Workshop Report Environment Friendly Techniques in Textiles Sector

Workshop Report

Environment Friendly Techniques in Textiles Sector

March 01, 2013

Center of Excellence (COE), GIDC Industrial Estate, Vatva (Gujarat)

Page | 2

Contents

1. Background ... 3

2. Introduction ... 3

3. Programme of the Workshop ... 4

4. Participants in the Workshop ... 5

5. Inaugural Session of the Workshop... 5

6. Technical Sessions of the Workshop ... 7

7. Concluding Session of the Workshop ... 7

Page | 3

1. Background

The on-going Indo German Development Cooperation has “urban and industrial environmental policy & management” as one of priority areas of cooperation. The Indo German Environment Partnership (IGEP) Programme forms a part of this priority area, under which technical cooperation is being provided to the identified Indian partner organisations by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ), on behalf of the German Ministry for Economic Cooperation and Development (BMZ).

The IGEP Programme, which is implemented jointly by the Ministry of Environment and Forests (MoEF) of the Government of India and GIZ has a thrust area on Sustainable Industrial Development (SID). Under the SID component, the relevant activities for which the advisory services are sought are related to the following core topics:

 “Environment Friendly Techniques in Identified Industry Sectors”

 “Planning of New Industrial Parks and Investment Zones”

 “Waste Water Management”

The overall objective of the technical cooperation on the core topic of “Environment Friendly Techniques in Identified Industry Sectors” is, “The use of environment-friendly technologies and techniques is promoted in selected SME sectors”. This core topic has focus on textiles and pulp & paper sectors with following activities:

 Baseline Surveys / Situation Analysis is to be undertaken for the Textile and Pulp &

Paper industries in India and core issues related to environment, resource efficiency and climate change are assessed.

 Regional/State/Local level Workshops will be organised to exchange information on potential solutions.

 Volunteering industries will be identified for demonstration of viable environment friendly techniques on pilot basis.

 Pilot experiences/results will be documented and disseminated.

 Supportive policy documents/instruments will be worked put for application of viable solutions across the pulp & paper industry sector in the country.

2. Introduction

The environmental concerns are growing leading to higher environmental litigation risks for the industries, particularly those from the SME sector. According to a World Bank study

“India: Strengthening Institutions for Sustainable Growth”, South Asia Environment and Social Development Unit, SME contributes to nearly 70% of industrial pollution load in India.

The major forms that have been highlighted include, air pollution, water pollution, soil contamination, radioactive contamination, noise pollution, light pollution, visual pollution, and thermal pollution. Also, a recent study by the Bureau of Energy Efficiency (BEE), which takes into consideration the SME sector, revealed that the overall energy saving potential of the clusters is about 72,432 TOE (tonnes of oil equivalents), which is 27.4% of the total energy consumption in SMEs.

The Indian textiles industry is one of the largest textile industries in the world. Today, Indian economy is largely dependent on textile manufacturing and exports. India earns around 27%

of the foreign exchange from exports of textiles. Further, India’s t industry contributes about 14% of the total industrial production of India. Furthermore, its contribution to the gross

Page | 4 domestic product of India is around 3% and the numbers are steadily increasing. India’s textile industry involves around 35 million workers directly and it accounts for 21% of the total employment generated in the economy.

The textiles sector can benefit by making improvements targeting resource efficiency, process improvements, energy efficiency and reduced negative environmental impacts. By employing appropriate technologies, both environmental and economic gains can be achieved.

For referencing viable environment friendly techniques in the textiles sector, various sources of information are available. For example, the BREF (Best Available Techniques Reference Documents) from Germany and the Comprehensive Industrial Documents (COINDS) of the Central Pollution Control Board provide useful information. Also, possibly some of the textiles industries in India might have championed in pioneering efforts in technological innovation. In addition, there are also technology providers that are dealing with relevant technologies for the textiles sector, such as the insulation systems, low energy motors, online pollution monitoring systems etc. Agencies such as the Gujarat Cleaner Production Centre have undertaken pilot studies in the pulp & paper industries.

To gather information and to facilitate information exchange, under the IGEP Programme, strategically stakeholder consultation are being organised periodically. Such consultations are organised at local, regional, state and national levels to facilitate identification of core issues faced by the sector and to look out for viable technical solutions. The consultations are organised through workshops, meetings and conferences.

Against this background, as a part of the Phase I activities, GIZ collaborated with the Gujarat Cleaner Production Center (GCPC) and organized the 1-day Regional Workshop on

“Environment Friendly Techniques in Textiles Sector” on March 01, 2013 at the Centre of Excellence, GIDC Industrial Estate, Vava (Gujarat). The workshop was aimed to share knowledge, experiences and case examples and to discuss on the core issues, including policy and regulatory related, and technological and management related aspects that need to be addressed for ensuring improved environmental performance by the textiles sector in India.

