INTEGRATED POLLUTION REGULATIONS AT TEXTILE SECTOR Hüseyin KARIŞLI ERKA-EVD Enerji Verimliliği Danışmanlık Ltd., Türkiye hk@erka-evd.com PREFACE Notification of integrated pollution regulation at textile industry, published at official newspaper, which is for minimizing and controlling of negative effect of due from textile industry producing pollutions, that, discharging emissions to soil, water and air. According to this notification, pre operating plants like washing, bleaching, mercerization, sizing, de sizing, printing, etc. and finishing operating like dyeing plant, are responsible this notification items. The Ministry will be provide need to required, coordination, program, policy, technology, management system, national and international collaborations and application of notification for decreasing of emission and waste which is due textile industry producing process. This is for compatibility to environment of textile industry. The Ministry where required; may want increasing of level of target of cleaner producing (eco efficiency) plan. After notification publishing, liable plant s EIA (Environmental Impact Assessment Report) shall be include cleaner producing plan and they shall prepare cleaner producing plan and shall undertake for approval. Textile manufacturers is responsible for emission and discharging control during producing process and all emissions, according to integrated pollution prevention and controlling approach. As well as, they shall use best available technic, preparing of developing report of applications of prepared cleaner producing plan, according to given format and they shall present to provincial environmental offices. Al parameter measurement and all analysis must be provided by authorized laboratory by the Ministry at present report. Textile manufacturers will be responsible according to indicated principles of notification for all applications of cleaner producing technics Developing reports of cleaner producing, shall present to provincial environment office for approval for following every. Recently establishing plant, for taking environmental permit shall be present approved cleaner producing report according to at published Official Newspaper which is date :29 April 2009 and number :27214 Regulation of Environmental Law Required Permits and Licenses Textile manufacturer is responsible shall make all works and operations, according to published at Official Newspaper which is date 12 November 2010 and number: 27757 Regulation of Environmental Officer and Environmental Consulting Firms CLEANER ( SUSTAINABLE) PRODUCING Planning and organization Management confirmation Establishment of cleaner production team Determination of policy, target and goals Clean production plan making 274
CLEANER PRODUCING STEPS Pre-Assessment 1) Company information and flow diagram providing 2) First examine, 3) Focus point description Evaluations 1) Quantitative data collection 2) Mass balance 3) Flow and emission audit 4) Cleaner producing possibilities determination 5) Prioritization of possibilities Prioritization of possibilities of examples Type of Problem Description of Problem Cleaner (Sustainable ) producing possibilities Examples: -Resource generation -Energy consumption -Air pollution -Solid waste -Hazardous waste - Occupational health and safety Examples: -Name of process -History of process -Wastage quantity and pollution - Cost of the source material loss Examples: - How the problem can be solved - Short-term solutions - Long-term solution - Estimates of resource consumption and waste generation Analysis and Feasibility Study 1) Preliminary Analysis 2) Technical Analysis 3) Economic Analysis 4) Environmental Analysis 5) Selection of possibility applications and sustainability 1) Preparation of the Application Plan 2) Selected possibilities application 3) Performance surveillance 4) Cleaner Production Activities Sustainability THE STATE OF CLEAN PRODUCING In textile industries, with integrated pollution and control notification, majority producing plant oriented to change their producing process. Textile manufacturers have now started to place the concept of ecology. Ecology concept defines that, the product not harmful to human health and the least damaging to the environment during the manufacturing process. Bu ürün, eşdeğerlerinden daha az enerji, kimyasal, su, yakıt kullanarak daha az kaynakla üretilmiş anlamına gelmektedir. It means that, this product produce with less power, less chemical, less water, less fuel and less resources using, according to equivalent product. The basis of ecological production; first time target is inexpensive producing according to competitors, however, recently environmental anxiety increasing has been motivated to develop cleaner producing techniques. Thus, the unit production cost will reduce and with it will be further reduced emissions into the environment. 275
