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HAMS Washing & Dyeing Ltd.

Sustainability Report (2016-2017)

Prepared by

Md. Riyajul Haq, Asst. Manager (Environment & Chemical)

HAMS Group

January 2017

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EXECUTIVE SUMMARY

Introduction

HAMS Washing & Dyeing Ltd. has been working to adopt & implement various strategies

and an approach towards sustainability. As part of this work, water consumption, waste

wastewater generation and energy consumption are recorded. Besides, greenhouse gas

emission and solid waste inventory are maintained. The water & energy consumption, waste

generation and greenhouse gas emission are reviewed by the authority of HAMS Washing &

Dyeing Ltd through sustainability report which is drafted yearly. The authority of HAMS

Washing & Dyeing Ltd sets target and define strategies to reduce water & energy

consumption as well as to improve environmental performance.

Water consumption Record

The source of water for HAMS Washing & Dyeing Ltd is underground water. The main

purpose of water metering system is; to track & measure total water withdrawal from

underground, total water consumption for production & domestic purpose and the total

wastewater generation from HAMS Washing & Dyeing Ltd.

Energy Consumption & GHG emission Record

In textile, energy is an important component and without this textile industry cannot be

operated. Energy resources are limited and these must be used reasonably and responsibly.

HAMS Washing & Dyeing Ltd mainly uses natural gas & diesel for generating power &

steam. Besides, purchase electricity is also used from REB.

Table: GHG emission record from HAMS Washing & Dyeing Ltd in 2016

GHG Emission Summery

Year Direct emission (stationery

fuel combustion)

Indirect emission (purchased

electricity consumption) Total in

tCO2e

2016 1951.9 777.4 2729.3

Dyeing Production, Solid waste record, ETP outlet water quality & sources of air

emission

The production activities of HAMS Washing & Dyeing Ltd is washing & dyeing of finish

garments specially denim. The production record is maintained in pcs but to convert in

weight, every pcs is considered equivalent to 450 gram.

Hazardous waste: Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge,

Wastage oil, Chemical Drum, Medical waste, Poly and plastic bag.

Non Hazardous waste: Cartoon

The solid waste generated from HAMS washing & Dyeing Ltd is segregated with 11 classes.

Only one item was found nonhazardous waste namely cartoon and others are hazardous.

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Table: Solid waste record of 2016

Year Non Hazardous waste

in kg

Hazardous waste

in kg Total Solid

waste in kg

2016 1311 6507.5 7818.5

Air emission inventory is presented in table-5. Air emission inventory is maintained annually.

The air emission test is conducted by third party annually for HAMS Washing & Dyeing Ltd.

There is no accredited body in Bangladesh for air emission test. That’s why third part air

emission test results are not presented in air emission inventory.

HAMS Washing & Dyeing Ltd. has an in-house ETP laboratory to analysis wastewater

(before & after treatment). Almost all kind of parameter like as COD, BOD, TSS, pH, TDS,

MLSS, SV, SVI, F/M can be analyzed by ETP laboratory

Target Setting & Action Plan

HAMS Washing & Dyeing Ltd. sets target to improve environmental performance as well as

reduce energy & water consumption. The concern authority review improvement against

target annually and take corrective action plan to achieve target.

Action plan to reduce energy consumption: Hot water/Condensate Recovery, Install solar

panel, Use LED & Energy saving Light & Replacing conventional boiler with energy saving

boiler including economizer.

Action plan to reduce water consumption: Rain Water Harvesting, Using Water Efficient

Equipment, Reuse Blower cooling water & Awareness & Monitoring.

The chemical management system will be formulated and it will work through Plan-Do-

Check-Act framework.

