Page 83 - Materials Chemistry, Second Edition

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Sustainable Industrial Design and Waste Management
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• Final fabric products are not given adequate protection during storage,
so that soilage can easily occur.
• Various parts of steam and hot water pipes are not insulated and a
great amount of heat is lost.
• Steam condensate from all departments is put directly to the drain
rather than re-circulated as feed water, causing an unnecessary wastage
of water.
• Huge amounts of thermal energy are lost in the flue gases of the boiler
which are exhausted to air.
• Considerable amounts of hot effluent from the different units in the
pre-treatment and dyeing departments are directly discharged to the
sewer, with great heat losses.
• Huge quantities of final washing water in the bleaching ranges are
directly discharged without reuse.

The measures which have been identified for implementation are briefly
outlined below. During the audit stage, particular attention was paid to
those improvements that could be carried out at low or no cost to the fac-
tory. These are easy to implement and often entail significant savings.

CP techniques implemented
• Improve storage facilities – dyes and fabrics (good housekeeping): The
storage conditions in the dyehouse store were investigated and rec-
ommendations made to prevent the hydrolysis and lumping of reac-
tive dyestuffs, which was achieved by ensuring that the dye containers
were tightly closed and the storage space was closed when not in use.
• Material substitution and optimization of chemical usage (input mate-
rial change): The different process chemicals used in the factory were
thoroughly examined, with the aim of identifying optimum process
chemicals, taking into account process and fabric requirements,
resource, and environmental constraints. The following alternatives
were identified:

Application Original Substitute/Alternative

Neutralization Acetic acid Formic acid
Dyeing Sulfur and Other dyes.
naphthol dyes. Dyes which do not
Dyes which involve heavy
involve the use metals
of heavy metals
Printing Ammonium Ammonium sulfate
phosphate
Desizing/scouring poly/ Leonil LB-ET Ammonium persulfate
cotton blend