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ETP - Pollution Prevention & Water Recycling
Textile Industry
14th Nov 2019
15-11-2019
-- KANHAYA LAL KUMAWAT
Points to be Discussed
2
1. Introduction to Compliance, Sustainability,
CMS, BMP , NPO
2. Textile Effluent & Pollutants
3. ETP & Water Recycling
4. BMP, CMS & Zero waste Concept
15-11-2019
3
1)
Introduction to
Compliance, Sustainability, CMS, BMP , NPO
15-11-2019
4
Important & Common words in
ETP & Water Recycling
Compliance & Sustainability
15-11-2019
5
What is Compliance & Sustainability
Sustainability focuses on meeting
the requirements of the present
needs without compromising the
ability of future generations to
meet their needs.
Sustainability is composed of
three pillars: economic,
environmental, and social
also known informally as
profits, planet, and people.
Compliance
means conforming
to environmental laws,
regulations, standards and
other legal requirements
such as Consent to Operate.
15-11-2019
6
Why we need a compliance?
To improve Human Health &
To protect environment.
15-11-2019
7
What are the biggest challenges faced for
Compliance / Sustainability?
Chemical Consumption
Cost Competition
Quality Standards
Treatments & Waste Generation
15-11-2019
15-11-2019 8
Local legislation
Consumer Safety
Brand RSL
Eco-Labels
Compliance for Protection of Environment
Sustainability & Compliance
A - WayForward
9
What is the solution to Compliance /
Sustainability?
Reduce Non Productive Output (NPO)
By implementing
Chemical Management System (CMS)
&
Best Management Practices (BMP)
15-11-2019
A way Forward –
Sustainable DESIGN for Industry
Green design 1980
Eco design 2000
Sustainable design Now
Sustainability-Through
• Reduce
• Reuse
• Recycle
• Research
Industry
Minimum
Natural
Resources
Minimum Chemicals
Safe Process
(Selection, Storage & Handling)
Eco friendly
Raw material
Product
Minimum Waste –
Water, Energy, Effluent, Sludge
1015-11-2019
11
2)
Textile Effluent & Pollutants
15-11-2019
Pollutants--Textile Effluent
12
• The liquor discharged after the completion of unit operations in industry is
known as Effluent
• The effluent consists of remaining unused or modified chemicals, dyes,
auxiliaries and finishing agents & traces of raw material used & Energy
consumed,
• It is essential to treat effluent to reduce toxic pollutants either by
separation method & / or by cracking molecule in to normal element or
Both.
15-11-2019
Pollutant and their Nature
13
Process
Effluent Composition Pollutant nature
Sizing Starch, waxes, CMC, PVA, etc High in BOD,COD
Desizing Starch, CMC, PVA, Fats, Waxes, etc High in BOD,COD,SS,TDS
Bleaching
Sodium Hypochlorite, NaOH, H2O2, acid, Surfactants, Sodium
Phosphate, Short Cotton Fibre, Etc
Highly alkalinity, High SS
Mercerization Sodium Hydroxide, Cotton Wax High pH, Low BOD, High DS
Dyeing
Dyestuff, Reducing Agent, Acetic Acid, Detergents, Wetting Agent,
Salt, Etc
Strongly Colored, High BOD, DS, Low SS,
heavy metal
Printing
Paste, Urea, Starches, Gums, Oils, Binders, Thickners, Cross- Linkers,
Reducing Agent, Alkali,etc.
Strongly Colored, High BOD,DS,SS,
Slightly Alkaline.
Finishing Emulsifiers, Silicones, Various finishing agents
Harmful - non biodegradable
substances
15-11-2019
Textile Effluent & Discharge Norms
14
Parameters for
Dyehouse
Untreated
waste water
Treated
waste water
pH 4.0 to 10.5 6 to 9
Colour Dark, offensive
No Colour,
not offensive
Foam Persistent No foam or dissipates
Heavy metals 10 to 15 ppm 0.01 to 1.5 ppm
Suspended solids 200 to 300 ppm 30 To 45 ppm
Total Dissolved Solids 3500 to 6000 ppm 2100 ppm
Chemical Oxygen Demand 900 to 1500 ppm 250 ppm
Biochemical Oxygen Demand 300 to 500 ppm 30 ppm
15-11-2019
Analysis of Pollutants: Textile Effluents
15
A. Relatively Harmless Inorganic Contaminants
 Alkalis
 Mineral acids
 Neutral salts
 Oxidizing agents
B. Moderate to high BOD but readily Biodegradable
 Starch sizes
 Vegetable oils, fats and waxes
 Biodegradable surfactants
 Organic acids
 Reducing agents
15-11-2019
Analysis of Pollutants: Textile Effluents
16
C. Dyes and Polymers Difficult to Biodegrade
 Dyes and fluorescent brighteners
 Most fibres and polymeric impurities
 Polyacrylate sizes
 Synthetic –polymer finishes ( crease –resistant, flame-retardent)
 Silicones
D. Moderate BOD and Difficult to biodegrade
Wool grease
Poly(vinyl alcohol) sizes
Starch ethers and esters
Mineral oil (spin finishes)
Surfactants resistant to biodegradation
Anionic and non-ionic surfactants15-11-2019
Analysis of Pollutants: Textile Effluents
17
E. Negligible BOD but Unsuitable for Conventional Treatment
 Formaldehyde and N-methylol reactants
 Chlorinated solvents and carriers
 Cationic retarders and softeners
 Biocides
 Sequestering agents (EDTA, NTA)
 Heavy metal Salts (Cr, Cu, Hg, Cd)
15-11-2019
Classification of Pollutants
1815-11-2019
Probable Toxic Elements of Pollutants
19
1) Phthalates
2) APEO
3) Azo Dyes
4) Brominated and Chlorinated Flame Retardants
5) Chlorophenols: Pesticides
6) Chlorinated Solvents
7) Chlorobenzenes
8) Organotin Compounds: Antifungal
9) Short chain Chlorinated Paraffin’s: Flame retardant
10) Heavy Metals: Ca,Pb,Hg,Cr
11) Per –flourinated Chemicals (PFCS)
15-11-2019
20
3)
ETP & Water Recycling
15-11-2019
ETP
2115-11-2019
Process flow of standard ETP & Recycling
Collection tank Screening
Grit Separation
Primary treatmentSecondary treatmentTertiary treatment
Sludge for drying
Reject effluent to check &
multi stage evaporator Sludge disposal / Burn in
Boiler 2215-11-2019
Various Treatments in ETP
Primary
Involves sedimentation of
solid waste within the
water.
