Cleaner ProduCtion in TexTile industry

Transcription

1 Cleaner ProduCtion in TexTile industry TEXTILE SCENARIO IN INDIA: The Indian Textile Industry has an overwhelming presence in the economic life of the country. Apart from providing one of the basic necessities of life, the textiles industry also plays a vital role through its contribution to industrial output, employment generation, and the export earning of the country. India is the 2nd largest textile economy by production in the world after China. The sector contributes about 14 percent to industrial production, 4 percent to the gross domestic product (GDP), and 17 percent to the country s export earnings. It provides direct employment to over 35 million people. The textiles sector is the second largest provider of employment after agriculture. Thus, the growth and all around development of this industry has a direct bearing on the improvement of the economy of the nation. India has the potential to increase its textile and apparel share in the world trade from the current level of 4.5 percent to 8 percent and reach US$ 80 billion by Currently consumption of Technical Textiles in India forms only 9% of total global consumption. Gujarat Technical Textiles market is estimated around Rs. 6,100 crore in ; contributing around 10% to the national Technical Textiles output. Currently, 1,000 plus Technical Textiles units are already present in Gujarat, with presence in all the 12 sub-sectors of Technical Textiles. There are more than 200 products classified as Technical Textiles. Technical Textiles units are mainly concentrated in Ahmedabad, Surat, Vadodara and Kutch

2 ENVIRONMENTAL ISSUES: EFFLUENT CHARACTERISTICS FROM THE TEXTILE INDUSTRY Process Composition Nature Sizing starch, waxes, carboxymethyl High in BOD and COD cellulose, polyvinyl alcohol Desizing starch, glucose, carboxymethyl high BOD, COD, cellulose, polyvinyl alcohol, fats and suspended solids, waxes dissolved solids Scouring caustic soda, waxes, grease, soda ash, sodium silicate, fibres, surfactants, sodium phosphate dark coloured, high ph, high COD, dissolved solids Bleaching hypochlorite, chlorine, caustic soda, alkaline, suspended solids hydrogen peroxide, acids, surfactants, sodium silicate, sodium phosphate Mercerising caustic soda high ph, low COD, high dissolved solids Dyeing various dyes, mordants, reducing strongly coloured, high agents, acetic acid, soap COD, dissolved solids, low suspended solids, heavy metals Priniting pastes, starch, gums, oil, mordants, highly-coloured, high COD, acids, soaps oily appearance, suspended solids Finishing inorganic salts, toxic compounds slightly alkaline, low BOD

3 LIST OF CP OPTIONS GENERATED BY GCPC: Based on baseline assessment at selected units and literature survey we have listed some of the CP Options as below: SR. NO. CP OPTIONS 1. Substitution of hypochlorite for bleaching: Substitute hypochlorite with hydrogen peroxide in two stage bleaching 2. Recover the sizing agents by ultra filtration 3. Recover the caustic soda from mercerization process 4. Carry out the Enzymatic scouring in place of alkaline scouring process 5. Enzymatic removal of residual hydrogen peroxide after bleaching 6. Minimization of dyeing liquor losses in cold pad batch dyeing 7. Silicate free fixation method for cold pad batch dyeing 8. Enzymatic after soaping in reactive dyeing 9. Environment-friendly dyeing with sulphur dyestuffs 10. Printing technology: Ink jet printing 11. Electrochemical dyeing 12. Combine the Desize/scour and Scour/Bleach process 13. Use of enzymes in Bleach Clean-up 14. Low Wet Pick-up technology Foam Technology Spray technology Use of high performance squeezers Vacuum extractors 15. Low temperature dyeing, printing or finishing 16. Replacement of conventional jigger dyeing by pad-develop process of dyeing, whenever possible 17. Combination of finishing and transfer printing in one step for cotton/polyester blends 18. Use of Hot Mercerization

4 LIST OF ECONOMIC ACHIEVABLE BEST AVAILABLE TECHNOLOGIES Optimization of Chemical Use Automated Chemical Dosing Systems Dye Machine Controllers Chemical Substitution NPE Surfactant Substitution Dye Substitution Advanced Dyeing Low Liquor Ratio Dyeing Machines Cold Pad Batch Dyeing Improved Quality Control Quality Control for Raw Materials Process Alternatives Pulsating Rinse Technology Water Recycling and Reuse Recycling and Reuse of Cooling Water and Condensate Water Bleach Bath Recovery System Chemical Recovery and Salt Bath Recovery System Reuse

5 CP RESULTS: In one of the process house based at Ahmedabad, some of the CP options were identified and implemented successfully. The summary of CP options tabulated below: Sr.No. Specific measure to conserve the energy Annual saving In Rs. Total Investment In Rs. Pay-back period In Months 1 Energy conservation in lighting system- Switch off tube-lights during day time 5,956/- Nil Immediate 2 Energy conservation in lighting system- Replacement of conventional 36W & 40W tube light by 28W tubes 2,14,110/- 1,43,550/- 8 months 3 Energy conservation in lighting system- Implementing 4 X 24 Watt Street Light 36,293 26,000/- 9 Months 4 Replace D.C. motors by A.C. motors with variable frequency drive for Main & Mangle motors in Stenter 1 & 2. 85,915 70,000/- 10 Months 5 Energy Conservation in Compressed Air System- Leak arresting in Compressed air System. 2,36,900/- Nil Immediate 6 Energy Conservation in Compressed Air System- Reduce pressure setting in Compressor 21,869/- Nil Immediate

6 7 Installation of Economiser 4.0 Lacs (Approx.) 4.0 Lacs (Approx.) 12 Months (Approx.) 8 Improvement of Existing Power Factor 13,197 18,000/- 16 Months Total 10,14,240 6,57, Months The implementation of CP solutions resulted in both financial as well as environmental benefits. The unit was able to benefit annually by about Rs 10, 14,240 through the implementation of CP solutions, with an investment of Rs. 6, 57, Saving 10,14,240 Investment, 6,57,550 Saving Investment