by Engr. Kh. Mashiur Rahman | May 19, 2019 | ETP WTP
Water Treatment Equipment
Water Treatment Equipment – Implementing measures to reduce wastewater generation will not only reduce the amount of wastewater generated, but may also improve the quality of your effluents, therefore reducing pollutants released. Recovering some substances from your wastewater streams can also reduce your need for raw materials..
After analysing its wastewater streams, one company recovered and reused the Ethyl acetate solvent from its wet processes. This led to the recovery of 70% of the solvent and savings up to 6 900 USD/year.
Except for the working time of employees involved in the project, no extra costs are associated with this option. The measure will help you to identify “low-hanging” improvement options, which can be realised at a low cost and allow large reductions of your environmental impacts.
This option supports you in getting an
overview of the amount and toxicity of chemical use in your company.
Chemical consumption is one of the major
sources of health and safety risks in the textile industry. It also implies
high operating costs and environmental impacts. Therefore, it is important to
manage your chemical consumption by collecting and generating data, to improve
your efficiency. The reason behind it is simple: “if you don’t measure it,
you can’t manage it”. Using the generated data will help you to draw a
trend line of your performance over different time-periods (benchmark), to
identify improvement options and to set targets. With a benchmarking process
you can compare your performance internally as well as externally, with
industry averages or competitors.
In order to determine the chemical consumption
you can use the following table. Point out the most important (both in amount
and toxicity) chemicals used and their respective processes location and list
them in the table. Where possible, specify the amount and the type of the
chemical used. In the case of chemicals, the possible impacts on the
environment and employee’s health and safety, e.g. toxicity, are important to
consider. For example, a very small quantity of a highly hazardous substance
may have more important economic and environmental impacts than some other less
toxic substance. If available, use data from the last fiscal year or the last
quarter and state the chosen time-period in the table. Otherwise collect the
necessary information.
Conclusion
Rest of the water treatment equipment is coming soon water equipment
by Engr. Kh. Mashiur Rahman | Dec 18, 2018 | ETP WTP
Wastewater Treatment System
We are blessed with abundant natural fresh water by Wastewater Treatment System. Availability of such fresh water has made things easier for us to do fabric processing businesses in such a small country. However, we use thousand liters of water for dyeing and other purposes every day. The more water we use, the more wastewater or liquid waste is generated from our fabric processing machines every day unlike other wastes. Sludge Recycle of ETP
Textile wastewater (water mixed with different dyes & chemicals) requires systemic treatment by effluent treatment facility. Hence, wastewater is a big issue for any textile industries. We have our own ETP (effluent treatment plant) to treat our wastewater. We are doing the following research & development activities to minimize or reduce wastewater-
Review meeting is held every three month regarding previous decisions and upcoming decisions to make. Our General Manager (GM) advises this meeting. Every waste management related issue is openly discussed and shared. Brainstorming and new idea sharing are done so that corrective actions can be taken in procedure level. We always consider 3R principle (Reduce, Reuse & Recycle) whether we can implement this idea in any aspect of waste management.
Adjusting Liquor Ratio:
Changing Liquor Ratio is another way to save water and chemicals during wet processing which is ultimately Waste or Wastewater Reduction step is taken by our innovative Waste Management Team. Changing Liquor Ratio should be encouraged as it can decrease concentration of dyes & chemicals in the wastewater. Otherwise alternative chemical should be adopted, which requires less Liquor ratio. For example, we use Avitera SE -the dyestuff of Huntsman after Technology Assessment, which is marketed by Huntsman under the logo of Save the Earth. We also use third generation Wash off like Dekol RSA (Resource Saving Agent) and Crosscolor BCSR, which help us to save natural resources like water. We always look for better innovations than the above-mentioned dyestuffs in the market.
Awareness building up can save a lot resources and helps to reduce waste generation. Imparting training program may help workers & employees to be more conscious about resource management & waste management. Ideas should be discussed and shared among workers. Little awareness can save lots of paper, dyes, chemicals & water every day. We have posted awareness building up posters on appliances use, water consumption and energy efficiency in many places of our factory premises so that awareness among the workers can be developed and energy efficiency & better waste management practices may rise thereby.
