Volume 88, 1 February 2015, Pages 116–124
Sustainable Development of Energy, Water and Environment Systems
Evaluation of Integrated Pollution Prevention Control in a textile fiber production and dyeing mill
Highlights
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- Cleaner production studies were conducted in a textile mill based on IPPC.
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- Water, energy and chemical consumptions may be significantly reduced by BAT.
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- Wastewater, waste and gas discharges/emissions may be significantly reduced by BAT.
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- Specific wastewater streams may be reused in production even without treatment.
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- Pay-back period of the suggested BAT options was generally up to 4 years.
Abstract
Cleaner
production assessment studies were conducted in a textile mill
employing wool and acrylic fiber production and subsequent dyeing. A
company-wide mass-balance analysis was performed. Various specific
consumptions, emissions and waste generations were determined. The
performance of the mill was evaluated based on BREF Documents. Water
quality analysis indicated that process wastewaters from wool yarn
softening, LP-VP printing machines and acrylic yarn washing could be
reused in these processes, even without further treatment. Process
wastewaters from wool yarn washing and softening in hank dyeing machines
could be directly reused in tank washings and/or blended with process
waters for direct reuse in the same or other processes. By the
application of suggested BAT including wastewater reuse, machinery
modifications, reuse of steam condensate, and good management practices,
total water consumption may be reduced 35–65%. Substitution of 12
chemicals with more biodegradable and less toxic ones and installation
of automatic chemical dosage systems may decrease COD loads about
25–50%. Furthermore, chemical and dyestuff consumptions could be reduced
31%. Energy consumption could be reduced by BAT suggestions including
implementation of energy recovery systems for high temperature
wastewater flows and flue gas emissions; process monitoring-control and
various machinery optimization. Thus, potential reductions in total
energy consumption in the mill may be up to 70%. Waste gas emissions
could be reduced 25–65%. Waste generations may be decreased 5–10% with
good management practices and reuse of especially textile wastes.
Pay-back period of the suggested BAT options was found to be generally
up to 4 years.
Keywords
- BAT;
- Cleaner production;
- Energy;
- IPPC;
- Textile;
- Water
- Corresponding author. Tel.:
+90 2463412363; fax: +90 2463412042.
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