IMPLEMENTATION OF CHEMICAL REDUCTION AND CHEMICAL SUBSTITUTION IN AN INTEGRATED TEXTILE FACILITY

Abstract

In this study, it was aimed to reduce chemical consumption and replace environmentally risky chemicals with environmentally friendly substitutes in an integrated textile facility that mainly produces cotton woven and knitted fabrics. Detailed on-site investigations and data collection studies were carried out in the facility. Specific dyestuff and specific auxiliary chemical consumptions were calculated on the basis of processes. Specific dyestuff and auxiliary chemical consumptions of the facility were compared with similar textile facilities in the literature and Best Available Techniques Reference Document for the Integrated Pollution Prevention and Control (IPPC) Textile Industry (BREF). Thus, the reduction potentials of the facility in terms of dyestuff and chemical consumptions were evaluated. In addition, material safety data sheets (MSDS) of a total of 450 chemicals were examined in terms of biodegradation ratios, toxic properties and micropollutant contents. Accordingly, 48 chemicals were determined to be environmentally risky and their replacement with environmentally friendly substitutes was suggested. It was decided to implement 10 chemical reduction techniques together with the facility management and technical personnel, using the information obtained from field and data analysis studies carried out in the facility. For each determined technique, reduction ratios, investment costs and payback periods were calculated. It was found that with the application of all the techniques determined in the facility, a reduction of 14.9-27.3% could be achieved in the consumption of dyestuffs and auxiliary chemicals. Payback period of the practices could be less than 41 months.

Keywords

• Chemical Inventory
• Chemical Substitution
• Chemical Reduction
• Textile
• Cleaner Production

ENTEGRE BİR TEKSTİL İŞLETMESİNDE KİMYASAL AZALTIMI VE KİMYASAL DEĞİŞİMİ UYGULAMASI

Abstract

Bu çalışmada ağırlıklı olarak pamuklu dokuma ve örgü kumaş üretimi yapan entegre bir tekstil işletmesinde kimyasal tüketimlerinin azaltılması ve çevresel açıdan riskli kimyasalların çevre dostu ikameleriyle değişimi amaçlanmıştır. Tesiste yerinde detaylı incelemeler ve veri toplama çalışmaları yapılmıştır. Prosesler bazında spesifik boyarmadde ve spesifik yardımcı kimyasal tüketimleri hesaplanmıştır. Tesisin spesifik boyarmadde ve yardımcı kimyasal tüketimleri literatürde ve Entegre Kirlilik Önleme ve Kontrol (IPPC) Tekstil Sektörü için Mevcut En İyi Teknikler Referans Dokümanında (BREF) yer alan benzer tesis verileriyle kıyaslanmıştır. Böylelikle tesisin boyarmadde ve kimyasal kullanımı açısından azaltım potansiyelleri değerlendirilmiştir. Ayrıca tesiste toplam 450 kimyasalın malzeme güvenlik bilgi formları (MGBF) biyodegradasyon oranları, toksik özellikleri ve mikrokirletici içerikleri açısından incelenmiştir. Buna göre 48 kimyasalın çevresel açıdan riskli olduğu belirlenmiş ve çevre dostu ikameleriyle değişimleri önerilmiştir. Tesiste yürütülen saha çalışmaları ve veri analizi çalışmaları sonucunda elde edilen bilgilerden yararlanılarak tesis yönetimi ve teknik personeliyle birlikte 10 adet kimyasal azaltım tekniğinin uygulanmasına karar verilmiştir. Belirlenen her bir teknik için azaltım oranları, yatırım maliyetleri ve geri ödeme süreleri belirlenmiştir. Tesiste belirlenen tekniklerin tümünün uygulanmasıyla boyarmadde ve yardımcı kimyasal tüketimlerinde %14,9-27,3 arasında azaltım sağlanabilineceği bulunmuştur. Uygulamaların geri ödeme süresinin 41 aydan daha kısa olacağı hesaplanmıştır.

Keywords

• Kimyasal Envanteri
• Kimyasal Değişimi
• Kimyasal Azaltımı
• Tekstil
• Temiz Üretim

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