Proper Metering:
Water is the vital resource for fabric processing. So water consumption should be properly metered. We cannot manage waste consumption without measuring. Total consumption and total disposal of wastewater should be metered. Furthermore, section wise water consumption record should be kept so that assessment and analysis of wastewater can be done properly. We have two inlets for our dyeing section and two flow meters installed on that inlet give us water consumption data.
Fabric processing is a continuous cycle, which involves a lot of chemicals & dyes. A slight change in the fabric recipe can save a lot of chemical/dyes, water and reduce wastewater generation rate. Our production team optimizes the dosage of chemical/auxiliaries by trial and error method. For example, if we use a detergent 1gm/liter, then it is deducted by 10% (.1gm) and some trial batches (by .9gm/liter) are executed. The reports of the batches are reviewed and process designed is Redefined. Dosage Optimization of every chemical/dye is done by this way without deteriorating the quality. Existing process design is re-evaluated if any single process step can be skipped to form new process design which might help to generate less wastewater. our production team re-engineer the process step whether it could be possible to eliminate the rinsing by a single filled wash drain cycle and if it is viable for wastewater reduction. Same importance is given to both energy consumption and natural resources. Our Senior Manager (Production) continuously generates concepts and monitors the overall dyeing process if consumption of dyes & chemicals could be decreased in order to minimize waste water as well. Forming new process design cannot be done in a day or month. Continuous efforts are required for this.
Technology Assessment:
Technological assessment & advancement can help us to save our time, money & resource and generate lesser waste. Existing processing system should be assessed & analyzed if existing machineries can support lowest Liquor Ratio. Old and backdated machineries should be replaced if possible in order to minimize liquid waste or wastewater generation, which is a big issue for textile industries. Our team always looks for any innovations regarding dyestuff, dye auxiliaries that may help to reduce liquor ratio and skip wash cycle, e.t. waste prevention initiative.
Conclusion
If any advanced technology is available in the market, our team tries to figure out the pons & cons and efficiency of that technology and discusses with entrepreneurs about the viability of that Wastewater Treatment System
by Engr. Kh. Mashiur Rahman | Dec 17, 2018 | ETP WTP
Methods of Waste Management
Methods of Waste Management -Production of necessary products & goods is increasing everywhere around the world with a view to keep pace with increasing human demand. Our natural resources are limited. After utilizing resources, production processes give off various unwanted materials or wastes, which cannot stopped or ignored. Products and wastes are like the two opposite sides of a coin; one cannot leave other. Read about Principles of Industrial Waste Management
Complete and useful products are consumed very easily whereas left over unwanted materials or wastes need to be taken care of to keep the environment clean and sound. With the advancement of time, people are becoming more aware of environmental protection, conservation and sustainability. As an Environment concerned business unit of Auto Group, Auto Textiles Limited is committed to do business in an eco-friendly manner. We are ready to comply with all rules and legislation regarding environment, health & safety. The main objective of this Environment Management System or Waste Management System is to manage all our wastes according to Environment Conservation Act, 1997 (ECR’97) to do production/ business activities in a safer way and keep the surrounding environmentally friendly. Actually, waste management should go beyond pollution prevention and disease prevention for humans. Furthermore, it should benefit society by providing economic gain for organizations, communities and families. The preferred approach for dealing with waste is Integrated Waste management (IWM). ISWM means considering not only the appropriate disposal of wastes but integrating this with other management options such as minimizing waste production, recycling, composting and other waste recovery options. The advantages of IWM are that we can consider all options and aim to manage wastes in ways that are most effective in protecting human health and the environment. IWM can also have many economic and
Waste Classification:
Wastes may become resources if they are properly segregated and utilized. Different wastes have different properties. Waste treatment procedures follow those properties to manage that waste. We have classified all our wastes according to different points of view. Depending on the states of the wastes, wastes are classified as-
- Solid Waste (solid in nature),
- Liquid Waste (such as wastewater that is mixed with different dyes & chemicals),
- Gaseous Waste (Smoke or gas emitted from combustion channels like generators, boilers, dryers etc.).