Secondary
Makes use of oxidation
to further purify
wastewater
Tertiary
This is basically a
polishing stage.
15-11-2019 23
Primary
Treatment
Floatation
Dissolved Air
Floatation
Sedimentation
Horizontal
Flow Clarifier
Solids contact
clarifier
Inclined
Surface
Clarifier
Dissolved Air Floatation
Horizontal Flow Clarifier
Solids contact clarifierLamella Clarifier
Tube Settler15-11-2019 24
Secondary
Treatment
Physiochemical
Fenton/ Photo-
Fenton
Ozone based
AOPs
Photocatalytic
oxidation with
TiO2
UV + H2O2
Biological
Aerobic
Suspended
Growth
Attached
Growth
Anaerobic Anoxic
Aerobic
Anaerobic
Physiochemical
15-11-2019 25
Tertiary
Treatment
Activated
Carbon Filters
Pressure Sand
Filters
15-11-2019 26
Water Recycling
Recycling of water means, reuse of water. It can be done in various manners.
• Recycle of good quality of water back to process without treatment -
Cooling water, ETP effluent used in chemical dosing / culture making
system instead of fresh water being used.
• Internal reuse of water - Discharge water of one process can be a starting
water for another process by little modifications – Peroxide bleach water to
be reused in scouring or Desizing, drain of selected Polyester dye-bath to
use for cotton soaping. Mercerize wash liquor to be recycled in Bleaching
process.
• Recycle of effluent after full treatment – To recycle effluent after partial or
full treatment & reuse in selective / all processes – ETP – PSF / ACF - Bag
filter – Cartridge filter, - Membrane Filters
15-11-2019 27
Membrane Filtration
• A membrane is a selective barrier. it allows some
things to pass through but stops others. Such things
may be molecules, ions, or other small particles
• Synthetic membranes are men made for selective
usage as per requirements. (Mostly Polyamides /
Ceramic / Carbon )
15-11-2019 28
Types of Membrane processes
• Microfiltration (MF)
• Ultrafiltration (UF)
• Nanofiltration (NF)
• Reverse Osmosis (RO)
15-11-2019 29
Membrane
15-11-2019 30
Process Configuration - General
Concentrate
Product
Feed
Influent to the membrane
module: Feed water / feed
stream
Liquid that passes through the semi-permeable
membrane: permeate / product stream /
permeating stream
Semi-permeable membrane
Liquid containing the retained constituents: Concentrate /
retentate / reject / retained phase / waste stream
15-11-2019 31
15-11-2019 32
ETP with Membrane System
15-11-2019 33
Membrane Actions
15-11-2019 34
Filtration Mode terms -
15-11-2019 35
Membrane Configurations
15-11-2019 36
More Membrane Configurations
15-11-2019 37
RO Package System
15-11-2019 38
Membrane Fouling
Fouling : Potential deposition and accumulation of constituenst in the feed
stream on the membrane.
Biological fouling: Various microorganisms can deposit on membrane
surface.
Chemical Fouling: Controlled by disinfection of ww. Chlorination,
Incorrect pH
Avoid damage of the membrane by the disinfectant.
Follow standard cleaning process given by suppliers
15-11-2019 39
MBR (Membrane Biological reactor)
 Consists of a biological reactor with suspended biomass and solids
seperation by microfiltration membranes.
 Nominal pore size 0.1 – 0.4 micron
 MBRs can be used with:
Aerobic / anaerobic suspended growth bioreactors to seperate
treated ww from active biomass
 Eliminates secondary clarification and operate at higher MLSS
15-11-2019 40
MBR Modules

15-11-2019 41
42
4)
BMP, CMS &
Zero waste Concept
15-11-2019
BMP – Best Management Practices
43
Action to be taken for Reducing Water Consumption in Various Process Operations
Process Suggested Action Steps to be Taken by Mill
Pretreatment
(Desizing,
Scouring &
Bleaching)
1) Try to recycle internally
o Can explore possibility to use bleaching water in scouring & desize.
o Can use water from washes of each process wherever possible through
counter current method in soaper & also by storage in tank & re use.
1) Avoid overflow rinses
o Overflow rinses consumes 40% more water as compared to smart washing
techniques.
1) Combined Scouring & Bleaching process (Single bath
scouring & Bleaching)
o This will save water by 40%
o Use counter current system for washing machines
1) Use enzyme base technology
o One can reduce water & energy consumption by reduction in temperature
& number of washes.
o One can recycle this water back to process by topping-up of chemicals
Dyeing
1) Use single bath dyeing for PC blends o Saving of water, power , energy & time
1) Use low salt dyes,
2) Use high exhaustion dyes,
3) Use of pad dry method instead of exhaustion method.
o Approx. 205 to 60% water can be saved.
Finishing
1) Use of standing bath for batch wise application of finishing
chemicals
o Can save 15% of water & chemicals
1) Can use hi suction slit on stenter
o Can save 15% of water with compared to padding mangle. This also can
reduce energy used in drying.
1) To recycle cooling water on sanforise finish o 80% of water saving (Used in cooling)
Other areas
Use equipment’s with low MLR o Can save 15% to 20% of water
Recycle chiller plant water o Can save 80% of water
Auto control of humidification room o Can save 25% to 30% of water
Auto level control in processing machines o Can save 30% of water.
