5/14/2016

Cleaner Production
Case Study Textile Company

Dr. Edi Munawar

Chemical Engineering Department
Syiah Kuala University
Contact: edi.munawar@che.unsyiah.ac.id

Environmental impacts and risks of

textile production
 Air emissions
o Nitrogen and sulfur oxides from boilers which
create
t acidity
idit iin th
the natural
t l environment
i t and
d lead
l d
to the deterioration of metal and building
structures. They also contribute to smog
formation in urban areas.
o Solvent content peaks in the ambient air from
ovens used for coating operations
o Solvents released from cleaning activities
(general facility cleanup and maintenance, print
screen cleaning
o Volatile emissions of hydrocarbons

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Environmental impacts and risks of

textile production
 Waste water pollutants
o BOD
o COD
o Total suspended solids
o Oil and grease
o Phenol
o Sulfide
o Ch
Chromium
i
o Copper.

Environmental impacts and risks of

textile production
 Solid waste
o Ashes and sludge
o Cardboard boxes, bale wrapping film or fabric
o Plastic bags containing chemical raw material
o Paper cones and tubes
o Waste fabrics, yarns, fiber from processing.

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Textile Manufacturing Processes

1. Processing of Cotton Based Textiles

p
 Spinning g
 Knitting
 Weaving
 Wet Processing

Textile Manufacturing Processes

 Spinning
Spinning is the process which converts raw fiber into
yarn or thread. The fibers are prepared and then drawn
out and twisted to form the yarn, which is then wound
onto a bobbin or cone. The spinning process is entirely
dry, although some yarns maybe dyed and finished as a
final customer
p
product.

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Textile Manufacturing Processes

Textile Manufacturing Processes

 Knitting
Knitting is carried out by interlocking a series of yarn
loops usually
loops, s all using
sing sophisticated,
sophisticated high speed
machinery. This process is almost completely dry,
although some oils may be applied during the
process for lubrication

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Textile Manufacturing Processes

Textile Manufacturing Processes

 Weaving
Weaving is the most common method used for
prod cing fabrics
producing fabrics. The process is carried o
outt on a loom
(of which numerous varieties exist) which interlaces
lengthwise yarns (warp yarns) with widthwise ones (weft
or filling yarns)

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Textile Manufacturing Processes

Textile Manufacturing Processes

 Wet Processing
The stages of wet processing of cotton textiles,
both woven and knitted include:
o Pretreatment Processes (Sizing and
Desizing, Scouring, Bleaching, Mercerizing,
Combined mercerizing)
o Dyeing
o Printing
o Finishing

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Textile Manufacturing Processes

2. Processing of Wool Based Textiles

 Conversion of raw wool into woolen and
worsted yarns
 Weaving or knitting
 Finishing of woolen or worsted fabric

Textile Manufacturing Processes

 Conversion of raw wool into woolen and

worsted yarns

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Textile Manufacturing Processes

 Weaving or knitting

Knitting Knitted fiber

Yarn
Winding
(woolen or worsted) 

Slashing Weaving Weaving fiber 

Textile Manufacturing Processes

 Finishing of woolen or worsted fabric

Burling & Felting 

Fabric  Tackling Fulling Washing
mending 

Bleaching  Piece dye Dusting Carbonizing 

Finished
Finishing 
product
 

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Summary of the operating

conditions
Process Conditions
Scouring NaOH, 1.5-2.5 g/l, detergent 1-18 g/l, temperature > 65 oC
Carbonizing 100g H2SO4 (98%) per kg of wool,
wool heating by indirect steam for
45 minutes
Bleaching Bleaching of wool can be carried out using sulphure dioxide,
hydrogen peroxide followed by optical brightening
Dyeing The dye formulation depends on the nature of the dye (acid or
metalized dye), grade of wool and the type of dyeing machine
being used. Acid dyeing temperature ranges from 60-100
degrees centigrade, whilst the metalized dyeing temperature
range is »85
degrees centigrade
Finishing o Insect repellent finishes: Mitin, Dieldrin and Boconize for
permanent moth-proofing.
o Water and oil repellent finishes: fluoro-chemicals

Cleaner Production Vernitas case

study
o Products:
o Bulk,
Bulk polyacryl nitrile (PAN) yarns;
o Production capacity:
o 6.000 tons of yarns per year;
o Market:
o export
p to EU approximately
pp y 70%.

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Production processes
o Yarn Preparation, sub-processes:
o Stretch-breaking
g
o Re-breaking
o Intersecting
o Finishing
o Spinning
o Twisting
o Bulking
o Dyeing
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Auxiliary processes
o Ventilation
o Boiler house – heating and steam
production
o Water preparation
o Compressed air production

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Methodology
o A ‘top-down’ investigation
p y was analyzed
o The company y on three levels:
o Level 1: Main data for black box - entire company;
o Level 2: Main process data (building a ‘layer cake’);
o Level 3: Detailed data and measurements for one or two
specific processes.
o In the initial phase focus on level 1 and 2.
o Later level 3 data were collected/measured for
the 2-3 focus areas.