Conclusion

Table: Production, water & energy consumption and wastewater generation in 2016

Year 2016

Washing production(MT) 4798.7

Water consumption(m3) 151258.7

Waste water(m3) 137909.8

Energy consumption(GJ) 43799.5

Table: Base year water & energy KPI for per ton production

Year Base year 2016 Target year 2018

Water consumption 31.5 Reduce by 10% from base year

Energy consumption 9.1 Reduce by 5% from base year

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Table of Contents

Executive Summery 2

Introduction 5

Water consumption Record 6

Energy Consumption & GHG emission Record 7

Dyeing Production, Solid waste record, ETP outlet water quality & sources of air emission 8

Target Setting & Action Plan 11

Conclusion 16

Acronyms and Abbreviations

EMS Environmental Management System

BMD Bangladesh Meteorological Department

GJ Giga Joule

MT Metric ton

GHG Green House Gas

ETP Effluent Treatment Plan

COD Chemical Oxygen Demand

BOD Biological Oxygen Demand

TDS Total Dissolved Solid

TSS Total Suspended Solid

MLSS Mixed Liquor Suspended Solid

SV Sludge Volume

SVI Sludge Volume Index

F/M Food to Microorganism

REB Rural Electrification Board

KWH Kilowatt Hour

LED Light Emitting Diode

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Chapter 1

Introduction

The textile & garment industry has become the backbone of the economy of Bangladesh.

About three million people are involved with garment and textile industries. It is essential to

promote sustainability in this large industrial sector. When the world textile & garment

market and companies are focusing on environment friendly products, the Bangladeshi

garment and textile industries are far beyond of it and it poses a risk of losing the world

market. It is high time to adopt special strategies and an approach towards sustainability.

Manufacturing environment friendly products in a sustainable way is the most important and

emerging issue at the present phase of industrialization. The main focus comprises not only to

the products quality sustainability but also it focuses on the manufacture processes including

raw material resources from cradle to grave. Nowadays many companies and organizations

focus on the environment friendly way of production. Sustainability of the textile & garments

industry is also a burning issue, needed to adopt cleaner and improved technology and

management for better environment.

Despite the significant economic contribution of the textile industries in Bangladesh, it has

brought with it a range of environmental problems, mostly pollution of water resources of the

country, energy resources degradation/CO2 emission & eutrophication. Water is very

important resources in our ecology. In textile, water is an important component and without

this textile industry cannot be operated. Huge quantity of water is used specially in dyeing &

washing section. Water & energy resources are limited and these must be used reasonably

and responsibly.

HAMS Washing & Dyeing Ltd. has been working to adopt & implement various strategies

and an approach towards sustainability. As part of this work, water consumption, waste

wastewater generation and energy consumption are recorded. Besides, greenhouse gas

emission and solid waste inventory are maintained. The water & energy consumption, waste

generation and greenhouse gas emission are reviewed by the authority of HAMS Washing &

Dyeing Ltd through sustainability report which is drafted yearly. The authority of HAMS

Washing & Dyeing Ltd sets target and define strategies to reduce water & energy

consumption as well as to improve environmental performance.

Based on water & energy consumption data of 2016, the authority of HAMS Washing &

Dyeing Ltd sets three years long target to improve environmental performance. It should be

mentioned here that HAMS Washing & Dyeing Ltd was shifted in current potion in 2016 and

production has been starting from April, 2016.

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Chapter 2

Water Consumption Record

HAMS Washing & Dyeing Ltd has installed water metering system to track & measure total

water consumption from natural resource and wastewater generation from manufacturing of

products. The activities within HAMS Washing & Dyeing Ltd are washing & dyeing. Wet &

Dry both are available. Most of the water is used for washing & dyeing purpose. The source

of water for HAMS Washing & Dyeing Ltd is underground water. The main purpose of water

metering system is; to track & measure total water withdrawal from underground, total water

consumption for production & domestic purpose and the total wastewater generation from

HAMS Washing & Dyeing Ltd.

The water consumption record for production purpose, water consumption in utility section

(boiler), domestic use purpose and the wastewater generation record are presented in table-1:

Table-1: Water consumption record in 2016

Water consumption & Wastewater generation in m3 for HAMS Washing & Dyeing Ltd-2016

Month/Year Use for

Production

Use for

Domestic

Use

for

Utility

Total water

consumption

Wastewater

generation

January

February

March

April 9930.0 9930 8639.1

May 15035.2 15035.2 13080.6

June 28588.9 228 1312 30128.9 26301.8

July 16424.7 211 953 17588.7 15110.8

August 19127.2 281 1301 20709.2 17597.0

September 10532.1 181 794 11507.1 9689.6

October 17172.6 268 1237 18677.6 15798.8

November 12206.8 239 1177 13622.8 11230.3

December 22241.2 258 1145 23644.2 20461.9

Total 151258.7 1666 7919 160843.7 137909.8

HAMS Washing & Dyeing Ltd has been starting production from April, 2016. That’s why

water consumption is not available from January to March. The water record for domestic &

utility use is not also available from April to May due to lack of metering system.

