HAMS Washing & Dyeing Ltd. Sustainability Report ( )

Transcription

1 HAMS Washing & Dyeing Ltd. Sustainability Report ( ) Prepared by Md. Riyajul Haq, Asst. Manager (Environment & Chemical) HAMS Group January

2 Introduction EXECUTIVE SUMMARY HAMS Washing & Dyeing Ltd. has been working to adopt & implement various strategies and an approach towards sustainability. As part of this work, water consumption, waste wastewater generation and energy consumption are recorded. Besides, greenhouse gas emission and solid waste inventory are maintained. The water & energy consumption, waste generation and greenhouse gas emission are reviewed by the authority of HAMS Washing & Dyeing Ltd through sustainability report which is drafted yearly. The authority of HAMS Washing & Dyeing Ltd sets target and define strategies to reduce water & energy consumption as well as to improve environmental performance. Water consumption Record The source of water for HAMS Washing & Dyeing Ltd is underground water. The main purpose of water metering system is; to track & measure total water withdrawal from underground, total water consumption for production & domestic purpose and the total wastewater generation from HAMS Washing & Dyeing Ltd. Energy Consumption & GHG emission Record In textile, energy is an important component and without this textile industry cannot be operated. Energy resources are limited and these must be used reasonably and responsibly. HAMS Washing & Dyeing Ltd mainly uses natural gas & diesel for generating power & steam. Besides, purchase electricity is also used from REB. Table: GHG emission record from HAMS Washing & Dyeing Ltd in 2016 GHG Emission Summery Direct emission (stationery Indirect emission (purchased Total in Year fuel combustion) electricity consumption) tco2e Dyeing Production, Solid waste record, ETP outlet water quality & sources of air emission The production activities of HAMS Washing & Dyeing Ltd is washing & dyeing of finish garments specially denim. The production record is maintained in pcs but to convert in weight, every pcs is considered equivalent to 450 gram. Hazardous waste: Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge, Wastage oil, Chemical Drum, Medical waste, Poly and plastic bag. Non Hazardous waste: Cartoon The solid waste generated from HAMS washing & Dyeing Ltd is segregated with 11 classes. Only one item was found nonhazardous waste namely cartoon and others are hazardous. 2

3 Table: Solid waste record of 2016 Year Non Hazardous waste in kg Hazardous waste in kg Total Solid waste in kg Air emission inventory is presented in table-5. Air emission inventory is maintained annually. The air emission test is conducted by third party annually for HAMS Washing & Dyeing Ltd. There is no accredited body in Bangladesh for air emission test. That s why third part air emission test results are not presented in air emission inventory. HAMS Washing & Dyeing Ltd. has an in-house ETP laboratory to analysis wastewater (before & after treatment). Almost all kind of parameter like as COD, BOD, TSS, ph, TDS, MLSS, SV, SVI, F/M can be analyzed by ETP laboratory Target Setting & Action Plan HAMS Washing & Dyeing Ltd. sets target to improve environmental performance as well as reduce energy & water consumption. The concern authority review improvement against target annually and take corrective action plan to achieve target. Action plan to reduce energy consumption: Hot water/condensate Recovery, Install solar panel, Use LED & Energy saving Light & Replacing conventional boiler with energy saving boiler including economizer. Action plan to reduce water consumption: Rain Water Harvesting, Using Water Efficient Equipment, Reuse Blower cooling water & Awareness & Monitoring. The chemical management system will be formulated and it will work through Plan-Do- Check-Act framework. Conclusion Table: Production, water & energy consumption and wastewater generation in 2016 Year 2016 Washing production(mt) Water consumption(m3) Waste water(m3) Energy consumption(gj) Table: Base year water & energy KPI for per ton production Year Base year 2016 Target year 2018 Water consumption 31.5 Reduce by 10% from base year Energy consumption 9.1 Reduce by 5% from base year 3

4 Table of Contents Executive Summery 2 Introduction 5 Water consumption Record 6 Energy Consumption & GHG emission Record 7 Dyeing Production, Solid waste record, ETP outlet water quality & sources of air emission 8 Target Setting & Action Plan 11 Conclusion 16 Acronyms and Abbreviations EMS BMD GJ MT GHG ETP COD BOD TDS TSS Environmental Management System Bangladesh Meteorological Department Giga Joule Metric ton Green House Gas Effluent Treatment Plan Chemical Oxygen Demand Biological Oxygen Demand Total Dissolved Solid Total Suspended Solid MLSS Mixed Liquor Suspended Solid SV SVI F/M REB Sludge Volume Sludge Volume Index Food to Microorganism Rural Electrification Board KWH Kilowatt Hour LED Light Emitting Diode 4

