GHG Emission Calculator Intro

GHG Emission Calculation Tool for
Indian Apparel Sector

THE TREND [1]

Lean manufacturing, ISO driven quality
1990s
practices

2000s Ethical sourcing and labour practices

Sustainability and optimally using natural
2010s
resources

[1] - cKinetics (2010). Exporting Textiles: March to Sustainability

Apparel Tool. Version 1.0

What the WEST is doing?


Indian Scenario
• Trends travel east…

• Sustainability practices: mandatory!

• No quantitative approach to measure work done in this
direction.

“You can’t manage what you don’t
measure!”


Objective

Primary:
•To adapt a GHG Emission calculation tool for the Indian
Apparel Sector.

Secondary:
• To study the work processes of apparel industry with focus
on energy sources.

• To design an Excel based tool and its user manual.

• To road-test the tool.


Research Process Flow

• Ratification of the tool by TERI

• Road-test the tool. Find out the problems faced by
the user. Amend changes.


Research Methodology
Nature of Research Quantitative

Coverage Macro Study

Utility Applied Research

Mode of data generation Documentary Research, Field Studies

Method of Research Experimental and Historical

Time Frame Single Time Period

Type of Study Analytical, Evaluation, Exploratory

Sampling Random


Types of Emissions [4]

[4] - (2004). GHG Protocol - A Corporate Accounting and Reporting
Standard

Concept of Scope [5]
Scope 1: Direct Scope 2: Energy Scope 3: Other
Indirect Indirect
Fuels Combustion Purchased materials and fuels
(e.g. boilers, furnaces or turbines) (e.g. extraction, processing
and production)
Owned Transport
(e.g. trucks, trains, ships, Transport-related activities
airplanes, cars) Consumption of (e.g. commuting, business
purchased travel, distribution)
Process Emissions
electricity, heat, Waste disposal
(e.g. cement,aluminium, waste
steam and cooling (e.g. waste, recycling)
processing)
Fugitive Emissions Leased assets, franchising and
(e.g. air conditioning & outsourcing
refrigeration leaks, methane Sold Goods and Services (e.g.
leaks from pipelines) Use of goods and services)

Focus of [5] – (September 2009). Guidance on how to measure and report your
research greenhouse gas emissions. DEFRA

Study Of Processes With A Focus On Energy

Fabric Spreading
Washing
Store & Cutting

Fusing

Finishing Ironing Sewing

Packing

Shipment

Greenhouse Gases
• The Kyoto Protocol refers to the following gases:

Gas Global Warming
Potential* [6]
CO2 1
CH4 21
N2O 310

SF6 23900
11700
Hydro flourocarbons (HFCs)
-- [7]
Per flourocarbons (PFCs)

[6] - http://unfccc.int/ghg_data/items/3825.php
[7] - http://www.ipcc.ch/publications_and_data/ar4/wg1/en/ch2s2-
10-2.html [Accessed on 19:34, 18/03/2012]
* GWP over 100 years

Greenhouse Gases
• Departments where gases are emitted:

Gas Emission areas in apparel mfg unit

CO2 All departments consuming electricity, transport of
fabric, garments, boilers, gensets

CH4 Boilers, gensets
Boilers, gensets
N2O
Circuit breakers
SF6
Air conditioners, refrigeration, heating equipment
Hydro flourocarbons
(HFCs)


RESEARCH GAP
• Sufficient of work done in other sectors such as Cement industry,
Power sector, Aviation and Telecom

• Absence of standard, reliable, accurate way of calculating the GHG
emissions from Apparel Sector

• Lack of bottom-up GHG inventory building approach for the T&A
sector.

• The more that our industry works toward a common goal, the more
likely we are to develop scalable, viable environmental solutions.


• The tool calculates the carbon footprint of an apparel
manufacturing unit.
• Apart from carbon dioxide it takes into account,
– CH4
– N2O
– HFC
– SF6


Worksheets: 5/14
Introductory Sheets

User Introducti- Flowchart General Plant My Fuels
Agreement on Information

Facilitate
Informatio plant level
n about the About the About the information
To estimate
copyright, tool, pre- plant, of fuels/fuels
GHG not
acknowled requisites, contact
emissions mentioned in
gments, etc. details, etc.
disclaimer the drop
down menu.


Worksheets:10/14
Calculation Sheets

Stationary Mobile HFC SF6 Purchased
Combustion Combustion Emissions Emissions Electricity

Fugitive Emissions
Emissions emissions from
Emissions Fugitive
from from AC, electricity
from emissions
vehicles refrigerato purchased
boilers, from circuit from State
owned by rs owned
gensets, etc breakers Electricity
company by the
Board.
company.

Scope 1 Scope 2

Worksheets:14/14
Summary Sheets Information Sheets

Summary Summary Defaults Conversion
for the for the NCVs factors
facility company

Fugitive
Emissions emissions
Emissions Fugitive
from from AC,
from emissions
vehicles refrigerato
boilers, from circuit
owned by rs owned
gensets, etc breakers
company by the
company.


Data Required Before Starting
• Desired Reporting time (Annual/Half/Quarter)

• Quantity of fuel used in boilers, gensets, (litres/kg/metric tonne)

• Company owned vehicles:
• Quantity of fuel used //OR//
• Distance travelled by each vehicle (kms)

• Refrigerators, ACs heating equipments present in the plant
• Number of ACs, refrigerators
• Type of refrigerant used in them
• Refrigerant charge (kg)


Data Required Before Starting
• Inventory, Sales and Purchase of SF6 used in circuit breakers

• Amount of electricity consumed from the grid in kWh

 NOTE: All these data have to be gathered for the reporting period only.


List of Formulae Used
CO2, CH4, N2O (stationary and mobile) emissions
= ∑ fuel consumed X Net Calorific Value X Gas Emission Factor
(kg) (TJ) (kg/TJ)

CO2 Mobile emissions (Vehicle Km travelled method)
= Emissions = ∑ [Distance travelled X EF]
(km) (g/km)

HFC Emissions No. of units × Refrigerant charge × Annual leakage factor
Equivalent CO 2 emissions of HFC = × GWP (1
= 10 5

Purchased Electricity
= Emissions = ∑ [ Power Consumption X EF ]
(kWh) (Grid
Specific)


List of Formulae Used
Converting other gases into CO2 equivalent:

t CO2 e of gas a = (Gasa emissions in tonne) x GWPa


Road test: Findings
• Road test was carried out in 3 export houses based in NCR.

• Findings:
– Explanation of each sheet needed in more detail.
– Inclusion of air and rail travel emissions calculated.
– Need to know the next steps to reduce their emissions.


BENEFITS OF USING THE TOOL
• Establish baseline emissions.
• To participate in voluntary or mandatory emission
reduction programmes.
• Create GHG inventories through a bottom-up approach
• Can be used during LCA of apparel products.


FUTURE SCOPE OF WORK
• The same tool can be applied to the textile industry after
research into any other greenhouse gases emitted during
finishing, dyeing, printing process.
• Methods to quantify emissions from rail, air and ocean
transport may be explored.
• Explore the possibilities of storing the data generated
from each factory in a centrally located server online to
form a comprehensive GHG inventory.
• More features can be added to move up in the hierarchies
of a sustainability measurement tool.


Apparel Sector Tool User Manual

For more info,
cfptool@gmail.com
(M) - +919650595637
Thank you…
Dhawal Mane
MFTech IV
NIFT, New Delhi

GHG Emission Calculator Intro

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