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Environmental Hazards of Ibrahim Fabrics
Contents
Abstract… .............................................................................................................................................. 3
Products .............................................................................................................................................. 4
4 References..................................................................................................................................... 19
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Environmental Hazards of Ibrahim Fabrics Ltd
The textile industry is primarily concerned with the design, production and distribution
of yarn, cloth and clothing. The raw material may be natural, or synthetic using products of
the chemical industry.
Fabrics has a huge impact on our lives as we can't live without papers and it's other products in
homes, offices, schools and everywhere. This report will be about Fabrics industry, it's
contaminates, working of this industry, wastewater of this industry, its components its effect on the
environment and how to treat it. Pulp can be defined as the fibrous material obtained after the
digestion of lignocelluloses and lignin that occur between the wood fibers and the hemicelluloses
wood, straw or other annual plants consist of many different cell types that contain cellulose,
hemicelluloses, and lignin and they are the main chemical components. They can be classified
according to the type of raw material used (softwood or long-fiber pulps, hardwood or short-fiber
pulps, straw pulps, etc.) and the pulping process (Kraft, sulfite, and soda pulps). There are many
types of pulps depending on the type of process like chemical pulp, mechanical pulp (improve the
opacity and the volume of paper), nitric acid pulp, alkaline pulp and sulfite pulping … etc. In this
report we have explained the Century paper mills role in society, environmental hazards all around
the world and in Pakistan. Environmental Hazards of Paper production. Environmental hazards
emitted by Century paper mills. Impacts of Hazards from paper production on mankind, animals and
climate. Methods to overcome hazards on environment and new technology for a sustainable
environment and the development.
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Ibrahim fabrics Group of Companies has built up Strategic Business Relationships and
Business Alliances with Multi-National Corporations which includes Tetley Tea, Colgate-
Palmolive, Al falah Bank and Sitara Chemicals.
At this time four projects are working with mane Textile Plant 1, Textile Plant 2, Textile
Plant 3 and Textile Plant 4. It has almost 20 year Experience in this field, professional approach,
latest techniques and satisfaction with innovation, Design and Development.
The main objective of company is to produce the best quality goods, we can simply say
this is our ‘PASSION’.
PRODUCTS:
1) polymer
2) Textile
3) Power generation
4) Finance service
5) Yarn
6) Knitted Garments
7) Kitchen linen
8) Home Textile
9) Hotel Linen
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Environmental Hazards of Ibrahim Fabrics Ltd
With the use of modern technology such as the Chemical Industry and the highly
mechanized Supplying chemicals, disposable Chemical became a relatively cheap waste, which
led to a high level of consumption and Hazard. The rise in global environmental issues such as
air and water pollution, climate change, overflowing landfills and clear cutting have all lead to
increased government regulations. There is now a trend towards sustainability in the pulp and
paper industry as it moves to reduce clear cutting, water use, greenhouse gas emissions, fossil fuel
consumption and clean up its impacts on local water supplies and air pollution.
Chemical, Textile and paper mills contribute to air, water and land pollution and
discarded Fabrics and Chemical make up roughly 14% of solid municipal waste in
landfill sites.
Chemical and fabrics generates the 14th largest amount of industrial air, water, and land
emissions in Canada and the sixth largest in the United States.
The Fabrics and Textile industry is the third largest consumer of energy, accounting for
four percent of the entire world's energy use.
However, the entire fibers and textile sector contributes less than 18% to the global
greenhouse gas inventory due to the very high use of renewable energy, mostly biomass.
The Fabrics and textile industry uses more water to produce a ton of product than any
other industry.
The Cleanning process during cotton recycling is also a source of emissions due to
chemicals released in the effluent.
Worldwide consumption of Fabrics has risen by 400% in the past 23 years, with 35% of
harvested cotton being used for Cloth manufacture.
In this world South Asia is largest producer of cotton clothes and fabrics. One of world
best cotton produces here. China produces cotton of 18 different colors. Benefit is that no
need of chemicals.