Use nozzle with stop motion at the end of pipe during cleaning o Can save 25% of water
15-11-2019
Equipment’s required for internal lab of ETP Frequency of the Analysis
Instruments No of pcs
pH Meter 1
pH Pen 3
TSS Meter 1
TDS Meter 1
DO Meter 1
BOD testing kits with Incubator 1 set
COD testing kits with digester 1 set
Oven 1
Digital weighing Balance with 0.1
mg accuracy and 10 gms accuracy
1 each
Necessary Glass ware As per mentioned in
test procedure
Chemical reagents
Parameters Frequency of Testing
pH Once in a shift of 8 Hours
TSS Once in a Shift of 8 hours
TDS Once in a Shift of 8 Hours
Dissolved Oxygen Once in a shift of 8 hours
Color Once in a shift of 8 Hours
Treatability study Once in a Day
MLVSS/MLSS Once in a Day
COD Once in a day
BOD Once in a week15-11-2019 44
Minimum Strength of Technical staff
Minimum strength in ETP
Post Education / Experience No of employees
Environment Officer Graduate in Science / B.E. with 5 years’
experience
1
Shift Supervisor cum lab technician Graduate in Science 3 ( 1 per shift)
Fitters ITI pass 3 ( 1 per shift)
Wireman ITI Pass (Electrician) 1
Helpers Adult workers 1 per shift
Necessary strength of relievers to be maintained for
working on 7 days a week
Environmental Management Cell (EMC)
 Unit /Business Head
 ETP In-charge and one officer
 Process Operations Heads
 Factory Manager
15-11-2019 45
Operation and Maintenance of ETP and Water cycling system
SR. NO. Process Unit Brief Purpose
Activity and Preventive Maintenance
Daily Weekly Monthly Yearly
1
Screen cum Oil and
Grease Trap
For removal Floatable
matter from the effluent
Cleaning and remove
waste
Greasing Twice in a
month
Replacement of non
effective parts
2 Equalization Tank
For ensuring continuous
and uniform quality feed
to the ETP system.
Check floating material
and remove
Blow air at all Corners
and mix well from
Bottoms
Check working of
submersible pumps by
taking out.
Replacement of Non
effective parts of pump
and pipe lines.
3 Flocculation Tank
For floc formation and
mixing
Treatability study, adjust
chemical dosages Confirm
pump working
Calibration of dosing
pumps , Cleaning of
chemical tanks.
Stirrer and gear box
checking
Replacement of non
effective parts
4 Primary Clarifier
For settling settable
solids
Check overflow water
clarity, check sludge
thickness while
transferring to sludge tank
RPM of rotating
system,
Check and Clear Chock-
ups of Valve and Pipelines
Full cleaning of Valves
and pipe lines
5 Aeration Tank
For reduction of organic
load (BOD and COD) by
aerobic process
Check DO, pH, Smell
MLSS
Remove calculated
numbers of diffusers
and clean
Cleaning of Headers
Clean settled sludge at
bottom and clean the tanks
during yearly maintenance
6
Blowers and Diffused
Aeration System
For supplying air for
mixing in the culture,
Aeration Tank.
Oil level check, Check
smell
Filter cleaning
Check vibrations of
Blowers, Current drawn.
Oil replacement
7
Sludge collection/
Holding tank
For storage of Sludge for
further treatment.
Sludge volume in tank and
check impact of chemical
on it.
Cleaning of valves and
pipe line. For chock-up
Check De watering
system and do
maintenance work like
change cloth of press,
plates movements, etc..
Overhauling
15-11-2019 46
8
Culture Dosing
System
For activation aeration
tank and Maintain the
bacteria Population.
pH, MLSS, MLVSS, DO
Compare reports of aeration
tank for MLSS and MLVSS
Air blow at corners of tanks,
Check Bacteria activity and
growth
Tanks cleaning
9
Pressure Sand
Filter
For Removal of
Suspended solid,
Back wash with air blow
Overflow wash with chemical
dose to clean sand.
Check volume of sand
Replace / top-up sand
media
10
Activated
Carbon filter
For colour , dour and
Trace Organic Matter.
Back wash with air blow
Overflow wash with chemical
dose to clean sand.
Check volume and Iodine value
of media
Replace / top-up
media
11 Bag Filters
Removal of suspended
particles
Change Bag filters, Check
sticky material inside bag to
understand any abnormal
situation.
Check leakage from "O rings"
Assembly to check. Check and
compare quality of replacement
filters against original ones
12 UF system
For removal suspended
and colloidal impurities.
Permeate and rejected
effluent quality check.
Check daily reports for DP
(Differential Pressure)
Follow CIP (Chemical in
process system.
Clean pipelines and follow
flushing system
Double CIP for better cleaning
. Check the chemical
consumption used for CIP
during month and compare
against previous few months
Open membrane and
check module (one
from each raw)
13 RO-I System
For recovering low TDS
permeate for process
pH, Operating Pressure,
Quality of Ok and Rej
effluent, Efficiency of
membrane for the day CIP
activity, Flushing ,
Temperature of effluent
Compare reports of current
week against previous weeks.
Any abnormality to be studied.
Check run and rest time of
membrane Check dosing
volume of CIP, DP, and
leakages if any. Check
chemical consumption and
stock of chemicals used in CIP.
Open membrane and
check module (one
from each raw)
14 RO-II System
For recovering low TDS
permeate for process
15 RO-III System
For recovering low TDS
permeate for process
16
Evaporator
System
all calenderias for
evaporation of effluent
and concentrate same
Check Specific Gravity of
effluent from last CIGAR/
Evaporator/ Calendria.
Check steam pressure,
Vacuum and temperature in
CIGAR, Check any chock-
ups in tubes.
Cleaning and Flushing of
water and chemicals if needed.
Cleaning of tubes by
scrubber and High
Pressure pumps / jet
pumps
15-11-2019 47
17
Crystallizer and
Pusher
To allow crystal formation
and removal of sludge
Temperature of vessel,
Quality of crystals
Vacuum, Cleaning and Flushing
Cleaning of tanks by
chemical
18 ATFD
Agitated Thin Film Dryer
to remove excess of
moisture
Steam pressure Cleaning and flushing. Over hauling
19 Cooling Towers
To maintain temperature of
effluent for better
crystallization
Inlet and outlet temp of water
Circulation and
cooling fan
Cleaning
Maintenance as per
suppliers
20 Tanks To store water or Effluent Levels, pH Leakage from tank
Check quality of water / effluent
from top and bottom of each tank
Cleaning by Pressure jets
21
Electrical Panel
boards and Motors
Normal electrical
maintenance - check
current drawn etc…
Loose connections,
Fix temp.
Connections if any.
Clean panel boards
from inside
Normal electric checking as per
schedule,
22 Lab Equipments As per manual
Follow guidelines as per
manual.
Calibration of
equipments
Compare once with outside lab for
test reports and compare process,
and deviation in reports.
23 Reports Check daily log sheet
Check equipment
working sheet.
Compare reports of month and
compare against previous months.
For Effluent quality, Volume, Cost
and disposal of sludge, Chemical
consumption.
Any change in
regulations.
