towef0 paris - meeting 6 - pag. 1 towef0 project meeting paris, 2-3 october 2003

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Paris - Meeting 6 - Pag. 1

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Project meeting

Paris, 2-3 October 2003

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WORKPACKAGE 02

Quantitative evaluation of GEP application. Case studies in the synthetic fibres and silk

industries

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ACTIVITIES OF THE REPORTING PERIOD(MARCH 2003 - OCTOBER 2003)

WP02.02.3 Process identification

WP02.03.3 Collection and elaboration of process data

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The selected five industries

Data were collected using a methodology consisting in an environmental audit inside the factory and to the issuing of a document called PIDACS.

Company NamePredominant

productProduct for LCA

%ge on production of LCA product

I06 Xxxxx CO-PES fabric FLAX-PES fabric 16%

I09 Xxxxx Silk yarn Silk yarn 75%

I02 Xxxxx Viscose fabric Viscose fabric 27%

I15 Xxxxx Silk fabric Silk fabric 59%

I04 Xxxxx Viscose fabric Viscose fabric 35%

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PIDACS results – I15 company

Fibre Type(%) on total

weightprocessed

meterskg per linear

meterprocessed kg

SILK (SF) Fabric 58,73 4569810 0,36 1645132

PES (PF) Fabric 14,44 1123517 0,36 404466

SYNTHETIC (SYF) Fabric 17,24 1341010 0,36 482764

NATURAL (OF) Fabric 9,59 746332 0,36 268680

TOTAL 100 7780669 2801041

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PIDACS results – I15 companyWater consumption& Water flow chart

Mass balances: W1+W2=W3+W4+W5;

W4=S*(W1+W2);W5=E*(W1+W2-D2);

W5=S1+S2+S3;D3=W6;

D1=D2+D3.

Potable water Industrial water Well water

Domestic use

Fire fighting plant

Rapid filtration

Storage

Storage

Production

Cooling water

recovery

Steam production

Condensate

recovery

Sewer

Screening

S1 S3S2

Iron removal

Softening Demineralizing

Backwashing

Regeneration

Regeneration

Regeneration

Equalization tank

W1W2

W3

W4

W5

W6

D3 D2

D1

D2

D2

(W1)

(W3)

(W3)

(W3)

(W4) (S3)

D2

W3

Legenda: Supply line:Feedback line:Discharge line:Flow-meter:

W4

Water type Source Treatment Use Quantity [m3/yr]

W1 industrial w ater rapid f iltration production 351380

W2 w ell w ater de-ironing production 224004

W3 W1+W2 untreated production 575384

W4 W1+W2 softening production 155929

W5 W1+W2 demineralisation steam production 30121

W6 potable w ater untreated domestic use 8655

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PIDACS results – I15 company Department water consumption

Preparation and printing departments are the most water requiring (about 16% and 68% on total).

Among preparation, “continuous scouring” consumption is about the 97% on department and about the 15% on total consumption (86646 m3).

Among printing, “printing equipment washing” consumption is about the 80% on department and about the 54% on total consumption (306302 m3).

TW m3 tot TW m3 [%] TW l/mt TW l/kgGeneral facilities 47165 8,36 6,06 16,84

Preparation 89393 15,84 20,78 57,72

Dyeing 21985 3,90 7,17 19,93

Printing 384580 68,15 156,58 434,95

Steaming 1722 0,31 0,70 1,95

Fabric washing 16616 2,94 6,77 18,79

Finishing 2818 0,50 0,43 1,20

Total 564279 100 198,49 551,37

Total 2001-measured 575384

Difference 11105

Total water consumption

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Department water discharges

The total organic load generated by preparation processes is about 46% on total (169078 kg as COD), for an average COD concentration equal to 1902 mg/l; load generated by “continuous scouring” processes is equal to 161713 kg as COD (about 96% on department, 44% on total), for an average COD concentration equal to 1878 mg/l.

The total organic load generated by printing processes is about 42% on total (157022 kg as COD), for an average COD concentration equal to 409 mg/l; load generated by “printing accessories washing” is equal to 82076 kg as COD (about 52% on department, 22% on total), for an average COD concentration equal to 268 mg/l.

D2 m3 tot D2 m3 [%] COD [mg/l] COD [kg] COD [%]General facilities 1891 0,37 95 180 0,05

Preparation 88875 17,29 1902 169078 45,61

Dyeing 21985 4,28 614 13501 3,64

Printing 383952 74,69 409 157022 42,35

Steaming 1116 0,22 300 335 0,09

Fabric washing 15791 3,07 295 4664 1,26

Finishing 467 0,09 55628 25957 7,00

Total 514078 100 721 370737 100

Total 2001-measured 525183 627 329290

Difference 11105 -41447

Discharge type D2

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Fibre Type(%) on total

weightprocessed

meterskg per linear

meterprocessed kg

Acetate (AF) Fabric 1,23 446000 0,14 62440

Bemberg (BF) Fabric 15,59 5642000 0,14 789880

Mix acetate (MF) Fabric 29,13 10545000 0,14 1476300

Viscose (VF) Fabric 35,06 12688000 0,14 1776320

Other (OF) Fabric 18,99 6873000 0,14 962220

TOTAL 100 36194000 5067160

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PIDACS results – I04 companyWater consumption& Water flow chart

