1. Cleaner Production Workshop 2008, Ankara March 31, 2008 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 METU Ayşe Merve KOCABAŞ Dept. of Environmental Engineering

2. Cleaner Production Workshop 2008, Ankara March 31, 2008 Introduction Introduction –IPPC Directive –BREF Documents Project: Project: –Target –Objective –Scope Improvements in energy and water consumption performances Improvements in energy and water consumption performances Conclusion Conclusion Outline

3. Cleaner Production Workshop 2008, Ankara March 31, 2008 IPPC (Integrated Pollution Prevention and Control) Directive

4. Cleaner Production Workshop 2008, Ankara March 31, 2008 IPPC Directive - Target The IPPC Directive aims at achieving integrated prevention and control of pollution from industrial installations listed in Annex I

5. Cleaner Production Workshop 2008, Ankara March 31, 2008 IPPC Directive “Integrated approach” means: “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. Cleaner Production Workshop 2008, Ankara March 31, 2008 IPPC Directive To achieve a high level of protection of the environment as a whole based on the implementation of “Best Available Techniques” included in BREF Documents for industrial activities covered by the Directive

7. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 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 BREF Documents-Textile Sector

9. Cleaner Production Workshop 2008, Ankara March 31, 2008 BREF Documents-Textile Sector Being a water intensive industry Being a water intensive industry –Water consumption –Wastewater discharges and chemical load it carries –Energy consumption

10. Cleaner Production Workshop 2008, Ankara March 31, 2008 What does BAT application bring?? Minimized water consumption and waste generation Minimized water consumption and waste generation Reduced waste disposal costs Reduced waste disposal costs Increased energy efficiency Increased energy efficiency  ECONOMICAL BENEFITS...

11. Cleaner Production Workshop 2008, Ankara March 31, 2008 PROJECT

12. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Project Objectives Identification of textile facilities covered by the IPPC Directive and their production processes; Identification of textile facilities covered by the IPPC Directive and their production processes; Investigation of the applicable BAT Options for a selected mill; Investigation of the applicable BAT Options for a selected mill; Selection of BAT for the pilot mill Selection of BAT for the pilot mill Dissemination of the results obtained. Dissemination of the results obtained.

15. Cleaner Production Workshop 2008, Ankara March 31, 2008 Scope of the Project 1. IPPC Directive and Turkish Textile Industry 2. Adoption of IPPC Directive to the selected mill Evaluation of the enterprise Evaluation of the enterprise Wastewater management Wastewater management Cost analysis Cost analysis Risk analysis Risk analysis

16. Cleaner Production Workshop 2008, Ankara March 31, 2008 IPPC Directive and Turkish Textile Industry Scope: Identification of enterprises in Turkish textile industry-Survey studies Identification of enterprises in Turkish textile industry-Survey studies Dissemination of the studies – Workshops Dissemination of the studies – Workshops

17. Cleaner Production Workshop 2008, Ankara March 31, 2008 Survey Studies A survey study to identify textile mills within the IPPC have been initiated to collect information on: 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 Feedback from 126 textile mills in 12 provinces At least 66 textile mills are under the scope of IPPC Directive in Turkey

18. Cleaner Production Workshop 2008, Ankara March 31, 2008 Workshops Two workshops conducted: Two workshops conducted: –In the beginning – introduction of the project to the textile sector –At the end - dissemination of results of the project

19. Cleaner Production Workshop 2008, Ankara March 31, 2008 ADOPTION OF IPPC DIRECTIVE TO THE SELECTED MILL

20. Cleaner Production Workshop 2008, Ankara March 31, 2008 Selected Textile Mill

21. Cleaner Production Workshop 2008, Ankara March 31, 2008 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 yarn manufacturing, dyeing, sizing, weaving and finishing

22. Cleaner Production Workshop 2008, Ankara March 31, 2008 WELLS Ion Exchangers Reverse Osmosis Supplementary Facilities (Cogeneration Plant) FINISHING WEAVING SIZING DYEING Product Others Air Conditioners Compressors Staff Canteen Irrigation Company Dwelling Cotton Fibre Prep. Soft Water Hard Water Product Line Wastewater

23. Cleaner Production Workshop 2008, Ankara March 31, 2008 Evaluation of the Enterprise

24. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Evaluation of the enterprise Methodology: Analysis of processes, use of raw materials, chemicals and emissions 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 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 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Wastewater Management

27. Cleaner Production Workshop 2008, Ankara March 31, 2008 Wastewater Management Characterization of wastewater streams in the facility Characterization of wastewater streams in the facility Collection and analysis of wastewaters seperately according to the type and load of pollution 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 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Wastewater treatability studies Current wastewaters (without BAT measures) Wastewaters after the application of BAT measures

29. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Improvements in Energy and Water Consumption Performances of the selected mill

32. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 BAT Options-energy minimization Use of waste heat from finishing and dyeing wastewater streams 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 BAT Options-energy minimization Use of waste heat from finishing and dyeing wastewater streams 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. Cleaner Production Workshop 2008, Ankara March 31, 2008 Scope Assessment of water and energy consumption performances of the selected mill by considering the water intensive wet processes: 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 prior to the application of BATs Water and energy consumptions after the application of BATs Water and energy consumptions after the application of BATs

