctional reactive dyestuffs

Bifunctional (polyfunctional) reactive dyes offer very high levels of fixation in exhaust dyeing of cellulosic fibres

high reproducibility, low dependency on dyeing conditions and therefore right-first-time dyeing

Fixation rate is increased from 60 % to 80 % Reduction of waste water pollution (e.g. TDS)

Data for new dyes:90°C fixation temperature40 % reduction of water consumption40 % reduction of energy consumption30 % reduction of salt conumption

BREF Textile Industry Chapter 4.6.10

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Process improvements for dyeing (IV)Exhaust dyeing with low-salt reactive dyes

exhaust dyeing of cellulosic fibres with reactive dyestuffs requires usually 50 - 60 g salt/l (up to 100 g salt/l for dark shades)

Low-salt reactive dyes need only about two-thirds of this quantity

low-salt dyes can be kept in solution at a higher concentration use of low liquor ratio (L.R.) dyeing machines further reduction of salt consumption

low-salt reactive dyes are not combinable with other dyes, processing parameters have to be complied in an exact way

Winch (L.R. 1:20) Jet (L.R. 1:10) Low L.R. Jet (L.R. 1:5) 

Traditional dyes (salt 60 g/l)  1200 kg 600 kg 300 kg

Low salt dyes (salt 40 g/l)  800 kg 400 kg 200 kg 

Quantities of salt required for dyeing 1000 kg of fabric to a medium depth of shade BREF Textile Industry Chapter 4.6.11

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Process improvements for dyeing (V)Minimisation of dye liquor losses in pad dyeing techniques

Main emission sources in pad dyeing processes arise from the discharge of the residual dyeing liquor in the pad, pumps and pipes

Reduction of these losses can be achieved by• minimising the capacity of the dip trough (e.g. flex-

shaft, U-shaft)

• dosage of the padding liquor based on measurement of the pick-up reduction of liquor loss in the tanks from 150 litres to 5 – 15 litres

The use of a U‐trough reduces the bath residue by 60–90%.

BREF Textile Industry Chapter 4.6.7

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of water consumption (I)Efficient washing processes

Replacement of overflow rinsing with “drain and fill rinsing” or “smart rinsing”.

Use of “Drain and fill” in combination with low liquor ratio machines equipped with time-saving devices (power draining and filling, combined cooling and rinsing, full volume heated tanks)

50 – 75 % less water consumption Water conservation in continuous washing and

rinsing:• Water flow control• countercurrent washing• Use of squeeze rollers or vacuum extractors

for the reduction of carry-over

Water consumption (l/kg)

Pretreatment process

Washing for desizing 3 ‐ 4

Washing after bleaching 4 ‐ 5

Washing to remove NaOHafter mercerisation

4 ‐ 5

Washing after dyeing

Reactive dyestuffs 10 ‐ 15

Vat dyestuffs 8 ‐ 12

Washing after printing

Reactive dyestuffs 15 ‐ 20

Vat dyestuffs 12 ‐ 16

BREF Textile Industry Chapter 4.9.1, 4.9.2

Achievable specific water consumption levels for continuous washing processes

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of water consumption (II)Water re-use/recycling in batch dyeing processes

exhausted hot dye baths are analysed for residual colourant and auxiliary concentration, replenished and re-used to dye further batches

easiest systems for re-use are dye classes with high affinity (exhaustion) and mimimum changes during the dyeing process (e.g. acid dyes for nylon and wool, basic dyes for acrylic, direct dyes for cotton and disperse dyes for synthetic fibres)

on average four cycles of the same shade are possibleReduction of overall water consumption of 33 %Cost savings (depending on water price and effluent disposal

costs)

BREF Textile Industry Chapter 4.6.22

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of energy consumption (I)General technical measures to increase energy efficiency

heat-insulation of pipes, valves, tanks, machines segregation of hot and cold waste water streams

prior to heat recovery and recovery of heat from the hot stream.

optimising boiler houses (re-use of condensed water, preheating of air supply, heat recovery in combustion gases)

installing frequency-controlled electric motors installing heat recovery systems on waste off-

gases energy savings up to 70% for heat recovery on waste gases on stenters

BREF Textile Industry Chapter 4.1.1

Increased insulation on the stenters alone from 120 mm to 150 mm saves 20 percent of energy

heat-insulation of pipes

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of energy consumption (II)Control of energy consumption

Monitoring and control of energy consumption is an essential precondition for energy efficiency increase in companies

For monitoring consumption, indicators are defined for the entire company and for single processes e.g.

