Cleaner Production Workshop 2008, Ankara March 31, 2008 Improvements in Energy and Water Consumption...

March 31, 2008 Cleaner Production Workshop 2008, Ankara

Improvements in Energy and Water

Consumption Performances of a Textile Mill

After BAT Applications

Adoption of EU’s IPPC Directive to a Textile Mill in TurkeyAdoption of EU’s IPPC Directive to a Textile Mill in Turkey

METU

Ayşe Merve KOCABAŞDept. of Environmental Engineering


IntroductionIntroduction– IPPC DirectiveIPPC Directive– BREF DocumentsBREF Documents

Project: Project: – TargetTarget– ObjectiveObjective– ScopeScope

Improvements in energy and water Improvements in energy and water consumption performancesconsumption performances

ConclusionConclusion

OutlineOutline


IPPC IPPC (Integrated Pollution Prevention and (Integrated Pollution Prevention and

Control)Control) Directive Directive


IPPC Directive - TargetIPPC Directive - Target

The IPPC Directive aims at achieving integrated prevention and control of pollution from industrial installations listed in Annex I


IPPC DirectiveIPPC Directive ““Integrated approach” means:Integrated approach” means:

Permits must take into account the Permits must take into account the whole whole environmental performanceenvironmental performance of the plant, of the plant, covering covering

emissions to air, water and land, emissions to air, water and land, generation of waste, generation of waste, use of raw materials, use of raw materials, energy efficiency, energy efficiency, prevention of accidents,prevention of accidents, restoration of the site upon closure.restoration of the site upon closure.


IPPC DirectiveIPPC Directive

To achieve a high level of protection of the environment as a whole based on

the implementation of “Best Available Techniques”

included in BREF Documents for industrial activities covered by the

Directive


BREF DocumentsBREF Documents

Published by European IPPC Bureau Specific to the industrial activities

described in Annex I of the IPPC Directive (textile, pulp and paper, steel etc.)

Provide an exchange of information between Member States


Plants for the pre-treatment (operations such as washing,

bleaching, mercerization) or dyeing of fibres or textiles where the

treatment capacity exceeds 10 tonnes per day

BREF Documents-Textile BREF Documents-Textile SectorSector


BREF Documents-Textile BREF Documents-Textile SectorSector Being a water intensive industryBeing a water intensive industry

– Water consumptionWater consumption– Wastewater discharges and chemical Wastewater discharges and chemical

load it carriesload it carries– Energy consumptionEnergy consumption


What does BAT application What does BAT application bring??bring??

Minimized water consumption and Minimized water consumption and waste generationwaste generation

Reduced waste disposal costsReduced waste disposal costs Increased energy efficiencyIncreased energy efficiency

ECONOMICAL BENEFITS...ECONOMICAL BENEFITS...


PROJECTPROJECT


A RESEARCH PROJECTA RESEARCH PROJECT

Adoption of EU’s IPPC Directive to Adoption of EU’s IPPC Directive to a Textile Mill in Turkeya Textile Mill in Turkey

Principle Investigator: Prof. Dr. Ülkü YetişPrinciple Investigator: Prof. Dr. Ülkü YetişDepartment of Environmental EngineeringDepartment of Environmental Engineering

Middle East Technical UniversityMiddle East Technical UniversityANKARAANKARA

Funding AgencyFunding Agency: The Scientific and : The Scientific and Technological Research Council of Turkey Technological Research Council of Turkey

((TÜBİTAKTÜBİTAK))


Project TargetsProject Targets

• To conduct the first plant scale application of IPPC Directive to a textile mill in Turkey

• A reference study for the Ministry of Environment and Forestry and other institutions


Project ObjectivesProject Objectives

Identification of textile facilities Identification of textile facilities covered by the IPPC Directive and covered by the IPPC Directive and their production processes; their production processes;

Investigation of the applicable BAT Investigation of the applicable BAT Options for a selected mill; Options for a selected mill;

Selection of BAT for the pilot millSelection of BAT for the pilot mill Dissemination of the results Dissemination of the results

obtained.obtained.