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Energy balance

Elec. heaters Dyeing

Compressed 4,4% 2,5%
Lighting
air
i Twisting
T i ti
5,0%
6,4% 22,9%
Yarn
preparation
7,4%

Spinning
Bulking 22,1%
8,1%
Ventilation
21,2%

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Heat consumption

Yarn prep.,
steam Bulking,
9% steam
Dyeing,
steam 35%
16%

Ventilation,
steam
18% Radiators,
R di t
hot water
22%

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Energy savings (electricity savings)

Elec.
Electricity savings Savings Investment Pay back
savings
Units kWh/year EUR/ year EUR years
Optimisation of 120,000 7 800* 30 000 3.8
humidification
system
Installation of 551,300 29 000 68 000 2.4
variable speed
drives on fans
Total 671,300 36 600 98 000 2.7

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Energy savings (heat recovery )

Heat
Heat recovery Savings Investment Pay back
savings
Units kWh/year EUR/ year EUR years
Modernisation of 160,000 7 800* 40 600 5.2
heating substation
Heat recovery on 303,300 7 500 15 000 2.0
air compressors
Recycling of steam 290,000 9 500* 14 500 1.5
condensate in
dyeing dept.

Optimization of the humidification system -

replacement of the spraying nozzles
o Savings by reduction of consumption of both water and compressed air.

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Installation of Variable Frequency

Drives on Fans
o Significantly increased energy efficiency of
the fans at part load (50
(50-90%),
90%), which was
approx. 75% of the operation time.

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Heat Recovery in the Compressed

Air System

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Recycling of Steam Condensate in

Dyeing Department
Hot water Clean condensate
from drying
block 

Dying
Block
Steam

Condensate
Water to
drain 

Air Filter
compressor Fe2O3

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Main Cleaner Production projects

1. Treatment of waste water from dyeing

p
department
2. Possibility of recycling the waste water
from dyeing department
3. Reduction and substitution of chemicals
used in dyeing processes
4. Recycling of cooling water from spinning
machines

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Minimisation/Optimisation of
Chemicals Used
1. Investigate the use of the chemicals
2. Investigate the possibilities to omit the use of the
chemicals
3. Investigate the possibilities to reduce the use of
chemicals (this step should not be considered if the
chemicals are evaluated to be hazardous, unless
substitution is not possible)
4. Investigate the possibilities to substitute the chemicals
with alternatives that have less negative impacts on the
environment.
Vernitas:
•160 different chemicals
•Total quantity of 26,419 kg. 31

Zinc emission to effluent

o Stop treating the effluent for removal of zinc
(Zn)
o Find the source of the zinc (Zn) emission in the
effluent.

It is much cheaper and more environmental

friendly to change the source

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Dyes Containing Heavy Metals

Heavy Metal Concentration
Name of chemical Co
Zn Cu Cr

Astrazon Blue BG 200% 4 2%

4.2%
Astrazon blue FGGL 300% 4.0%
Astrazon Red FBL 200% In German ?
Astrazon Blue FGRL 200% 4.1%
Cibacron Blue FN_R 4.6%
Lanaset Red 2B 1.3%
Lanaset Grey G 2.5% 0.79%
Lanaset Orange RN 1.1%
Lanaset BORDEAUX B 2.3% 0.2%
Lanaset BROWN B 2.8%
Lanaset BLAK B 3.2%
Irgalan BORDEAUX EL 200% 3.7%
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Maxilon Blue SL 200% 4.1%

Continual Improvements
Elimination/reducing of:
o dyestuff containing heavy metals
o azo-dyestuff, which splits off carcinogenic
amines.
o toxic chemicals (T or Tx marked according to
EU regulations)
o hazardous surfactants giving rise to
environmental concerns do to their poor
biodegradability, their toxicity and potential
to act as endocrine disrupters.
o hazardous complexion agent
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Wastewater from dyeing department

Parameter Wastewater quantity

[m3/h] [m3/d] [m3/month] [m3/year]

Wastewater for 2.0 50 1,100 13,000
reuse
Wastewater for 4.2 100 2,300 27,500
discharge
Total 6.2 150 3,400 40,500
wastewater

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Wastewater Treatment Plant

Wastewater from dyeing steps

Effluent wastewater for

Dyeing capacity

discharge to municipal
wastewater treatment plant
Equalization tank

Sedimentation tanks

Feed tank Membrane

e b a e filter
te

Permeate (water for reuse)

Bag filter
Concentrate (residue material for discharge)

Equalization tank Concentrate (recirculation)

Wastewater from washing steps

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Membrane filtration

• Investment:
Feed Feed Back pressure • EUR. 250 000.
tank  pump  valve

Concentrate • Pay back:

outlet
Recirculation • 17.5 years
pump

Flow controller
valve 

Permeate
outlet

Membrane
module 

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Reuse of Cooling Water from

Spinning Machines
o Total use of water is about:
,
o 24,000 m3/year
y
o Total installation cost is:
o 818 EUR.
o Simple payback period is:
o 1.67 year.
(not including usage of electricity by water
pump and water pumping from well)

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