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
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
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
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
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
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
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
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