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Chapter 3

Energy Consumption & GHG Emission Record

In textile, energy is an important component and without this textile industry cannot be

operated. Energy resources are limited and these must be used reasonably and responsibly.

HAMS Washing & Dyeing Ltd mainly uses natural gas & diesel for generating power &

steam. Besides, purchase electricity is also used from REB.

The gas & diesel consumption record and the amount of electricity used from REB are

presented in table-2.

Table-2: Energy consumption record of HAMS Washing & Dyeing Ltd.

Natural gas, diesel & electricity from REB are recorded in cubic meter, litter & KWH

respectively. All of these energy units (m3, litter & KWH) converted to common unit GJ

using the following conversion factors:

Natural Gas: 38.4 MJ/Nm3

Diesel/fuel oil: 43.1 MJ/liter

Electricity (KWH): 3.6 MJ/KWH

Table-3: GHG emission record from HAMS Washing & Dyeing Ltd in 2016

GHG Emission Summery

Year Direct emission (stationery

fuel combustion)

Indirect emission (purchased

electricity consumption) Total in

tCO2e

2016 1951.9 777.4 2729.3

Energy Consumption record in 2016

Month/Year Gas (m3) Diesel (L) Electricity

(KWH)

January 636

February 11448

March 20670

April 3821 111936

May 6095 100329

June 13233 117501

July 7739 142941

August 429403 8668 179670

September 80816 4880 101124

October 172070 7896 217989

November 123630 5737 178716

December 130963 10531 168858

Total 936882 68600 1351818

Total in GJ 35976.3 2956.7 4866.5

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Chapter 4

The record of Production, waste generation, ETP outlet water quality & sources of air

emission

The production activities of HAMS Washing & Dyeing Ltd is washing & dyeing of finish

garments specially denim. The production record is maintained in pcs but to convert in

weight, every pcs is considered equivalent to 450 gram.

Table-4: Production record for 2016

Solid waste:

Waste is any substance or object which is discarded, intended to be discarded or is required to

be discarded. Waste can include expired raw materials generated from a process for which

there is no further use on-site, expired finished products, process or non-process by-products,

customer returns, redundant equipment, etc.

"A hazardous waste is a waste that could cause harm to public health and/or the environment

because of its chemical, physical or biological characteristics (e.g., it is flammable, explosive,

toxic, radioactive, or infectious). Hazardous wastes that is dangerous or potentially harmful to

our health or the environment. Hazardous wastes can be liquids, solids, gases, or sludge.

They can be discarded commercial products, like cleaning fluids or pesticides, or the by-

products of manufacturing processes. (The U.S. Environmental Protection Agency).

Table-5 presents the amount of solid waste including hazardous & non-hazardous was

generated from HAMS Washing & Dyeing Ltd.

Table-5: Solid waste record in 2016

Year Non Hazardous waste

in kg

Hazardous waste

in kg Total Solid

waste in kg

2016 1311 6507.5 7818.5

Month name Production in Pcs Production in MT

January

February

March

April 584118 262.9

May 939699 422.9

June 2042065 918.9

July 1190199 535.6

August 1346984 606.1

September 752295 338.5

October 1244389 560.0

November 904210 406.9

December 1659788 746.9

Total 10663747 4798.7

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Hazardous waste:

Iron+Tin+Steel, Aluminum, Broken Glass, Broken tub-light, ETP Sludge, Wastage oil,

Chemical Drum, Medical waste, Poly and plastic bag.

Non Hazardous waste: Cartoon

The solid waste generated from HAMS washing & Dyeing Ltd is segregated with 11 classes.

Only one item was found nonhazardous waste namely cartoon and others are hazardous.

Air Emission Inventory:

Air emission inventory is presented in table-6. Air emission inventory is maintained annually.

The air emission test is conducted by third party annually for HAMS Washing & Dyeing Ltd.

There is no accredited body in Bangladesh for air emission test. That’s why third part air

emission test results are not presented in air emission inventory.