Water type Source Treatment Use Quantity [m3/yr]

W1 industrial w ater f iltration production 229112

W2 w ell w ater+W1+W4 untreated production 378512

W3 W2 softening production 151503

steam production 36233

W4 discharge type D4 conditioning for nano-filtration 19344

W5 w ater type W4 nano-filtration production 15750

W6 potable w ater untreated domestic use 4413

Potable water Industrial water Well water

Domestic use

Fire fighting plant

Filtration

Storage

Storage

Production

Cooling water

recovery

Steam production

Condensate

recovery

Sewer

Screening

S1

Softening

Backwashing

Regeneration

Equalization tank

W1

W2

W3

W6

D3 D3

D1

D3

D3

(W2)

(W2)

(W2)

(S1)

Mass balances: W2=Well water+W1+W5;

W3=S*W2;S1=E*W3;

W5=S1+S2+S3;D4=W4;D2=W6;

D1=D2+D3.

D3

W2

Legenda: Supply line:Feedback line:Discharge line:Flow-meter:

W2

Storage

W5

D2

Membrane treatment

Conditioning

W4

D4

Backwashing

(W2)

A quantity of water estimated equal to 15750 m3 (2,5% on total consumption) is recovered by means of a membrane nano-filtration system (W5 type)!!!!

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PIDACS results – I04 company Department water consumptions

Preparation department operations require a quantity of water of about 37% on total (216608 m3); among these, “continuous scouring” process requires 81598 m3 (about 38% on department consumptions, 14% on total).

Dyeing department operations require a quantity of about 53% on total (308938 m3); among these, “dark reactive dyeing” processes require 49308 m3 (about 16% on department, 8,5% on total).

TW m3 tot TW m3 [%] TW l/mt TW l/kgGeneral facilities 54132 9,31 1,50 10,68

Preparation 216608 37,27 5,578 39,84

Dyeing 308938 53,15 6,067 43,33

Finishing 1579 0,27 0,051 0,36

Total 581256 100 13,19 94,22

Total 2002-measured 579887

Difference -1369

Total water consumption

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PIDACS results – I04 company Department water discharges

Discharges coming from rinsing steps of “direct dyeing” processes are sent to membrane nano-filtration unit for water recovery (type D4: 19344 m3), the average COD concentration of this stream is equal to 140 mg/l.

The total organic load generated by preparation processes is about 52%on total (232551 kg as COD), for an average COD concentration equal to 1081 mg/l; the total organic load generated by “continuous scouring” is equal to 159666 kg as COD (about 69% on department discharges, 38% on total), for an average COD concentration equal to 1993 mg/l.

The total organic load generated by dyeing processes is about 47% on total (210194 kg as COD), for an average COD concentration equal to 730 mg/l. The total organic load generated by “dark reactive dyeing” is equal to 48373 kg as COD (about 23% on department, 11% on total), for an average COD concentration equal to 1267 mg/l.

D3 m3 tot D3 m3 [%]COD

[mg/l] COD [kg] COD [%] D4 m3 tot D4 m3 [%]COD

[mg/l] COD [kg]

General facilities 21768 4,15 146 3188 0,71 0,00 0,00 0,00 0,00Preparation 215136 40,99 1081 232551 52,14 0,00 0,00 0,00 0,00Dyeing 287949 54,86 730 210194 47,13 19344 100,00 140 2707Finishing 29 0,01 2276 65 0,01 0,00 0,00 0,00 0,00Total 524882 100 850 445998 100 19344 100 140 2707

Discharge type D4Discharge type D3

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- PIDACS data elaboration -Validity of PIDACS application to textile industry:

Water consumptions

CompanyWater

consumption m3 (measured)

Water consumption m3

(estimated)

Difference on measured

value m3

Difference on measured value %

I06 93264 94035 771 0,82%

I09 291568 291570 2 0,00%

I02 137575 137636 61 0,04%

I15 575384 564279 -11105 -1,90%

I04 579887 581256 1369 0,20%

I15 company value is under-estimate and the difference is of about 2%; in the other cases values are over-estimated, but the difference is less than 1%.

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Water discharges

CompanyWater

discharges m3 (measured)

Water discharges m3

(estimated)


value m3


I06 85295 85599 304 0,36%

I09 267619 266608 -1011 -0,38%

I02 132014 131996 -18 -0,01%

I15 525183 514078 -11105 -2,10%

I04 538988 524226 -14762 -2,60%

The higher difference on estimation is for I04 company (about 2,5%); in the other cases the difference is +/- 0,4%.For I15 company, the difference between water discharges is the same that the value found for water consumptions (about 11000 m3)

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COD concentration

Company

COD concentration

mg/l (measured)

COD concentration

mg/l (estimated)


value mg/l


I06 931 1097 166 17,80%

I09 1600 1872 272 17,00%

I02 967 1112 145 15,00%

I15 627 721 94 15,00%

I04 835 850 15 1,80%

Values are over-estimated in all cases; for I04 company the difference is about 2%, in the other cases difference is of about 15-18%.

