Indian textile industry environment issue ppt, nitra
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Transcript of Indian textile industry environment issue ppt, nitra
1I I T DelhiDec.7,2002
INDIAN TEXTILE INDUSTY-ENVIRONMENTAL ISSUES
Prof.R.B.CHAVAN
DEPT. OF TEXTILE TECHNOLOGY
INDIAN INSTITUTE OF TECHNOLOGY
HAUZ-KHAS, NEW DELHI
2I I T DelhiDec.7,2002
PRESENT PAPER
STRUCTURE OF TEXTILE INDUSTRY
PROBLEMS
IMPACT ON ENVIRONMENT
POLLUTION CONTROL STRATEGY
GERMAN BAN
RESPONSE OF MINISTRY OF TEXTILES
TO COPE WITH GERMAN BAN
Dec.7,2002 I I T Delhi 3
Decentralized Sector
TEXTILE INDUSTRY IN INDIA
NATURAL FIBRES / FABRICS
MAN-MADE FIBRES / FABRICS
Organized Sector(Mills)
Spinning Composites Handloom Powerloom Khadi
WOOL
JUTE
SILK
COTTON
RAYONCellulose / viscose
BLENDED(Synthetic + Natural)
SYNTHETIC(Nylon, PET, PAN)
Dec.7,2002 I I T Delhi 4
11
33
0
10
20
30
40No
. of S
pind
les in
m
illio
n
Spinning Capacity
1951 1997
2.1
1.24
0
0.5
1
1.5
2
2.5
No.
of L
oom
s in
lakh
s
weaving Capacity
1951 1997
Dec.7,2002 I I T Delhi 5
Share of Cloth Production
1990's
6%
74%
20%
1950's
70%
20%
10%
Organized Sector
Power Loom
Handloom
6I I T DelhiDec.7,2002
INDIAN TEXTILE INDUSTRY AND ITS PROBLEMS
ONE OF THE OLDEST AND SINGLE LARGEST INDUSTRIAL SECTORS SHARE OF TEXTILE PRODUCTION IN 50S ORGANIZED SECTOR >75%
DENCENTRALIZED POWERLOOM 25%
PRESENTLYORGANIZED SECTOR 6%
BALANCE POWERLOOME, HANDLOOM, HOSIERY
7I I T DelhiDec.7,2002
DIFFICULT PHASE 60S AND 70S
OBSOLETE MACHINERY LACK OF MAINTENANCE LACK OF MODERNIZATION LOW PRODUCTIVITY LOW CAPACITY UTILIZATION STAGNANT DOMESTIC MARKETS SAGGING EXPORTS
WIDE SPREAD SICKNESS
8I I T DelhiDec.7,2002
EMERGING TRENDSEMERGENCE OF SYNTHETIC AND
BLENDED FABRICS
PHENOMENAL EXPANSION OF SPINNING
RAPID EXPANSION OF DECENTRALIZED POWERLOOM SECTOR
BROUGHT SICKNESS COMPOSIT ORGANIZED SECTOR
LARGE NUMBER OF MILLS WENT BANKRUPT
2/3 OF THEM WERE COMPOSIT MILLS
9I I T DelhiDec.7,2002
NATIONALIZATION (1967)
SETTING UP OF NATIONAL TEXTILE CORPORATION (NTC)
MAIN OBJECTIVE: EMPLOYMENT RELIEF TO THOUSANDS OF WORKERS
PRODUCTION OF CONTROLLED CLOTH
EXPERIMENT MISERABLY FAILED
MANY NTC MILLS CLOSED DOWN
10I I T DelhiDec.7,2002
NEW TEXTILE POLICY (1980)
OBJECTIVE: DEVELOP HARMONIOUSLY
MILL, POWERLOOM AND HANDLOOM SECTORS
RECOGNITION OF LACK OF MODERNIZATION AS MAIN CAUSE OF SICKNESS
750 CRORE AS TEXTLE MODERNIZATION FUNDS IN 1986
11I I T DelhiDec.7,2002
SHIFT IN PRODUCTION PATTERN 1987 GLOBAL INCREASE IN COTTON
PRICES SPINNING THOUGH TECHNOLOGICALLY
ADVANCED, LABOUR INTENSIVEDEVELOPED COUNTRIES PREFERRED
TO BYU YARN FROM DEVELOPING COUNTRIES
LED TO YARN EXPORT GROWTH IN INDIA FROM 1987 ONWARDS
5% YARN EXPORT IN 1990 INCREASED TO 22% IN 1997
12I I T DelhiDec.7,2002
