1. TOWEF0 Paris - Meeting 6 - Pag. 1 TOWEF0 Project meeting Paris, 2-3 October 2003

2. TOWEF0 Paris - Meeting 6 - Pag. 2 WORKPACKAGE 02 Quantitative evaluation of GEP application. Case studies in the synthetic fibres and silk industries

3. TOWEF0 Paris - Meeting 6 - Pag. 3 ACTIVITIES OF THE REPORTING PERIOD (MARCH 2003 - OCTOBER 2003) WP02.02.3Process identification WP02.03.3Collection and elaboration of process data

4. TOWEF0 Paris - Meeting 6 - Pag. 4 The selected five industries Data were collected using a methodology consisting in an environmental audit inside the factory and to the issuing of a document called PIDACS.

5. TOWEF0 Paris - Meeting 6 - Pag. 5 PIDACS results – I15 company

6. TOWEF0 Paris - Meeting 6 - Pag. 6 PIDACS results – I15 company Water consumption & Water flow chart

7. TOWEF0 Paris - Meeting 6 - Pag. 7 PIDACS results – I15 company Department water consumption Preparation and printing departments are the most water requiring (about 16% and 68% on total). Among preparation, “continuous scouring” consumption is about the 97% on department and about the 15% on total consumption (86646 m3). Among printing, “printing equipment washing” consumption is about the 80% on department and about the 54% on total consumption (306302 m3).

8. TOWEF0 Paris - Meeting 6 - Pag. 8 PIDACS results – I15 company Department water discharges The total organic load generated by preparation processes is about 46% on total (169078 kg as COD), for an average COD concentration equal to 1902 mg/l; load generated by “continuous scouring” processes is equal to 161713 kg as COD (about 96% on department, 44% on total), for an average COD concentration equal to 1878 mg/l. The total organic load generated by printing processes is about 42% on total (157022 kg as COD), for an average COD concentration equal to 409 mg/l; load generated by “printing accessories washing” is equal to 82076 kg as COD (about 52% on department, 22% on total), for an average COD concentration equal to 268 mg/l.

9. TOWEF0 Paris - Meeting 6 - Pag. 9 PIDACS results – I04 company

10. TOWEF0 Paris - Meeting 6 - Pag. 10 PIDACS results – I04 company Water consumption & Water flow chart A quantity of water estimated equal to 15750 m3 (2,5% on total consumption) is recovered by means of a membrane nano-filtration system (W5 type)!!!!

11. TOWEF0 Paris - Meeting 6 - Pag. 11 PIDACS results – I04 company Department water consumptions Preparation department operations require a quantity of water of about 37% on total (216608 m3); among these, “continuous scouring” process requires 81598 m3 (about 38% on department consumptions, 14% on total). Dyeing department operations require a quantity of about 53% on total (308938 m3); among these, “dark reactive dyeing” processes require 49308 m3 (about 16% on department, 8,5% on total).

12. TOWEF0 Paris - Meeting 6 - Pag. 12 PIDACS results – I04 company Department water discharges Discharges coming from rinsing steps of “direct dyeing” processes are sent to membrane nano- filtration unit for water recovery (type D4: 19344 m3), the average COD concentration of this stream is equal to 140 mg/l. The total organic load generated by preparation processes is about 52%on total (232551 kg as COD), for an average COD concentration equal to 1081 mg/l; the total organic load generated by “continuous scouring” is equal to 159666 kg as COD (about 69% on department discharges, 38% on total), for an average COD concentration equal to 1993 mg/l. The total organic load generated by dyeing processes is about 47% on total (210194 kg as COD), for an average COD concentration equal to 730 mg/l. The total organic load generated by “dark reactive dyeing” is equal to 48373 kg as COD (about 23% on department, 11% on total), for an average COD concentration equal to 1267 mg/l.

13. TOWEF0 Paris - Meeting 6 - Pag. 13 - PIDACS data elaboration - Validity of PIDACS application to textile industry: Water consumptions I15 company value is under-estimate and the difference is of about 2%; in the other cases values are over-estimated, but the difference is less than 1%.