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- PIDACS data elaboration -Comparison of process data: Company 1/2

Department Company FibreTotal water

m3% on total

consumption

Specific consumption

l/kgCOD kg

% on total load

Specific load gCOD/kg

I06 F-PES-C/PES-F/PES-S/PES 31324 33,31 60,71 440 0,47 0,85

I09 S-S/O-N-PES-A 35982 12,34 33,32 41386 8,29 38,33

I02 C-V-S-W-PA-PES-S/A 7571 5,50 18,21 431 0,29 1,04

I15 SF-SYF-PF-OF 47165 8,36 38,06 180 0,05 0,15

I04 AF-BF-MF-VF-OF 54132 9,31 10,68 3188 0,71 0,63


I09 S-S/O-N-PES-A 157883 54,15 93,91 384199 76,99 228,52

I15 SF-SYF 89393 15,84 57,72 169078 45,61 109,17

I04 AF-BF-MF-VF-OF 216608 37,27 39,84 232551 52,14 42,78


I09 S-S/O-N-PES-A 86425 29,64 94,74 58058 11,63 63,64

I15 SF-SYF-PF-OF 21985 3,90 19,93 13501 3,64 12,24

I04 AF-BF-MF-VF-OF 308938 53,15 43,33 210194 47,13 29,48

I02 C-V-S-W-PA-PES-S/A 57269 41,61 138,66 110023 74,97 266,39

I15 SF-SYF-PF-OF 384580 68,15 434,95 157022 42,35 177,59

I02 C-V-S-W-PA-PES-S/A 765 0,56 1,84 25 0,02 0,06

I15 SF-SYF-PF-OF 1722 0,31 1,95 335 0,09 0,38

I02 C-V-S-W-PA-PES-S/A 71713 52,10 172,48 36159 24,64 86,97

I15 SF-SYF 16616 2,94 18,79 4664 1,26 5,27


I09 S-S/O-N-PES-A 11280 3,87 10,58 15386 3,08 14,43

I02 C-V-S-W-PA-PES-S/A 318 0,23 1,18 121 0,08 0,45

I15 SF-SYF-PF-OF 2818 0,35 1,20 25957 7,00 11,04

I04 AF-BF-MF-VF-OF 1579 0,27 0,36 65 0,01 0,02

General Facilities

Preparation

Dyeing

Printing

Steaming

Fabric Washing

Finishing

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- PIDACS data elaboration -Comparison of process data: Company 2/2

General Facilities consumptions vary from 10% to 30% on the total; discharged load is less than 0,5% on the total (I09 load is higher due to the membrane treatment).

Preparation consumptions are 40% as average on the total; discharged loads is 60% on the total as an average.

Dyeing consumptions are 30% on total as an average; discharged load is 30% on total.

Printing consumptions are 50% on total as an average; discharged load is 60% on total.

Fabric Washing consumptions vary from 3% to 50%; discharged load vary from 2% to 25% on total.

Finishing consumptions are less than 5% on total (0,45% as an average); discharged load is less than 10% on total (5% as an average).

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- PIDACS data elaboration -Comparison of process data: General Facilities 1/2

Process FibreTotal water

m3% on total

consumption


l/kgCOD kg

% on total load


E.1:Filtration F-PES-C/PES-F/PES-S/PES 2105 2,24 4,08 21 0,02 0,04

E.2:Softening F-PES-C/PES-F/PES-S/PES 15407 16,38 29,86 154 0,16 0,30

E.3:Steam production F-PES-C/PES-F/PES-S/PES 8717 9,27 16,89 40 0,04 0,08

E.1:Filtration S-S/O-N-PES-A 408 0,14 0,38 4 0,00 0,00

E.2:Softening S-S/O-N-PES-A 6497 2,23 6,02 65 0,01 0,06

E.3:Steam production S-S/O-N-PES-A 23734 8,14 21,98 0 0,00 0,00

E.5: Membrane ultrafiltration S-S/O-N-PES-A 63 0,02 0,06 40493 8,11 37,50

E.1: Softening C-V-S-W-PA-PES-S/A 693 0,50 1,67 35 0,02 0,08

E.2: Steam production C-V-S-W-PA-PES-S/A 2918 2,12 7,02 0 0,00 0,00

E.1: Rapid filtration SF-SYF-PF-OF 1111 0,20 0,90 95 0,03 0,08

E.2: De-ironing SF-SYF-PF-OF 51 0,01 0,04 6 0,00 0,00

E.3: Softening SF-SYF-PF-OF 478 0,08 0,39 52 0,01 0,04

E.4: Demineralisation SF-SYF-PF-OF 251 0,04 0,20 27 0,01 0,02

E.5: Steam production SF-SYF-PF-OF 45274 8,02 36,54 0 0,00 0,00

E.1: Rapid filtration AF-BF-MF-VF-OF 16706 2,87 3,30 1432 0,32 0,28

E.2: Softening AF-BF-MF-VF-OF 862 0,15 0,17 93 0,02 0,02

E.3: Steam production AF-BF-MF-VF-OF 36233 6,23 7,15 0 0,00 0,00

E.4: Conditioning AF-BF-MF-VF-OF 101 0,02 0,02 39 0,01 0,01

E.5: Membrane nanofiltration AF-BF-MF-VF-OF 230 0,04 0,05 1624 0,36 0,32

Filtration 5083 1,36 2,16 388 0,09 0,10

Softening 4788 3,87 7,52 80 0,05 0,10

Steam production 23375 6,76 17,92 8 0,01 0,02

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- PIDACS data elaboration -Comparison of process data: General Facilities 2/2

