MANUFACTURE OF TEXTILES # 13

Background:

Beijing No.3 Printing & Dyeing Mill (new plant) is located in a residential area named Balizhuang, Sihuan Road, Chaoyang district, China. The new plant, which was built in 1984, has an area of about 65,000 m². Since 1988 it has become a large printing and dyeing production unit.

The major products in this Mill include a variety of bleach, dyeing and printing cloth, with pure cotton and polyester cotton. The total annual output has reached 20 millions meters in recent years. The total output value was 60-80 million Yuan, of which half is exported.

The main waste discharges are wastewater containing dyeing materials from the production workshop. The waste discharge fee over the years has been about 240 thousand Yuan RMB a year. An industrial wastewater treatment plant was built in the  new Mill. The capacity of treatment is about 2,000 m³/day with COD discharge less than 500mg/L. All the wastewater is discharged into the Beijing Municipal Gaobeidian wastewater treatment plant through municipal sewers. There are three boilers with capacity of 10 tons / hr.,  provided with water film dust remover.

The air emission in the form of smoke dust complies with the government standard. The burning dregs and ashes treated as powders are sold as construction materials.

Beijing No.3 Printing and Dyeing Mill began considering cleaner production as an option in March of 1995. Through several marketing and training sessions, the senior management of this company were convinced of the need to use cleaner production practices to protect the environment while improving the business economy.   The objective of the mill was to use CP to  eliminate the waste at the source in order to improve their efficiency, reduce the costs, increase the quality and quantity of the products and effect a raise in company profits and provide a safe and healthy environment for workers and surrounding residents.

Through the CP assessment, a lot of issues such as unexpected loss of materials (dyeing), leaking, dripping, water loss etc. came to light. Acid corrosion emerged as a serious problem in the pipes that are used to transfer slag and dust.

Cleaner Production Principle:

Process modification, Housekeeping

Cleaner Production Application:

A total of 26 options were generated through the CP assessment process. These options include 14 options for strengthening management, 3 options for improving technological processes and equipment, 5 options for waste recycling and reusing, 3 options for the improvement of raw material and 4 options for technological change.

Based on the classification principle of cleaner production options, these options were divided into three parts: In Class A there were fifteen options which required little or no investment; in Class B, there were seven options that required medium or high investment that had both environmental and economic benefits and were implemented within a short time; and, Class C, there were four options that required a high investment that could be considered later, according to the specific production situation of the Mill.

Options implemented immediately in Class A:

1. Prevent the loss of dyeing materials;
2. Clean the melt dyeing materials in the container;
3. Recycle and reuse the residue dyeing material when the cloth variety is changed;
4. Control the amount of concentrated alkali used to strengthen light alkali recycling and reusing;
5. Decrease the additive rate of grey cloth;
6. Streamline repairs;
7. Improve technological and operational processes and strengthen technical training;
8. Reduce the unqualified cloth to improve the qualified rate of product and save outlay;
9. Strengthen the equipment maintenance to reduce or eliminate loss, emissions, dripping and leakage;
10. Save cleaner water;
11. Control and adjust the liquid surface to eliminate the long-flowing water loss;
12. Reduce the use of technological water for regeneration and displacement;
13. Select high quality regenerated materials;
14. Catch the waste slag and ash from the sediment pool;
15. Select high quality coal.

Class B options with a medium or high investment that could be implemented within a short time.

7. Systematize cleaner production; integrate it into the economic assessment processes in every department; and, add measuring instruments;

13. Recycling and reusing the condensed steam generated in the production workshop;

14. Purchase and install a new printing machine;

20. Select a high efficiency exchange agent;

21. Replenish the exchange agent periodically;

25. Use the waste water with light alkali from the production unit to neutralize and replenish the water for removing slag and dust; and

26. Use the coal slag sediment pool to filter and absorb the organic wastes.

Class C options with high investment :

12. Modify and clean the water recycling pipes;

15. Modify the gas burner;

16. Save energy by using new technology, such as adjusting frequency modulation; and

24. Recycle the regenerated waste water.

All 15 options in Class A were implemented during the assessment course. Two options in the Class B list (25 and 26) have also been implemented. One more option in Class B (14) with a 2900 thousand Yuan investment, had been installed by the end of September 1995.

