Improvements in Energy and Water Consumption Performances of a Textile Mill After BAT Applications

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• Improvements in Energy and Water Consumption
  Performances of a Textile Mill After BAT
  Applications
• Adoption of EUs IPPC Directive to a Textile Mill
  in Turkey

Ayse Merve KOCABAS Dept. of Environmental
Engineering
METU
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Outline

• Introduction
• IPPC Directive
• BREF Documents
• Project
• Target
• Objective
• Scope
• Improvements in energy and water consumption
  performances
• Conclusion

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IPPC (Integrated Pollution Prevention and
Control) Directive
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IPPC Directive - Target

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

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IPPC Directive

• Integrated approach means
• Permits must take into account the whole
  environmental performance of the plant, covering
• emissions to air, water and land,
• generation of waste,
• use of raw materials,
• energy efficiency,
• prevention of accidents,
• restoration of the site upon closure.

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IPPC 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

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BREF 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

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BREF Documents-Textile Sector
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
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BREF Documents-Textile Sector

• Being a water intensive industry
• Water consumption
• Wastewater discharges and chemical load it
  carries
• Energy consumption

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What does BAT application bring??

• Minimized water consumption and waste generation
• Reduced waste disposal costs
• Increased energy efficiency
• ? ECONOMICAL BENEFITS...

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PROJECT
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A RESEARCH PROJECT

• Adoption of EUs IPPC Directive to a Textile Mill
  in Turkey
• Principle Investigator Prof. Dr. Ülkü Yetis
• Department of Environmental Engineering
• Middle East Technical University
• ANKARA
• Funding Agency The Scientific and Technological
  Research Council of Turkey (TÜBITAK)

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• Project 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

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Project Objectives

• Identification of textile facilities covered by
  the IPPC Directive and their production
  processes
• Investigation of the applicable BAT Options for a
  selected mill
• Selection of BAT for the pilot mill
• Dissemination of the results obtained.

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Scope of the Project

• IPPC Directive and Turkish Textile Industry
• Adoption of IPPC Directive to the selected mill
• Evaluation of the enterprise
• Wastewater management
• Cost analysis
• Risk analysis

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IPPC Directive and Turkish Textile Industry

• Scope
• Identification of enterprises in Turkish textile
  industry-Survey studies
• Dissemination of the studies Workshops

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Survey Studies

• A survey study to identify textile mills within
  the IPPC have been initiated to collect
  information on
• Total production and wet production capacity
• Type of production
• Number of employees
• Feedback from 126 textile mills in 12 provinces
• At least 66 textile mills are under the scope of
  IPPC Directive in Turkey

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Workshops

• Two workshops conducted
• In the beginning introduction of the project to
  the textile sector
• At the end - dissemination of results of the
  project

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ADOPTION OF IPPC DIRECTIVE TO THE SELECTED MILL
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Selected Textile Mill
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Selected Mill

• A denim manufacturing plant in operation since
  1953
• Among Worlds 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

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Cotton
Others Air Conditioners Compressors Staff
Canteen Irrigation Company Dwelling
Fibre Prep.
Supplementary Facilities (Cogeneration Plant)
DYEING
SIZING
Reverse Osmosis
WEAVING
Wastewater
Hard Water
Ion Exchangers
Soft Water
Product Line
FINISHING
WELLS
Product
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Evaluation of the Enterprise
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Evaluation of the enterprise

• Scope
• Assesment of current situation
• Optimization of water and energy consumption
• Optimization and consumption of chemicals
• Determination of alternative chemicals
• Possible process modifications
• Determination of recycle, resue and recovery
  options

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Evaluation of the enterprise

• Methodology
• Analysis of processes, use of raw materials,
  chemicals and emissions
• Comparison of the techniques applied in the
  facility with the ones indicated in the BREF
  Textile Document and suggestion of BAT measures
• Determination and analysis of possible
  modifications in processes and reduction of
  emissions by considering the most cost effective
  techniques regarding the quality of the final
  product

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Wastewater Management
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Wastewater Management

• Characterization of wastewater streams in the
  facility
• Collection and analysis of wastewaters seperately
  according to the type and load of pollution
• Identification of the most appropriate treatment
  techniques 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

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Wastewater treatability studies

• Current wastewaters (without BAT measures)
• Wastewaters after the application of BAT measures

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Cost Analysis

• Scope
• Evaluation of investment and operational costs of
  suggested and applied reuse, recycle and
  treatment options
• Estimation of return period
• Selection of BAT

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Risk 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.

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Improvements in Energy and Water Consumption
Performances of the selected mill
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BAT Options-water minimization

• 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

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BAT Options-water minimization

• 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

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BAT Options-energy minimization

• 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

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BAT Options-energy minimization

• 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

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Scope

• Assessment of water and energy consumption
  performances of the selected mill by considering
  the water intensive wet processes
• Dyeing
• Finishing
• Via
• Water and energy consumptions prior to the
  application of BATs
• Water and energy consumptions after the
  application of BATs

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Methodology

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

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Water Consumption

• In textile industry water is consumed for
• Cleaning purposes
• Removing impurities
• Applying dyes and finishing agents
• Generation of steam

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Water Consumption in Processes
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Dyeing

• BAT measures in dyeing process
• Installation of flow control devices
• Application of semi-counter current rinsing
  system
• Reuse of washwaters by a membrane system (ongoing)

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Water consumption in dyeing process
22 reduction in specific water consumption in
2006-2007
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Finishing

• BAT measures in finishing process
• Installation of flow control devices
• Application of semi-counter current rinsing system

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Water consumption in finishing process
16 reduction in specific water consumption in
2006-2007
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Overall water consumption
30 reduction in overall specific water
consumption of the mill
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Energy Consumption

• Energy is used for
• Heating up process baths
• Runing machinery equipment
• Processing textiles
• Lightening
• Air-conditioning

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Energy Consumption

• Energy sources
• Natural gas
• Cogeneration unit
• Boilerhouse
• Staff canteen
• Processing textiles
• Electricity (optional)

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Energy consumption

• Energy requirement inside the mill
• Steam (cogeneration unitboilerhouse)
• Natural gas
• Electricity (cogeneration unitcentral netwrok)

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Overall energy consumption
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Energy required
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Energy consumption

• Energy consumption is directly related to water
  consumption since most of the energy is consumed
  in order to heat up process baths!!!!
• Therefore
• Water intensive processesEnergy intensive
  processes

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Dyeing

• Energy consumed
• Steam
• Electricity
• Applied BAT measures
• Insulation and maintenance
• BAT measures applied for water minimization

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Energy consumption in dyeing
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Energy consumption in dyeing
27 reduction in specific energy consumption of
dyeing process in 2006-2007
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Finishing

• 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

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Energy consumption in finishing
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Energy consumption in finishing
3 reduction in specific energy consumption of
finishing process in 2006-2007
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Overall energy consumption

• Mill

9 reduction in overall specific
energy consumption of the mill
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Overall energy consumption

• Inside the mill

2.4 reduction in overall specific
energy consumption of the mill
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General assessments

• BREF Textile Document
• Water consumption 50-100 L/kg fabric
• Energy consumption 8-20 kWh/kg fabric

• Achieved level of consumptions
• Water consumption 55 L/kg fabric
• Energy consumption 11 kWh/kg fabric

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General conclusions

• Requirements of IPPC Directive
• Techniques mentioned in BREF Textile Document
• are applicable in Turkish textile industry.
• Serious improvements in environmental performance

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Conclusions-water consumption

• 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

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Conclusions-energy consumption

• 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

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Thank you...