Filtration is used as a pre-treatment for Industrial Aqueduct water; the quantity of water amount required for this process (due to rinsing and backwashing steps) varies from 0,15% to about 3% on total. The percentage on total generated load is less than 0,1%, as an average value.

Softening process is necessary to operate with high temperature waters and to generate steam (demineralisation process has been observed only in I15 company): the average quantity of water amount required for this process is about 4% on total. The percentage on total generated load is less than 0,05%, as an average value.

The average quantity of softened (de-mineralised) water required to generate steam is about 7% on total.

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- PIDACS data elaboration -Comparison of process data: Preparation 1/2

Company Process Fibre Total kg Total water m3% on total

consumption


l/kgCOD kg

% on total load


I06 I06 scouring total F-PES-C/PES-F/PES-S/PES 165731 9314 9,90 56,20 9180 9,78 55,39

I06 I06 desizing total PES-C/PES-F/PES 88256 7317 7,78 82,91 24469 26,06 277,25

I06 I06 double scouring total F-PES-C/PES-F/PES-S/PES 56598 8549 9,09 151,04 17355 18,48 306,63

I06 I06 special scouring total F-PES-C/PES-F/PES 32934 1652 1,76 50,16 6999 7,45 212,50

I06 I06 bleaching total F-C/PES-F/PES-S/PES 32746 3052 3,25 93,20 3622 3,86 110,61

I06 F.8.1: Barking in torpedo at 110-130°C PES 5341 579 0,62 108,41 1171 1,25 219,21

I09 I09 yarn scouring total S-N-PES-A 1323663 36973 12,68 27,93 63768 12,78 48,18

I09 I09 fabric scouring total S-S/O 94076 15920 5,46 169,23 120844 24,22 1284,53

I09 F.2: Polymer charge S 198387 5048 1,73 25,44 43770 8,77 220,63

I09 I09 fabric continuous scouring total S-S/O 65130 32196 11,04 494,33 25651 5,14 393,85

I15 I15 continuous scouring total SF-SYF 1434654 86646 15,36 60,39 161713 43,62 112,72

I15 I15 scouring total SF 114116 2747 0,49 24,07 7365 1,99 64,54

I04 I04 continuous scouring total AF-BF-MF-VF-OF 4017349 81598 14,04 20,31 159666 35,80 39,74

I04 I04 scouring total AF-BF-MF-VF-OF 1049811 41157 7,08 39,20 44313 9,94 42,21

I04 I04 soda treatment total BF-OF 369390 54203 9,33 146,74 20642 4,63 55,88

Discontinuous scouring (synthetic fibres) 607771 7963 6,31 84,61 60422 12,11 1284,53

Discontinuous scouring (silk) 104096 3948 4,20 95,66 12820 13,65 248,23

Continuous scouring (silk fibres) 749892 2352 2,50 71,68 5310 5,66 161,56

Continuous scouring (synthetic fibres) 4017349 36973 12,68 27,93 63768 12,78 48,18

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- PIDACS data elaboration -Comparison of process data: Preparation 2/2

Single scouring processes for synthetic fibres (I06;I04) require a specific consumption of about 50 l/kg; specific load is about 50 COD g/kg of fibre. For silk fabric (I09;I15) consumptions and loads are very different and do not seem to be reliable.

Continuous scouring processes specific consumption decreases to the increase of fibre quantity; this is due to the use of equipments requiring high water quantities. Specific consumption equal to 60 l/kg seems more indicated for silk fabrics, while for synthetic fibres a specific consumption equal to 20 l/kg can be considered. Such processes generate a specific load of 120 COD g/kg of fibre for silk fabrics, while synthetic fibres processes generate a specific discharge of 40 COD g/kg of fibre .

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- PIDACS data elaboration -Comparison of process data: Dyeing 1/3


consumption


l/kgCOD kg

% on total load


I06 I06 light disperse dyeing total PES-C/PES-F/PES-S/PES 44003 2586 2,75 58,78 2786 2,97 63,32

I06 I06 medium disperse dyeing total PES-C/PES-F/PES-S/PES 21073 1222 1,30 58,01 1563 1,66 74,18

I06 G3.1: Dark disperse dyeing in torpedo PES-C/PES-F/PES-S/PES 4097 208 0,22 50,72 223 0,24 54,53

I06 I06 light direct dyeing total F-C/PES-F/PES-S/PES 13968 1232 1,31 88,22 699 0,74 50,02

I06 I06 dark direct dyeing total F-C/PES-F/PES-S/PES 4678 471 0,50 100,73 90 0,10 19,20