Table-6: Air emission Inventory

S.l.No EMISSION POINT NAME OF POLLUTANTSOURCE/

EQUIPMENT

EMISSION

AMOUNT

(AND UNITS)

LEGAL EMISSION

LIMIT(DoE)

MONITORING

FREQUENCY

1 Diesel Generator-1 NOX Generator N/A200 (mg/Nm3),

DoE StandardAnnual

2 Diesel Generator-1 Sox Generator N/A0.14 ppm 24 hrs &

0.03 ppm annualAnnual

3 Diesel Generator-1 CO Generator N/A9 ppm 8 hrs & 35

ppm 1 hrAnnual

4 Diesel Generator-2 NOX Generator N/A 0.053 ppm annual Annual

5 Diesel Generator-2 SOx Generator N/A

150 mg/Nm3 24

hrs & 50 mg/Nm3

annual

Annual

6 Diesel Generator-2 CO Generator N/A

65 mg/Nm3 24 hrs

& 15 mg/Nm3

annual

Annual

7 Gas boiler SOx Boiler N/A200 (mg/Nm3),

DoE StandardAnnual

8 Gas boiler NOx Boiler N/A0.14 ppm 24 hrs &

0.03 ppm annualAnnual

9 Gas boiler CO Boiler N/A9 ppm 8 hrs & 35

ppm 1 hrAnnual

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In-house laboratory wastewater test report:

HAMS Washing & Dyeing Ltd. has an in-house ETP laboratory to analysis wastewater

(before & after treatment). Almost all kind of parameter like as COD, BOD, TSS, pH, TDS,

MLSS, SV, SVI, F/M can be analyzed by ETP laboratory. The activity of this laboratory was

started from March, 2016. In table-7, only ETP outlet water test results are presented.

Table-7: ETP outlet water quality test report (In house laboratory)

Date COD in

ppm

BOD in ppm TSS in

ppm

pH

6/4/2016 20 7.3

12/4/2016 60 40 7.7

17/4/16 66 7.3

23/4/16 30 7.5

24/4/16 59 40 7.5

25/4/16 70 30 7.6

26/4/16 65 20 7.5

1/5/2016 30 8 7.5

8/5/2016 20 7.7

21/5/2016 149 35 7.3

19/6/16 122 35 7.35

25/6/16 45 7.7

17/7/16 34 12 7.8

26/7/16 20 7.7

1/8/2016 14 7.8

11/8/2016 20 7.6

18/8/16 35 16 7.9

27/8/16 15 7.7

4/9/2016 12 7.7

21/9/16 10 7.5

2/10/2016 130 40 7.7

9/10/2016 68 26 20 7.8

19/10/16 11 7.4

7/11/2016 17 10 7.2

22/11/16 17 7 7.6

3/12/2016 40 6 7.5

18/12/16 17 10 20 7.7

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Chapter 5

Target Setting & Action Plan

HAMS Washing & Dyeing Ltd. sets target to improve environmental performance as well as

reduce energy & water consumption. The concern authority review improvement against

target annually and take corrective action plan to achieve target.

Energy

Target Name 5% energy consumption reduction for

per ton production

Target Type Normalized

Base year 2016

Target Start date 01/01/2017

Target End Year 31/12/2019

% Reduction from base year N/A

Metric for Normalized targets per ton of production

Base year consumption amount 9.1GJ

The current reporting period's normalized

energy consumption amount

N/A

Water

Target Name 10% Water consumption reduction for

per ton production

Target Type Normalized

Base year 2016

Target Start date 01/01/2017

Target End Year 31/12/2019

% Reduction from base year N/A

Metric for Normalized targets per ton of production

Base year consumption amount 31.5 m3

The current reporting period's normalized

energy consumption amount

N/A

Chemical management

Target Name Achieve 80% score in chemicals

management performance in self-

assessment module

Target Type Absolute

Base year 2016

Target Start date 01/01/2017

Target End Year 31/12/2018

% increase chemicals management

Performance score from base year

N/A

Metric for Absolute targets Total score in self-assessment module

Base year score 49%

The current reporting period's score N/A

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Action Plan:

Energy:

Hot water/Condensate Recovery:

Projection Time: 2017-2018.

If 1 ton/h of steam is supplied to equipment for a heating process, then the same amount of

condensate (1 ton/h) needs to be discharged from the equipment. Condensate recovery is a

process to reuse the water and sensible heat contained in the discharged condensate.

