BREF Process, Role of author, CPCB, SPCB and Technical...

BREF Process, Role of author, CPCB, SPCB and Technical Working Group in preparation of BREF

Dr. Harald Schoenberger

International expert on integrated industrial pollutionprevention and controlSpecial fields: textile industry, chemical industry, iron&steelindustry, electroplating industry, paper industry

Studied env. techn. and env. sciences, PhD on textile wastewater, permit writer and inspector on regional level, policy maker on national and European level, author of very first BREF (1997/98), Head of European IPPC Bureau, co-author of the EU BREF for the Textiles Industry, stand-in professor at the University ofStuttgart/Germany, senior adviser to the Partnership for Sustainable Textiles – more than 30 years ofexperience in the textile sector

Background

The objective of this new project on BAT is the ‘development of a

BREF/COINDS Document for the textile industry covering the Best Available Techniques adapted to the Indian context’.

Basis:1.) Sector-specific Comprehensive Industry Documents (COINDS)2.) Best Available Techniques REFerence Document for the Textiles Industry (2003) (BREF Textiles Industry)…. additional key documents (CPCB, IFC, OECD etc.)

New project in India on best available techniques (BAT)

supported by the German Agency for Technical Cooperation

Why we are here?

The moon view

Somewhere in India in February 2017

Discharge ofuntreatedtextile wastewater

7

"Sustainable development is development that

meets the needs of the present without

compromising the ability of future generations to

meet their own needs."

Brundtland Report „Our common future“ - 1987

take it serious

8

Aerial view of a textile finishing industry (textile wet processing)

9

The “Textile Chain”

Disposal

(of the textiles)

Consumption

Manufacture of ready-made

clothing

Primary production of

natural and synthetic fibres

Wet processing(pretreatment, dyeing,

printing and finishing)

Production of yarns,

knittings and fabrics

Raw materials

A

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rawmaterials

seeds

end-of-life

Raw materials

e.g. reactive black 5 e.g. H acid

Raw materials

e.g. Naphthalene, H2SO4, HNO3, NaOH

brand

disposal

re-use, recycling

AccessoiresRaw materials

rawmater.

Raw materials

Rawmater.

.

.

Synt. fibre prod.

Natur. fibre prod.

Fibre production

Weaving/knitting

Sizing agents

Preparations

Textile auxiliaries

Dyestuff manuf. Dyestuff intermed.

Washing agents

Textile finishing

en

erg

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wat

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che

mic

als

was

tew

ate

r

was

tega

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solid

was

te

Garment manuf.

Use phase

Optical brightenersDiamino stilbene-disulphonic acid

Raw materials

e.g. softeners

Raw materialsPreparations

The textile value chain and mass stream thinking

plus transport activities at all stages

11

rawmaterials

seeds

end-of-life

Raw materials

e.g. reactive black 5 e.g. H acid

Raw materials

e.g. Naphthalene, H2SO4, HNO3, NaOH

brand

disposal

re-use, recycling

AccessoiresRaw materials

rawmater.

Raw materials

Rawmater.

.

.

Synt. fibre prod.

Natur. fibre prod.

Fibre production

Weaving/knitting

Sizing agents

PreparationsTextile auxiliaries

Dyestuff manuf. Dyestuff intermed.

Washing agents

Textile finishing

en

erg

y

wat

er

che

mic

als

was

tew

ate

r

was

tega

s

solid

was

te

Garment manuf.

Use phase

Hot spot: cotton production

Hot spot: Dyestuff production

Hot spot: Textile finishing

Environmental hot spots of the value-added chain

12

Globalisation

In the past 30 years, from Europe, most of the textile production shifted to Asia (China, India, Pakistan, Bangladesh, Vietnam…..)

end of 90ies: Indians said „We cannot compete with China“, now China says „We cannot compete with India, Bangladesh, Pakistan….“

In the past 30 years, from Europe, almost the completedyestuff production shifted from Europe to China and India

Why we are here?

Brands and retailers in Europe and the US demand more sustainability from suppliers –Zero discharge of hazardous chemicals (ZDHC) programme, Global Organic Cotton Standard (GOTS), Sustainable Textile Production (STeP) ……

The textile chain – actors- and framework-oriented

Examplefrom NIKE

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What to do?