I06 I06 light reactive dyeing total F-C/PES-F/PES-S/PES 10529 2563 2,73 243,44 2376 2,53 225,70

I06 I06 dark reactive dyeing total F-C/PES-F/PES-S/PES 10529 2565 2,73 243,61 2262 2,41 214,79

I09 I09 yarn light disperse dyeing total PES-A 17387 1133 0,39 65,19 605 0,12 34,77

I09 I09 yarn medium disperse dyeing total PES-A 5796 378 0,13 65,19 266 0,05 45,94

I09 I09 yarn dark disperse dyeing total PES-A 3003 197 0,07 65,60 216 0,04 71,84

I09 I09 yarn light acid dyeing total S-N 91297 4988 1,71 54,64 1860 0,37 20,38

I09 I09 yarn medium acid dyeing total S-N 67628 3695 1,27 54,64 3098 0,62 45,82

I09 I09 yarn dark acid dyeing total S-N 179213 9792 3,36 54,64 10766 2,16 60,08

I09 G.7: Yarn light reactive dyeing S 62281 4344 1,49 69,75 2136 0,43 34,29

I09 G.8: Yarn medium reactive dyeing S 27365 1921 0,66 70,21 1391 0,28 50,83

I09 G.9: Yarn dark reactive dyeing S 298631 20852 7,15 69,83 26428 5,30 88,50

I09 I09 fabric light acid dyeing total S-S/O 48194 6983 2,40 144,90 1570 0,31 32,58

I09 I09 fabric medium acid dyeing total S-S/O 28221 4902 1,68 173,69 1415 0,28 50,14

I09 I09 fabric dark acid dyeing total S-S/O 58830 15454 5,30 262,69 4145 0,83 70,46

I09 I09 fabric light reactive dyeing total S 1303 246 0,08 188,69 64 0,01 48,82

I09 I09 fabric medium reactive dyeing total S 1303 309 0,11 237,53 131 0,03 100,64

I09 I09 fabric dark reactive dyeing total S 10421 3493 1,20 335,21 1558 0,31 149,52

I09 I09 fabric light direct/acid dyeing total S/O 1522 154 0,05 101,40 72 0,01 47,18

I09 I09 fabric medium direct/acid dyeing total S/O 2537 139 0,05 54,86 63 0,01 24,96

I09 I09 fabric dark direct/acid dyeing total S/O 7295 529 0,18 72,57 222 0,04 30,43

I15 I15 light acid dyeing total SF 184054 2173 0,39 11,81 229 0,06 1,25

I15 I15 medium acid dyeing total SF 230067 3435 0,61 14,93 782 0,21 3,40

I15 I15 dark acid dyeing total SF 243214 3800 0,67 15,63 2914 0,79 11,98

I15 I15 light direct-disperse dyeing total SYF 91712 1475 0,26 16,08 433 0,12 4,72

I15 I15 medium direct-disperse dyeing total SYF 66033 2124 0,38 32,17 783 0,21 11,86

I15 I15 dark direct-disperse dyeing total SYF 209104 6726 1,19 32,17 4485 1,21 21,45

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consumption


l/kgCOD kg

% on total load


I15 I15 light disperse dyeing total PF 1142 14 0,00 12,13 6 0,00 5,66

I15 I15 medium disperse dyeing total PF 14394 295 0,05 20,47 338 0,09 23,52

I15 I15 dark disperse dyeing total PF 17554 367 0,06 20,89 765 0,21 43,56

I15 I15 light reactive dyeing total OF 20755 317 0,06 15,28 292 0,08 14,09

I15 I15 medium reactive dyeing total OF 14298 387 0,07 27,08 438 0,12 30,61

I15 I15 dark reactive dyeing total OF 11069 323 0,06 29,17 350 0,09 31,60

I04 I04 light direct dyeing total BF-VF-OF 793889 25568 4,40 32,21 3900 0,87 4,91

I04 I04 medium direct dyeing total BF-VF-OF 742978 27391 4,71 36,87 16744 3,75 22,54

I04 I04 dark direct dyeing total BF-VF-OF 824779 39486 6,79 47,87 34188 7,67 41,45

I04 I04 light direct-disperse dyeing total AF-MF 331877 2138 0,37 6,44 1811 0,41 5,46

I04 I04 medium direct-disperse dyeing total AF-MF 265502 3420 0,59 12,88 4669 1,05 17,59

I04 I04 dark direct-disperse dyeing total AF-MF 350841 9418 1,62 26,84 9502 2,13 27,08

I04 I04 light disperse dyeing total OF 22315 1106 0,19 49,58 1810 0,41 81,13

I04 I04 medium disperse dyeing total OF 22315 2213 0,38 99,16 2434 0,55 109,07

I04 I04 dark disperse dyeing total OF 22991 2630 0,45 114,41 3222 0,72 140,13

I04 I04 light reactive dyeing total BF-MF-VF-OF 533925 16556 2,85 31,01 13921 3,12 26,07

I04 I04 medium reactive dyeing total BF-MF-VF-OF 522092 21239 3,65 40,68 18835 4,22 36,08