14. TOWEF0 Paris - Meeting 6 - Pag. 14 - PIDACS data elaboration - Validity of PIDACS application to textile industry: Water discharges The higher difference on estimation is for I04 company (about 2,5%); in the other cases the difference is +/- 0,4%. For I15 company, the difference between water discharges is the same that the value found for water consumptions (about 11000 m3)

15. TOWEF0 Paris - Meeting 6 - Pag. 15 - PIDACS data elaboration - Validity of PIDACS application to textile industry: COD concentration Values are over-estimated in all cases; for I04 company the difference is about 2%, in the other cases difference is of about 15-18%.

16. TOWEF0 Paris - Meeting 6 - Pag. 16 - PIDACS data elaboration - Comparison of process data: Company 1/2

17. TOWEF0 Paris - Meeting 6 - Pag. 17 - PIDACS data elaboration - Comparison of process data: Company 2/2 General Facilities consumptions vary from 10% to 30% on the total; discharged load is less than 0,5% on the total (I09 load is higher due to the membrane treatment). Preparation consumptions are 40% as average on the total; discharged loads is 60% on the total as an average. Dyeing consumptions are 30% on total as an average; discharged load is 30% on total. Printing consumptions are 50% on total as an average; discharged load is 60% on total. Fabric Washing consumptions vary from 3% to 50%; discharged load vary from 2% to 25% on total. Finishing consumptions are less than 5% on total (0,45% as an average); discharged load is less than 10% on total (5% as an average).

18. TOWEF0 Paris - Meeting 6 - Pag. 18 - PIDACS data elaboration - Comparison of process data: General Facilities 1/2

19. TOWEF0 Paris - Meeting 6 - Pag. 19 - PIDACS data elaboration - Comparison of process data: General Facilities 2/2 Filtration is used as a pre-treatment for Industrial Aqueduct water; the quantity of water amount required for this process (due to rinsing and backwashing steps) varies from 0,15% to about 3% on total. The percentage on total generated load is less than 0,1%, as an average value. Softening process is necessary to operate with high temperature waters and to generate steam (demineralisation process has been observed only in I15 company): the average quantity of water amount required for this process is about 4% on total. The percentage on total generated load is less than 0,05%, as an average value. The average quantity of softened (de-mineralised) water required to generate steam is about 7% on total.

20. TOWEF0 Paris - Meeting 6 - Pag. 20 - PIDACS data elaboration - Comparison of process data: Preparation 1/2

21. TOWEF0 Paris - Meeting 6 - Pag. 21 - PIDACS data elaboration - Comparison of process data: Preparation 2/2 Single scouring processes for synthetic fibres (I06;I04) require a specific consumption of about 50 l/kg; specific load is about 50 COD g/kg of fibre. For silk fabric (I09;I15) consumptions and loads are very different and do not seem to be reliable. Continuous scouring processes specific consumption decreases to the increase of fibre quantity; this is due to the use of equipments requiring high water quantities. Specific consumption equal to 60 l/kg seems more indicated for silk fabrics, while for synthetic fibres a specific consumption equal to 20 l/kg can be considered. Such processes generate a specific load of 120 COD g/kg of fibre for silk fabrics, while synthetic fibres processes generate a specific discharge of 40 COD g/kg of fibre.

22. TOWEF0 Paris - Meeting 6 - Pag. 22 - PIDACS data elaboration - Comparison of process data: Dyeing 1/3

23. TOWEF0 Paris - Meeting 6 - Pag. 23 - PIDACS data elaboration - Comparison of process data: Dyeing 2/3

24. TOWEF0 Paris - Meeting 6 - Pag. 24 - PIDACS data elaboration - Comparison of process data: Dyeing 3/3 Data for same processes are very different and hardly reliable; generally I04 and I15 companies data are sensibly lower than others but not correlated between (only average values can be discussed). Highest specific consumptions values are observed for reactive and acid dyeing (more than 80 l/kg of fibre), used to process natural fabric (mainly silk fabric); also the quantity increase sensibly moving from light to dark dyeing (about 50 l/kg as increase). For disperse and direct dyeing, mainly used to process synthetic fibres (PES and viscose), values are lower (less than 70 l/kg); the increase necessary for dark dyeing is about 20 l/kg as increase. Specific loads values are similar for direct and acid dyeing (less than 50 COD g/kg of fibre) and increase for disperse and reactive dyeing (up to 120 COD g/kg of fibre). No great increase is observed moving from light to dark dyeing, except for reactive dyeing (about 50 COD g/kg of fibre as increase).

