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CPERATIONS
David B. Williams, Environmental Engineer
N.C. Office of Waste Reduction
A m i t a l S p i n n i n g Corp. i n s t i t u t e d a w a t e r c o n s e r v a t i o n and
r e u s e program. N o n c o n t a c t c o o l i n g w a t e r i s r e u s e d f o r dye
l i q u o r p r e p a r a t i o n , and s p e n t d y e b a t h s a r e r e u s e d whenever
p o s s i b l e . Because the c o o l i n g w a t e r i s r m e r (SOOF) t h a n
t a p water, steam requirements f o r h e a t i the d y e b a t h a r e
;educed, and t i m e b a t h i s r e d u c e d by
8 to 10 minutes p e r hs a l l o w s c h e m i c a l s
t h a t r e m a i n i n the sed a s w e l l .
Chemical costs fo p e r b a t c h lower
than f o r n e w b a t c h e s . Water u reduced f r o m
320,000 t o 92,000 g a l l o n s roduc tion h a s
i n c r e a s e d f r o m 12 o f y a r n p e r day.
E s t i m a t e d co December 1991
t o t a l l e d $21 for w a t e r s a v i n g s and $ 5 2 1 , 1 0 0 f o r e n e r g y
savings.
Chemical substitution
As discussed, it is a good idea to review all chemicals used,
particularly those used in large quantities, to identify those
that may contribute to wastewater problems or other problems. In
many situations, alternative chemicals are available f o r
chemicals that contribute to particular environmental concerns.
Process modification may sometimes be necessary to accommodate
substitute chemical. Situations where chemical substitution is
often employed are discussed below.
Metal containins dyes. Many dyes and pigments, particularly
blues and greens, contain metals such as copper and nickel as
part of the dye molecule. In many situations these metal-
containing dyes can be replaced with dyes that do not contain
metals or that contain lower metal content. An example is
substituting metal-free vat dyes for metal-containing direct or
fiber reactive dyes for dyeing cellulosic materials. Typically
for direct dyes, only 85-95% of the metals exhaust into the
fiber; the remainder is left in the dyebath and is dumped.
Dyeing conditions should be optimized to maximize exhaustion
where metalized dyes are used.
Surfactants. Surfactants are contained in nearly every chemical
specialty. Surfactants vary in their toxicity to aquatic life
depending on their structure. The ultimate toxicity of
surfactants is affected by the degree to which they biodegrade
during wastewater treatment processes. Relatively toxic
surfactants that biodegrade easily are actually less harmful to
aquatic life than less toxic surfactants that do not biodegrade
well. For example, ethoxylated octyl- or nonylphenol (AP)
surfactants are less toxic than linear alcohol ethoxylates (LAE),
but they are only 2 5 % degradable, whereas LAEs are nearly 100%
degradeable.6 The result is that LAE exhibits far less pass-
through toxicity than AP. Therefore, LAE is commonly substituted
for AP to help reduce effluent toxicity. Unfortunately, more
biodegradable surfactants generally have a higher biological
oxygen demand (BOD), so much consideration must go into
substitute surfactants to ensure that one problem does not
replace a different one.
Phosphates. Effluent phosphorus limitations have forced many
companies to evaluate strategies reduce phosphorus. A number of
common processing chemicals contain high levels of phosphorus
including buffers, builders for scouring, water conditioners, and
surfactants. Alternatives which do not contain phosphates exist
for Almost every situation where phosphates are used. As was the
case with surfactants, many of the non-phosphate alternative
chemicals may have a higher BOD or may be more toxic than those
they replaced. Material safety data sheets do not always
indicate the presence of phosphates since they are not generally
considered hazardous materials. It may be necessary to contact
chemical suppliers to obtain information about phosphorus
content.
CAL S U B S T I T U T I O N
Summary
Pollution prevention offers textile manufacturers an opportunity
to reduce water pollutant loadings and VOC and HAP emissions and
save money at the same time. Many companies may be able to come
into full compliance with all environmental regulations without
installing expensive pollution control equipment. Pollution
control equipment can only pay for itself through avoided
environmental fines and other intangible costs such as improved
environmental quality and improved public relations. The case
studies presented here show companies which have reduced water
pollutants and air emissions with less than one year payback
through reduced water, chemical, and energy use. These companies
also realized the intangible savings mentioned above.
Pollution prevention has been proven by countless companies to be
the most cost-effective approach to environmental protection.
The North Carolina Pollution Prevention Program is available to
help companies identify opportunities for pollution prevention.
Companies interested in receiving free non-regulatory technical
assistance should call ( 9 1 9 ) 571-4100. .
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REFERENCES