3. Programme of the Workshop

The workshop focused on:

 Policy/Legal/Regulatory Aspects – Challenges and Opportunities

 Technological aspects – Challenges and Opportunities

 Roles of Key Stakeholders (industries, industrial associations, government, regulatory bodies) – innovative approaches/actions, capacity building requirement The workshop programme included:

 Inaugural session.

 Technical Session 1: Environmental Policies, Laws and Challenges.

 Technical Session 2: Technological Aspects for Improved Environmental Performance in Textile Sector.

 Concluding session.

The programme details are given in Annexure I. The programme covered 11 technical presentations on various relevant topics.

Page | 5

4. Participants in the Workshop

The workshop received had over 80 participants including representatives of government bodies, industries, technology providers, infrastructure developers, investors and consultants. The list of participants that have registered is given at Annexure II.

Pic: Participants at the workshop

5. Inaugural Session of the Workshop

The workshop started with an inaugural session. Mr. Lalit Sharma, Senior Technical Expert, GIZ-IGEP presented the welcome and theme address, and set the context for the workshop.

There were three special addresses from:

 Dr. K U Mistry, Chairman, Gujarat Pollution Control Board.

 Mr. A. A. Dolti, Regional Officer, Gujarat Pollution Control Board.

 Mr. Shankar Patel, President, Vatva Industries Association.

 Mr. H.D. Shrimali, Addl. IC, Industries Commissionerate, GoG.

The inaugural session concluded with Mr. Bharat Jain, Member Secretary, Gujarat Cleaner Production Center (GCPC), Gandhinagar delivering the concluding remarks and thanking all the participants, speakers, project partner GIZ, press and media.

Page | 6

Pic: Inaugural Session of the Regional Workshop

Pic: Mr. H.D. Shrimali, Addl. IC, Industries

Commissionerate, GoG giving address to participants

Pic: Dr. Chandan Chaterjee, Director, CED & Advisor (Project & Technology) IndextB, GoG giving address to the participants

Page | 7

6. Technical Sessions of the Workshop

In the technical sessions of the workshop, the details of the topics presented are given below.

Technical Session I: Environmental Policies, Laws and Challenges:

 Environmental Policies, Standards and Regulatory Aspects in Textile Industries

 Statutory Compliance in Industries

 Environment Related Issues For Textile Sector

 Emerging Opportunities & Policy initiatives for the Growth of Textile

Technical Session – II: Technological Aspects for Improved Environmental Performance in Textile Sector:

 Environment Friendly Techniques “Best Available Techniques (BAT) Reference Document – Textile Sector

 Conservation of Water in Textile

 Sustainable and Eco Friendly Alternatives in Textile Wet Processing area - ATIRA Developments

 Core Environmental Issues in Textile Sector

 Promoting Total Natural Organic and Environment Friendly Textile

 Accelerated Coagulation for wastewater Treatment and Reuse in Textile Processing House

The presentations are attached at Annexure III. The presentations made by the speakers are uploaded on the GIZ website on www.ecoindustrialparks.net.

7. Concluding Session of the Workshop

The Concluding Session of the workshop focused on collecting inputs and suggestions from the participants through meta-plan cards and then the points were discussed The topics covered fro discussions include:

 Topic 1: Policy/Legal/Regulatory Aspects – Challenges and Opportunities.

 Topic 2: Technological aspects – Challenges and Opportunities

Pic: Mr. Lalit Sharma, GIZ conducting Technical Session I

Pic: Mr. Bharat Jain conducting Technical Session II

Page | 8

 Topic 3: Roles of Key Stakeholders (industries, industrial associations, government, regulatory bodies) – innovative approaches/actions, capacity building requirement

Pic: Participants at the workshop

Pic: Individual reviews and comments provided by participants on the topics

Pic: Discussion and Conclusion of individual reviews and comments provided by participants on the topics.

Page | 9 The following important points emerged from the group discussions.

 Presently, there is no comprehensive reference document on the Textile industries that reflects the technological, availability, management and other relevant aspects, which can be used as a reference document guide for selecting and implementing Environment Friendly Techniques (both techniques & technologies). Preparation of such a comprehensive document should be taken up. The COINDS of CPCB documents are very old and are to be updated.

 Pilot projects should be undertaken and case examples documented.

 Operations for dye and finish knitwear require dyeing cycle of nearly 8 hours and consists of several dye baths with high and low temperatures resulting in high resource consumption (water & energy), which in turn leads to effluent discharge.