25. TOWEF0 Paris - Meeting 6 - Pag. 25 - PIDACS data elaboration - Comparison of process data: Printing Colour preparation process consumption is equal to 1,40 l/kg of fibre the same for the two companies studied (I02;I15); great difference are otherwise observed in specific load (I15 value is 17,5% on I04 value). Thickener preparation process require an average quantity equal to 30,5 l/kg of fibre, generating an average load equal to 24,12 COD g/kg of fibre, but great differences occur between observed values.

26. TOWEF0 Paris - Meeting 6 - Pag. 26 - PIDACS data elaboration - Comparison of process data: Washing (printing department) I15 process consumption for printing equipment washing processes is five times higher than I02 but discharged specific load is not so different (about 100 COD g/kg of fibre). As an average value, discontinuous mode (rope) fabric washing processes require 170 l/kg of fibre as consumption and generate 93 COD g/kg of fibre as load, but observed data are very different. Continuous mode (open width) fabric washing observed data are as well very different; as an average value such processes require 38 l/kg of fibre as consumption and generate 13 COD g/kg of fibre as load.

27. TOWEF0 Paris - Meeting 6 - Pag. 27 - PIDACS data elaboration - Comparison of process data: Finishing Softener finishing processes specific consumptions are similar (about 1,29 l/kg); specific loads are different and have an average value equal to 3,12 COD g/kg. Water finishing processes specific consumptions are not so different (average value 1,31 l/kg); as well as specific loads (average value 0,04 COD g/kg).

28. TOWEF0 Paris - Meeting 6 - Pag. 28 WORKPACKAGE 02 - Quantitative evaluation of GEP application. Case studies in the synthetic fibres and silk industries Conclusions at the end of reporting period I15 and I04 audit ended on July 2003 and relative PIDACS issued and sent during August 2003 PIDACS methodology has been reported in the document n° IE-302-001 (“Manual for process identification and data collection sheet “), edited in substitution of Deliverable n°4 (“Material resources data input of textile industry”). PIDACS data discussion and elaboration has been reported in a the document referenced as n° TM-302-002-TY-302-001 (“Report on textile process identification for silk and synthetic fibres industries“ and ” Data sheet of relevant parameters of the manufacturing processes of synthetic fibres and silk finishing industries”). Lariana Depur activities on WP02 have been completed.

29. TOWEF0 Paris - Meeting 6 - Pag. 29 WORKPACKAGE 05 Characterisation and design of waste water

30. TOWEF0 Paris - Meeting 6 - Pag. 30 ACTIVITIES OF THE REPORTING PERIOD (MARCH 2003 - OCTOBER 2003) WP05.05.3Tests for water reuse (with P1 partner)

31. TOWEF0 Paris - Meeting 6 - Pag. 31 Processes selection Processes have been selected on the basis of workpackage WP2 activity elaboration, reported in the document n° TM-302-002-TY-302-001.

32. TOWEF0 Paris - Meeting 6 - Pag. 32 Water characterisation Characterisation Program has been decided to connect the differences in textile results (if existing) to the values of indicated parameters. (*: P1 partner)

33. TOWEF0 Paris - Meeting 6 - Pag. 33 Laboratory scale processes Samples collected in each factory (after membrane treatment) have been used to perform typical processes on the same fibre manufactured by the company itself. Results have been compared with the results obtained by the same processes on the same fibres, carried out with conventional supply water (Industrial Aqueduct). Processes have been performed by Tessile di Como, an italian company devoted in research and support to Como district textile companies, chosen as partner for this workpackage.

34. TOWEF0 Paris - Meeting 6 - Pag. 34 Laboratory efficiency tests Also efficiency tests have been performed by Tessile di Como.

35. TOWEF0 Paris - Meeting 6 - Pag. 35 WORKPACKAGE 05- Characterisation and design of waste water Conclusions at the end of reporting period All the samples have been collected, sent to partner for membrane treatment, and delivered to Tessile di Como for processes and tests performance, during the period May-July 2003. Laboratory scale processes and efficiency tests have been completed by Tessile di Como and result will be available in a couple of weeks. WP05.05.3 activity and results description will be reported in the document n° TM-305-001 (“Report on tests for water direct and indirect re-use in the silk and synthetic fibres and industries“).

36. TOWEF0 Paris - Meeting 6 - Pag. 36 Lariana Depur S.p.A. Via Laghetto 1 22073 Fino Mornasco (CO) - Italy Tel. ++39 31 920518 Fax ++39 31 921880 lariana@lariana.it