5 Chapter 1 Introduction The textile & garment industry has become the backbone of the economy of Bangladesh. About three million people are involved with garment and textile industries. It is essential to promote sustainability in this large industrial sector. When the world textile & garment market and companies are focusing on environment friendly products, the Bangladeshi garment and textile industries are far beyond of it and it poses a risk of losing the world market. It is high time to adopt special strategies and an approach towards sustainability. Manufacturing environment friendly products in a sustainable way is the most important and emerging issue at the present phase of industrialization. The main focus comprises not only to the products quality sustainability but also it focuses on the manufacture processes including raw material resources from cradle to grave. Nowadays many companies and organizations focus on the environment friendly way of production. Sustainability of the textile & garments industry is also a burning issue, needed to adopt cleaner and improved technology and management for better environment. Despite the significant economic contribution of the textile industries in Bangladesh, it has brought with it a range of environmental problems, mostly pollution of water resources of the country, energy resources degradation/co 2 emission & eutrophication. Water is very important resources in our ecology. In textile, water is an important component and without this textile industry cannot be operated. Huge quantity of water is used specially in dyeing & washing section. Water & energy resources are limited and these must be used reasonably and responsibly. HAMS Washing & Dyeing Ltd. has been working to adopt & implement various strategies and an approach towards sustainability. As part of this work, water consumption, waste wastewater generation and energy consumption are recorded. Besides, greenhouse gas emission and solid waste inventory are maintained. The water & energy consumption, waste generation and greenhouse gas emission are reviewed by the authority of HAMS Washing & Dyeing Ltd through sustainability report which is drafted yearly. The authority of HAMS Washing & Dyeing Ltd sets target and define strategies to reduce water & energy consumption as well as to improve environmental performance. Based on water & energy consumption data of 2016, the authority of HAMS Washing & Dyeing Ltd sets three years long target to improve environmental performance. It should be mentioned here that HAMS Washing & Dyeing Ltd was shifted in current potion in 2016 and production has been starting from April,

6 Chapter 2 Water Consumption Record HAMS Washing & Dyeing Ltd has installed water metering system to track & measure total water consumption from natural resource and wastewater generation from manufacturing of products. The activities within HAMS Washing & Dyeing Ltd are washing & dyeing. Wet & Dry both are available. Most of the water is used for washing & dyeing purpose. The source of water for HAMS Washing & Dyeing Ltd is underground water. The main purpose of water metering system is; to track & measure total water withdrawal from underground, total water consumption for production & domestic purpose and the total wastewater generation from HAMS Washing & Dyeing Ltd. The water consumption record for production purpose, water consumption in utility section (boiler), domestic use purpose and the wastewater generation record are presented in table-1: Table-1: Water consumption record in 2016 Water consumption & Wastewater generation in m 3 for HAMS Washing & Dyeing Ltd-2016 Month/Year Use Use for Use for Total water Wastewater for Production Domestic consumption generation Utility January February March April May June July August September October November December Total HAMS Washing & Dyeing Ltd has been starting production from April, That s why water consumption is not available from January to March. The water record for domestic & utility use is not also available from April to May due to lack of metering system. 6

7 Chapter 3 Energy Consumption & GHG Emission Record In textile, energy is an important component and without this textile industry cannot be operated. Energy resources are limited and these must be used reasonably and responsibly. HAMS Washing & Dyeing Ltd mainly uses natural gas & diesel for generating power & steam. Besides, purchase electricity is also used from REB. The gas & diesel consumption record and the amount of electricity used from REB are presented in table-2. Table-2: Energy consumption record of HAMS Washing & Dyeing Ltd. Energy Consumption record in 2016 Month/Year Gas (m 3 ) Diesel (L) Electricity (KWH) January 636 February March April May June July August September October November December Total Total in GJ Natural gas, diesel & electricity from REB are recorded in cubic meter, litter & KWH respectively. All of these energy units (m 3, litter & KWH) converted to common unit GJ using the following conversion factors: Natural Gas: 38.4 MJ/Nm3 Diesel/fuel oil: 43.1 MJ/liter Electricity (KWH): 3.6 MJ/KWH Table-3: GHG emission record from HAMS Washing & Dyeing Ltd in 2016 GHG Emission Summery Direct emission (stationery Indirect emission (purchased Total in Year fuel combustion) electricity consumption) tco2e