Scope of the ProjectScope of the Project

1.1. IPPC Directive and Turkish Textile IPPC Directive and Turkish Textile IndustryIndustry

2.2. Adoption of IPPC Directive to the Adoption of IPPC Directive to the selected millselected mill

Evaluation of the enterprise Evaluation of the enterprise Wastewater managementWastewater management Cost analysisCost analysis Risk analysisRisk analysis


IPPC DirectiveIPPC Directive and Turkish Textile and Turkish Textile IndustryIndustry

Scope:

Identification of enterprises in Identification of enterprises in Turkish textile industry-Survey Turkish textile industry-Survey studiesstudies

Dissemination of the studies – Dissemination of the studies – WorkshopsWorkshops


Survey StudiesSurvey Studies

A survey study to identify textile mills within A survey study to identify textile mills within the IPPC have been initiated to collect the IPPC have been initiated to collect information on:information on:

Total production and wet production capacityTotal production and wet production capacity Type of productionType of production Number of employeesNumber of employees

Feedback from 126 textile mills in 12 Feedback from 126 textile mills in 12 provincesprovinces

At least 66 textile mills are under the At least 66 textile mills are under the scope of IPPC Directive in Turkeyscope of IPPC Directive in Turkey


WorkshopsWorkshops

Two workshops conducted:Two workshops conducted:

– In the beginning – introduction of the In the beginning – introduction of the project to the textile sectorproject to the textile sector

– At the end - dissemination of results of At the end - dissemination of results of the projectthe project


ADOPTION OF IPPC ADOPTION OF IPPC DIRECTIVE TO THE DIRECTIVE TO THE

SELECTED MILLSELECTED MILL


Selected Textile MillSelected Textile Mill


Selected MillSelected Mill

A denim manufacturing plant in operation since 1953

Among World’s top denim producers 20,000 tons of cotton fibre/year 45 Mio.m denim fabric/ year Integrated facility with yarn

manufacturing, dyeing, sizing, weaving and finishing


WELLS

Ion Exchangers

Reverse Osmosis

Supplementary Facilities(Cogeneration Plant)

FINISHING

WEAVING

SIZING

DYEING

Product

OthersAir Conditioners

CompressorsStaff Canteen

IrrigationCompany Dwelling

CottonFibre Prep.

Soft WaterHard Water

Product Line

Wastewater


Evaluation of the Evaluation of the EnterpriseEnterprise


Evaluation of the enterpriseEvaluation of the enterprise

Scope:Scope:– Assesment of current situationAssesment of current situation– Optimization of water and energy Optimization of water and energy

consumptionconsumption– Optimization and consumption of Optimization and consumption of

chemicals chemicals – Determination of alternative chemicalsDetermination of alternative chemicals– Possible process modificationsPossible process modifications– Determination of recycle, resue and Determination of recycle, resue and

recovery optionsrecovery options


Evaluation of the enterpriseEvaluation of the enterprise

Methodology:Methodology: Analysis of processes, use of raw materials, Analysis of processes, use of raw materials,

chemicals and emissionschemicals and emissions

Comparison of the techniques applied in the facility Comparison of the techniques applied in the facility with the ones indicated in the BREF Textile with the ones indicated in the BREF Textile Document and suggestion of BAT measuresDocument and suggestion of BAT measures

Determination and analysis of possible Determination and analysis of possible modifications in processes and reduction of modifications in processes and reduction of emissions by considering the most cost effective emissions by considering the most cost effective techniques regarding the quality of the final techniques regarding the quality of the final productproduct


Wastewater ManagementWastewater Management


Wastewater ManagementWastewater Management Characterization of wastewater streams in the Characterization of wastewater streams in the

facilityfacility

Collection and analysis of wastewaters seperately Collection and analysis of wastewaters seperately according to the type and load of pollutionaccording to the type and load of pollution