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Let us go for close co-operation towardsmore sustainability in the textile sector

Let us work together as a team

Let us develop a BAT

Reference Document

(BREF) for the Indian

textile sector

T ogetherE verybodyA chievesM ore

Composition of the Technical Working Group (TWG) for developing a BREF

CPCB, Indian gov.

Authorsupported/guided byCPCB, HS, UBA

Industrial associations, textile industry representatives

NGOs

State Pollution Control Boards and other regulatory bodies

Expert organis.

Industry EU Member States+ EFTA and Accession Countries

TWGkick-off meeting

Draft 1 (D1)

Draft 2 (D2) *

Final TWG meeting

The ‘Sevilla process’

Final draft

Bulk of info. needed(incl. questionnaires)

Comments

BREF

BATconclu-sions

• Forum opinion on BREF

• Adoption of BAT conclusions through the IED Art. 75 Committee

BATconclu-sions

* D2 optional

Total duration:

• 24 – 29 months (without D2)

• 29 – 39 months (with D2)

The BREF Development Process

Typical workflow for the drawing up and review of BREFs (source: BREF Guidance Document, 2012)

Technical Working Group (TWG) – multistakeholder process

Composition

- CPCB (Member Secretary, senior scientists)- CPCB author- Indian Government- Industrial associations- Representatives of individual textile companies- Regulatory bodies- Non-governmental organisations- Expert organisations

Technical Working Group (TWG)

Indian Government

- The Ministry of Environment, Forest and Climate Change (MoEFCC)- Ministry of Textiles, Textiles Committee, Government of India- Department of Industrial Policy and Promotion (DIPP)- The Ministry of Micro, Small and Medium Enterprises (MoMSME)


Industrial associations- Confederation of Indian Textile Industry (CITI)- Federation of Indian Chambers of Commerce and Industry (FICCI)- Textile Machinery Manufacturer’s Association (TMMA)- Denim Manufacturers Association- Indian Textile Accessories & Machinery Manufacturer’s Association (ITAMMA)- The Southern India Mills Association- The Millowner’s Association- Ahmedabad Textile Mills Association- Northern India Textile Mills Association- The Madhya Pradesh Textile Mills Association- The Rajasthan Textile Mills Association- The Cotton Textiles Export Promotion Council- Ahmedabad Textile Industry’s Research Association (Atira)- Bombay Textile Research Association (BTRA)- The South India Textile Research Association (SITRA)- Indian Spinner’s Association


- Rajaratna Mills P. Ltd. - Vardhman Textiles Limited- Precot Meridian Ltd- Sree Narasimha Textiles P Ltd.- Sri Gomathy Mills Private Ltd- Sri Mahasakthi Mills Limited- T T Limited- Thiagarajar Mills Ltd- K.P.R Mill Limited- SCM Textile Spinners- Welspun India Ltd.- S Kumar Ltd.- Kotak Ginning & Pressing Industries Ltd.- Arvind Mills- Trident Limited

Representatives of individual textile companies

- NSL Textiles Limited- Aarti International Limited- Nahar Industrial Enterprises Limited- RSWM Limited (LNJ Bhilwara Group)- Reliance Industries Limited- Sakku Spinning Mills Limited- Grasim Industries Ltd.- Raymond Luxury Cottons Ltd.- Indo Rama Synthetics (I) Ltd.- Mysore Silk Factory- Lakshmi Mills- JCT Mills- Bombay Dyeing- Alok Industries- BSL Limited


Non-Governmental Associations

- The Energy and Resource Institute (TERI)- Centre for Science and Environment (CSE)- Development Alternatives (DA)- Indian Environmental Society (IES)- World Wide Fund (WWF-India)- Shakti Sustainable Energy Foundation- Toxics Link- Council on Energy, Environment and Water (CEEW)- Greenpeace, India


Regulatory bodies

- Gujarat Pollution Control Board- Maharashtra State Pollution Control Board- Tamil Nadu Pollution Control Board- Punjab Pollution Control Board- Delhi Pollution Control Committee- Central Silk Board, Bangalore- National Jute Board, Kolkata- Karnataka Pollution Control Board- Andhra Pradesh Pollution Control Board- Rajasthan Pollution Control Board