24 Training Check working of operators provide training for any bad habits.
25
Submissions of
legal documents
Check actual against figures in
Consent to operate.
Submit application if any
change in equipments,
system, procedure.15-11-2019 48
Operation and Maintenance of ETP
Do’s
o Ensure proper and optimum conditions of each section of ETP
o Avoid fluctuation in effluent flow and pollution load
o Ensure proper addition of nutrients in aeration tank.
o Maintain required level of MLSS/MLVSS concentration during
biological treatment.
o Maintain desired level of DO in the aeration tank (1.5 to 2.2
mg/l).
o Ensure periodic and timely withdrawal of sludge from the
clarifiers and settled bio mass from aeration tanks.
o Proper maintenance of electric motors, pumps and blowers with
diffuser system. etc.
o Use of power saving technique in ETP operation are suggested
 Optimization of blower speed (by VFD) in aeration
tank linked with DO in aeration tank
 pH control (Dosing of acid) to be linked with pH
meter reading of effluent.
o Record keeping and Documentation
o Fresh water consumption, effluent discharge, effluent analysis,
and ETP chemical and utility (like steam and power)
consumption to be properly recorded.
Dont’s
o It is essential to maintain constant flow of effluent
o Never fluctuate effluent flow beyond margin of +/- 10%
o Never allow effluent with alkaline pH to enter in Bio-mass
tank
o Never dose chemicals without treatability study this should
be performed daily once
o Never keep alternate pumps/motors in breakdown
condition.
o Stabilize chemical supplier (especially for ETP) . Avoid
changing them frequently.
o Never Skip any step in SOP back wash system for filters
o Never allow iron, chlorine in membrane.
o Never stop circulation of effluent and air from blower in
bio-mass tank
o Never use spent acid for neutralization
o Follow proper SOP while RO is going to be stopped for
more than 24 hours.
15-11-2019 49
Best Management Practices- Action plan to reduce consumption of NPO
NPO means non productive output
The Raw material , dyes and chemicals, water fuel, power, manpower are basic inputs in
textile industries.
The input consumed is not being sold along with end product is NPO.
One must try to reduce NPO, which can reduce cost and improve environmental aspects
A. Reduction in Water Consumption
 Fixing leakages, repair faulty valves,
 Study and reduce diameter of water pipe line
 Use pressurized water spray during cleaning of equipments ( Use nozzles at the end)
 While cleaning, one can apply knob to control water volume (On/Off Knob)
 Reduce MLR in batch wise process
 Reduce overflow washing steps and select smart wash system.
 In case of continuous process reduce level of water in selected compartments of m/c and also control pressure of
water during overflow.
 Use counter current wash system in washing ranges.
 Internal recycling of process water in selected process, Back wash water of softener plant can be used in
preparation of ETP chemicals, floor cleaning, Toilet flushes etc..
 Turn off running taps and hoses (especially in toilets and also at cleaning area of production section)
 Turn off water valves when machines are not running
 Reduce the number of processing steps
 Optimize process water by several trials
 Recycle cooling water
 Re use process water in selected processing steps
 Using water efficient process and equipment
15-11-2019 50
Best Management Practices- Action plan to reduce consumption of NPO
B. Reducing Chemical Consumption
 Recipe optimization
 Control of dosing chemicals
 Pre screen chemicals and raw materials (study MSDS)
 Chemical substitution ( by less toxic one)
 Correct storage and handling (Generally chemical has storage instructions and by following
storage conditions, one can reduce possibility of degradation on storage
 Chemical recovery and reuse
 Process changes
 Improve scheduling of dyeing machines and reduce cleaning of equipment
C. Reduce Energy Consumption (Fuel and Power)
Good housekeeping.
Maintenances of
 Pressure Reducing Valves, Steam traps,
 Escape of energy by Exhaust control of Hot equipments
 Auto temperature control devices
 Boiler blow-down by linked by TDS
 Energy saving by right use of Heat Exchanger
 Use of Heat from hot drains from process
 Proper insulation of hot lines (Water, Steam and Condensate steam), Boiler feed tank. Hot water storage tanks Etc...
 Auto control of ID/FD fans depending upon O2 level of flue gases through chimney.
 Reduce cooling steps in process.
 Avoid direct steam by Installing heat exchangers (indirect steam heating)
 Energy audit by Boiler engineers and implement suggestions.
Use Invertors drives wherever is possible
 Blower speed in aeration tank of ETP
 Speed control of stenter motors.
 Pumps of Pressurized water line to be regulated by pressure switch.
Maintenance and cleaning of all panel boards
Energy audit by electrical engineer and implement all suggested options.
Switch over to power saving lights.
Auto level controllers for UG and OH water storage tanks
15-11-2019 51
Water saving techniques in the textile process house
 Work practices and engineering control
 Flow control on washers.
 Flow control on cooling water (use minimum
necessary).
 Counter current washing.
 High extraction squeezers.
 Recycle and reuse.
 Detection and repair of leaks.
 Detection and repair of defective toilets and
water coolers
 Reusing uncontaminated/first quality water
 Replacing overflow washes by captive washing
 Reusing wash water by counter current flow
washing
 Reuse of wash water for cleaning purposes
 Back gray blanket washing.
 Screen and squeegee cleaning.
 Color shop cleanup.
 Equipment and facility cleaning.
A typical preparation department may also reuse
wash water as follows:
 Reuse scour rinses for desizing. This is will
save water by 4 lit/kg of the fabric
 Reuse mercerizer wash water for scouring
and wherever possible. This will save the use
of fresh caustic in scouring, bleaching and
also in reactive dye fixation process. One
should ensure the adjustment of the caustic
concentration.
 Reuse bleach wash water for scouring.
 Reuse water-jet loom wash water for
desizing.
 Recycle kier drains to the saturator
 Final Rinse reuse as Loading Bath for Next Lot
 Reuse of neutralization bath
15-11-2019 52
Water saving by 3R concept (reduce, reuse, and recycle)
Sr. no. What to do Where to do
1 Reduce Water consumption due to
wastage
Audit of the process house, Modify the washing
process (over flow/running wash to fill-wash and
drain technique)
2 Reuse the uncontaminated/ first quality
water as it is
Cooling water, steam condensates etc
3 Reuse second-hand quality water (process
water) without treatment
Neutralisation baths, counter current washing,
4 Reuse second-hand quality water (process
water) with filtration or little modification
Neutralisation baths, pastel to light shades post
soaping hot wash baths cane reused for the other or
same process, cleaning purpose
5 Recycle effluent after partial treatment Water after Nano filtration can be used for reactive
dyeing as it contains the only salt. Also, it can be
used for cleaning purpose
6 Recycle after full treatment RO water suitable for all the process.15-11-2019 53
.