Environmentally friendly production techniques at the beginning of the 1980s began in Europe. In today's world pollution control approach, has evolved to pollution prevention approach. In many countries, the manufacturer labeled with "environmentally friendly products" label, this labeling target is emphasizing of differs from the equivalent product. Status of our Country: Our country is a major producer of textiles. We have a close relationship with the European Union and union affiliation in order to attain significant changes in our laws are made. Laws relating to environmental protection in European countries that inevitably affects our country. Day to day competition is difficult with China and other in developing countries which is they provide inexpensive workmanship. Dependence to foreign energy, and high energy cost, put to his trump the manufacturers. Environmentally conscious consumers in Europe prefer green products are "environmentally friendly" label claims for products; manufacturers also are oriented to this direction. Therefore, engaged to the production of clean and environmentally friendly eco production companies marketing possibilities will increase with more producing cost to European countries. Turkey's leading industrial organizations and scientific institutions emphasize the importance of clean production, although much is a fact that has not been applied yet sufficiently. In our country, the first in 1999 and by TUBITAK TTGEV "Cleaner Production-clean product, Environmentally Friendly Technologies Group Industry Sector Report" was published later in the national policy and strategy documents has taken place in A few years ago, the number of eco-labeled products is in Italy over three hundred, over two hundred in France in Germany close to the hundred but in Turkey only few. Manufacture of machinery for the textile industry, showing the necessary sensitivity to this subject, they developed machine which is this machines use less energy and less water. Likewise, textile dyes and chemicals products manufacturers are very keen for produce minimize environmental pollution. When compare traditional systems with new systems, results are promising. NEEDS TO BE DONE FOR CLEAN PRODUCING AND POLLUTION REDUCING The basic principles of cleaner production and pollution reduction, pollution decreasing at source, not pollution control. Basic assumption is pollution reducing during producing process. Primarily with process management to minimize waste, then the waste to reclaim the latest to investigate ways of waste disposal should be considered as a basic principle. For clean producing and pollution controlling short information, may obtain at below. More detail can be found in notification. THE BEST AVAILABLE TECHNIQUES (BAT) APPLICATION EXAMPLES IN PLANT GENERAL APPLICATIONS Plant management: -Establishment of Environmental Management System. -Environmental awareness training programs applications. -All material based mass balances must prepare and annual waste report must be prepared. -All production process inputs and outputs (raw materials, chemicals, energy, water, products, waste water, air emissions, sludge, solid waste, hazardous waste and second products) in terms of quantity and quality must monitoring. 276
-Production prescription optimizing, considering the environmental impact. -All chemical substances storage according to given Safety Guides Data. Preventing of all material spills, fast cleaning and area controlling after spilling is necessary. General Precautions: -For chemical dosing (paint excluded): automatic chemical dosing and dispensing systems establishment. In the selection and use of chemicals: -If it is possible without use of chemicals, if it is necessary less risk include chemicals selection. -Biodegradable chemicals are chosen instead of dangerous substances, to minimizing of complex substances. For Water and Energy Management: -Water and energy consumption controlling. -Process time optimization, short time arrangement for all steps of producing process. -Searching of different step merging possibilities. -Low and very low liquor ratio user machine selection at batch process. -Reusing of cooling water at process (as well as by providing heat recovery). - According to wastewater characterization, material recovery and water reusing. -To prevent the loss of steam, full steam insulation done on the machines. -To minimize energy losses, the pipes, valves, tanks and machines isolation. -For reusing of steam condensate, boiler applications optimizing. - Hate recovery from waste gas and waste hot water. THE APPLICATIONS FOR VARIOUS TEXTILE PRODUCTION PROCESSES Fore sizing material removing: -Low material using process and effective washing system selection with biodegradable sizing material selection and using. - When raw materials cannot be controlled by oxidation sizing applying. - Merging of sizing/washing and bleaching steps. -Sizing material recovering by suitable method and reusing. For bleaching: -Hydrogen peroxide bleaches application; with hydrogen peroxide stabilizers, which is decrease hydrogen peroxide using and high biodegradable complex agent using technique. For Mercerization: -Mercerizing alkaline rinsing water recycling and reusing. - Reusing of alkaline waste water at pre-treatment step. For dyeing: -Dye and auxiliary chemicals selection must be suitable to high rate holding to fibers. -Sulfur content lower than 1% pre-reduced or stabilized liquid paint formulations without prereduced sulfur dyes using, instead of conventional powder and liquid sulfur dyes. -High rate holding to fiber and low salt required reactive dyes using. For Printing: -In rotary printing, printing paste losses reduction -Reduced consumption of water in the cleaning process -If possible, implementation of digital printing techniques using For Finishing: 277