LIBERALIZATION
DE-LICENSING OF TEXTILE INDUSTRY
(1991)
IMPORT OF MODERN MACHINES TO SET UP NEW UNITS
IMPROVEMENT IN YARN QUALITY
INDIA BECAME GLOBAL PLAYER IN
YARN EXPORTS
13I I T DelhiDec.7,2002
COLLAPSE OF YARN EXPORTS
IN 1990 70% EXPORT TO QUOTA COUNTRIES 30% TO NON-QUOTA COUNTRIES
AFTER LIBERIZATION INCREASE IN PRODUCTION STAGNANT QUOTA EXPORTS SHOT UP IN NON-QUOTA EXPORS 80% DROP IN QUOTA EXPORTS 20% UNINTENTIIONAL EXPORT DEPENDENCE
ON NON-QUOTA COUNTRIES
14I I T DelhiDec.7,2002
COLLAPSE OF YARN EXPORTS
IN 1997
CURRENCY CRISIS IN SOUTH EAST ASIAN COUNTRIES
SEVERE EFFECT ON EXPORTS
EXPORT BELOW COST
DUMP EXPORT QUALITY YARN IN DOMESTIC MARKET
CRIPPLING EFFECT ON TEXTILE INDUSTRU
HUGE OVERSUPPLY POSITION
SUNRISE INDUSTRY BECAME SUNSET INDUSTRY
15I I T DelhiDec.7,2002
WTO REGIME
MEMBER OF WTO
SIGNATORY TO GATT( GENERAL AGREEMENT ON TRADE AND TARRIF)
END OF ATC (AGREEMENT OF TEXTILES AND CLOTHING) BY DECEMBER 2004.
END OF QUOTA ERA
TO FACE THE GLOBAL COMPETITION
LIMITED TIME FOR
INDUSTRY RESTRUCTURE
IMPROVED QUALITY PRODUCTS AT COMPETITIVE PRICE
16I I T DelhiDec.7,2002
NEED OF THE HOUR
MODERNIZE TO COMPETE GLOBALLY
WITHSTAND CHEAPER IMPORTS FROM CHINA, PAKISTAN AND OTHER SOUTH-EAST ASIAN COUNTRIES
TECHNOLOGY UPGRADATION FUND SCHEME (TUFS)
Rs 25 000 CRORE FOR MODERNIZATION
5% RE-IMBERSEMENT OF INTEREST CHARGED BY FINANCIAL INSTITUTIONS
IN OPERATION FOR FIVE YEARS FROM APRIL 1999 – MARCH 2004
17I I T DelhiDec.7,2002
INDIA IS FIRST COUNTRY TO HAVE CONSTITUTIONAL PROVISION FOR ENVIRONMENT PROTECTION.
NO SPECIFIC ENVIRONMENTAL NORMS FOR TEXTILE SECTOR
INDUSTRY SPECIFIC STANDARDS EXIST STRINGENT ENVIRONMENTAL LEGISLATION POORLY EMFORCED JUDICIARY HAS TO INTERVENE TO ENFORCE
ENVIRONMENTAL POLICIES JUDICIARY HAS GOT ITS OWN LIMITATIONS AND CAN
NOT ACT AS ENFORCING AGENCY. MAKING LAW ONLY DOES NOT HELP ENVIRONMENT IS A SOCIAL RESPONSIBILITY DESIRABLE COMPLIENCE SHOULD COME VOLUNTARILY
FROM INDUSTRY AND NOT BY POLICING
ENVIROMENT LEGISLATION
18I I T DelhiDec.7,2002
IMPACT ON ENVIRONMENTINDUSTRIAL ACTIVITY IS ASSOCIATED WITH
POLLUTIONEXTENT VARIESCONCEPT: TO KEEP POLLUTION LEVEL AS
LOW AS POSSIBLEANOTHER DIMENSION: SOCIAL
ACCOUNTABILITY STANDARDS SAS 1800NO CHILD LABOURMINIMUM LABOUR WAGESPROVISION OF HYGIENIC CONDITIONS AT
WORK PLACECOMPLIANCE WITH GERMAN BAN INTRODUCED
IN 1996
Dec.7,2002 I I T Delhi 19
Input / output analysis of Textile Finishing Processes
Textile Auxiliaries
Dyes
Base chemicals(e.g. acid, Alkali, sodium chloride)
Textile EnergyNatural Fibres; 10-20 MJ/kgSynthetic Fibres: 5-50 MJ/kg
Water60-360 l/kg textile
Polluted Air
Water Effluent
WasteSewage sludge:
60-70 g/kg textile
Wet Processing (pre-treatment,
dyeing, printing,
finishing.)