Contact +91 7768883361
harane27@gmail.com
Design Sustainability
ForFutureGrowth
Join Hands with Environment
5415-11-2019
Sustainable Development
Take care of mother earth with
social responsibility and
environmental protection.
This is our contribution to a better
future for us and for coming
generations
It simply means: Give back what you take!15-11-2019 55
Thank you
.
FOLLOW THE NATURE RULE
15-11-2019 56

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Pollution prevention in textile industry

  • 1. 1 ETP - Pollution Prevention & Water Recycling Textile Industry 14th Nov 2019 15-11-2019 -- KANHAYA LAL KUMAWAT
  • 2. Points to be Discussed 2 1. Introduction to Compliance, Sustainability, CMS, BMP , NPO 2. Textile Effluent & Pollutants 3. ETP & Water Recycling 4. BMP, CMS & Zero waste Concept 15-11-2019
  • 4. 4 Important & Common words in ETP & Water Recycling Compliance & Sustainability 15-11-2019
  • 5. 5 What is Compliance & Sustainability Sustainability focuses on meeting the requirements of the present needs without compromising the ability of future generations to meet their needs. Sustainability is composed of three pillars: economic, environmental, and social also known informally as profits, planet, and people. Compliance means conforming to environmental laws, regulations, standards and other legal requirements such as Consent to Operate. 15-11-2019
  • 6. 6 Why we need a compliance? To improve Human Health & To protect environment. 15-11-2019
  • 7. 7 What are the biggest challenges faced for Compliance / Sustainability? Chemical Consumption Cost Competition Quality Standards Treatments & Waste Generation 15-11-2019
  • 8. 15-11-2019 8 Local legislation Consumer Safety Brand RSL Eco-Labels Compliance for Protection of Environment
  • 9. Sustainability & Compliance A - WayForward 9 What is the solution to Compliance / Sustainability? Reduce Non Productive Output (NPO) By implementing Chemical Management System (CMS) & Best Management Practices (BMP) 15-11-2019
  • 10. A way Forward – Sustainable DESIGN for Industry Green design 1980 Eco design 2000 Sustainable design Now Sustainability-Through • Reduce • Reuse • Recycle • Research Industry Minimum Natural Resources Minimum Chemicals Safe Process (Selection, Storage & Handling) Eco friendly Raw material Product Minimum Waste – Water, Energy, Effluent, Sludge 1015-11-2019
  • 11. 11 2) Textile Effluent & Pollutants 15-11-2019
  • 12. Pollutants--Textile Effluent 12 • The liquor discharged after the completion of unit operations in industry is known as Effluent • The effluent consists of remaining unused or modified chemicals, dyes, auxiliaries and finishing agents & traces of raw material used & Energy consumed, • It is essential to treat effluent to reduce toxic pollutants either by separation method & / or by cracking molecule in to normal element or Both. 15-11-2019
  • 13. Pollutant and their Nature 13 Process Effluent Composition Pollutant nature Sizing Starch, waxes, CMC, PVA, etc High in BOD,COD Desizing Starch, CMC, PVA, Fats, Waxes, etc High in BOD,COD,SS,TDS Bleaching Sodium Hypochlorite, NaOH, H2O2, acid, Surfactants, Sodium Phosphate, Short Cotton Fibre, Etc Highly alkalinity, High SS Mercerization Sodium Hydroxide, Cotton Wax High pH, Low BOD, High DS Dyeing Dyestuff, Reducing Agent, Acetic Acid, Detergents, Wetting Agent, Salt, Etc Strongly Colored, High BOD, DS, Low SS, heavy metal Printing Paste, Urea, Starches, Gums, Oils, Binders, Thickners, Cross- Linkers, Reducing Agent, Alkali,etc. Strongly Colored, High BOD,DS,SS, Slightly Alkaline. Finishing Emulsifiers, Silicones, Various finishing agents Harmful - non biodegradable substances 15-11-2019
  • 14. Textile Effluent & Discharge Norms 14 Parameters for Dyehouse Untreated waste water Treated waste water pH 4.0 to 10.5 6 to 9 Colour Dark, offensive No Colour, not offensive Foam Persistent No foam or dissipates Heavy metals 10 to 15 ppm 0.01 to 1.5 ppm Suspended solids 200 to 300 ppm 30 To 45 ppm Total Dissolved Solids 3500 to 6000 ppm 2100 ppm Chemical Oxygen Demand 900 to 1500 ppm 250 ppm Biochemical Oxygen Demand 300 to 500 ppm 30 ppm 15-11-2019
  • 15. Analysis of Pollutants: Textile Effluents 15 A. Relatively Harmless Inorganic Contaminants  Alkalis  Mineral acids  Neutral salts  Oxidizing agents B. Moderate to high BOD but readily Biodegradable  Starch sizes  Vegetable oils, fats and waxes  Biodegradable surfactants  Organic acids  Reducing agents 15-11-2019
  • 16. Analysis of Pollutants: Textile Effluents 16 C. Dyes and Polymers Difficult to Biodegrade  Dyes and fluorescent brighteners  Most fibres and polymeric impurities  Polyacrylate sizes  Synthetic –polymer finishes ( crease –resistant, flame-retardent)  Silicones D. Moderate BOD and Difficult to biodegrade Wool grease Poly(vinyl alcohol) sizes Starch ethers and esters Mineral oil (spin finishes) Surfactants resistant to biodegradation Anionic and non-ionic surfactants15-11-2019
  • 17. Analysis of Pollutants: Textile Effluents 17 E. Negligible BOD but Unsuitable for Conventional Treatment  Formaldehyde and N-methylol reactants  Chlorinated solvents and carriers  Cationic retarders and softeners  Biocides  Sequestering agents (EDTA, NTA)  Heavy metal Salts (Cr, Cu, Hg, Cd) 15-11-2019
  • 19. Probable Toxic Elements of Pollutants 19 1) Phthalates 2) APEO 3) Azo Dyes 4) Brominated and Chlorinated Flame Retardants 5) Chlorophenols: Pesticides 6) Chlorinated Solvents 7) Chlorobenzenes 8) Organotin Compounds: Antifungal 9) Short chain Chlorinated Paraffin’s: Flame retardant 10) Heavy Metals: Ca,Pb,Hg,Cr 11) Per –flourinated Chemicals (PFCS) 15-11-2019
  • 20. 20 3) ETP & Water Recycling 15-11-2019
  • 22. Process flow of standard ETP & Recycling Collection tank Screening Grit Separation Primary treatmentSecondary treatmentTertiary treatment Sludge for drying Reject effluent to check & multi stage evaporator Sludge disposal / Burn in Boiler 2215-11-2019
  • 23. Various Treatments in ETP Primary Involves sedimentation of solid waste within the water. Secondary Makes use of oxidation to further purify wastewater Tertiary This is basically a polishing stage. 15-11-2019 23
  • 24. Primary Treatment Floatation Dissolved Air Floatation Sedimentation Horizontal Flow Clarifier Solids contact clarifier Inclined Surface Clarifier Dissolved Air Floatation Horizontal Flow Clarifier Solids contact clarifierLamella Clarifier Tube Settler15-11-2019 24