I04 I04 dark reactive dyeing total BF-MF-VF-OF 633657 49308 8,48 77,81 48373 10,85 76,34

I04 I04 soaping total VF-OF 2062340 40273 6,93 19,53 28854 6,47 13,99

I09-I15 Fabric light acid dyeing 5796 378 1,39 78,35 900 0,19 16,92

I09-I15 Fabric medium acid dyeing 23503 1392 1,14 94,31 1099 0,25 26,77

I09-I15 Fabric dark acid dyeing 56185 3105 2,99 139,16 3530 0,81 41,22

I06-I04 Fabric light direct dyeing 16944 1533 2,85 60,22 2300 0,81 27,47

I04 Fabric medium direct dyeing 14394 295 4,71 36,87 16744 3,75 22,54

I06-I04 Fabric dark direct dyeing 11447 473 3,65 74,30 17139 3,88 30,32

I06-I15-I04 Fabric light disperse dyeing 303170 11602 0,98 40,16 1534 1,13 50,04

I06-I15-I04 Fabric medium disperse dyeing 366069 18930 0,58 59,21 1445 0,77 68,92

I06-I15-I04 Fabric dark disperse dyeing 301969 16040 0,25 62,01 1403 0,39 79,40

I06-I09-I15-I04 Fabric light reactive dyeing 421965 11055 1,43 119,60 4163 1,44 78,67

I09-I15-I04 Fabric medium reactive dyeing 112766 6702 1,28 101,76 6468 1,46 55,78

I06-I09-I15-I04 Fabric dark reactive dyeing 149865 8603 3,12 171,45 13136 3,42 118,07

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Data for same processes are very different and hardly reliable; generally I04 and I15 companies data are sensibly lower than others but not correlated between (only average values can be discussed).

Highest specific consumptions values are observed for reactive and acid dyeing (more than 80 l/kg of fibre), used to process natural fabric (mainly silk fabric); also the quantity increase sensibly moving from light to dark dyeing (about 50 l/kg as increase). For disperse and direct dyeing, mainly used to process synthetic fibres (PES and viscose), values are lower (less than 70 l/kg); the increase necessary for dark dyeing is about 20 l/kg as increase.

Specific loads values are similar for direct and acid dyeing (less than 50 COD g/kg of fibre) and increase for disperse and reactive dyeing (up to 120 COD g/kg of fibre).No great increase is observed moving from light to dark dyeing, except for reactive dyeing (about 50 COD g/kg of fibre as increase).

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- PIDACS data elaboration -Comparison of process data: Printing

C. Process FibreTotal

kg

Total water

m3

% on total consum.

Specific consum.

l/kgCOD kg

% on total load

Specific load

gCOD/kg

I02 I02 colours preparation total C-V-S-W-PA-PES-S/A413015 580 0,42 1,40 4973 3,39 12,04

I02 I02 thickeners preparation total C-V-S-W-PA-PES-S/A413015 2486 1,81 6,02 19890 13,55 48,16

I02 I02 reactive printing total C-V 179662 7272 5,28 40,47 15305 10,43 85,19

I02 I02 acid printing total S-W 99124 4012 2,91 40,47 8444 5,75 85,19

I02 I02 cationic printing total PA 10325 418 0,30 40,47 880 0,60 85,19

I02 I02 disperse printing total PES-S/A 123905 5015 3,64 40,47 10555 7,19 85,19

I15 I15 blender preparation total SF-SYF-PF-OF 884192 1906 0,34 2,16 1287 0,35 1,46

I15 I15 colours preparation total SF-SYF-PF-OF 884192 584 0,10 0,66 583 0,16 0,66

I15 I15 thickeners preparation total SF-SYF-PF-OF 884192 77 0,01 0,09 70 0,02 0,08

I15 I15 printing pastes preparation total SF-SYF-PF-OF 884192 72331 12,82 81,80 72331 19,51 81,80

I15 I15 acid printing total SF 503971 1922 0,34 3,81 384 0,10 0,76

I15 I15 disperse printing total PF 190127 729 0,13 3,83 146 0,04 0,77

I15 I15 reactive printing total SYF-OF 190094 728 0,13 3,83 146 0,04 0,77

I02-I15 Colour preparation 449374 1024 0,29 1,41 2281 1,30 4,72

I02-I15 Thickeners preparation 406659 1282 0,91 3,05 9980 6,79 24,12

I02-I15 Acid printing 10325 2967 1,63 22,14 4414 2,93 42,97

I02-I15 Disperse printing 123905 2872 1,89 22,15 5350 3,62 42,98

I02-I15 Reactive printing 1473266 4000 2,71 22,15 7725 5,23 42,98

Colour preparation process consumption is equal to 1,40 l/kg of fibre the same for the two companies studied (I02;I15); great difference are otherwise observed in specific load (I15 value is 17,5% on I04 value). Thickener preparation process require an average quantity equal to 30,5 l/kg of fibre, generating an average load equal to 24,12 COD g/kg of fibre, but great differences occur between observed values.