Identification of the most appropriate treatment Identification of the most appropriate treatment techniques to the wastewaters, treatability studiestechniques to the wastewaters, treatability studies

– Combination of biological, physical and chemical treatment methods

– Application of advanced oxidation (ozone, hydrogen peroxide, fenton) and treatment systems (membrane) before/after biological treatment


Wastewater treatability Wastewater treatability studiesstudies

Current wastewaters (without BAT measures)

Wastewaters after the application of BAT measures


Cost AnalysisCost Analysis

Scope:

– Evaluation of investment and operational costs of suggested and applied reuse, recycle and treatment options

– Estimation of return period– Selection of BAT


Risk AnalysisRisk Analysis

Scope:– According to the IPPC Directive, industries

must have an accident management plan.

Methodology:– Identification of the hazard of the facility

and activities in the facility– Analysis of potential risks and taking

necessary measures to reduce the risk, revision of emergency action plan.


Improvements in Energy and Improvements in Energy and Water Consumption Water Consumption

Performances of the selected Performances of the selected millmill


BAT Options-water BAT Options-water minimizationminimization Installation of flow meters Semi-counter current rinsing in dyeing and finishing

processes Reuse of dyeing and finishing wash waters after a

treatment scheme Change in the rope route in dyeing process Recovery and reuse of sodium hydroxide from

mercerization wash waters in the finishing process Reuse of concentrate stream of reverse osmosis

plant Minimization of wash water consumption in the

water softening plant (reuse of wash waters from regeneration of ion exchangers)

Reuse of compressor cooling waters in production processes


BAT Options-energy BAT Options-energy minimizationminimization

Use of waste heat from finishing and dyeing wastewater streams in heating up the washing waters

Heat-insulation of pipes, valves, tanks, machines

Maintenance of heating systems and stenters

Heat recovery from hot air discharges in finishing line

Optimization of stenter frames


ScopeScope Assessment of water and energy consumption Assessment of water and energy consumption

performances of the selected mill by considering performances of the selected mill by considering the water intensive wet processes:the water intensive wet processes:

– Dyeing Dyeing – FinishingFinishing

Via:Via: Water and energy consumptions prior to the Water and energy consumptions prior to the

application of BATsapplication of BATs Water and energy consumptions after the Water and energy consumptions after the

application of BATsapplication of BATs


MethodologyMethodology

Monthly water and energy Monthly water and energy consumptionsconsumptions

Specific water and energy Specific water and energy consumptions evaluated (per consumptions evaluated (per kilogram fabric produced)kilogram fabric produced)


Water ConsumptionWater Consumption

In textile industry water is consumed In textile industry water is consumed for:for:

– Cleaning purposesCleaning purposes– Removing impuritiesRemoving impurities– Applying dyes and finishing agentsApplying dyes and finishing agents– Generation of steamGeneration of steam


Water Consumption in Water Consumption in ProcessesProcesses


DyeingDyeing

BAT measures in dyeing process:BAT measures in dyeing process:

Installation of flow control devicesInstallation of flow control devices Application of semi-counter current Application of semi-counter current

rinsing systemrinsing system Reuse of washwaters by a membrane Reuse of washwaters by a membrane

system (ongoing)system (ongoing)


Water consumption in dyeing Water consumption in dyeing processprocess

22% reduction in specific water consumption in 2006-2007


FinishingFinishing

BAT measures in finishing processBAT measures in finishing process

Installation of flow control devicesInstallation of flow control devices Application of semi-counter current Application of semi-counter current

rinsing systemrinsing system


Water consumption in finishing Water consumption in finishing processprocess

16% reduction in specific water consumption in 2006-2007


Overall water consumptionOverall water consumption

30% reduction in overall specific water consumption of the mill


Energy ConsumptionEnergy Consumption

Energy is used for;Energy is used for;