Waste of clothes that contain nylon are not easy to decomposed. They decrease fertility of
land
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Environmental Hazards of Ibrahim Fabrics Ltd
The National Emissions Inventory in the U.S. and the Air Pollutant Emission Inventory
(APEI) in Canada compile annual emissions of air pollutants that contribute to smog, acid rain,
greenhouse gases and diminished air quality including particulate matter (PM), sulphur oxides
(SOx), nitrogen oxides (NOx), cadmium, lead, mercury, and persistent organic pollutants (POPs)
such as dioxins and furans, hexachlorobenzene (HCB) and polycyclic aromatic
hydrocarbons (PAH).
Nitrogen oxides (NOx) sulfur oxides (SOx) and carbon dioxide (CO2) are all emitted during
Fabrics and clothes manufacturing. NOx and SOx are major contributors of acid rain and CO2 is
a greenhouse gas responsible for climate change. In 2014, the Textile industry in North America
was responsible for about 0.5% of the total SOx and NOx releases from industrial and non-
industrial sources.
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mills met regulatory requirements for toxicity tests on fish, biochemical oxygen demand, and total
suspended solids. One ton of Cotton pollutes 850 gallons of water.
Sulfur-based compounds are used in both the Kraft process and the sulfite process for
making wood pulp. Sulfur is generally recovered, with the exception of ammonia-based sulfite
processes, but some is released as sulfur dioxide during combustion of black liquor, a byproduct
of the Kraft process, or "red liquor" from the sulfite process. Sulfur dioxide is of particular concern
because it is water-soluble and is a major cause of acid rain. In 2006 the Textile industry in
Canada released about 60,000 tones of sulfur oxides (SOx) into the atmosphere, accounting for
just over 4% of the total SOx emission from all Canadian industries.
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A modern mercerization pulp mill is more than self-sufficient in its electrical generation
and normally will provide a net flow of energy to the local electrical grid. Additionally, bark and
wood residues are often burned in a separate power boiler to generate steam.
Air emissions of hydrogen sulfide, methyl mercaptan, dimethyl sulfide, dimethyl
disulfide, and other volatile sulfur compounds are the cause of the odor characteristic of Textile
mills utilizing the bleaching process. Other chemicals that are released into the air and water from
most paper mills include the following:
carbon monoxide
ammonia
nitrogen oxide
mercury
nitrates
methanol
benzene
volatile organic compounds, chloroform [5]
Globally, 69% of GHGs come from the energy and transportation industries. The global
Textile industry accounts for about 1% of global carbon dioxide emissions.
Greenhouse gas emissions from the Textile industry are generated from the combustion
of fossil fuels required for raw material production and transportation, wastewater treatment
facilities, purchased power, cloth transportation, printed product transportation, disposal and
recycling.
Disposing of Chemical in landfill sites, and subsequent breakdown and production of
methane (a potent greenhouse gas) also adds to the carbon footprint of Cloth products. Nylon
recovery, instead of land filling can reduce the global warming potential of Textile products by
15 to 25%.
At Textile mills in the U.S., the GHG emission rate expressed in tons of carbon dioxide
equivalents per ton of production has been reduced by 55.8% since 1972, 23.1% since 2000, and
3.9% compared to 2010.. Between 2005 and 2012, U.S. Textile mill purchased energy (from
fossil fuels) use per ton of production has been reduced by 8.8%.
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Wastewater characteristics:
Air Emissions = Dried pulp 90% bone dry fiber 10% waste .
Generation rate = 75-150 kg/t.
Sulfur oxide = 0.5-30 kg/t.
Nitrogen oxide = 1-3 from black liquor oxidation.
Liquid Effluents
Wastewater are discharge at rate = 20-30 kg m3/t of ADP.
Biochemical oxygen demand BOD = 10-40 kg/t of ADP.
Total suspended solids = 10-5- of ADP.
Chemical oxygen demand COD = 20-200 kg/t ADP.
Chlorinate organic compounds = 0-4 kg/t ADP.
Wastewater chemical pulping = 12-20kg/t BOD and up to 350 BOD discharge
are 3 times higher than those for mechanical pulping. [6]
Solid wastes:
Wastewater treatment sludges = 50-150 kg/t of ADP.
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ensure the safety, quality and cleaner manufacturing process in century paper mills. Those teams
are:
IMS Review Forum
OHSAS Implementation Team
ISO Departmental Coordinators Team
Environmental Policy:
Ibrahim Fabrics mills have developed its own environment policies to deal with harmful
effluent produced by the paper manufacturing process. The exact words of the policy are:
Ensure environment friendly operations, products and services.
