tomas pivoras - cp assessment "vernitas"1 case study textile company cleaner production...
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Tomas Pivoras - CP assessment "Vernitas" 1
Case Study Textile company
Cleaner Production Assessment
Tomas Pivoras
Kaunas University of Technology
Kaunas, Lithuania
Tomas Pivoras - CP assessment "Vernitas" 2
Information about “Vernitas”
Products: Bulk, polyacryl nitrile (PAN) yarns;
Production capacity: 6.000 tons of yarns per year;
Market: export to EU approximately 70%.
Tomas Pivoras - CP assessment "Vernitas" 3
Production processes
Yarn Preparation, sub-processes: Stretch-breaking Rebreaking Intersecting Finishing
Spinning Twisting BulkingDyeing
Tomas Pivoras - CP assessment "Vernitas" 4
Auxiliary processes
VentilationBoiler house – heating and steam
productionWater preparationCompressed air production…
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Methodology
A ‘top-down’ investigation The company was analyzed on three levels:
Level 1: Main data for black box - entire company; Level 2: Main process data (building a ‘layer cake’); Level 3: Detailed data and measurements for one or two
specific processes.
In the initial phase focus on level 1 and 2. Later level 3 data were collected/measured for
the 2-3 focus areas.
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Energy balance
Yarn preparation
7,4%
Bulking8,1%
Dyeing2,5%
Elec. heaters4,4%
Lighting5,0%
Twisting22,9%
Spinning22,1%
Ventilation21,2%
Compressed air
6,4%
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Heat consumption
Bulking, steam35%
Ventilation, steam18%
Dyeing, steam16%
Yarn prep., steam
9%
Radiators, hot water
22%
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Energy savings (electricity savings)
Electricity savings Elec. savings
Savings Investment Pay back
Units kWh/year EUR/ year
EUR years
Optimisation of humidification system
120,000 7 800* 30 000 3.8
Installation of variable speed drives on fans
551,300 29 000 68 000 2.4
Total 671,300 36 600 98 000 2.7
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Energy savings (heat recovery )
Heat recovery Heat savings
Savings Investment Pay back
Units kWh/year EUR/ year
EUR years
Modernisation of heating substation
160,000 7 800* 40 600 5.2
Heat recovery on air compressors
303,300 7 500 15 000 2.0
Recycling of steam condensate in dyeing dept.
290,000 9 500* 14 500 1.5
Total 753,300 25 000 70 000 2.8
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Optimisation of the humidification system - replacement of the spraying nozzles Savings by reduction of consumption of both water and compressed air.
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Installation of variable frequency drives on fans
Significantly increased energy efficiency of the fans at part load (50-90%), which was approx. 75% of the operation time.
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Heat recovery in the compressed air system
N e w s t o r a g e
E x i s t i n g
s t o r a g e
C o m p r e s s o r
6 b a r
C o m p r e s s o r
3 b a r
C o m p r e s s o r
6 b a r
V 6 0 m / s
t = 5 0 - 7 0 C
3
f l o o r i n
t e c h n i c a l
A i r t o t h e
s u m m e r t i m e
F a n
V 6 0 m / s
t = 1 0 - 1 5 C
F a n
3
6 0 m
10,5
m
T e c h n i c a l f l o o r
Tomas Pivoras - CP assessment "Vernitas" 13
Recycling of steam condensate in dyeing dept.
Clean condensate
Wat
er to
dra
in
Dyeing block
Air Over flow Filter
Hot water
Steam
To utilization
Clean condensate Hot water
from drying block
* - pump must have static pressure af condensate (~4 m) Fe2O3
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Main Cleaner Production projects
1)Treatment of waste water from dyeing department
2)Possibility of recycling the waste water from dyeing department
3)Reduction and substitution of chemicals used in dyeing processes
4)Recycling of cooling water from spinning machines
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Minimisation/optimisation of chemicals used1. investigate the use of the chemicals
2. investigate the possibilities to omit the use of the chemicals
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)
4. investigate the possibilities to substitute the chemicals with alternatives that have less negative impacts on the environment.
Vernitas:
•160 different chemicals
•Total quantity of 26,419 kg.
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Zinc emission to effluent
Stop treating the effluent for removal of zinc (Zn)
Find the source of the zinc (Zn) emission in the effluent.
It is much cheaper and more environmental friendly to change the source
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Dyes containing heavy metals Name of chemical Concentration
of Zinc (Zn)Concentra-tion of Cop-per (Cu)
Concentra-tion ofChromium(Cr)
Concen-tration ofCobalt(Co)
Astrazon Blau BG 200% 4.2%
Astrazon Blau FGGL 300% 01 4.0%
Astrazon Rot FBL 200% In German ?
Astrazon Blau FGRL 200% 01 4.1%
Cibacron blue FN_R 4.6%
Lanaset Red 2B 1.3%
Lanaset grey G 2.5% 0.79%
Lanaset orange RN 1.1%
Lanaset BORDEAUX B 2.3% 0.2%
Lanaset BROWN B 2.8%
Lanaset BLAK B 3.2%
Irgalan BORDEAUX EL 200% 3.7%
Maxilon Blue SL 200% 4.1%
Maxilon Goldyellow GL granules 200% (nr 148 6946)Maxilon Red GRL granules 200% (nr 1462977)Maxilon Blue GRL granules 300% (nr 1463033)Maxilon blue 5G granules 200% (nr 1486924)
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Continual improvements:
Elimination/reducing of: dyestuff containing heavy metals
azo-dyestuff, which splits off carcinogenic amines.
toxic chemicals (T or Tx marked according to EU regulations)
hazardous surfactants giving rise to environmental concerns do to their poor biodegradability, their toxicity and potential to act as endocrine disrupters.
hazardous complexing agent
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Wastewater from dyeing department
Wastewater quantity
[m3/h] [m3/d] [m3/month] [m3/year]
Wastewater forreuse
2.0 50 1,100 13,000
Wastewater fordischarge
4.2 100 2,300 27,500
Total waste-water
6.2 150 3,400 40,500
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Membrane filtration
Feed tank
Feedpump
Recirculationpump
Membranemodule
Back pressurevalve
Concentrateoutlet
Permeateoutlet
Flow controllervalve
Investment:
EUR. 250 000.
Pay back:
17.5 years