Recovering condensate instead of throwing it away can lead to significant savings of energy,

chemical treatment and make-up water. Reusing hot condensate can lead to considerable

savings in terms of energy and water resources, as well as improve working conditions and

reduce your plant's carbon footprint. Condensate contains a significant amount of sensible

heat that can account for about 10% to 30% of the initial heat energy contained in the steam.

Feeding the boiler with high-temperature condensate can maximize boiler output because less

heat energy is required to turn water into steam. When efficiently recovered and reused, it can

even be possible to reduce boiler fuel needs by up to 10 to 20%.

Theoretically one m3 water is required to produce one ton steam. HAMS Washing & Dyeing

Ltd has a NG boiler with the capacity of 5.5 ton per hour. Presently this boiler is being

operated with at 70% load of their capacity. Steam is used mainly in washing & drying. It is

assume that around 65% steam is used for washing and 35% is used for drying section. At

present steam condensate from drying section is drained out. However, this condensate will

be recovered to feed water tank that use to pre heat the boiler again up to 90-920c.

Upgrade generator monitoring to electrical power management control system

Projection Time: 2017 to 2018

The present generator monitoring provides too little information for monitoring their

performance. Fortunately a better generator monitoring system is available. However even

this system can be improved and extended as to include real-time diesel consumption and

overall generator efficiency along with the complementing power consumption from the grid.

By installing an electricity measuring system for generator and by upgrading this monitoring

system to calculate effective efficiency at varying load and adding automatic modulating

controls a true electrical power management system can be realized automatically control all

generators which switches the generators on/off according to demand and optimizes the

production of each generators as to achieve maximum the overall efficiency while

minimizing the total cost of power consumption including grid and stand-by diesel

generators.

Install solar panel:

Projection Time: 2017 to 2019

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The authority of HAMS Washing & Dyeing Ltd has a planned to use solar panel for lighting

purpose to save energy as well as reduce carbon foot print for entire factory. Already a solar

panel has been installed which capacity is 2.5 KW.

Use LED & Energy saving Light:

Projection time: 2016

All lights of entire factory of HAMS Washing & Dyeing Ltd are LED & energy saving light.

The authority of HAMS Washing & Dyeing Ltd uses LED & energy saving light for lighting

purpose to save energy as well as reduce carbon foot print.

Replacing conventional boiler with energy saving boiler including economizer:

Projection time: 2017

Previously, HAMS washing & Dyeing used a conventional boiler which consumed more fuel

to generate steam. The authority of HAMS Washing & Dyeing Ltd decided to replace this

conventional boiler with a modern boiler which has economizer & others energy saving

accessories. Inserting an economizer in the flue gas outlet of the steam boilers as to preheat

the boiler feed water would save about 2.7% on the fuel consumption for steam production.

Around 30% less energy is consumed by new modern boiler to produce similar amount of

steam compare to old boiler.

Water:

Rain Water Harvesting

Projection Time: 2017 to 2018. HAMS Washing & Dyeing Ltd has a plan for rainwater

harvesting on roof top area of the shads & buildings. Table-8 presents the roof top area of the

shads & buildings with the annual volume of rainfall. From figure-1, it can be seen that the

lowest annual rainfall is 4.4 mm in January and the maximum annual rainfall is 388.5 mm in

July. In average, at Dhaka & Gazipur region, the annual rainfall is 1960 mm from 2001 to

2015.

Figure-1: Monthly averages of Rainfall & Humidity data at the Dhaka & Gazipur region

(From Dhaka BMD Station), 2001-2015. Source: Bangladesh Meteorological Department

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Table-8: Roof top area of the shads & buildings with the yearly volume of rainfall

Building/shad Area in m2 Annual average

rainfall in mm

Volume of rainfall

(Annual) in m3

Main Building 4673

1960

9159

Chemical store room 576 1129

Total 5249 10288

http://www.calctool.org/CALC/other/default/rainfall(this tool use to convert rainfall in mm to

rainfall in m3 considering roof top area)

From table-8 it can be seen that, HAMS Washing & Dyeing Ltd can use approximately

10288 m3 water annually from rainwater harvesting instead of using from ground water.

According to figure-1, the maximum possible rainfall is 388 mm (4817 m3 for area of

12415.35 m2) in July throughout the year.