8 Chapter 4 The record of Production, waste generation, ETP outlet water quality & sources of air emission The production activities of HAMS Washing & Dyeing Ltd is washing & dyeing of finish garments specially denim. The production record is maintained in pcs but to convert in weight, every pcs is considered equivalent to 450 gram. Table-4: Production record for 2016 Month name Production in Pcs Production in MT January February March April May June July August September October November December Total Solid waste: Waste is any substance or object which is discarded, intended to be discarded or is required to be discarded. Waste can include expired raw materials generated from a process for which there is no further use on-site, expired finished products, process or non-process by-products, customer returns, redundant equipment, etc. "A hazardous waste is a waste that could cause harm to public health and/or the environment because of its chemical, physical or biological characteristics (e.g., it is flammable, explosive, toxic, radioactive, or infectious). Hazardous wastes that is dangerous or potentially harmful to our health or the environment. Hazardous wastes can be liquids, solids, gases, or sludge. They can be discarded commercial products, like cleaning fluids or pesticides, or the byproducts of manufacturing processes. (The U.S. Environmental Protection Agency). Table-5 presents the amount of solid waste including hazardous & non-hazardous was generated from HAMS Washing & Dyeing Ltd. Table-5: Solid waste record in 2016 Year Non Hazardous waste in kg Hazardous waste in kg Total Solid waste in kg

9 Hazardous waste: Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge, Wastage oil, Chemical Drum, Medical waste, Poly and plastic bag. Non Hazardous waste: Cartoon The solid waste generated from HAMS washing & Dyeing Ltd is segregated with 11 classes. Only one item was found nonhazardous waste namely cartoon and others are hazardous. Air Emission Inventory: Air emission inventory is presented in table-6. Air emission inventory is maintained annually. The air emission test is conducted by third party annually for HAMS Washing & Dyeing Ltd. There is no accredited body in Bangladesh for air emission test. That s why third part air emission test results are not presented in air emission inventory. Table-6: Air emission Inventory S.l.No EMISSION POINT NAME OF POLLUTANT SOURCE/ EQUIPMENT EMISSION AMOUNT (AND UNITS) LEGAL EMISSION LIMIT(DoE) MONITORING FREQUENCY 1 Diesel Generator-1 NOX Generator N/A 200 (mg/nm3), DoE Standard Annual 2 Diesel Generator-1 Sox Generator N/A 0.14 ppm 24 hrs & 0.03 ppm annual Annual 3 Diesel Generator-1 CO Generator N/A 9 ppm 8 hrs & 35 ppm 1 hr Annual 4 Diesel Generator-2 NO X Generator N/A ppm annual Annual 5 Diesel Generator-2 SOx Generator N/A 150 mg/nm 3 24 hrs & 50 mg/nm 3 annual Annual 6 Diesel Generator-2 CO Generator N/A 65 mg/nm 3 24 hrs & 15 mg/nm 3 annual Annual 7 Gas boiler SOx Boiler N/A 200 (mg/nm3), DoE Standard Annual 8 Gas boiler NOx Boiler N/A 0.14 ppm 24 hrs & 0.03 ppm annual Annual 9 Gas boiler CO Boiler N/A 9 ppm 8 hrs & 35 ppm 1 hr Annual 9

10 In-house laboratory wastewater test report: HAMS Washing & Dyeing Ltd. has an in-house ETP laboratory to analysis wastewater (before & after treatment). Almost all kind of parameter like as COD, BOD, TSS, ph, TDS, MLSS, SV, SVI, F/M can be analyzed by ETP laboratory. The activity of this laboratory was started from March, In table-7, only ETP outlet water test results are presented. Table-7: ETP outlet water quality test report (In house laboratory) Date COD in BOD in ppm TSS in ph ppm ppm 6/4/ /4/ /4/ /4/ /4/ /4/ /4/ /5/ /5/ /5/ /6/ /6/ /7/ /7/ /8/ /8/ /8/ /8/ /9/ /9/ /10/ /10/ /10/ /11/ /11/ /12/ /12/

