Improvements in Energy and Water Consumption Performances of a Textile Mill After BAT Applications Adoption of EU’s IPPC

1. Improvements in Energy and Water Consumption Performances of a Textile Mill After BAT Applications Adoption of EU’s IPPC Directive to a Textile Mill in Turkey Ayşe Merve KOCABAŞ Dept. of Environmental Engineering METU

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

3. IPPC (Integrated Pollution Prevention and Control) Directive

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

5. 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.

6. IPPC Directive To achieve a high level of protection of the environment as awhole based on the implementation of “Best Available Techniques” included in BREF Documents for industrial activities covered bythe Directive

7. 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

8. 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

9. BREF Documents-Textile Sector • Being a water intensive industry • Water consumption • Wastewater discharges and chemical load it carries • Energy consumption

10. What does BAT application bring?? • Minimized water consumption and waste generation • Reduced waste disposal costs • Increased energy efficiency  ECONOMICAL BENEFITS...

11. PROJECT

12. A RESEARCH PROJECT Adoption of EU’s IPPC Directive to a Textile Mill in Turkey Principle Investigator: Prof. Dr. Ülkü Yetiş Department of Environmental Engineering Middle East Technical University ANKARA Funding Agency: The Scientific and Technological Research Council of Turkey (TÜBİTAK)

13. 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

14. 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.

15. 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

16. IPPC Directiveand Turkish Textile Industry Scope: • Identification of enterprises in Turkish textile industry-Survey studies • Dissemination of the studies – Workshops

17. 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

18. Workshops • Two workshops conducted: • In the beginning – introduction of the project to the textile sector • At the end - dissemination of results of the project

19. ADOPTION OF IPPC DIRECTIVE TO THE SELECTED MILL

20. Selected Textile Mill

21. Selected Mill • A denim manufacturing plant in operation since 1953 • Among World’s top denim producers • 20,000 tons of cotton fibre/year • 45 Mio.m denim fabric/ year • Integrated facility with yarnmanufacturing, dyeing, sizing,weaving and finishing

22. 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

23. Evaluation of the Enterprise

24. 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

25. 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

26. Wastewater Management

27. 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

28. Wastewater treatability studies • Current wastewaters (without BAT measures) • Wastewaters after the application of BAT measures

29. 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

30. 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.

31. Improvements in Energy and Water Consumption Performances of the selected mill

32. 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

33. 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

34. BAT Options-energy minimization • Use of waste heat from finishing and dyeing wastewaterstreams 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

35. BAT Options-energy minimization • Use of waste heat from finishing and dyeing wastewaterstreams 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

36. 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

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

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

41. Water Consumption in Processes

42. 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)

44. Water consumption in dyeing process 22% reduction in specific water consumption in 2006-2007

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

47. Water consumption in finishing process 16% reduction in specific water consumption in 2006-2007

48. Overall water consumption 30% reduction in overall specific water consumption of the mill

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

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