Using Water Efficient Equipment

Projection time: 2017

Water consumption for production purpose can be saved by replacing outdated equipment

with modern machines which operate at low liquor ratio. HAMS washing & Dyeing Ltd has

26 washing machines which operate with 1:9 liquor ratio. The authority of HAMS washing &

dyeing ltd has planned to install 10 Brongo-L4200 washing machines which operate with low

liquor ratio (1:5). Two Brongo-L4200 washing machines have already been installed and 8

more Brongo-L4200 washing machines will be installed by May, 2017. At least 35% less

water is consumed by Brongo-L4200 washing machine compare to existing washing

machine.

Reuse Blower cooling water:

Projection Time: 2017 to 2018

HAMS Washing & Dyeing Ltd has a biological ETP with the capacity of 2000 m3 per day.

Continuous aeration is necessary for biological ETP and aeration is provided by blower.

Three blowers are running simultaneously in ETP and these blowers are needed to be cooled

by supplying soft water. For this purpose, around 35 m3 water per day is required. HAMS

Washing & Dyeing Ltd has planned to save 35m3/day

water by reuse blower cooling water.

Awareness & Monitoring

Projection time: 2017 to 2018

The significant amount of water consumption for dyeing & washing section can be saved by

monitoring & creating awareness.

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Turn off Running Taps and Hoses

This simple procedure can result in substantial savings. People are often unaware of the cost

of leaving taps and hoses running. They are more likely to turn off running taps and hoses if

they are made aware of the annual cost of waste. Meanwhile, fixing hand triggers to hoses is

a simple way of reducing water use and saving money.

Turn off Water when Machines are not running.

Encourage workers to turn off machines and water during breaks and at the end of the day.

Avoid circulating cooling water when machines are not in use. The concern department of

HAMS Washing & Dyeing Ltd has been working to formulate & implement an integrated

Environmental Management System (EMS). A relevant program for creating awareness &

monitoring regarding water consumption will be included of that EMS.

Improve chemicals management performance:

The concern authority of HAMS Washing & Dyeing Ltd. committed to:

Continual improvement of chemical management performance

Expand win of economic, environmental, safety & health and organizational benefits

through implementing systematic management of chemicals

Complying with national legislation and conforming to emerging customer

requirements and international standards on management of chemicals

strengthening in-house competence of personnel in companies (workers, middle

management), integrating CM training into in-house training units

enabling EHS managers/officers and company personnel concerned with handling of

chemicals in textile companies to improve the condition of chemical management in

the factory

The chemical management system will be formulated and it will work through Plan-Do-

Check-Act framework. The following jobs will be conducted through Plan-Do-Check-Act

framework to establish an appropriate chemical management system:

Maintaining legal register including National and other laws and regulations

Systematically identify and document chemicals used and stored

Material flow accounting; Process flow diagram, Chemical trajectory & NPO

identification

Maintaining Chemical inventory

Chemical risk analysis

Hazard & risk mapping

Chemical risk management action; Training, Document Development, Document and

Record Control,

Chemical Management Work Practices & Emergency Procedures; Exposure control

measures, Safety data sheet management(procedure for making SDS available),

Chemical handling( procedure for SOP development, format), Chemical storage in

well design store, Chemical transportation, Chemical use –Regular and optimization,

Personal protective equipment (procedures for selection, use, maintenance),

Laboratory practices, Maintenance and housekeeping, Waste and disposal.

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Chapter 6

Conclusion

The total washing production (MT), water (m3) & energy (GJ) consumption for production

and wastewater (m3) generation in 2016 of HAMS Washing & Dyeing Ltd. are presented in

table-9.

Table-9: Production, water & energy consumption and wastewater generation record of

HAMS washing & dyeing Ltd. in 2016

Year 2016

Washing production(MT) 4798.7

Water consumption(m3) 151258.7

Waste water(m3) 137909.8

Energy consumption(GJ) 43799.5

Figure-2: presents the production, water & energy consumption and wastewater generation of

HAMS washing & dyeing Ltd in 2016

Table-10: Base year water & energy KPI for per ton production

Year Base year 2016 Target year 2018

Water consumption (m3) 31.5 Reduce by 10% from base year

Energy consumption (GJ) 9.1 Reduce by 5% from base year

………………

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