Expert organisations

- National Institute of Fashion Technology (NIFT)- Sardar Vallabhbhai Patel International School of Textiles and Management- Northern India Textile Research Association (NITRA)- The Synthetic & Art Silk Mills' Research Association (SASMIRA) - Man-Made Textiles Research Association (MANTRA)- Indian Jute Industries' Research Association (IJIRA)- Wool Research Association (WRA)- National Institute of Fashion Technology (NIFT)- Indian Institute of Technology, Delhi (IIT)

1. Preparatory activities

2. Sensitisation workshop

3. Defining the scope and contents of BREF document

4. Data/information collection

5. 1st draft BREF document

6. Comments on 1st draft

7. 2nd draft BREF document

8. Comments on 2nd draft

9. Final draft BREF document

10. Review of the final draft BREF:

11. Approval of the BREF document

Key steps involved in preparing the BREF document for the Indian textile sector

see manual from Gujarat

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Define the scope

Disposal

(of the textiles)

Consumption

Manufacture of ready-made

clothing

Primary production of

natural and synthetic fibres

Wet processing(pretreatment, dyeing,

printing and finishing)

Production of yarns,

knittings and fabrics

Raw materials

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Stages up-stream to wetprocessing included?

Size of the installationsconsidered (large, medium, small, micro)?

Type of textile substrates(CO, CV, PES, PA, PAN, PUR, WO, SI, Jute …)

Make-ups (woven fabric, knitted fabric, yarn, loosefibre)

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Define the scope

Grouping of installations such as

- Large and medium TFI finishing mainly woven fabric consisting of CO andCO/PES blends (without printing)

- Large and medium TFI finishing mainly woven fabric consisting of CO andCO/PES blends (with printing)

- Large and medium TFI finishing mainly knitted fabric consisting of CO andCO/PES blends

- Small TFI finishing yarn mainly consisting of PES- TFI…….- TFI…….- TFI…….- TFI…….

Coordinated data collection

Principles:- Site level- Process level- Consumption data for water, energy and chemicals- Emission data with detailed information how sampleshave been taken, which analysis methods were applied, were results averaged etc.

There is a manual available how to carry out data collection

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Site level: Annual massstream overview

1. Textile finishing

industry with a certain

sequence of defined

processes

2.2 Energy

2.3 Water

2.4 Chemicals/auxiliaries

Quantity [t/a]:

- dyestuffs and pigments:

- organic auxiliaries:

- basic chemicals:

- annual consumption [m3/a]:

- own wells/supply [%]:

- kind of pretreatment:................................

- oil [t/a]:

- coal [t/a]:

- gas [m3/a]:

- electricity [kWh/a]:

- steam generation [t/a]:

3.5 Wastewater

3.4 Solid waste

3.3 Off gas

Sources and quant. [t/a] of SO2, NOx, org.C, others:

- ...............................................................

- ...............................................................

- ...............................................................

Kind and quantities [t/a]:

- ....................................

- ....................................

- ....................................

- ....................................

- Quantity [m3/a]:

- Load [t/a] of COD: BOD5: AOX: Cu:

Ni: Cr: SS: Total-N: Total-P:

- Indirect/direct discharge:.................

- Separate cooling water discharge [Yes/no]:..... if yes [m3/a]:

2.1 Raw materials 3.1 Products

- year of reference:

- age of the site [a]:

- no. of employees:

- annual turnover

[ECU/a]:

- working days[d/a]:- nearest distance to the

neighbourhood [m]:

Kind and quantities [t/a]:

- Co: - PES:

- Co/PES: - PA:

- ................................

- ................................

- ................................

- ................................

Make-ups [%]

- fabrics:

- knitted material:

- yarn:

- floc:

Textile finishing industry - mass stream overview *

Kind and quant. [t/a]:

- ...........................

- ...........................

- ...........................

- ...........................