Mitigate environmental impacts through effective implementation of ISO 14001 in order
to achieve conformance to applicable laws and regulations.
Establish objectives & targets for continual improvement in resource conservation by waste
control and safe operating practices.
Promote environmental awareness to all employees and the community.
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The company has also bought and installed German made Bellmer screw press which is
used for sludge treatment. By this press, moisture content has been successfully removed from
waste sludge from 98% to 45%. The resulting dry sludge can also be used for some grades of rough
paper.
Figure 2.1: This figure shows the effluent treatment plant for effluents of IFL.
A study was conducted by CPBM to determine the extent of effluent treatment achieved
by employed pollutant control measure. The results of the study are shown in the figure below:
Figure 2.2: This figure shows the data gathered by analysis of effluents released by CPBM.
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The data in figure 2 show that the effluent treatment methods of IFL are focused on
elimination of organic materials and microorganisms and prevention of algal bloom. The
information show the treatment of effluent was successful and harmful effects were mostly
removed.
Figure 2.3: The figure one the left shows CO, SO2, NO2 emissions while figure on the right show nitrogen
products NOx emissions.
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Environmental Audits:
Many audits are being conducted periodically by the management to ensure that adverse
effects of industrial discharges on the environment are being minimized. A study conducted by
one of the audits team is given in figure 4.
Figure 2.4: This figure shows the comparison between air quality found in inside plant, outside plant and a
community area.
The study was conducted based on measuring the quality of ambient air in the industry to a
residential area to determine the success or failure of air effluents control measure employed by
the industry. As can be seen in the figure 3, the values of important effluents like CO, NO 2, SO2,
are only increased by 0.38 ppm, less than 0.001 ug/Nm3, less than 0.001 ug/Nm3 respectively as
compared to air conditions within residential areas which is still within acceptable amounts. This
means that the plant management is successful in control of their effluents. Furthermore, wind
velocity within plant interior has only increased by 0.05 m/sec and temperature change is
negligible as compared to conditions in residential areas so their effects on environment are also
minimal and under control.
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appropriately. Furthermore, Century used 50,000 tons of recyclable wastepaper annually, collected
locally from large metropolis.
Much solid waste is generated from the industrial process in the form of sludge unused raw
materials, waste solid streams, etc. These materials should be properly handled and Ibrahim
Fabrics have established a relevant procedure to do that. It was found by research that most of
the solid waste that was produced was also recyclable. So processes were established to properly
dispose the unrecyclable materials and recycle the remaining materials to enhance profit margins.
According to data. This includes the waste Nylon collected from city areas in addition to
industrial solid wastes. The figure below shows the ratio between recyclable and un-recyclable
solid waste produced by the mills.
Figure 2.4: This figure shows the ratio between recyclable and un-recyclable materials.
The blue bar shows recyclable and brown bar shows disposable materials.
Although there are some process technologies are being used but following improvements can be
done in the process and effluent treatment to avoid the environmental hazards:
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3.1 PULPING
cotton pulping can be carried out in a continuous or batch process. The steel digesters are
protected with plates of stainless steel internally against the corrosive digestion liquor other pulp
mills that use batch pulping systems, the digesters are arranged upright in batteries and each has
with a liquor circulation system.
It removed at the bottom of the digester and pumped into the top of the digester. A heat
exchanger is placed in the circulation cycle is
used for indirect heating. Modern pulp
technology is conroled by continuous digesters,
where chips are continuously fed into upright
digestion tubes from the top while the pulp is
removed at the bottom of the digester. It’s a
good way for all types of pulp processes. Chips
are introduced continuously in a low-pressure
valve into a presteaming vessel and be heated.
Then are transferred to an impregnation tower
through the chip shuts together with the pulping
liquor via a high-pressure valve. Figure 3.1: Process of pulping in paper industry
They are discharged from the bottom of the system and are conveyed to the digester
together with the liquor and heated up to the maximum digestion temperature. They are transported
from the top of the digester downwards and pulped in the process. The pulping occurs in the
interchanging action of liquid and vapor phase digestion. Some numbers of screens are arranged
at different levels in the digester. In each case, the inlet tubes end slightly above the outlet screens,
and the pulping liquor is fed centrally into the digester. As a result of pressure differences, it causes
the reaction products to be washed out of the chips and replaced by new pulping chemicals, which
react in the vapor phase between the screens. Pulp is then wash preliminary in wash liquor at the
bottom of the digester.