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- PIDACS data elaboration -Comparison of process data: Washing (printing department)


consumption


l/kgCOD kg

% on total load


I06 I06 printed washing total PES-C/PES 38758 10331 10,99 266,56 15532 16,54 400,75

I06 I06 equipment washing total - 0 1681 1,79 0,00 704 0,75 0,00


I02 I02 printing equipment washing total - 413015 31547 22,92 76,38 47007 32,03 113,81

I02 I02 rope washing total PES-PA-W-V 178423 44780 32,53 250,97 29524 20,12 165,47

I02 I02 open w idth washing total PES-S/A-S-W-C-S 237348 16177 11,75 68,16 5603 3,82 23,61

I02 I02 washers washing total - 0 7391 5,37 0,00 696 0,47 0,00


I15 I15 printing equipment washing total - 884192 306302 54,28 346,42 82076 22,14 92,83

I15 I15 rope washing total PF-SYF 98821 8943 1,58 90,50 1994 0,54 20,18

I15 I15 open w idth washing total SF-SYF-PF-OF 785371 6088 1,08 7,75 2353 0,63 3,00

I15 I15 washers washing total - 0 1584 0,28 0,00 317 0,09 0,00


I02-I15 Printing equipment washing 648604 168924 38,60 211,40 64541 27,08 0,00

I06-I09-I02-I15-I04 Equipment washing 0 5599 2,32 0,00 2009 0,64 80,46

I02-I15 Discontinuous mode (rope) washing 138622 26861 17,06 170,74 15759 10,33 113,81

I02-I15 Continuous mode (open w idth) washing 511360 11133 6,42 37,96 3978 2,23 165,47

I15 process consumption for printing equipment washing processes is five times higher than I02 but discharged specific load is not so different (about 100 COD g/kg of fibre).As an average value, discontinuous mode (rope) fabric washing processes require 170 l/kg of fibre as consumption and generate 93 COD g/kg of fibre as load, but observed data are very different.Continuous mode (open width) fabric washing observed data are as well very different; as an average value such processes require 38 l/kg of fibre as consumption and generate 13 COD g/kg of fibre as load.

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- PIDACS data elaboration -Comparison of process data: Finishing


consumption


l/kgCOD kg

% on total load


I06 I06 softener finishing total F-PES-C/PES-F/PES-S/PES 115311 166 0,18 1,44 859 0,91 7,45

I06 H2: Water finishing F-PES-C/PES-F/PES-S/PES 149456 219 0,23 1,47 10 0,01 0,07

I06 H3: Non slip finishing F-PES-C/PES-F/PES-S/PES 29647 44 0,05 1,47 243 0,26 8,19

I06 H4:Antistatic finishing F-PES-C/PES-F/PES-S/PES 165458 243 0,26 1,47 1161 1,24 7,02

I06 H5: Fixing colour finishing F-PES-C/PES-F/PES-S/PES 56487 70 0,07 1,24 212 0,23 3,75

I09 I09 softener finishing total S-A 763954 10560 3,62 13,82 14983 3,00 19,61

I09 H.2: Antistatic finishing N 13172 149 0,05 11,33 243 0,05 18,42

I09 H.3: Fabric softener finishing (Recolsoft) S-S/O 115786 180 0,06 1,56 154 0,03 1,33

I09 H.4: Fabric water finishing S-S/O 173680 391 0,13 2,25 6 0,00 0,03

I02 I.1:Water finishing C-V-S-W-PA-PES-S/A 187097 220 0,16 1,18 11 0,01 0,06

I02 I.2: Softener finishing C-V-S-W-PA-PES-S/A 83154 98 0,07 1,18 109 0,07 1,32

I15 I15 easy care finishing total SF 425531 510 0,09 1,20 12580 3,39 29,56

I15 I15 non slip finishing total SF 157604 189 0,03 1,20 2777 0,75 17,62

I15 I15 softener finishing SF-SYF-PF-OF 1201219 1440 0,26 1,20 6558 1,77 5,46

I15 I15 waterproof finishing total SF 567375 680 0,12 1,20 4041 1,09 7,12

I04 I04 water finishing total AF-MF-VF-OF 2303980 838 0,14 0,36 6 0,00 0,00

I04 I04 softener finishing total BF-VF-OF 2035880 741 0,13 1,09 59 0,01 0,03

I06-I09-I02-I15-I04 Softener finishing 710270 525 0,14 1,29 1548 0,56 3,12

I06-I09-I02-I04 Water finishing 703553 417 0,17 1,31 8 0,01 0,04

Softener finishing processes specific consumptions are similar (about 1,29 l/kg); specific loads are different and have an average value equal to 3,12 COD g/kg.

Water finishing processes specific consumptions are not so different (average value 1,31 l/kg); as well as specific loads (average value 0,04 COD g/kg).

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WORKPACKAGE 02 - Quantitative evaluation of GEP application. Case studies in the synthetic fibres and silk industries

Conclusions at the end of reporting period

• I15 and I04 audit ended on July 2003 and relative PIDACS issued and sent during August 2003

• PIDACS methodology has been reported in the document n° IE-302-001 (“Manual for process identification and data collection sheet “), edited in substitution of Deliverable n°4 (“Material resources data input of textile industry”).