-Waste water formation preventing using foam and spray techniques application. - Energy consumption minimization at Stenter; insulation, energy recovery and mechanical pre-drying method technique using. For washing: -Filling/emptying and logic rinsing using, instead of overflow rinsing/washing. - In continuous processes using highly efficient washing machines and energy recovery equipment using reducing energy and water consumptions. APPLICATIONS FOR SEPARATE WASTE WATER AND WASTES For painting waste water / wastes: -Waste reusing. (Washing water separate after dyeing bath, therefore, dyeing bath waste water may re-use.). Re-use of waste water flow from dyeing bath, BOD and COD load can be reduced significantly. By this method, may possible recovery od dyeing bath waste water. -Dyeing bath waste water may re-use, after completed with dye and auxiliary chemicals. For finishing waste water: Caustic recovery from finishing waste water can make, using evaporation method. General application: For other waste/waste water: For high content COD waste water, this water collecting and spate treatment method. For printing sludge: waste water recovery from sludge. For cooling water: re-using. For washing waste water from printing belt washing: re-using For include azo dye waste water of dyeing process: pre-treatment before aerobic digestion. For cooling water: separated collecting of cooling water and re-using. For wool washing waste water include oil-grease: evaporation of waste water include oilgrease and re-using at process and sludge disposal by burning method. BAT APPLICATIONS FOR TEXTILE WASTE WATER AT PIPE-END Textile waste water treatment and re-using at pipe-end: -Biological treatment. -Active sludge, include low food/microorganism (F/M) ratio. -Anaerobic-aerobic treatment system. -For coagulation/flocculation both inorganic (alum, lime, magnesium and iron salts) and organic (polymer) coagulants may use individually or in combinations. -Waste water treatment by flocculation/settling and burning of sludge. - Oxidation /advanced oxidation process (oxidants (ozone, chlorine dioxide, permanganate, oxygen, etc.) can provide COD reducing and water recovery by mineralizing and decolorization method). -In addition, advanced oxidation processes (ozone + hydrogen peroxide, ultraviolet radiation + hydrogen peroxide, ultraviolet radiation + ozone, TiO 2 + ozone, Fenton's reagent, etc..), They form hydroxyl radicals (OH ) is non-selective, both COD as well as color removal very successful in the treatment processes. By advanced oxidation process may provide 80-90% COD reducing and 85-90% color removing at textile waste water. -Membrane processes (textile wastewater treatment used in the pressure membrane processes Micro Filtration (MF), ultrafiltration (UF), Nano filtration (NF) and Reverse Osmosis are 278
(RO). Generally, NF and RO system are effective processes for color removing, organic matter and conductivity removal and water recycling. BAT APPLICATION FOR EMISSION AND WASTE MANAGEMENT GAS EMMISSION General applications: - For all textile production processes (textile raw materials, auxiliary materials and chemicals and machinery from) fugitive emissions. -Raw and auxiliary materials ingredient must be less toxic and lower emissions. -Pollution emission reducing by energy saving and less fuel consumption. For Steam Generation: -Blow down shall be at soft water circuit, (each blow down increase 5%, by this way fuel consumption will increase 1-1.5 %) - Combustion air temperature increasing, (by this way boiler efficiency will be increase 2%) For steam distribution and utilization: -All hot surface insulation at steam distribution system (insulation reduce heat loss 90% ratio from pipe surface) - To ensure full functions making of steam traps. -Steam leakage prevention. For compressed air system: -Required compressed air optimization: (10% pressure reducing will provide 5% operation cost) - Prevention of air leaks. - Inlet air temperature reducing 4 ºC, will increase 1% pressured air producing. For cooling system: -Cooling load reducing (preventing of unnecessary cooling and hot air inlet preventing will be providing less energy consumption). -Condensing temperature reducing (1 ºC reducing will provide 2-4% reducing of cooling cost). WATES: -For waste water treatment plant sludge: -Brick making from sludge. -Systematic storing at storing area. - According to environment laws of chimney emission, sludge disposing by burning method. For solid waste management: -Separately collecting of solid wastes. REFERENCES www.resmigazete.gov.tr www.ttgv.org.tr www.tubitak.gov.tr 279