AIR EMMISSION SOURCES
FOUR GENERAL CATEGORIES
OIL AND ACID MISTS
SOLVENT VAPOURS
ODOUR
DUST AND LINT
21I I T DelhiDec.7,2002
OIL AND ACID MISTS
MOST COMMON SOURCE IS STENTER
EVAPORATION OF SPINNING OILS, PLASTICIZERS, AND VOLATILE FINISHING AGENTS
ACID MISTS (CORROSIVE)
DURING WOOL CARBONIZATION
VOLATILIZATION OF ORGANIC ACIDS LIKE ACETIC ACID
22I I T DelhiDec.7,2002
SOLVENT VAPOURS
INCLUDE LARGE NUMBER OF TOXIC
CHEMICALS
KEROSENE OR MINERAL TURPENTINE
OIL
FORMALDEHYDE
CARRIERS FOR POLYESTER DYEING
CHLOROFLUORO HYDROCARBONS
23I I T DelhiDec.7,2002
ODOUR
ASSOCIATED WITH
OIL MIST OR SOLVENT VAPOURS
SULPHUR DYEING
BLEACHING WITH SODIUM
HYPOCHLORITE
24I I T DelhiDec.7,2002
DUST AND LINT
PRODUCED DURING
SPINNING AND WEAVING
CARPET SHEARING
CAUSE RESPIRATORY DISEASES
25I I T DelhiDec.7,2002
EFFLUENT CHARACTERISTICSTEXTILE EFFLUENTS GENERALLY ARE
COLOURED
HIGH BOD
HIGH TDS
HIGH RATIO BETWEEN BOD AND COD
RATIO OF 1:2 TO 1:3 INDICATES GOOD BIODEGRADABILITY
IN WOOL RATIO 1:5 INDICATING DIFFICULT BIODEGRADABILITY DUE
TO GREASE CONTENT
26I I T DelhiDec.7,2002
DETERGENTS AND
SURFACTANTS RISK TO AQUATIC LIFE
HEALTH RISK TO LARGE POPULATION IF DISCHARGED IN RIVER USED FOR DRINKING
27I I T DelhiDec.7,2002
METAL POLLUTANTS
METAL COMPLEX DYES
CHROMIUM SALTS USED FOR
SULPHUR DYE OXIDATION
CHROME DYEING OF WOOL
• MORDANTS FOR NATURAL
DYES
28I I T DelhiDec.7,2002
ORGANIC WASTES
SIZES
VARIOUS ORGANIC SOLVENTS AND ACIDS
29I I T DelhiDec.7,2002
CLASSIFICATION OF TEXTILE
WASTES
HARD TO TREAT
HAZARDOUS OR TOXIC
DISPERSIBLE
• HIGH VOLUME
30I I T DelhiDec.7,2002
HARD TO TREAT WASTES
COLOURS
METALS
PHENOL
TOXIC ORGANIC COMPOUNDS
PHOSPHATES
NON-BIODEGRADABLE SURFACTANTS
TOXIC TO AQUATIC LIFE
31I I T DelhiDec.7,2002
TOXIC WASTES
SUB GROUP OF HARD TO TREAT
WASTES
METALS
CHLORINATED SOLVENTS
BOILER CHEMICALS
32I I T DelhiDec.7,2002
DISPERSIBLE WASTES
PRINT PASTES
COATING CHEMICALS
UNUSED PROCESS CHEMICALS
HIGH VOLUME WASTES
WASH WATER FROM • PREPARATORY
• DYEING
• PRINTING
• EXHAUSTED DYEBATHS
34I I T DelhiDec.7,2002
POLLUTION CONTROL
STRATEGIES CLEANER PRODUCTION
TECHNIQUES
• END OF PIPE TREATMENTS
35I I T DelhiDec.7,2002
CLEANER PRODUCTION TECHNIQUES
WASTE MINIMIZATIONHIGHEST PRIORITY FOR REDUCTION IN WASTE