• PIDACS data discussion and elaboration has been reported in a the document referenced as n° TM-302-002-TY-302-001 (“Report on textile process identification for silk and synthetic fibres industries“ and ” Data sheet of relevant parameters of the manufacturing processes of synthetic fibres and silk finishing industries”).

• Lariana Depur activities on WP02 have been completed.

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WORKPACKAGE 05

Characterisation and design of waste water

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ACTIVITIES OF THE REPORTING PERIOD(MARCH 2003 - OCTOBER 2003)

WP05.05.3 Tests for water reuse (with P1 partner)

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Processes selection

Company Process PIDACS code Process description Step

I06 F.1.7 Scouring in overflow at 60°C 1st rinsing

I06 G.2.1 Medium disperse dyeing in torpedo rinsing

I09 F.1.3 HT scouring w arm rinsing

I15 G.3.1 Silk dark acid dyeing 1st rinsing

I04 G.3.3 Dark direct dyeing in overf low 1st continuous rinsing

• Processes have been selected on the basis of workpackage WP2 activity elaboration, reported in the document n° TM-302-002-TY-302-001.

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Water characterisation

Characterisation Program has been

decided to connect

the differences in textile results

(if existing) to the values of indicated

parameters .

(*: P1 partner)

Hardness [°F] YES YES

Chlorides [mg/l] YES YES

Sulphides [mg/l] NO YES

Sulphates [mg/l] NO YES

Nitrites [mgN/l] YES YES

Nitrates [mgN/l] YES YES

Ammonia [mgN/l] YES YES

TKN [mg/l] YES YES

426 nm abs [*1000] YES YES






Fe tot [mg/l] NO YES

Mg2+ [mg/l] NO YES

*pH [-] YES YES

*Conductivity [S/cm] YES YES

*Total suspended solids [mg/l] YES YES

COD [mg/l] YES YES

*Turbidity [NTU] YES YES

*Total Carbon [mg/l] YES YES

*Inorganic Carbon [mg/l] YES YES

*Total Organic Carbon [mg/l] YES YES

Analysis In membrane Out membrane

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Laboratory scale processes

• Samples collected in each factory (after membrane treatment) have been used to perform typical processes on the same fibre manufactured by the company itself.

• Results have been compared with the results obtained by the same processes on the same fibres, carried out with conventional supply water (Industrial Aqueduct).

• Processes have been performed by Tessile di Como, an italian company devoted in research and support to Como district textile companies, chosen as partner for this workpackage.

Company Fibre used for tests Process sampled StepPreparation processes performed

Dyeing processes performed

I06 PES F.1.7: Scouring in overflow at 60°C 1st rinsing scouringlight disperse dyeing dark disperse dyeing

I06 PES G.2.1: Medium disperse dyeing in torpedo rinsing scouringlight disperse dyeing dark disperse dyeing

I09 SILK YARN F.1.3: HT scouring w arm rinsingde-gumming

polymer chargelight acid dyeing dark acid dyeing

I15 SILK FABRIC G.3.1: Silk dark acid dyeing 1st rinsing de-gumminglight acid dyeing dark acid dyeing

I04 VISCOSE G.3.3: Dark direct dyeing in overf low 1st rinsing scouring

light direct dyeing dark direct dyeing

light reactive dyeing dark reactive dyeing

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Laboratory efficiency tests

• Also efficiency tests have been performed by Tessile di Como.

Process Efficiency tests Reference Process Efficiency tests Referencede-gumming de-gumming eff iciency acid dyeing Colour differences ISO 105-J03

Fastness to w ashing ISO 105-C06

polymer charge charge eff iciency UNI 9275/88 Fastness to rubbing ISO 105-X12

scouring eff iciency disperse dyeing Colour differences ISO 105-J03


w hite degree determination Fastness to rubbing ISO 105-X12

de-gumming eff iciency acid dyeing Colour differences ISO 105-J03


w hite degree determination Fastness to rubbing ISO 105-X12

scouring eff iciency direct dyeing Colour differences ISO 105-J03


w hite degree determination reactive dyeing Fastness to rubbing ISO 105-X12

DyeingPreparationFibre

scouring

de-gumming

scouring

SILK yarn

PES fabric

SILK fabric

VISCOSE fabric

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WORKPACKAGE 05- Characterisation and design of waste water

Conclusions at the end of reporting period

• All the samples have been collected, sent to partner for membrane treatment, and delivered to Tessile di Como for processes and tests performance, during the period May-July 2003.

• Laboratory scale processes and efficiency tests have been completed by Tessile di Como and result will be available in a couple of weeks.

• WP05.05.3 activity and results description will be reported in the document n° TM-305-001 (“Report on tests for water direct and indirect re-use in the silk and synthetic fibres and industries“).

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Lariana Depur S.p.A.Via Laghetto 1

22073 Fino Mornasco (CO) - ItalyTel. ++39 31 920518 Fax ++39 31 921880

[email protected]

towef0 paris - meeting 6 - pag. 1 towef0 project meeting paris, 2-3 october 2003

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