11 Chapter 5 Target Setting & Action Plan HAMS Washing & Dyeing Ltd. sets target to improve environmental performance as well as reduce energy & water consumption. The concern authority review improvement against target annually and take corrective action plan to achieve target. Energy Target Name 5% energy consumption reduction for per ton production Target Type Normalized Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2019 % Reduction from base year N/A Metric for Normalized targets per ton of production Base year consumption amount 9.1GJ The current reporting period's normalized N/A energy consumption amount Water Target Name 10% Water consumption reduction for per ton production Target Type Normalized Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2019 % Reduction from base year N/A Metric for Normalized targets per ton of production Base year consumption amount 31.5 m 3 The current reporting period's normalized N/A energy consumption amount Chemical management Target Name Achieve 80% score in chemicals management performance in selfassessment module Target Type Absolute Base year 2016 Target Start date 01/01/2017 Target End Year 31/12/2018 % increase chemicals management N/A Performance score from base year Metric for Absolute targets Total score in self-assessment module Base year score 49% The current reporting period's score N/A 11

12 Action Plan: Energy: Hot water/condensate Recovery: Projection Time: If 1 ton/h of steam is supplied to equipment for a heating process, then the same amount of condensate (1 ton/h) needs to be discharged from the equipment. Condensate recovery is a process to reuse the water and sensible heat contained in the discharged condensate. Recovering condensate instead of throwing it away can lead to significant savings of energy, chemical treatment and make-up water. Reusing hot condensate can lead to considerable savings in terms of energy and water resources, as well as improve working conditions and reduce your plant's carbon footprint. Condensate contains a significant amount of sensible heat that can account for about 10% to 30% of the initial heat energy contained in the steam. Feeding the boiler with high-temperature condensate can maximize boiler output because less heat energy is required to turn water into steam. When efficiently recovered and reused, it can even be possible to reduce boiler fuel needs by up to 10 to 20%. Theoretically one m3 water is required to produce one ton steam. HAMS Washing & Dyeing Ltd has a NG boiler with the capacity of 5.5 ton per hour. Presently this boiler is being operated with at 70% load of their capacity. Steam is used mainly in washing & drying. It is assume that around 65% steam is used for washing and 35% is used for drying section. At present steam condensate from drying section is drained out. However, this condensate will be recovered to feed water tank that use to pre heat the boiler again up to c. Upgrade generator monitoring to electrical power management control system Projection Time: 2017 to 2018 The present generator monitoring provides too little information for monitoring their performance. Fortunately a better generator monitoring system is available. However even this system can be improved and extended as to include real-time diesel consumption and overall generator efficiency along with the complementing power consumption from the grid. By installing an electricity measuring system for generator and by upgrading this monitoring system to calculate effective efficiency at varying load and adding automatic modulating controls a true electrical power management system can be realized automatically control all generators which switches the generators on/off according to demand and optimizes the production of each generators as to achieve maximum the overall efficiency while minimizing the total cost of power consumption including grid and stand-by diesel generators. Install solar panel: Projection Time: 2017 to

13 The authority of HAMS Washing & Dyeing Ltd has a planned to use solar panel for lighting purpose to save energy as well as reduce carbon foot print for entire factory. Already a solar panel has been installed which capacity is 2.5 KW. Use LED & Energy saving Light: Projection time: 2016 All lights of entire factory of HAMS Washing & Dyeing Ltd are LED & energy saving light. The authority of HAMS Washing & Dyeing Ltd uses LED & energy saving light for lighting purpose to save energy as well as reduce carbon foot print. Replacing conventional boiler with energy saving boiler including economizer: Projection time: 2017 Previously, HAMS washing & Dyeing used a conventional boiler which consumed more fuel to generate steam. The authority of HAMS Washing & Dyeing Ltd decided to replace this conventional boiler with a modern boiler which has economizer & others energy saving accessories. Inserting an economizer in the flue gas outlet of the steam boilers as to preheat the boiler feed water would save about 2.7% on the fuel consumption for steam production. Around 30% less energy is consumed by new modern boiler to produce similar amount of steam compare to old boiler. Water: Rain Water Harvesting Projection Time: 2017 to HAMS Washing & Dyeing Ltd has a plan for rainwater harvesting on roof top area of the shads & buildings. Table-8 presents the roof top area of the shads & buildings with the annual volume of rainfall. From figure-1, it can be seen that the lowest annual rainfall is 4.4 mm in January and the maximum annual rainfall is mm in July. In average, at Dhaka & Gazipur region, the annual rainfall is 1960 mm from 2001 to Figure-1: Monthly averages of Rainfall & Humidity data at the Dhaka & Gazipur region (From Dhaka BMD Station), Source: Bangladesh Meteorological Department 13

