- 1. Case Study T extile company Cleaner Production Assessment
Tomas PivorasKaunas University of Technology Kaunas, Lithuania
2. Information about Vernitas
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- Bulk, polyacryl nitrile (PAN) yarns;
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- 6.000 tons of yarn sper year;
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- export to EU approximately 70%.
3. Production processes
- Yarn Preparation,sub-processes:
4. Auxiliary processes
- Boiler house heating and steam production
- Compressed air production
5. Methodology
- The company was analyzed on three levels:
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- Level 1: Main data for black box - entire company;
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- Level 2: Main process data (building a layer cake);
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- 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.
6. Energy balance 7. H eat consumption 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. 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. Optimisation of
the humidification system - replacement of the spraying nozzles
- Savings by reduction of consumption of both water and
compressed air.
11. Installation of variable frequency drives on fans
- S ignificantlyincreasedenergy efficiency of the fans at part
load (50-90%), which was approx. 75% of the operation time.
12. Heat recovery in the compressed air system 13. Recycling of
steam condensate in dyeing dept. 14. MainCleaner
Productionprojects
- 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
15. Minimisation/optimisation of chemicals used
- 1. investigatethe use of the chemicals
- 2. investigatethe possibilities to omitthe use of the
chemicals
- 3. investigatethe possibilities to reducethe use of chemicals
(this step should not be considered if the chemicals are evaluated
to be hazardous, unless substitution is not possible)
- 4. investigatethe possibilities to substitutethe chemicals with
alternatives that have less negative impacts on the
environment.
- Total quantity of 26,419 kg .
16. Zinc emission to effluent
- Stoptreating the effluent for removalof zinc (Zn)
- Findthe source of the zinc (Zn) emission in the effluent.
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- It is much cheaper and more environmental friendly to change
the source
17. Dyes containing heavy metals 18. Continual improvements:
- dyestuffcontainingheavy metals
- azo-dyestuff , which splits off carcinogenic amines.
- toxic chemicals(T or T xmarked according to EU
regulations)
- hazardous surfactant s giving rise to environmental concerns do
to their poor biodegradability, their toxicity and potential to act
as endocrine disrupters.
- hazardous complexingagent
19. Wastewater from dyeing department 20. Wastewater treatment
plant 21. Membrane filtration
22. Reuse of cooling water fromspinning machines
- Total use of water is about:
- Total installation cost is:
- Simple payback period is:
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- ( not including usage of electricity by water pump and water
pumping from well )