Environmental and Economic Benefits:

After the implementation of option 14, there was an estimated large savings in the dyeing material ( no data reported).

No relevant report.

After the implementation of option 25 and 26, an estimated 52000 tons of clean water could be saved every year.

After the implementation of option 14, the product output could be increased to 300,00,000 meters per year.

After implementing 15 options in Class A, waste water has been reduced by 25%, meanwhile, the alkali in waste water has been reduced by 30%.

After implementing options 25 and 26 with a short-term investment, all acidic waste water could be reduced by 16000 ton/year with 100% elimination. The problem of the acid corrosion of pipes has been solved. At the same time, more than 170,000 tons of waste water will be recycled and reused, which uses more than 30% waste water from the Mill. Twenty-five percent of the wastes in waste water could be removed through slag filtration and absorption. This process could lighten 7.5% of the burden of "end-of-pipe" treatment. COD in the waste water could be reduced 34 tons per year.

Investment Costs (RMB)

For option 14 "Purchasing and installing a new printing machine ", the total investment is about 288.8 x 10/4 Yuan RMB including:

1. Equipment purchase: 171.9 x 10/4 Yuan (main engine:165 x 10/4 Yuan; spare parts: 1.5 x 10/4; transportation fee: 5.43 x 10/4 Yuan)
2. Materials and site: 1.5 x 10/4 Yuan
3. Connections to utilities & services: 2.0 x 10/4 Yuan
4. Installation fee and others: 10 x 10/4 Yuan
5. Invisible capital: 1.5 x 10/4 Yuan
6. Contingency fee: 0.5 x 10/4 Yuan
7. The bank interest during the construction period: 58.4 x 10/4 Yuan
8. Circulating capital: 48 x 10/4 Yuan

For options 25 & 26 "Using the waste water with light alkali from production workshop to neutralize and replenishing the water for removing slag and dust" and "Using the coal slag sediment pool to filtrate and absorbing the organic wastes", the total investment was about 230,000 Yuan.

For option 14: The yearly saving is about 1.05 million Yuan.

For option 25 & 26: The yearly saving in the first year is estimated at about 25000 Yuan; the yearly saving in the following years is estimated at 48000 Yuan.

Fifteen implemented options with no or little investment will save 300,000 Yuan every year.

After the implementation of option 14, the output could be increased to 300 x 10/4 m/year. If one meter of printed cloth can generate 0.35 Yuan in profit, the total annual profit could reach 1.05 million Yuan per year.

For implementing options 25 & 26, the total savings could reach 48000 Yuan each year.

Payback period:

For option 14 :  2.75 years

For options 25 & 26 : 4 months

Constraints:

None mentioned

Contacts:

Industry/Program Contact and Address

Mr. Gao Wang

Beijing No.3 Printing & Dyeing Mill, Balizhuang Beili, Chaoyang District

Beijing, 100025, P.R. China,

Tel: 86-10-5004444 ext. 207

 

Advisor Name and Address

Ms. Li Zhengsheng

No. 14 Chegongzhuangxi Road, Haidian District, Beijing 100044, P.R.China

Tel: 86-10-8414466 ext. 243

 

Miss Wang Jinghui & Mr. Shao Zhiqing

China International Training Center for Sustainable Development

No. 109 Wanquanhe Road, Haidian District, Beijing 100080, P. R. China

Tel: 86-10-2588146; Fax:: 86-10-2588139

Review Status:

This case study was submitted to UNEP IE by the Sino-Norwegian Cleaner Production Program. It was edited and formatted for the ICPIC diskette in May 1997. Subsequently it has undergone a formal technical review in September 1998 by Dr. Prasad Modak, Environmental Management Centre, Mumbai, India..