According to the potential degree of hazard, wastes have been classified as-
- Hazardous Waste (H)
- Low – hazardous Waste (L H)
- Non – hazardous Waste (N H)
According to production point of view, wastes has also been classified as-
- Production Waste (Generated directly from production process).
- Non Production Waste (Not directly associated with production).
Conclusion
Methods of Waste Management is not a waste until it is properly disposed of. It can be either a resource or a hazard. That is why it has to be segregated as resource material or hazard substance as early as possible. Hazardous wastes should be separated from other wastes since hazardous waste may contaminate the potential of non-hazardous wastes.
by Engr. Kh. Mashiur Rahman | Dec 17, 2018 | ETP WTP
Water Plants
Our source of Water Plants is underground water and we lift water more or less 300 cubic meter/day. Besides, we are going to complete our reserve tank for containing rainy water. After completion, our consumption of water from underground will be automatically reduced because of securing and re-use of rainy water. In this connection, we installed Water Treatment Plant (WTP) in a secured and clean place. On the other hand, we are installing Effluent Treatment Plant (ETP) and Sewerage Treatment Plant (STP) for saving our surrounding water from contaminated water and of course, we will re-use this water in our factory premises then automatically underground water use will be reduced more.
The company AUTO TEXTILE has a vision called vision 2020. Considering that in mind, the company took a decision to use the available resources efficiently. By doing so, the building construction of AUTO TEXTILE is done in such a way that building itself is the backbone of source of energy. It has got glass panels of 5000 sq m which will be used for putting on the solar cells vertically which will produce enough energy to light up the total building’s interior. As a part of it, the company contacted a manufacture in Australia who will supply those cells which works on temperature (>170C) to produce energy. The company has got a plan to use the rain Water Plants harvesting as well. Accordingly we are planning to store this to a central depository area (reservoir) nearby.
Pollutant Air Emission:
Regarding Air Emission through our production and supporting production process, we have already tested our emitted air by ITS Lab test Bangladesh Ltd. In this consequences, we found that Air Emission by production process is normal and for generator & Boiler, we have already increased stack height up to 60 ft to reduce pollution environment through air emission.
Waste Storage:
We don’t have combustion from generator as a by-products though we have an agreement with suppliers for withdrawing all wastage from production process or supporting process. Besides, our ETP will support us to reduce any contamination to our natural Water Plants . Regarding storage issue, we have a chemical and ink store for securing any combustion and wastage from direct production process, we have a secured waste storage for keeping all waste which withdrawn by third party in a regular basis
Mitigation Plan For Flood, Cyclone & Earthquake:
Floods:
Probable cause: Small creeks, gullies, dry streambeds, ravines, culverts or even low-lying areas flood quickly
Mitigation Plan: Monitor flood advisories; Determine flood potential to facilities; Pre-stage emergency power generating equipment; Assess damage.
Earth Quake:
Auto Garments all buildings are designed as per 8.5 rector scale.
Probable cause: The shaking of the earth’s crust, caused by underground volcanic forces of breaking and shifting rock beneath the earth’s surface
Mitigation Plan: Shut off utilities; evacuate building if necessary; Determine impact on the equipment and facilities and any disruption
CYCLONE:
Probable cause: Caused by a combination of strong winds driving water onshore and the lower atmospheric pressure in a tropical cyclone. In the hemisphere the onshore winds occur to the left of the tropical cyclone’s path.
Conclusion
Water Plants -Power off all equipment; listen to cyclone advisories; Evacuate area, if flooding is possible; Check gas, water and electrical lines for damage; Do not use telephones, in the event of severe lightning; Assess damage.