 Re-dyeing is common and washing efficiency is poor in the Indian SMEs. This needs solution to improve the dyeing efficiency in order to reduce resource consumption as well as effluent generation.

 In all recipes, auxiliaries are used in standard concentrations to ensure safe procedure.

However, parts of the recipes do not need the auxiliaries or only need minor doses.

There is need of preparing standard recipes for the common processes in dyeing.

 Units carrying out mercerizing operation should install Caustic Recovery Plant or any find other source where it can be used. The industries that have caustic recovery units have only 75% of the caustic soda from wash waters collected due to inefficient recovery systems and techniques. This should be taken upto 85%. Also, the caustic soda recovery is maximum 81% in process houses, as opposed to the normal possible 90%.

 The traditional method of taking the original dye to the affinity form is through treatment with an aqueous solution of highly polluting sodium sulphide. This causes an increase in the sulphide content of the mill's effluent.

 The traditional method needs removal of bleaching agent by rinsing the fabric, for which large amounts of water are required for rinsing: upto 40 litres per kg of fabric.

 Washing liquor contains a low concentration of the removed sizing agent, contributing highly to the chemical oxygen demand in the textile effluent.

 Inefficient steam consumption and steam condensate recovery are to be looked into.

 Inefficiency of the electrical equipment due to usage of inappropriate capacities used and due to inefficient designs of the equipment and auxiliaries. There is very less knowledge on the efficiency of the equipment.

 Energy losses in drying section are significant due to non-availability of the side insulations for dryer, which is due to constant dynamic motion.

 Units are facing difficulties in operating secondary ETP, particularly for maintaining MLSS.

 Due to space constraints, new technology with minimum land area for treatment is required.

Page | 10

 Feasibility of common ESP for steam boiler (capacity between 5 TPH to 10 TPH) and thermic fluid heater should be looked into.

 Upgradation of APCM with TFH (whether bag filters can be provided)

 Need for auto fuel feeding system into Boiler (capacity 3 TPH or more) as well as Thermic Fluid Heaters, irrespective of type of fuel used.

 Feasibility of utilization of fly ash in bricks manufacturing should be seen.

^^^

Page | 11

Annexures

Page | 12 Annexure 1

Workshop Programme

“ Environment Friendly Techniques in Textile Sector”

March 01,2013; COE (Centre Of Excellence), Vatva GIDC, Ahmedabad

09:30 hrs Registration& Tea Inaugural Session

10:00 hrs Welcome &Theme Address by

Mr. Lalit Sharma

GIZ, Indo German Environment Partnership Programme

10:15 hrs Address by Mr. H.D. Shrimali,

Addl. IC, Industries Commissionerate

10:25 hrs Address by Mr. Shankar Patel

President, VIA (Vatva Industrial Association)

10:35 hrs Address by Mr. A. A. Dolti,

Regional Officer, GPCB

10:45 hrs Special Address by Dr. K.U. Mistry

Chairman, Gujarat Pollution Control Board

10.55 hrs Vote of Thanks by Mr. Bharat Jain

Member Secretary, Gujarat Cleaner Production Center Technical Session I: Environmental Policies, Laws and Challenges

11:00 hrs Introductory remarks

Mr. Lalit Sharma

GIZ, Indo German Environment Partnership Programme

11:05 hrs

Environmental Policies, Standards and Regulatory Aspects in Textile Industries

Mr. D.S. Kharat, Environment Engineer, Central Pollution Control Board

11:20 hrs

Core Environmental Issues (Technological) in Textile Industries

Mr.HirenBhendwal / Mr.PunamRathod Project Engineer, Gujarat Cleaner Production Center

11:35 hrs Environment related issues for Textile Sector

Mr.DevangThaker

Gujarat Pollution Control Board 11:50 hrs Environmental Challenges & Mr. Nitin Thakkar

Page | 13 Opportunities in Textile Sector –

Industry’s Perspective

President, ATPA (Ahmedabad Textile Processors’ Association)

12:05 hrs

Emerging Opportunities & Policy Initiatives for Growth of Textile Sector

Dr. Chandan Chaterjee

Director, CED& Advisor (Project & Technology) IndextB, GoG

12:20 hrs Q&A, Discussions (30 min) Lunch 12:50 – 13:30 hrs

Technical Session – II : Technological Aspects for Improved Environmental Performance in Textile Sector

13:30 hrs Introductory remarks

Mr. Bharat Jain

Member Secretary, Gujarat Cleaner Production Center

13:35 hrs

Best Available Techniques in Europe for Textile Sector – EU

Reference Documents

Mr. Lalit Sharma

GIZ, Indo German Environment Partnership Programme

13:50 hrs Water Conservation in Textile Dyeing

Mr. Lalit Sanghvi Textile Expert

14:05 hrs

Opportunity to Utilize ATIRA for Research / Analytical Solutions / Pilot Project by Textile Industries