WATER COUNTER CURRENT WASHING OPERATIONS OPTIMUM USE OF PROCESS CHEMICALSSUBSTITUTION OF TOXIC CHEMICALS BY ECO
FRIENDLY CHEMICALSGOOD HOUSE KEEPINGRECOVERY OF CHEMICALS SUCH AS SIZE, CAUSTIC
SODA, DYES AND GREASEREPLACEMENT OF HIGH BOD CHEMICALS BY LOW
BOD ONESUSE OF LOW LIQUOR RATIO DYEING EQUIPMENTSIMPROVED PRODUCTION PROCESSES TO ELIMINATE
AND REDUCE WASTE AS MUCH AS POSSIBLE
36I I T DelhiDec.7,2002
CLEANER PRODUCTION TECHNIQUES
END OF PIPE TREATMENTS
SEGREGATION AND SEPARATE TREATMENT OF SPECIFIC EFFLUENT STREAM IS MORE EFFICIENT COMPARED TO
COMBINED AND COMPLEX EFFLUENTS
SUCH STRATEGY PROVIDE OPPORTUNITY TO
RE-USE WATER
RECOVER CHEMICALS
• REDUCE SIZE OF TREATMENT PLANT
EFFLUENT TREATMENT
COMMON PROCESS
PRIMARY SETTLING
FLOCULATION/CHEMICAL COAGULATION
BIOLOGICAL TRETMENT
SECONDARY PHYSICAL ADSORPTION
TERTIARY TREATMENT IF NECESSARY
38I I T DelhiDec.7,2002
SLUDGE TREATMENT AND DISPOSAL
FORMATION OF LARGE QUANTITIES OF
SLUDGE DURING
BIOLOGICAL TREATMENT
SUBJECT SLUDGE TO AEROBIC
DIGESTION
DEWATER BY CENTRIFUGE
DISPOSE OFF TO LAND FILL
39I I T DelhiDec.7,2002
SOLID WASTES
INCLUDE
CANS
REJECTED FABRIC PIECES
CART AWAY TO LAND FILL OR
INCINERATE ON OR OFF SITE
DURING INCINERATION ADEQUATE AIR
POLLUTION CONTROL MEASURES
40I I T DelhiDec.7,2002
AIR EMMISSION CONROL
OIL MISTS AND VOLATILE ORGANIC CARBON (VOC)
MORE DIFFICULT TO CONTROL
CONTROL THE APPLICATION OF SPINNING
OILS AND FINISHING AGENTS
PROPER AIR DUCTING
INSTALLATION OF MIST ELIMINATORS
CONDENSATION OF VAPOURS BY COOLING THE
CONTAMINATED AIR
41I I T DelhiDec.7,2002
MANAGING AND AUDITING RESOURCE CONSUMPTION
RESEARCH ASSOCIATIONS DEVELOPED MANUFACTURING NORMS FOR
DESIRABLE USAGE OF RESOURCES SUCH AS WATER, LABOUR, ELECTRICITY AND COMMON CHEMICALS
NORMS NOT IMPOSED LEGALLY
ACT AS GUIDELINES
MEMBERMILLS ARE ENCOURAGED TO FOLLOW THESE NORMS
RECORD OF SIMPLE MATERIAL BALANCE
WORTH EXAMINING THE RECORD OF STORE KEEPER AND PROCESSING DEPRTMENTS TO TRACK LOSSES OF EXPENSIVE AND/OR HAZARDOUS CHEMICALS DURING HANDLING AND PROCESSING
Dec.7,2002 I I T Delhi 42
MANAGING AND AUDITING RESOURCE CONSUMPTION
• ASSESSMENT AT INTERVALS THE PERFORMANCE
OF EFFLUENT TREATMENT PLANT AND AIR
POLLUTION CONTROL EQUIPMENTS
IT IS NECESSARY TO EMPLOY A FULL TIME