General infos

(* see also explanation sheet)

3.2 Waste heat

in[kWh/a]:- off gas:- wastewater:

- others:

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Cotton fabric finisherPerformance indicator Unit

INPUT

Substrate %

CO 97

Natural gas m3/yr 5166970 kWh/yr 58903458 18,0 kWh/kg

Calorific value kWh/l 11,4

Electricity kWh/yr 3506240 1,1 kWh/kg

Heating oil t/yr 22,4 kWh/yr 262080 0,1 kWh/kg

Calorific value kWh/l 11,7

Consumption of dyestuffs kg/yr 20664 6,3 g/kg

Consumption of organic auxiliaries kg/yr 833500 254 kg/kg

Consumption of basic chemicals kg/yr 1143400 349 kg/kg

OUTPUT

Production quantity t/yr 3280

t/d 14,5

Waste water flow m3/yr 715775 218 l/kg

Environmental performance indicators

Number of the wet processing unit: Country-region-……… Tick and fill in as appropriate

Quantity of textiles processed t/yr All figures are on annual basis, e.g. for the last calendar year

2016 2017 2018

Textile substrates

Make-up (%): e.g. yarn (100%) m3/yr

Woven fabric %

Knitted fabric Trousers Surface water %

Yarn T-shirts Public supply %

Loose material Shirts Private network supply %

name others ………….. name other

Final Products Garments Home textiles Name others

Textile substrate (%) Process sequence(s)

CO (100%) Pre-treatment dyeing printing finishing

PES (100%) Desizing Exhaust Rotary Exhaust

CO/PES blends Scouring Semi-contin. Flat On stenter

CO/PUR Oxid. bleaching with H2O2 Contin. Inkjet Softening

WO (100%) Oxid. bleaching with NaOCl Reactive …………………. Easy care

WO/PAN blends Mercerisation Vat Pigment Water repell.

WO/PES blends Washing Sulphur Reactive ………………….

…………….. ………………….. Disperse Disperse …………………

…………….. ………………….. ………………… ……………….. …………………

Hazardous chemicals

no:… yes:…….

Wastewater treatment Direct discharge (DD) Indir. dischar. (IDE) m3/yr

Screen Neutralisation Equalisation Wastew. cooling Activat. sludge

Adsorpt. Oxidation (e.g. O3, NaOCl) Precipit./floccul. Membrane (UF) Membrane (RO)

Influent: COD BOD5 Total N

Achieved average conc. (mg/l): COD BOD5 Total N Total P

Ammonia Total Cr Total Cu Additional parameters………………………………………………………

Sludge t/yr % dry matter

Describe sludge disposal:……………………………………………………………………………………………………………………………………………………………………………….

Other and addit. treatmen steps (incl. recycling):…………………………….………………………………………………………………………………………………………………..

……………………………………………………………………………………………………………………………………………………………………………………………………………………

Name of known chemicals and their annual input in kg/yr which are listed on the ZDHC MRSL or ZDHC Research list:

Confirmation available for all chemical products that they do not contain substances listed on the ZDHC MRSL:

Description of the

WWTP (in case of

DE or IDE):

Finishing ready-made

textiles

Wastewater flow

Sludge generation in the WWTP Sludge solid content

Effluent (dis-

charged wastew.):

Bore well (groundw.)

Water consumption

………………………….……

……………………………..……………………………………………………………….

Other one pageapproach

Cotton/Polyester Fabric

Chamb 195°C

Chamb2 95°C

Steamer ca. 20 min,

110°C

Chamb 4 90°C

Chamb5

95°C

Big Squeezer

Chamb 6 60°C

HAC

Big Squeezer

Fabric : 30 X 30 (76 x 54) Cotton

Chamb 3 80°C

DIP SET 1

DIP SET 2

Steamer

ca. 22 min, 110°C

Chamb 7 95°C

Chamb 8 95°C

Chamb 9 95°C

Chamb 10 80°C

Chamb 11 Neutralization

Water Consumption: ca. 16 l/kg

Chemical Name ml/kg

Stabilizer 6

Caustic 12

Wetting agent 4

Sequesting Agent 2

Hydrogen Peroxide 26

Chemical Name ml/kg

Caustic 30

Wetting agent 2

Sequesting Agent 2

Big Squeezer

Sample Description pH TDS PVA COD TKN

Bleach # 1, Chamber 1 Drain7.00 8,400 610 34,500 1,500

Bleach # 1, Steamer 1 Drain12.40 18,280 100 8,000 810

Bleach # 1, Chamber 4 Drain12.50 11,480 65 16,800 900

Bleach #1, Chamber 7 Drain 11.5 1950 0 5740 190

Continuous Bleaching # 1

Process level

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Data inventory of textile auxiliaries, basic chemicals and dyestuffs

Form 3 TFI: Year:

3. Textile auxiliaries for dyeing and printing

3.1 Dyestuff solubilizing and hydrophobic agents

3.2 Dispersing agents and protective colloids 3.11 Bonding agents for pigment dyeing and printing 3.20 Mordants

3.3 Dyeing wetting agents, deaeration agents 3.12 Printing thickeners 3.21 Brightening and stripping agents

3.4 Levelling agents 3.13 Emulsifiers for gasoline printing 3.22 Fibre-protective agents

3.5 Carriers 3.14 Agents to remove printing thickeners 3.23 pH-regulators, acid and alkali dispensers

3.6 Crease-preventing agents 3.15 Printing and edge adhesives

3.7 Dyestuff protecting agents, boildown protecting agents 3.16 Oxidizing agents

3.8 Padding auxiliaries 3.17 Reducing agents

3.9 Fixing accelerators for continuous dyeing and printing 3.18 Discharging agents and discharging assistants

3.10 Aftertreatment agents for fastness improvement 3.19 Resist agents

No. Commercial name Chemical characterisation Process, Danger Annual Biological degradation spec. COD- spec. BOD5- Heavy metal Org. halogen COD-load

application symbol consumption resp. elimination value value content content

[kg/a] [%] and testing method [mg O2/g] [mg O2/g] [mg/g] [mg/g] [kg O2/a]

3.16 Revatol S Gran. Nitobenzene sulfonic acid, Na-salt dyeing Xi 5.400 >90; OECD 302 B 0,990 5346

3.04 Alviron OG-BM fl. Formulation of surfactants and high-boiling

alcohols

dyeing --- 3.800 >80; after adaptation 0,760 2888

3.17 Cyclanon ARC Plv. Sulfinic acid derivative and dispersing agent dyeing Xi 3.650 20-70; OECD

Confirmatory

0,335 1223

3.02 Lamepon UV fl. Polysaccharide dyeing --- 2.500 >70; OECD 302 B 0,350 875

3.04 Drimagen E2R fl. Aromatic polyether sulfonate dyeing Xi 1.300 46; OECD 302B 0,616 801

3.23 Sandacid PBD fl. Aliphatic carbonic acid derivative dyeing --- 1.250 80; OECD 302 B 0,309 386

3.04 Peregal P fl. Polyamidoamine dyeing --- 850 >70; OECD Confirmatory 0,430 366

3.23. Egasol 910 Plv Mixture of organic and inorganic salts dyeing Xi 620 --- ---

3.10 Indosol E-50 fl. Aliphatic polyamine dyeing --- 480 89; OECD 302 B 0,420 202

Chapter 4 provides a lot of information on each Technique:

• Technical description

• Achieved environmental benefits

• Environmental performance and operational data

• Cross-media effects

• Technical considerations relevant to applicability

• Economics

• Driving force for implementation

• Example plants

• Reference literature

Description of more environmentally-friendly techniques

The objective of this new project on BAT is the ‘development of a

BREF/COINDS Document for the textile industry covering the Best Available Techniques adapted to the Indian context’.

Basic approach

New project in India on best available techniques (BAT)

supported by the German Agency for Technical Cooperation

Look for frontrunners in a certain sector

Selection procedure and justification of BAT -Frontrunner approach – well/best performing plants

Frontrunner approach

Study and describe the front-runner technique

Followers of the frontrunner techniques

Bath 1 83.5 °C

Bath 2 91.4 °C

Bath 3 82.0 °C

steamer102 °C

scouringliquor

Bath 1 81.5 °C

Bath 2 79.5 °C

Big squeezer

Bath 3 83.1 °C

Bath 4 82.0 °C

Securon AN Ruco Acid

Freshwater consumption: ca. 2.5 l/kg

steamer102 °C

ww fromdesizing

Bath 2 81.2 °C

Bath 4 79.8 °CBath 1

86.0 C

Bath 5 75.3 °C

ww frombleaching

and scouringwashing waterfrom merceri-

sation

hot freshwater

Legend:

fabric

water

waste water (ww)

Improvement of continuous pre-treatment of woven cotton fabric

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Wastewater from desizing

Anaerobic pre-treatment of desizing liquors

Calculation with 8 % starch and 2 % PVA and a water

consumption for desizing of 4 l/kg

80 g COD/kg from starch

34 g COD/kg from PVA

Calculated COD concentration of desizing liquor: 28,000 mg/l

Measured: 29,200 mg/l (we were lucky)

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Comparison: Aerobic and Anaerobic Processes

Carbon (mainly CH4 and CO2) in biogas90 – 95 %

Organic carbon in raw waste water

100 %

Residual organic carbonin excess sludge

1 - 5 %Residual organic carbon in treated waste water

1 - 5 %

Carbon balance of the anaerobic biodegradation oforganic compounds

.