Heating up process bathsHeating up process baths Runing machinery equipmentRuning machinery equipment Processing textilesProcessing textiles LighteningLightening Air-conditioningAir-conditioning


Energy ConsumptionEnergy Consumption

Energy sources:Energy sources:

– Natural gasNatural gas Cogeneration unitCogeneration unit BoilerhouseBoilerhouse Staff canteenStaff canteen Processing textilesProcessing textiles

– Electricity (optional)Electricity (optional)


Energy consumptionEnergy consumption

Energy requirement inside the mill:Energy requirement inside the mill:

– Steam (cogeneration unit+boilerhouse)Steam (cogeneration unit+boilerhouse)– Natural gasNatural gas– Electricity (cogeneration unit+central Electricity (cogeneration unit+central

netwrok)netwrok)


Overall energy consumptionOverall energy consumption


Energy requiredEnergy required


Energy consumptionEnergy consumption

Energy consumption is directly related to water Energy consumption is directly related to water consumption since most of the energy is consumed in consumption since most of the energy is consumed in

order to heat up process baths!!!!order to heat up process baths!!!!

ThereforeThereforeWater intensive processes=Energy intensive Water intensive processes=Energy intensive

processesprocesses


DyeingDyeing

Energy consumed:Energy consumed:– SteamSteam– ElectricityElectricity

Applied BAT measures:Applied BAT measures:– Insulation and maintenanceInsulation and maintenance– BAT measures applied for water BAT measures applied for water

minimizationminimization


Energy consumption in Energy consumption in dyeingdyeing


Energy consumption in Energy consumption in dyeingdyeing

27% reduction in specific energyconsumption of dyeing process in 2006-2007


FinishingFinishing

Energy consumed:– Steam– Electricity– Natural gas

Applied BAT measures:– Use of waste heat from finishing wastewater

streams in heating up the washing waters– Insulation and maintenance– BAT measures applied for water

minimization


Energy consumption in Energy consumption in finishingfinishing


Energy consumption in Energy consumption in finishingfinishing

3% reduction in specific energyconsumption of finishing process in 2006-2007



MillMill

9% reduction in overall specific energyconsumption of the mill



Inside the millInside the mill

2.4% reduction in overall specific energyconsumption of the mill


General assessmentsGeneral assessments

BREF Textile BREF Textile DocumentDocument

– Water consumption: Water consumption: 50-100 L/kg fabric50-100 L/kg fabric

– Energy Energy consumption: 8-20 consumption: 8-20 kWh/kg fabrickWh/kg fabric

Achieved level of Achieved level of consumptionsconsumptions

– Water consumption: Water consumption: 55 L/kg fabric55 L/kg fabric

– Energy Energy consumption: 11 consumption: 11 kWh/kg fabrickWh/kg fabric


General conclusionsGeneral conclusions

Requirements of IPPC DirectiveRequirements of IPPC Directive Techniques mentioned in BREF Textile Techniques mentioned in BREF Textile

DocumentDocument

are applicable in Turkish textile industry.are applicable in Turkish textile industry.

Serious improvements in environmental Serious improvements in environmental performanceperformance


Conclusions-water Conclusions-water consumptionconsumption

Water consumption: Dyeing (2006-2007) 22.2% reduction Finishing (2006-2007) 15.8%

reduction Overall 30% reduction

Achieved level is in the range of BREF Textile Document


Conclusions-energy Conclusions-energy consumptionconsumption

Energy consumption: Dyeing (2006-2007) 27% reduction Finishing (2006-2007) 3% reduction Overall 9% reduction

Achieved level is in the range of BREF Textile Document


Thank you...Thank you...

Cleaner Production Workshop 2008, Ankara March 31, 2008 Improvements in Energy and Water Consumption...

Documents

Transcript of Cleaner Production Workshop 2008, Ankara March 31, 2008 Improvements in Energy and Water Consumption...