PROFESSIONAL ENVIRONMENTAL TEAM OR TRAIN
SENIOR STAFF AND WORKERS TO UNDERTAKE
ENVIRONMENT MONITORING AND AUDIT TASKS
COMMITMENT BY TO MANAGEMENT TO
ESTABLISH SOUND ENVIRONMENT MANAGEMENT
SYSTEM
THIS WOULD ALSO IMPROVE THE PRODUCTIVITY
AND PROFITABILITY OF THE ORGANIZATION
43I I T DelhiDec.7,2002
SIMPLE OPTIONS
IMPROVED HOUSEKEEPINGBETTER EQUIPMENT MAINTENANCEOPTIMIZATION OF VARIOUS PROCESS
SEQUENCESTHE MANAGERS MUST HAVE BASELINE
DATA FOR SIMILAR OPERATIONA IN OTHER INDUSTRIES
COMPARE AND INTERPRET THE RESULTS WITH OPEN MIND
ALLOW DISCUSSION BETWEEN STAFF AND ENCOURAGE TEAM MEMBERS TO BRING FORWARD INNOVATIVE IDEAS
EVALUATE THE IDEAS FROM TECHNICAL AND ECONOMIC PERSPECTIVE
44I I T DelhiDec.7,2002
POLICY MANAGEMENT BY GOVT OF INDIA
GERMAN BAN AND GOVERNMENT RESPONSE
• RECOGNITION THAT NUMBER OF DYES AND CHEMICALS ARE HAZARDOUS
• AFFECT THE CONSUMER HEALTH
• CAUSE IRREPARABLE DAMAGE TO ENVIRONMENT
• GERMANY IMPOSED BAN ON THE USE OF AZO DYES
BASED ON CARCINOGENIC AMINE
• ABOUT 300 AZO DYES SUSPECTED TO BE CARCINOGENIC HAVE BEEN WITHDRAWN
• ENVIRONMENTAL PERMISSIBILITY NORMS FOR
HAZARDOUS CHEMICALS ARE AVAILABLE FROM
VARIOUS INTERNATIONAL ORGANIZATIONS
45I I T DelhiDec.7,2002
ECO STANDARDS AND ECO LABLES CONCEPT OF ECO FRIENDLY TEXTILES IS
PROMOTED BY ECO STANDARDS AND ECO LABLES
ECO LABLES ARE BASED ON ENVIRONMENT
FRIENDLY NORMS FOR VARIOUS CHEMICALS STIPULATED ON THE BASIS OF CRADLE TO GRAVE APPROACH
USE OF ECO LABLES IS VOLUNTARY IN
NATURE
46I I T DelhiDec.7,2002
ECO STANDARDS AND ECO LABLES
CHEMICALS CONSIDERED FOR ECO NORMS
FORMALDEHYDE
TOXIC PESTICIDES
PENTACHORO PHENOL
HEAVY METAL TRACES
CARCINOGENIC AZO DYES
HALOGEN CARRIERS
CHLORINE BLEACHING
47I I T DelhiDec.7,2002
EFFORTS MADE BY GOVERNMENT OF INDIA
REGULATORY MEASURES
• PROHIBITION ON THE USE OF BANNED DYES
• EVOLUTION OF ECO STANDARDS AND LOGO FOR ECO FRIENDLY TEXTILES
48I I T DelhiDec.7,2002
EFFORTS MADE BY GOVERNMENT OF INDIA
DEVELOPMENTAL MEASURES• ORGANIZATION OF EDUCATIVE SEMINARS,
WORKSHOPS FOR THE AWARENESS OF ECO FRIENDLY CONCEPTS
• ASSISTANCE TO INDUSTRY FOR THE SECURING ISO 9000 AND EMS 14000 CERTIFICATION
• FINACIAL ASSISTANCE THROUGH TUFS FOR MODERNIZATION
• MASSIVE PROGRAMME ON SETTING ECO TESTING FACILITIES
•