  • 25. Secondary Treatment Physiochemical Fenton/ Photo- Fenton Ozone based AOPs Photocatalytic oxidation with TiO2 UV + H2O2 Biological Aerobic Suspended Growth Attached Growth Anaerobic Anoxic Aerobic Anaerobic Physiochemical 15-11-2019 25
  • 27. Water Recycling Recycling of water means, reuse of water. It can be done in various manners. • Recycle of good quality of water back to process without treatment - Cooling water, ETP effluent used in chemical dosing / culture making system instead of fresh water being used. • Internal reuse of water - Discharge water of one process can be a starting water for another process by little modifications – Peroxide bleach water to be reused in scouring or Desizing, drain of selected Polyester dye-bath to use for cotton soaping. Mercerize wash liquor to be recycled in Bleaching process. • Recycle of effluent after full treatment – To recycle effluent after partial or full treatment & reuse in selective / all processes – ETP – PSF / ACF - Bag filter – Cartridge filter, - Membrane Filters 15-11-2019 27
  • 28. Membrane Filtration • A membrane is a selective barrier. it allows some things to pass through but stops others. Such things may be molecules, ions, or other small particles • Synthetic membranes are men made for selective usage as per requirements. (Mostly Polyamides / Ceramic / Carbon ) 15-11-2019 28
  • 29. Types of Membrane processes • Microfiltration (MF) • Ultrafiltration (UF) • Nanofiltration (NF) • Reverse Osmosis (RO) 15-11-2019 29
  • 31. Process Configuration - General Concentrate Product Feed Influent to the membrane module: Feed water / feed stream Liquid that passes through the semi-permeable membrane: permeate / product stream / permeating stream Semi-permeable membrane Liquid containing the retained constituents: Concentrate / retentate / reject / retained phase / waste stream 15-11-2019 31
  • 33. ETP with Membrane System 15-11-2019 33
  • 35. Filtration Mode terms - 15-11-2019 35
  • 39. Membrane Fouling Fouling : Potential deposition and accumulation of constituenst in the feed stream on the membrane. Biological fouling: Various microorganisms can deposit on membrane surface. Chemical Fouling: Controlled by disinfection of ww. Chlorination, Incorrect pH Avoid damage of the membrane by the disinfectant. Follow standard cleaning process given by suppliers 15-11-2019 39
  • 40. MBR (Membrane Biological reactor)  Consists of a biological reactor with suspended biomass and solids seperation by microfiltration membranes.  Nominal pore size 0.1 – 0.4 micron  MBRs can be used with: Aerobic / anaerobic suspended growth bioreactors to seperate treated ww from active biomass  Eliminates secondary clarification and operate at higher MLSS 15-11-2019 40
  • 42. 42 4) BMP, CMS & Zero waste Concept 15-11-2019
  • 43. BMP – Best Management Practices 43 Action to be taken for Reducing Water Consumption in Various Process Operations Process Suggested Action Steps to be Taken by Mill Pretreatment (Desizing, Scouring & Bleaching) 1) Try to recycle internally o Can explore possibility to use bleaching water in scouring & desize. o Can use water from washes of each process wherever possible through counter current method in soaper & also by storage in tank & re use. 1) Avoid overflow rinses o Overflow rinses consumes 40% more water as compared to smart washing techniques. 1) Combined Scouring & Bleaching process (Single bath scouring & Bleaching) o This will save water by 40% o Use counter current system for washing machines 1) Use enzyme base technology o One can reduce water & energy consumption by reduction in temperature & number of washes. o One can recycle this water back to process by topping-up of chemicals Dyeing 1) Use single bath dyeing for PC blends o Saving of water, power , energy & time 1) Use low salt dyes, 2) Use high exhaustion dyes, 3) Use of pad dry method instead of exhaustion method. o Approx. 205 to 60% water can be saved. Finishing 1) Use of standing bath for batch wise application of finishing chemicals o Can save 15% of water & chemicals 1) Can use hi suction slit on stenter o Can save 15% of water with compared to padding mangle. This also can reduce energy used in drying. 1) To recycle cooling water on sanforise finish o 80% of water saving (Used in cooling) Other areas Use equipment’s with low MLR o Can save 15% to 20% of water Recycle chiller plant water o Can save 80% of water Auto control of humidification room o Can save 25% to 30% of water Auto level control in processing machines o Can save 30% of water. Use nozzle with stop motion at the end of pipe during cleaning o Can save 25% of water 15-11-2019
  • 44. Equipment’s required for internal lab of ETP Frequency of the Analysis Instruments No of pcs pH Meter 1 pH Pen 3 TSS Meter 1 TDS Meter 1 DO Meter 1 BOD testing kits with Incubator 1 set COD testing kits with digester 1 set Oven 1 Digital weighing Balance with 0.1 mg accuracy and 10 gms accuracy 1 each Necessary Glass ware As per mentioned in test procedure Chemical reagents Parameters Frequency of Testing pH Once in a shift of 8 Hours TSS Once in a Shift of 8 hours TDS Once in a Shift of 8 Hours Dissolved Oxygen Once in a shift of 8 hours Color Once in a shift of 8 Hours Treatability study Once in a Day MLVSS/MLSS Once in a Day COD Once in a day BOD Once in a week15-11-2019 44
  • 45. Minimum Strength of Technical staff Minimum strength in ETP Post Education / Experience No of employees Environment Officer Graduate in Science / B.E. with 5 years’ experience 1 Shift Supervisor cum lab technician Graduate in Science 3 ( 1 per shift) Fitters ITI pass 3 ( 1 per shift) Wireman ITI Pass (Electrician) 1 Helpers Adult workers 1 per shift Necessary strength of relievers to be maintained for working on 7 days a week Environmental Management Cell (EMC)  Unit /Business Head  ETP In-charge and one officer  Process Operations Heads  Factory Manager 15-11-2019 45
