Tomas Pivoras - CP assessment "Vernitas"1 Case Study Textile company Cleaner Production Assessment Tomas Pivoras Kaunas University of Technology Kaunas, Lithuania

Tomas Pivoras - CP assessment "Vernitas"2 Information about “Vernitas” Products:  Bulk, polyacryl nitrile (PAN) yarns; Production capacity:  tons of yarns per year; Market:  export to EU approximately 70%.

Tomas Pivoras - CP assessment "Vernitas"3 Production processes Yarn Preparation, sub-processes:  Stretch-breaking  Rebreaking  Intersecting  Finishing Spinning Twisting Bulking Dyeing

Tomas Pivoras - CP assessment "Vernitas"4 Auxiliary processes Ventilation Boiler house – heating and steam production Water preparation Compressed air production …

Tomas Pivoras - CP assessment "Vernitas"5 Methodology A ‘top-down’ investigation The company was analyzed on three levels:  Level 1: Main data for black box - entire company;  Level 2: Main process data (building a ‘layer cake’);  Level 3: Detailed data and measurements for one or two specific processes. In the initial phase focus on level 1 and 2. Later level 3 data were collected/measured for the 2-3 focus areas.

Tomas Pivoras - CP assessment "Vernitas"6 Energy balance

Tomas Pivoras - CP assessment "Vernitas"7 Heat consumption

Tomas Pivoras - CP assessment "Vernitas"8 Energy savings ( electricity savings ) Electricity savingsElec. savings SavingsInvestmentPay back UnitskWh/yearEUR/ year EURyears Optimisation of humidification system 120, * Installation of variable speed drives on fans 551, Total671,

Tomas Pivoras - CP assessment "Vernitas"9 Energy savings ( heat recovery ) Heat recoveryHeat savings SavingsInvestmentPay back UnitskWh/yearEUR/ year EURyears Modernisation of heating substation 160, * Heat recovery on air compressors 303, Recycling of steam condensate in dyeing dept. 290, *  Total753,

Tomas Pivoras - CP assessment "Vernitas"10 Optimisation of the humidification system - replacement of the spraying nozzles Savings by reduction of consumption of both water and compressed air.

Tomas Pivoras - CP assessment "Vernitas"11 Installation of variable frequency drives on fans Significantly increased energy efficiency of the fans at part load (50-90%), which was approx. 75% of the operation time.

Tomas Pivoras - CP assessment "Vernitas"12 Heat recovery in the compressed air system

Tomas Pivoras - CP assessment "Vernitas"13 Recycling of steam condensate in dyeing dept.

Tomas Pivoras - CP assessment "Vernitas"14 Main Cleaner Production projects 1)Treatment of waste water from dyeing 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

Tomas Pivoras - CP assessment "Vernitas"15 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.

Tomas Pivoras - CP assessment "Vernitas"16 Zinc emission to effluent Stop treating the effluent for removal of zinc (Zn) Find the source of the zinc (Zn) emission in the effluent. It is much cheaper and more environmental friendly to change the source

Tomas Pivoras - CP assessment "Vernitas"17 Dyes containing heavy metals

Tomas Pivoras - CP assessment "Vernitas"18 Continual improvements: Elimination/reducing of: dyestuff containing heavy metals azo-dyestuff, which splits off carcinogenic amines. toxic chemicals (T or T x marked according to EU regulations) hazardous surfactants giving rise to environmental concerns do to their poor biodegradability, their toxicity and potential to act as endocrine disrupters. hazardous complexing agent

Tomas Pivoras - CP assessment "Vernitas"19 Wastewater from dyeing department

Tomas Pivoras - CP assessment "Vernitas"20 Wastewater treatment plant

Tomas Pivoras - CP assessment "Vernitas"21 Membrane filtration Investment: EUR Pay back: 17.5 years

Tomas Pivoras - CP assessment "Vernitas"22 Reuse of cooling water from spinning machines Total use of water is about:  24,000 m 3 / year Total installation cost is:  818 EUR. Simple payback period is:  1.67 year. (not including usage of electricity by water pump and water pumping from well)