37. Cleaner Production Workshop 2008, Ankara March 31, 2008 Methodology Monthly water and energy consumptions Monthly water and energy consumptions Specific water and energy consumptions evaluated (per kilogram fabric produced) Specific water and energy consumptions evaluated (per kilogram fabric produced)

38. Cleaner Production Workshop 2008, Ankara March 31, 2008 Water Consumption In textile industry water is consumed for: In textile industry water is consumed for: –Cleaning purposes –Removing impurities –Applying dyes and finishing agents –Generation of steam

39. Cleaner Production Workshop 2008, Ankara March 31, 2008

40. Cleaner Production Workshop 2008, Ankara March 31, 2008

41. Cleaner Production Workshop 2008, Ankara March 31, 2008 Water Consumption in Processes

42. Cleaner Production Workshop 2008, Ankara March 31, 2008 Dyeing BAT measures in dyeing process: Installation of flow control devices Installation of flow control devices Application of semi-counter current rinsing system Application of semi-counter current rinsing system Reuse of washwaters by a membrane system (ongoing) Reuse of washwaters by a membrane system (ongoing)

43. Cleaner Production Workshop 2008, Ankara March 31, 2008

44. Cleaner Production Workshop 2008, Ankara March 31, 2008 Water consumption in dyeing process 22% reduction in specific water consumption in 2006-2007

45. Cleaner Production Workshop 2008, Ankara March 31, 2008 Finishing BAT measures in finishing process Installation of flow control devices Installation of flow control devices Application of semi-counter current rinsing system Application of semi-counter current rinsing system

46. Cleaner Production Workshop 2008, Ankara March 31, 2008

47. Cleaner Production Workshop 2008, Ankara March 31, 2008 Water consumption in finishing process 16% reduction in specific water consumption in 2006-2007

48. Cleaner Production Workshop 2008, Ankara March 31, 2008 Overall water consumption 30% reduction in overall specific water consumption of the mill

49. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy Consumption Energy is used for; Heating up process baths Heating up process baths Runing machinery equipment Runing machinery equipment Processing textiles Processing textiles Lightening Lightening Air-conditioning Air-conditioning

50. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy Consumption Energy sources: Energy sources: –Natural gas  Cogeneration unit  Boilerhouse  Staff canteen  Processing textiles –Electricity (optional)

51. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption Energy requirement inside the mill: Energy requirement inside the mill: –Steam (cogeneration unit+boilerhouse) –Natural gas –Electricity (cogeneration unit+central netwrok)

52. Cleaner Production Workshop 2008, Ankara March 31, 2008

53. Cleaner Production Workshop 2008, Ankara March 31, 2008 Overall energy consumption

54. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy required

55. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption Energy consumption is directly related to water consumption since most of the energy is consumed in order to heat up process baths!!!! Therefore Water intensive processes=Energy intensive processes

56. Cleaner Production Workshop 2008, Ankara March 31, 2008 Dyeing Energy consumed: Energy consumed: –Steam –Electricity Applied BAT measures: Applied BAT measures: –Insulation and maintenance –BAT measures applied for water minimization

57. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption in dyeing

58. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption in dyeing 27% reduction in specific energy consumption of dyeing process in 2006-2007

59. Cleaner Production Workshop 2008, Ankara March 31, 2008 Finishing Energy consumed: – –Steam – –Electricity – –Natural gas Applied BAT measures: – –Use of waste heat from finishing wastewater streams in heating up the washing waters – –Insulation and maintenance – –BAT measures applied for water minimization

60. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption in finishing

61. Cleaner Production Workshop 2008, Ankara March 31, 2008 Energy consumption in finishing 3% reduction in specific energy consumption of finishing process in 2006-2007

62. Cleaner Production Workshop 2008, Ankara March 31, 2008 Overall energy consumption Mill Mill 9% reduction in overall specific energy consumption of the mill

63. Cleaner Production Workshop 2008, Ankara March 31, 2008 Overall energy consumption Inside the mill Inside the mill 2.4% reduction in overall specific energy consumption of the mill

64. Cleaner Production Workshop 2008, Ankara March 31, 2008 General assessments BREF Textile Document –W–W–W–Water consumption: 50-100 L/kg fabric –E–E–E–Energy consumption: 8-20 kWh/kg fabric Achieved level of consumptions –W–Water consumption: 55 L/kg fabric –E–Energy consumption: 11 kWh/kg fabric

65. Cleaner Production Workshop 2008, Ankara March 31, 2008 General conclusions Requirements of IPPC Directive Requirements of IPPC Directive Techniques mentioned in BREF Textile Document Techniques mentioned in BREF Textile Document are applicable in Turkish textile industry. Serious improvements in environmental performance

66. Cleaner Production Workshop 2008, Ankara March 31, 2008 Conclusions-water consumption Water consumption: Dyeing (2006-2007) 22.2% reduction Finishing (2006-2007) 15.8% reduction Overall 30% reduction Achieved level is in the range of BREF Textile Document

67. Cleaner Production Workshop 2008, Ankara March 31, 2008 Conclusions-energy consumption Energy consumption: Dyeing (2006-2007) 27% reduction Finishing (2006-2007) 3% reduction Overall 9% reduction Achieved level is in the range of BREF Textile Document

68. Cleaner Production Workshop 2008, Ankara March 31, 2008 Thank you...