.

Carbon in CO2 formedca. 50 %

Organic carbon in raw waste water

100 %

Organic carbon in biomass (sludge) formed

ca. 50 %

Residual organic carbon in treated waste water

ca. 1 %

Carbon balance of the aerobic biodegradation in an acticated sludge system

.

.

Aerobic

process

Anaerobic

process







• Economics


• Example plants



Example of a technique which needs to be described because it isexisting at industrial scale (it is available) but which may not be BAT for the textile sector as a whole as it is not economically viable forthe whole sector

Zero Liquid Discharge (ZLD) plants

ZLD Plant

TFI near Tirupur, Tamil Nadu

Wet processing of cotton knitwear and CO/lycra blended knitwear

Layout of the zero liquid discharge effluent treatment plant

1. Equalisation2. Neutralisisation3. Flocculation/precipitation (taken out of operation in order to reduce sludge quanity as

the efficiency of the plant is not reduced by doing so)4. Activated sludge system with fine bubble aeration at low food-to-microorganism ratio

(< 0.15 kg BOD5/kg MLSS x d)5. De-colourisation with elemental chlorine (comment: should be avoided as toxic by-

products are formed – better to use ozone)6. Sand filtration7. Ultrafiltration (to remove all particles and colloids in order to protect the subsequent

reverse osmosis plant)8. 3-stage reverse osmosis plant (equipped with cartridge filters for additional protection)9. 4-stage multiple effect evaporator10. Chiller to cristallize sodium sulphate for re-use11. Flash dryer to obtain a solid (maximum pasty) residue to be stored without access to

rain water

Activated sludge tank

Chlorination to de-colourise

Microfiltration, ultrafiltration and 3-stage reverse osmosis

Multiple effect evaporator

Recovered glauber salt

Storage of salty residue (salt and recalcitrant organic compounds)

ETP feed RO I Feed RO I permeate RO III reject MEE I reject

Clean glauber salt

Evapor. condens.

Salt reject

Water samples from different stages of ZLD effluent treatment







• Economics


• Example plants



What is BAT?:

rule of thumb

about 10-20 % best performers (best performingplants or techniques) of a sector where sufficientdata is available (see examples) but could be just one or very few reference plants (often, there are not enough data to carry out statistical considerations)

0 5 10 15 20 25 30 35 40 45

Installations

Rep

ort

ed

em

issio

n l

evels

of

ind

ivid

ual

insta

llati

on

s

best performing installationsinstallations which need

to improve.

well performing

installations

potential range to conclude on BAT

BAT: about 10-20 % best performersDust emissions from 45 sinter plants

Range of VOC emissions from 65 car paintshops in Europe

BAT: about 10-20 % best performers

best performingplants

plants with needto improvement

Wellperfor-minge

xcep

ti. Car paint shops

VO

C e

mis

sio

ns

in [

g C

/m

2]

Technical working groups (TWGs)

•Expert judgement to conclude on BAT (no „algorithm“ orcertain (scientific) procedure)!!

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The new ZDHC Wastewater Guidelines

ZDHC: Zero Discharge of hazardous chemicals

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Sampling points for facility with own WWTP and direct discharge

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Sampling points for facility with indirect discharge; WWTP is managed

by third-party, or, optionally, company has pre-treatment (equalisation,

buffering etc) on-site.

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Conventional

parameters

showing

foundational,

progressive,

and

aspirational

limits; and

the standard

test methods

for

measurem.

Let‘s share a

dream

To convert rivers like this….

…. or this

... into clear, healthy rivers ...

Benzene

72

Thank you very muchDr. Harald Schoenberger

Independent International expert on integrated industrial pollutionprevention and control

E-Mail: hgschoe@t-online (privat)[email protected] (University of Stuttgart)

mailto:[email protected]

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