• energy consumption (gas, oil, etc.) per ton of steam produced

• electricity consumption of big aggregates per ton of product produced

• consumption of steam and electricity per processed goods or group of goods

• gas consumption for the stenter frame per group of goods

German textile plant:Cost savings of 175 000 €/a due to measures taken after monitoring/control of energy consumption. 

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of energy consumption (III)Energy recovery

Reuse of warm water by counterflow (e.g. washing of raw cotton, peroxide bleaching and alcalic boiling off, Dyeing, continuous washing and rinsing).

Use of warmed-up cooling water (e.g. from soda lye recovery, batch dyeing, water-cooled compressors) directly for warm processes like dyeing or rinsing.

Use of water/water heat exchanger for heating fresh water, e.g.:• Heat exchanger for waste water from reactive dyeing • Heat exchanger for waste water from washing and rinsing

Use of air/water or air/air heat exchange, e.g.:• Heat exchanger for waste gas from stenters for pre-heating of air

introduced into the stenter• Heat exchanger for cooling air of compressors for pre-heating of

process water or heating water

The use of heat content of rinsing water from continous washing for heating of fresh water leads to energy savings of approx. 75% .

The heat exchange from waste water of a pad‐steam dyeing to the water for the washing section saved yearly 1600 MWh natural gas. 

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Measures for reduction of energy consumption (IV)Minimisation of energy consumption of stenter frames

Reduction of moisture content of the fabric with vacuum extraction systems, squeezing rollers etc. before it enters the stenter

Energy saving of up to 15% Regular maintenance of the burners Use of optimised nozzles and air guidance systems (e.g. nozzle

systems that can be adjusted to the width of the fabric) Optimisation of air flow at the stenters (exhaust humidity between 0.1

and 0.15 kg water/kg dry air)Energy saving of up to 57%

installation of heat recovery systems Energy saving of up to 70%

insulation of thermal treatment units Energy saving of up to 20% BREF Textile Industry Chapter 4.8.1

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (I)General principles for waste water management and treatment

Characterizing the different waste water streams arising from the process Segregate the effluents at source

according to their contaminant type and load

• To ensure that a treatment facility receives only those pollutants it can cope with

• To enable the application of recycling or re-use options for the effluent

3-way valve for segregation of effluents

Segregated effluentsdestined fordifferent treatments

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (II)General principles for waste water management and treatment Do not send any waste water into the biological treatment facility that could cause

malfunctions there. Employ alternative cleaning techniques for waste water with relevant volumes of non-

biodegradable substances:• chemical oxidation for highly-polluted, selected, non-biodegradable waste water partial

flows (e.g. desizing baths)• Precipitation and flocculation for partial flows containing heavy metals• membrane process for heavily coloured waste water partial flows and waste water with a

high volume of dissolved substances If waste water with non-biodegradable compounds is not treated separately, then additional

physical-chemical treatment of the waste water as a whole is required. Specific process residue (e.g. printing paste residue, padding liquor residue) should not

enter the waste water but be disposed of in a more appropriate manner.

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (III)Pretreatment

Case example: De-colouring using membrane technology

Company finishes knitted fabric Pretreatment of waste water from pad batch

dyeing and from continuous washers 1. step: nanofiltration

• Efficiency of de-colouration: 80 - > 99%

2. step: electrochemical de-colouration• Efficiency of de-colouration:

35 – 78% Aftertreteatment in municipal waste water

treatment plant

1. step: nanofiltration

2. step: electrochemical de-colouration

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Case example: Anaerobic pretreatment of desizing effluents

Company finishes woven, knitted and non-woven fabric

1. buffering/pre-acidification 2. anaerobic treatment in fixed bed

reactor COD-removal efficiency:

60 – 70 % Aftertreatment in municipal waste

water treatment plantleft side: two Buffer tanks, right siede: fixed bed reactor

Waste water treatment (IV)Pretreatment

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (V)Treatment of mixed effluent

Case example A: Treatment of mixed effluent in activated sludge system effluent from one textile finishing mill is treated

company mainly finishes cotton fabric

about 5 % of the treated waste water is recycled for washing and cleaning operations (floor washing, cleaning of printing equipment such as pumps, pipes, squeegees and screens)

decolourisation is achieved through reductive cleavage of azo groups of dyestuffs by an iron(II)-salt

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Influent Effluent

pH 9 – 9.5 7.8 – 8.6

COD[mg O2/l]

1200 – 1500 90 – 110

BOD5

[mg O2/l]400 - 500 < 5

NH4-N[mg N/l]

11 - 25 0.3 – 1.6

N-org[mg N/l]

30 - 40 5 - 10

Ptotal

[mg P/l]10 - 25 1 – 2.5

Scheme of the treatment of mixedeffluent in activated sludge system

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (VI)Treatment of mixed effluent

Case example B: Combined treatment of textile waste water with municipal waste water effluent from about 30 textile finishing units is treated together with

municipal waste water textile waste water accounts for about 30 % of the hydraulic load and for

about 40 % of the COD the textile finishing industries discharge their waste water to the public

sewer after neutralisation on site various companies have pretreatment plants, especially pigment printing

units, which treat the waste water from cleaning the printing equipment by flocculation/precipitation

layout of the plant is typical with bar screen, aerated grit and grease chamber, primary clarifier, denitrification and nitrification stage

Specific characteristc: presence of an additional treatment with activated carbon powder in order to minimise COD and colour in the final effluent

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Bar screenInfluent

Aerated grit andgrease chamber

Primary clarifier(sedimentation)

De-nitrification

Activated sludge(nitrification)

Secondary clarifier

Returnsludge

Primary sludge

Excesssludge

Thickener

Anaerobicdigesters

Anaerobicallystabilised sludge,including activatedcarbon to securedmunicipal landfill

Chamberfilter press

Filtrate and overflow of anaerobic digesters

MixerActivated carbonpowder

Contact andequalisation tank

Pumpingstation

ClarifierScrew pumpSand filters

Dischargeto river

Polyelectrolyteand alum sulphate

BackwashWater containingActivated carbon

Influent Effluent

pH 6.8 – 7.5

COD [mg O2/l] 278 11

BOD5 [mg O2/l] 138 3

NH4-N [mg N/l] 12.5 0.4

Ptotal [mg P/l] 3.7 0.15Combined treatment of textile waste water withmunicipal waste water

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste Management

processes should be designed and operated to prevent, or minimize, the quantities of wastes generated

separate collection of unavoidable solid waste

minimize hazardous waste generation by implementing stringent waste segregation to prevent the contamination of non-hazardous with hazardous waste

reduction of packaging use of returnable containers

returnable containers

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Air emission abatement techniques

Different textile processes demand different off-gas abatement Case to case studies for the choice of the abatement technique is

necessary The following techniques are used separately or in combination:

• oxidation techniques (thermal incineration, catalytic incineration)

• condensation techniques (e.g. heat exchangers)• absorption techniques (e.g. wet scrubbers)• particulates separation techniques (e.g. electrostatic

precipitators, cyclones, fabric filters)• adsorption techniques (e.g. activated carbon adsorption)

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Environmental standards in the textile and shoe sector

Guideline on the basis of the BREFs

Developed in cooperation with brands, retailers and civic institutions

Objectives:• Facilitate the access to the BREFs

• Enter into a practical dialogue along the supply chain

http://www.umweltbundesamt.de/uba-info-medien-e/4128.html

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Conclusions (I)

The Textile BREF is a valuable source of information on available techniques, their applicability and their associated consumption and emission levels.

BAT is more than the application of specific technologies; good housekeeping, maintenance, input control and a proper monitoring system for the emissions are also relevant

As the structure/environmental problems of the European Textile industry is different, the BREF does not provide detailed BAT conclusions for all emissions relevant in India (e.g. TDS), but at least it gives some indication.

