Tp Case Study L


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Tp Case Study L

  1. 1. Case Study T extile company Cleaner Production Assessment Tomas Pivoras Kaunas University of Technology Kaunas, Lithuania
  2. 2. Information about “Vernitas” <ul><li>Products: </li></ul><ul><ul><li>Bulk, polyacryl nitrile (PAN) yarns; </li></ul></ul><ul><li>Production capacity: </li></ul><ul><ul><li>6.000 tons of yarn s per year; </li></ul></ul><ul><li>Market: </li></ul><ul><ul><li>export to EU approximately 70%. </li></ul></ul>
  3. 3. Production processes <ul><li>Yarn Preparation, sub-processes: </li></ul><ul><ul><li>Stretch-breaking </li></ul></ul><ul><ul><li>Rebreaking </li></ul></ul><ul><ul><li>Intersecting </li></ul></ul><ul><ul><li>Finishing </li></ul></ul><ul><li>Spinning </li></ul><ul><li>Twisting </li></ul><ul><li>Bulking </li></ul><ul><li>Dyeing </li></ul>
  4. 4. Auxiliary processes <ul><li>Ventilation </li></ul><ul><li>Boiler house – heating and steam production </li></ul><ul><li>Water preparation </li></ul><ul><li>Compressed air production </li></ul><ul><li>… </li></ul>
  5. 5. Methodology <ul><li>A ‘top-down’ investigation </li></ul><ul><li>The company was analyzed on three levels: </li></ul><ul><ul><li>Level 1: Main data for black box - entire company; </li></ul></ul><ul><ul><li>Level 2: Main process data (building a ‘layer cake’); </li></ul></ul><ul><ul><li>Level 3: Detailed data and measurements for one or two specific processes. </li></ul></ul><ul><li>In the initial phase focus on level 1 and 2. </li></ul><ul><li>Later level 3 data were collected/measured for the 2-3 focus areas. </li></ul>
  6. 6. Energy balance
  7. 7. H eat consumption
  8. 8. Energy savings ( electricity savings ) 2.7 98 000 36 600 671,300 Total 2.4 68 000 29 000 551,300 Installation of variable speed drives on fans 3.8 30 000 7 800* 120,000 Optimisation of humidification system years EUR EUR/ year kWh/year Units Pay back Investment Savings Elec. savings Electricity savings
  9. 9. Energy savings ( heat recovery ) 2.8 70 000 25 000 753,300 Total 1.5  14 500 9 500* 290,000 Recycling of steam condensate in dyeing dept. 2.0 15 000 7 500 303,300 Heat recovery on air compressors 5.2 40 600 7 800* 160,000 Modernisation of heating substation years EUR EUR/ year kWh/year Units Pay back Investment Savings Heat savings Heat recovery
  10. 10. Optimisation of the humidification system - replacement of the spraying nozzles <ul><li>Savings by reduction of consumption of both water and compressed air. </li></ul>
  11. 11. Installation of variable frequency drives on fans <ul><li>S ignificantly increased energy efficiency of the fans at part load (50-90%), which was approx. 75% of the operation time. </li></ul>
  12. 12. Heat recovery in the compressed air system
  13. 13. Recycling of steam condensate in dyeing dept.
  14. 14. Main Cleaner Production projects <ul><li>1) Treatment of waste water from dyeing department </li></ul><ul><li>2) Possibility of recycling the waste water from dyeing department </li></ul><ul><li>3) Reduction and substitution of chemicals used in dyeing processes </li></ul><ul><li>4) Recycling of cooling water from spinning machines </li></ul>
  15. 15. Minimisation/optimisation of chemicals used <ul><li>1. investigate the use of the chemicals </li></ul><ul><li>2. investigate the possibilities to omit the use of the chemicals </li></ul><ul><li>3. investigate the possibilities to reduce the use of chemicals (this step should not be considered if the chemicals are evaluated to be hazardous, unless substitution is not possible) </li></ul><ul><li>4. investigate the possibilities to substitute the chemicals with alternatives that have less negative impacts on the environment. </li></ul><ul><li>Vernitas: </li></ul><ul><li>160 different chemicals </li></ul><ul><li>Total quantity of 26,419 kg . </li></ul>
  16. 16. Zinc emission to effluent <ul><li>Stop treating the effluent for removal of zinc (Zn) </li></ul><ul><li>Find the source of the zinc (Zn) emission in the effluent. </li></ul><ul><ul><li>It is much cheaper and more environmental friendly to change the source </li></ul></ul>
  17. 17. Dyes containing heavy metals
  18. 18. Continual improvements: <ul><li>Elimination/reducing of: </li></ul><ul><li>dyestuff containing heavy metals </li></ul><ul><li>azo-dyestuff , which splits off carcinogenic amines. </li></ul><ul><li>toxic chemicals (T or T x marked according to EU regulations) </li></ul><ul><li>hazardous surfactant s giving rise to environmental concerns do to their poor biodegradability, their toxicity and potential to act as endocrine disrupters. </li></ul><ul><li>hazardous complexing agent </li></ul>
  19. 19. Wastewater from dyeing department
  20. 20. Wastewater treatment plant
  21. 21. Membrane filtration <ul><ul><ul><li>Investment: </li></ul></ul></ul><ul><ul><ul><li>EUR. 250 000. </li></ul></ul></ul><ul><ul><ul><li>Pay back: </li></ul></ul></ul><ul><ul><ul><li>17.5 years </li></ul></ul></ul>
  22. 22. Reuse of cooling water from spinning machines <ul><li>Total use of water is about: </li></ul><ul><ul><li>24,000 m 3 / year </li></ul></ul><ul><li>Total installation cost is: </li></ul><ul><ul><li>818 EUR. </li></ul></ul><ul><li>Simple payback period is: </li></ul><ul><ul><li>1.67 year. </li></ul></ul><ul><ul><li> ( not including usage of electricity by water pump and water pumping from well ) </li></ul></ul>