14 Table-8: Roof top area of the shads & buildings with the yearly volume of rainfall Building/shad Area in m 2 Annual average rainfall in mm Volume of rainfall (Annual) in m 3 Main Building Chemical store room Total tool use to convert rainfall in mm to rainfall in m 3 considering roof top area) From table-8 it can be seen that, HAMS Washing & Dyeing Ltd can use approximately m 3 water annually from rainwater harvesting instead of using from ground water. According to figure-1, the maximum possible rainfall is 388 mm (4817 m 3 for area of m 2 ) in July throughout the year. Using Water Efficient Equipment Projection time: 2017 Water consumption for production purpose can be saved by replacing outdated equipment with modern machines which operate at low liquor ratio. HAMS washing & Dyeing Ltd has 26 washing machines which operate with 1:9 liquor ratio. The authority of HAMS washing & dyeing ltd has planned to install 10 Brongo-L4200 washing machines which operate with low liquor ratio (1:5). Two Brongo-L4200 washing machines have already been installed and 8 more Brongo-L4200 washing machines will be installed by May, At least 35% less water is consumed by Brongo-L4200 washing machine compare to existing washing machine. Reuse Blower cooling water: Projection Time: 2017 to 2018 HAMS Washing & Dyeing Ltd has a biological ETP with the capacity of 2000 m 3 per day. Continuous aeration is necessary for biological ETP and aeration is provided by blower. Three blowers are running simultaneously in ETP and these blowers are needed to be cooled by supplying soft water. For this purpose, around 35 m 3 water per day is required. HAMS Washing & Dyeing Ltd has planned to save 35m 3 /day water by reuse blower cooling water. Awareness & Monitoring Projection time: 2017 to 2018 The significant amount of water consumption for dyeing & washing section can be saved by monitoring & creating awareness. 14

15 Turn off Running Taps and Hoses This simple procedure can result in substantial savings. People are often unaware of the cost of leaving taps and hoses running. They are more likely to turn off running taps and hoses if they are made aware of the annual cost of waste. Meanwhile, fixing hand triggers to hoses is a simple way of reducing water use and saving money. Turn off Water when Machines are not running. Encourage workers to turn off machines and water during breaks and at the end of the day. Avoid circulating cooling water when machines are not in use. The concern department of HAMS Washing & Dyeing Ltd has been working to formulate & implement an integrated Environmental Management System (EMS). A relevant program for creating awareness & monitoring regarding water consumption will be included of that EMS. Improve chemicals management performance: The concern authority of HAMS Washing & Dyeing Ltd. committed to: Continual improvement of chemical management performance Expand win of economic, environmental, safety & health and organizational benefits through implementing systematic management of chemicals Complying with national legislation and conforming to emerging customer requirements and international standards on management of chemicals strengthening in-house competence of personnel in companies (workers, middle management), integrating CM training into in-house training units enabling EHS managers/officers and company personnel concerned with handling of chemicals in textile companies to improve the condition of chemical management in the factory The chemical management system will be formulated and it will work through Plan-Do- Check-Act framework. The following jobs will be conducted through Plan-Do-Check-Act framework to establish an appropriate chemical management system: Maintaining legal register including National and other laws and regulations Systematically identify and document chemicals used and stored Material flow accounting; Process flow diagram, Chemical trajectory & NPO identification Maintaining Chemical inventory Chemical risk analysis Hazard & risk mapping Chemical risk management action; Training, Document Development, Document and Record Control, Chemical Management Work Practices & Emergency Procedures; Exposure control measures, Safety data sheet management(procedure for making SDS available), Chemical handling( procedure for SOP development, format), Chemical storage in well design store, Chemical transportation, Chemical use Regular and optimization, Personal protective equipment (procedures for selection, use, maintenance), Laboratory practices, Maintenance and housekeeping, Waste and disposal. 15

16 Chapter 6 Conclusion The total washing production (MT), water (m 3 ) & energy (GJ) consumption for production and wastewater (m 3 ) generation in 2016 of HAMS Washing & Dyeing Ltd. are presented in table-9. Table-9: Production, water & energy consumption and wastewater generation record of HAMS washing & dyeing Ltd. in 2016 Year 2016 Washing production(mt) Water consumption(m3) Waste water(m3) Energy consumption(gj) Figure-2: presents the production, water & energy consumption and wastewater generation of HAMS washing & dyeing Ltd in 2016 Table-10: Base year water & energy KPI for per ton production Year Base year 2016 Target year 2018 Water consumption (m 3 ) 31.5 Reduce by 10% from base year Energy consumption (GJ) 9.1 Reduce by 5% from base year Signature Authority 16