  • 46. Operation and Maintenance of ETP and Water cycling system SR. NO. Process Unit Brief Purpose Activity and Preventive Maintenance Daily Weekly Monthly Yearly 1 Screen cum Oil and Grease Trap For removal Floatable matter from the effluent Cleaning and remove waste Greasing Twice in a month Replacement of non effective parts 2 Equalization Tank For ensuring continuous and uniform quality feed to the ETP system. Check floating material and remove Blow air at all Corners and mix well from Bottoms Check working of submersible pumps by taking out. Replacement of Non effective parts of pump and pipe lines. 3 Flocculation Tank For floc formation and mixing Treatability study, adjust chemical dosages Confirm pump working Calibration of dosing pumps , Cleaning of chemical tanks. Stirrer and gear box checking Replacement of non effective parts 4 Primary Clarifier For settling settable solids Check overflow water clarity, check sludge thickness while transferring to sludge tank RPM of rotating system, Check and Clear Chock- ups of Valve and Pipelines Full cleaning of Valves and pipe lines 5 Aeration Tank For reduction of organic load (BOD and COD) by aerobic process Check DO, pH, Smell MLSS Remove calculated numbers of diffusers and clean Cleaning of Headers Clean settled sludge at bottom and clean the tanks during yearly maintenance 6 Blowers and Diffused Aeration System For supplying air for mixing in the culture, Aeration Tank. Oil level check, Check smell Filter cleaning Check vibrations of Blowers, Current drawn. Oil replacement 7 Sludge collection/ Holding tank For storage of Sludge for further treatment. Sludge volume in tank and check impact of chemical on it. Cleaning of valves and pipe line. For chock-up Check De watering system and do maintenance work like change cloth of press, plates movements, etc.. Overhauling 15-11-2019 46
  • 47. 8 Culture Dosing System For activation aeration tank and Maintain the bacteria Population. pH, MLSS, MLVSS, DO Compare reports of aeration tank for MLSS and MLVSS Air blow at corners of tanks, Check Bacteria activity and growth Tanks cleaning 9 Pressure Sand Filter For Removal of Suspended solid, Back wash with air blow Overflow wash with chemical dose to clean sand. Check volume of sand Replace / top-up sand media 10 Activated Carbon filter For colour , dour and Trace Organic Matter. Back wash with air blow Overflow wash with chemical dose to clean sand. Check volume and Iodine value of media Replace / top-up media 11 Bag Filters Removal of suspended particles Change Bag filters, Check sticky material inside bag to understand any abnormal situation. Check leakage from "O rings" Assembly to check. Check and compare quality of replacement filters against original ones 12 UF system For removal suspended and colloidal impurities. Permeate and rejected effluent quality check. Check daily reports for DP (Differential Pressure) Follow CIP (Chemical in process system. Clean pipelines and follow flushing system Double CIP for better cleaning . Check the chemical consumption used for CIP during month and compare against previous few months Open membrane and check module (one from each raw) 13 RO-I System For recovering low TDS permeate for process pH, Operating Pressure, Quality of Ok and Rej effluent, Efficiency of membrane for the day CIP activity, Flushing , Temperature of effluent Compare reports of current week against previous weeks. Any abnormality to be studied. Check run and rest time of membrane Check dosing volume of CIP, DP, and leakages if any. Check chemical consumption and stock of chemicals used in CIP. Open membrane and check module (one from each raw) 14 RO-II System For recovering low TDS permeate for process 15 RO-III System For recovering low TDS permeate for process 16 Evaporator System all calenderias for evaporation of effluent and concentrate same Check Specific Gravity of effluent from last CIGAR/ Evaporator/ Calendria. Check steam pressure, Vacuum and temperature in CIGAR, Check any chock- ups in tubes. Cleaning and Flushing of water and chemicals if needed. Cleaning of tubes by scrubber and High Pressure pumps / jet pumps 15-11-2019 47
  • 48. 17 Crystallizer and Pusher To allow crystal formation and removal of sludge Temperature of vessel, Quality of crystals Vacuum, Cleaning and Flushing Cleaning of tanks by chemical 18 ATFD Agitated Thin Film Dryer to remove excess of moisture Steam pressure Cleaning and flushing. Over hauling 19 Cooling Towers To maintain temperature of effluent for better crystallization Inlet and outlet temp of water Circulation and cooling fan Cleaning Maintenance as per suppliers 20 Tanks To store water or Effluent Levels, pH Leakage from tank Check quality of water / effluent from top and bottom of each tank Cleaning by Pressure jets 21 Electrical Panel boards and Motors Normal electrical maintenance - check current drawn etc… Loose connections, Fix temp. Connections if any. Clean panel boards from inside Normal electric checking as per schedule, 22 Lab Equipments As per manual Follow guidelines as per manual. Calibration of equipments Compare once with outside lab for test reports and compare process, and deviation in reports. 23 Reports Check daily log sheet Check equipment working sheet. Compare reports of month and compare against previous months. For Effluent quality, Volume, Cost and disposal of sludge, Chemical consumption. Any change in regulations. 24 Training Check working of operators provide training for any bad habits. 25 Submissions of legal documents Check actual against figures in Consent to operate. Submit application if any change in equipments, system, procedure.15-11-2019 48
  • 49. Operation and Maintenance of ETP Do’s o Ensure proper and optimum conditions of each section of ETP o Avoid fluctuation in effluent flow and pollution load o Ensure proper addition of nutrients in aeration tank. o Maintain required level of MLSS/MLVSS concentration during biological treatment. o Maintain desired level of DO in the aeration tank (1.5 to 2.2 mg/l). o Ensure periodic and timely withdrawal of sludge from the clarifiers and settled bio mass from aeration tanks. o Proper maintenance of electric motors, pumps and blowers with diffuser system. etc. o Use of power saving technique in ETP operation are suggested  Optimization of blower speed (by VFD) in aeration tank linked with DO in aeration tank  pH control (Dosing of acid) to be linked with pH meter reading of effluent. o Record keeping and Documentation o Fresh water consumption, effluent discharge, effluent analysis, and ETP chemical and utility (like steam and power) consumption to be properly recorded. Dont’s o It is essential to maintain constant flow of effluent o Never fluctuate effluent flow beyond margin of +/- 10% o Never allow effluent with alkaline pH to enter in Bio-mass tank o Never dose chemicals without treatability study this should be performed daily once o Never keep alternate pumps/motors in breakdown condition. o Stabilize chemical supplier (especially for ETP) . Avoid changing them frequently. o Never Skip any step in SOP back wash system for filters o Never allow iron, chlorine in membrane. o Never stop circulation of effluent and air from blower in bio-mass tank o Never use spent acid for neutralization o Follow proper SOP while RO is going to be stopped for more than 24 hours. 15-11-2019 49