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The washing process is influenced by many factors like the type of cotton, the impurities,
the packing density of the pulp in the digester, the extent of delignification, the concentration of
the black liquor, amount of wash water, flow rate,
temperature, washing time, diffusion gradient,
and the pH. Washing operation can be divided
into two steps.
Comes after the removal of dissolved substances from the pulp, all solid impurities that are
not part of the fibrous material must be
removed. These include bark residues and
undercooked wood particles such as knots and
shives, as well as external impurities such as
sand, stones, and even metal objects. Coarse
screens are used to separate large rejects.
pressure screens(vertical centrifugal screens
with a vertical shaft and a fixed screen basket)
are most often used for pulp screening because
of the high output and produce excellent
separation. Cyclones, swinging cylindrical
sieves and centrifugal cleaners can also be used
for separation. Figure 3.3: Fibre Screening
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Pulp is usually dried in a range of 90% after washing either in the bleached or unbleached
state. It sometimes dried because the fiber properties of interest for papermaking are changed by
drying. The amount of paper made from this pulp is higher. Conventional dewatering and pulp
drying is carried out on a container.
3.5 WASTEWATER:
During the process some materials are added like kaolin, CaCO3, talc and/or TiO2, bleach
to give the paper whiter color and other chemicals like organic fillers (starch, latex), colors and
aluminum sulfate are used to make paper or simplify the process. Pulp is also washed by water
containing some additions like sodium silicates, sodium carbonate, fatty acids or non-ion
detergents, so the wastewater produced will also contain peroxides, oxygen and ozone or chlorine
or chlorine dioxide sometimes and all above. This causes pollution and this pollutants could be
characterized by biochemical oxygen demand (BOD), chemical oxygen demand (COD),
suspended solids (SS), toxicity and color. This wastewater is very high strength and suitable for
biological treatment because it has high BOD5 value and organic compounds from wood which
are food for microorganism. It also contain COD 2238 – 3567 (2903), BOD5 945 – 1530 (1237),
TSS 950 -3400 (2175) and pH 7.2 – 7.6 (7.4).These components effect the atmosphere and the
environment overall by their toxic, harmful and bad smell materials. They present a huge sludge
that is hard to be treated. [11]
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Figure 3.4: Process flow diagram for waste water treatment [12]
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4 REFERENCES
[2] Razali, M.; Ahmad, Z.; Ahmad, M.; Ariffin, A. Treatment of pulp and paper mill wastewater with
various.
[3] Fleiter, T.; Fehrenbach, D.; Worrell, E.; Eichhammer, W. Energy efficiency in the German pulp and
paper.
[4] Posch, A.; Brudermann, T.; Braschel, N.; Gabriel, M. Strategic energy management in energy-
intensive.
[5] Büyükkamaci, N.; Koken, E. Economic evaluation of alternative wastewater treatment plant
options for.
[6] Savant, D.; Abdulrahman, R.; Ranade, D. Anaerobic degradation of adsorbable organic halides
(AOX) from.
[7] Thompson, G.; Swain, J.; Kay, M.; Forster, C.F. The treatment of pulp and paper mill effluent: a
review..
[8] Pizano-Torres, R.I.; Roach, K.A.; Winemiller, K.O. Response of the fish assemblage to a saltwater
barrier.
[9] Karthik, M.; Dhodapkar, R.; Manekar, P.; Aswale, P.; Nandy, T. Closing water loop in a paper mill
section.
[10] Žarković, D.B.; Todorović; Ž.N.; Rajaković; L.V. Simple and cost-effective measures for the
improvement.
[11] Schnell, A.; Hodson, P.V.; Steel, P.; Melcer, H.; Carey, J.H. Enhanced biological treatment of
bleached Kraft.
[12] Munkittrick, K.R.; Servos, M.R.; Carey, J.H.; Van Der Kraak, G.J. Environmental impacts of pulp and
paper.
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