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Conclusions (II)

We encourage you to benefit from the information provided in the Textile BREF

Where processes currently applied in India are not covered in the BREF, it might be beneficial to initiate an information exchange process on BAT in your country, based on the same principles as under the IED.

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Thank you for your attention!

[email protected]

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Useful links

BREF Textile Industry:http://eippcb.jrc.ec.europa.eu/reference/txt.html

Environmental standards in the textile and shoe sector:http://www.umweltbundesamt.de/publikationen/environmental-standards-in-textile-shoe-sector

Checklists based on BAT in the textile industry:http://www.umweltbundesamt.de/publikationen/checklist-based-on-best-available-techniques-in

Cleaner production Germany:http://www.cleaner-production.de/en.html

Blue Angel for textiles:http://www.blauer-engel.de/en/products_brands/search_products/produkttyp.php?id=573

Carbon Performance Improvement Initiativehttp://www.cpi2.org/home/

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

When carbon dioxide is heated to above 31°C and pressurized to above 74 bars, it becomes “supercritical” high (liquid-like) density that enables dissolution of compounds and the low viscosity that enables good penetration

For dyeing of textile the carbon dioxide is heated to 120°C and pressurized to 250 bars

During dyeing of polymer fibres, CO2 loaded with dyestuff penetrates deep into the polymer structure of the fibres and thus provides effective coloration of these materials

Benefits: no water consumption – and therefore no wastewater no off-gas emission (90-95% of the CO2 can be recycled) no drying step after dyeing no leveling and dispersing agents dyestuff residues can be recycled

Process improvements for dyeing Dyeing in supercritical carbon dioxide

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (III)Composition of total waste water stream prior treatment

Parameter Concentration in total wastewater stream

pH-value 5 - 13

COD 400 - 5000 mg O2/l

BOD5 80 – 1500 mg O2/l

AOX 0.05 – 1 mg Cl/l

NH4-N < 0.1 – 120 mg N/l*

HC < 0.1 – 110 mg/l**

Anionic tensides 2 – 24 mg/l

Nonionic tensides 5 – 50 mg/l

Cu < 0.001 – 0.5 mg/l

Zn 0.02 – 1.1 mg /l

Cr < 0.005 – 0.2 mg /l

Data from 50 textile finishing mills in Germany

* high values for vat printing and reactive printing where relevant amount of urea is used

** high values from pretreatment of polyester or polyamide (washed out preparations)

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Waste water treatment (IX)Treatment of mixed effluent

Case example C: Treatment of mixed waste water with about 60 % water recycling Company finishes cotton knitted fabric and dyes with reactive

dyestuffs Before treatment, the hot streams (> 40°C) are submitted to heat

recovery The following steps are then carried out on the mixed effluent:

• equalisation (about 20 h equalisation) and neutralisation• activated sludge treatment in a special system consisting of loop

reactors and clarifiers • adsorption stage• flocculation/precipitation and removal of the sludge by flotation• filtration in a fixed bed gravel filter

about one third of the flow is discharged to the river two-thirds are treated in an activated carbon filter and desalinated in a

reverse osmosis plant

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Influent Effluent* Recycelt stream**

pH 7.3 7.2 7.0

COD[mg O2/l]

515 20 10

BOD5

[mg O2/l]140 < 0.1 < 0.1

AOX[mg Cl/l]

0.56 0.2

Treatment of mixed waste water with about 60 % water recycling

* After filtration, before absorption

** after reverse osmosis

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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  B. Zietlow, Umweltbundesamt

Air emission abatement techniques (II)Examples of hazardous substances in waste air

Substance Possible sourceAcrylonitrile Polymer dispersionsAcrylamide Reactive polymers, flame-retardantsAcrylates (methyl, ethyl, butyl)

Coating agents and binders for non-wovens

Benzylalcohol Carriers

Caprolactam Polyamide 6 powder/textiles

Diethylenetriamine SoftenersDiphenylmethane-2,4 diisocyanate

Extender, polyurethanes

Hexamethylendiamine PolycondensationproductsOxalic acid Bleaching auxiliaryVinylacetate Polyvinylacetate

•Signifacantemissions occur at drying processes

•Emissions are from the fibres and from preparations and finishing chemicals