by Engr. Kh. Mashiur Rahman | Nov 1, 2018 | ETP WTP
WTP Water Management Procedure
The existence of this team has made types of water treatment job easier for Auto Textiles Ltd. to establish a better water management WTP system. Department of Environment (DoE) has some obligations regarding water consumption for fabric processing in industrial sectors. These obligations are followed as general guideline countrywide. We respect this guideline. However, the water consumption is directly dependent on technology use or the dyeing/washing machine we are using. It is also dependent on what type of fabric we are dyeing or what type of dyestuff we are using. ,-
Technology Assessment
Technological assessment & advancement can help us to save our time, money & resource. Existing processing system should be assessed if existing machineries can support lowest Liquor Ratio. Old and backdated machineries should be replaced if possible in order to minimize water & chemical consumption. Our team always looks for any innovations regarding dyestuff, dye auxiliaries that may help to reduce liquor ratio and skip wash cycle. If any advance technology is found in the market, our team tries to figure out the efficiency of that technology and discusses with entrepreneurs about the viability of that technology
Proper Metering
Water consumption should be properly metered. We cannot manage water consumption without measuring. Total consumption and total disposal of water should be metered. Furthermore, section wise water consumption record should be kept so that assessment and analysis of water consumption can be done properly. We have two inlets for our dyeing section and two flow meters installed on that inlet give us water consumption data. Water goes to ETP after being used in the dyeing & washing machines. We have two meters for the inlet and outlet of ETP. We generate useful data from the reading of these meters
Adjusting Liquor Ratio
Changing Liquor Ratio is another way to save water and chemicals during wet processing. Changing Liquor Ratio should be adjusted if it can be decreased. Otherwise alternative chemical should be adopted, which requires less Liquor ratio. We use Avitera SE -the dyestuff of Huntsman after Technology Assessment, which is marketed by Huntsman under the logo of Save the Earth. We also use third generation Wash off like Dekol RSA (Resource Saving Agent) and Crosscolor BCSR, which help us to save natural resources like water. We always look for better innovations than the above-mentioned dyestuffs in the market
Process Re-engineering
Fabric processing is a continuous cycle, which involves a lot of chemicals & dyes. A slight change in the fabric recipe can save a lot of chemical/dyes & water consumption. Our production team optimizes the dosage of chemical/auxiliaries by trial and error method. For example, we use a detergent 1gm/liter. Then it is deducted by 10% (.1gm) and some trial batches (by .9gm/liter) are executed. The reports of the batches are reviewed and process designed is redefined. Dosage Optimization of every chemical/dye is done by this way without deteriorating the quality. Existing process design is reevaluated if any single process step can be skipped to form new process design. Suppose, there is a five minute overflow rinsing in a certain process step; our production team reengineer the process step whether it could be possible to eliminate the rinsing by a single filled wash drain cycle and viable for the organization. Same importance is given to both energy consumption and natural resources. Our Senior Manager- Production continuously generates concepts and monitors the overall dyeing process. Forming new process design cannot be done in a day or month. Continuous efforts are required for this.
Spread of Awareness
Awareness building up can save a lot water usage. Imparting training program may help root level workers to be more conscious about water use. Ideas should be discussed and shared among workers. Little awareness can save tons of water everyday. We have posted awareness building up posters on water consumption and efficiency in washrooms and water using places so that awareness among the workers can be developed and water efficiency may rise thereby.
Review/Checking
A review meeting is held every six month regarding previous decisions and upcoming decisions to make. Our General Director (GD) advises this meeting. Every water related issue is openly discussed and shared. Brainstorming and new idea sharing are done so that corrective actions can be taken in procedure level. We always consider 3R principle (Reduce, Reuse & Recycle) whether we can implement this idea in any aspect of water usage
Corrective Actions
Error is a part of decision or action. Corrective actions must be taken to rectify previous faults or lacking. Slight mistakes or faults in procedure level may hamper total development process. So corrective actions must be implemented properly and regular follow-up is very crucial. In our Review Meeting every water usage procedure is scrutinize thoroughly. If any finding is found, they are considered for the next action plan.
We are enthusiastic enough to establish much better environmental practices, resource conservation, wastewater management & waste management for our own goodness and for the conservation of our environment. However, we are thinking and evaluating the chance of reuse & recycle of treated wastewater.
Conclusion
Salt recovery from different types of water treatment is under active consideration. We would like to follow national rules & regulations and apply any contemporary changes to make proper use of water and to save this valuable water. Fortunately, we have an agile Environmental Management Team, which is working relentlessly in this regard.