  • 50. Best Management Practices- Action plan to reduce consumption of NPO NPO means non productive output The Raw material , dyes and chemicals, water fuel, power, manpower are basic inputs in textile industries. The input consumed is not being sold along with end product is NPO. One must try to reduce NPO, which can reduce cost and improve environmental aspects A. Reduction in Water Consumption  Fixing leakages, repair faulty valves,  Study and reduce diameter of water pipe line  Use pressurized water spray during cleaning of equipments ( Use nozzles at the end)  While cleaning, one can apply knob to control water volume (On/Off Knob)  Reduce MLR in batch wise process  Reduce overflow washing steps and select smart wash system.  In case of continuous process reduce level of water in selected compartments of m/c and also control pressure of water during overflow.  Use counter current wash system in washing ranges.  Internal recycling of process water in selected process, Back wash water of softener plant can be used in preparation of ETP chemicals, floor cleaning, Toilet flushes etc..  Turn off running taps and hoses (especially in toilets and also at cleaning area of production section)  Turn off water valves when machines are not running  Reduce the number of processing steps  Optimize process water by several trials  Recycle cooling water  Re use process water in selected processing steps  Using water efficient process and equipment 15-11-2019 50
  • 51. Best Management Practices- Action plan to reduce consumption of NPO B. Reducing Chemical Consumption  Recipe optimization  Control of dosing chemicals  Pre screen chemicals and raw materials (study MSDS)  Chemical substitution ( by less toxic one)  Correct storage and handling (Generally chemical has storage instructions and by following storage conditions, one can reduce possibility of degradation on storage  Chemical recovery and reuse  Process changes  Improve scheduling of dyeing machines and reduce cleaning of equipment C. Reduce Energy Consumption (Fuel and Power) Good housekeeping. Maintenances of  Pressure Reducing Valves, Steam traps,  Escape of energy by Exhaust control of Hot equipments  Auto temperature control devices  Boiler blow-down by linked by TDS  Energy saving by right use of Heat Exchanger  Use of Heat from hot drains from process  Proper insulation of hot lines (Water, Steam and Condensate steam), Boiler feed tank. Hot water storage tanks Etc...  Auto control of ID/FD fans depending upon O2 level of flue gases through chimney.  Reduce cooling steps in process.  Avoid direct steam by Installing heat exchangers (indirect steam heating)  Energy audit by Boiler engineers and implement suggestions. Use Invertors drives wherever is possible  Blower speed in aeration tank of ETP  Speed control of stenter motors.  Pumps of Pressurized water line to be regulated by pressure switch. Maintenance and cleaning of all panel boards Energy audit by electrical engineer and implement all suggested options. Switch over to power saving lights. Auto level controllers for UG and OH water storage tanks 15-11-2019 51
  • 52. Water saving techniques in the textile process house  Work practices and engineering control  Flow control on washers.  Flow control on cooling water (use minimum necessary).  Counter current washing.  High extraction squeezers.  Recycle and reuse.  Detection and repair of leaks.  Detection and repair of defective toilets and water coolers  Reusing uncontaminated/first quality water  Replacing overflow washes by captive washing  Reusing wash water by counter current flow washing  Reuse of wash water for cleaning purposes  Back gray blanket washing.  Screen and squeegee cleaning.  Color shop cleanup.  Equipment and facility cleaning. A typical preparation department may also reuse wash water as follows:  Reuse scour rinses for desizing. This is will save water by 4 lit/kg of the fabric  Reuse mercerizer wash water for scouring and wherever possible. This will save the use of fresh caustic in scouring, bleaching and also in reactive dye fixation process. One should ensure the adjustment of the caustic concentration.  Reuse bleach wash water for scouring.  Reuse water-jet loom wash water for desizing.  Recycle kier drains to the saturator  Final Rinse reuse as Loading Bath for Next Lot  Reuse of neutralization bath 15-11-2019 52
  • 53. Water saving by 3R concept (reduce, reuse, and recycle) Sr. no. What to do Where to do 1 Reduce Water consumption due to wastage Audit of the process house, Modify the washing process (over flow/running wash to fill-wash and drain technique) 2 Reuse the uncontaminated/ first quality water as it is Cooling water, steam condensates etc 3 Reuse second-hand quality water (process water) without treatment Neutralisation baths, counter current washing, 4 Reuse second-hand quality water (process water) with filtration or little modification Neutralisation baths, pastel to light shades post soaping hot wash baths cane reused for the other or same process, cleaning purpose 5 Recycle effluent after partial treatment Water after Nano filtration can be used for reactive dyeing as it contains the only salt. Also, it can be used for cleaning purpose 6 Recycle after full treatment RO water suitable for all the process.15-11-2019 53
  • 54. . Contact +91 7768883361 harane27@gmail.com Design Sustainability ForFutureGrowth Join Hands with Environment 5415-11-2019
  • 55. Sustainable Development Take care of mother earth with social responsibility and environmental protection. This is our contribution to a better future for us and for coming generations It simply means: Give back what you take!15-11-2019 55
  • 56. Thank you . FOLLOW THE NATURE RULE 15-11-2019 56