Ms. Sarika Singh

Principal Scientific Officer, ATIRA

14:20 hrs Waste Minimization in Textile Industries – Case Example

Mr. Paresh Mevawala Textile Expert, ENPRO

14:35 hrs Promoting Total Natural Organic and Environment Friendly Textile

Mr.Arun Baid

Aura Herbal Textile Limited Spotlights

14:50 hrs Energy-Efficiency - moving India's SMEs towards a sustainable future

Mr. Yogesh S Pandey KAEFER

14:55 hrs Quick BOD measuring technique Mr. Vaibhav Savji Forbes Marshall 15:00 hrs Waste Water Treatment in Textile XH₂O

15:15 hrs Q&A, Discussions (30 min)

Concluding Session and Way Forward (Moderated by GCPC and GIZ) : 15:45 hrs Feedback Questions for Participants (tentative):

Page | 14

 Issues and challenges in Textile sector in India relevant to improved environmental performance.

 New government policies and supportive instruments required for supporting Textile sector in India.

 Scope and of new or best available technologies for the Textile sector in India.

17:00 hrs Concluding Remarks

 GIZ, Indo German Environment Partnership Programme

 Gujarat Cleaner Production Center

 Gujarat Pollution Control Board 17:30 hrs High Tea & End of Workshop

Page | 15 Annexure II

S. No. Company Name Participants Name Designation Mobile No E mail address

1. Nandan Exim Ltd. Ms. Shukti Ghadvi Manager 9879202768 [email protected]

2. Murlidhar Textile Mills Mr. C. N. Patel Partner 9825032402 -

3. Hemlines Textile & Exports

Pvt. Ltd. Mr. Pankaj Chief of Engineering 7878723216 [email protected]

4. Aarvee Denims & Exports

Ltd. Mr. G. G. Patel General Manager 9879597907 [email protected]

5. Jindal Texo Fab Ltd. Mr. H. C. Gajjar Engineering Dept. 9979868854 [email protected] 6. Karnavati Polyster Pvt. Ltd. Mr. Neil Desai Managing Director 9925246766 [email protected]

7. IIM Mr. G. D. Jasugi Individual 9879260064 [email protected]

8. GIZ-IGEP Mr. Lalit Sharma Senior Technical Expert 9818433411 [email protected]

9. GIZ-IGEP Mr. Nitesh Patel Junior Advisor 9376196871 [email protected]

10. Kadmawala Textile Mills Ltd. Mr. Murarilal Process Incharge 9327772551 -

11. Weizmann Ltd. Mr. R. B. Shiroyg Manager 9825972496 [email protected]

12. Weizmann Ltd. Mr. Ravjibhai Shiney Manager - [email protected]

13. Manyank Processors Pvt.

Ltd. Mr. B. Patel Manager 9638920490 [email protected]

14. Gujarat Pollution Control

Board Mr. T. H. Mehta AEE 8460231854 [email protected]

15. Soma Textiles Mr. M. A. Patel Deputy General

Manager 9824365408 -

16. Mangal Textile Mills Pvt. Ltd. Mr. J. K. Bothra Vice President 9978925744 [email protected]

One Day Workshop on “Environment Friendly Techniques in Textile Sector”

List of Participants

Page | 16

17. Kanksriya Textile Mr. Mukesh Engineer 9727735035 -

18. Chiripal Textiles Mr. Rajesh Director 9825038852 -

19. Jindal Texo Fab Ltd. Mr. Amit - 9925022700 [email protected]

20. Aura Herbal Mr. Arun Baid Director 9099935019 [email protected]

21. Vishwakarma Textile Mills

Pvt. Ltd. Mr. Ronak Mistry Director 9825436500 -

22. Kedar Cot Spin Mr. K. B. Buch - - -

23. Kedar Cot Spin Mr. Suresh Agarwal Director 9376125070 -

24. Chiripal Textiles Mr. Satyendra Pandey Deputy Manager 9879105150 - 25. Mukesh Industries Ltd. Mr. Devkinanad Aggarwal Director 9979866075 -

26. ATIRA Ms. Sarika Singh PSO 8905037419 -

27. ATIRA Mr. B. S. Parikh Assistant Director 9824366118 -

28. ATIRA Mr. M. R. Parikh SSA 9033072060 -

29. Kumar Cotton Mr. Atul Patel Manager 9712986785 -

30. Kumar Cotton Mr. Nitin Mehta Engineer 9925011833 -

31. Excel Enviro Tech. Mr. Parth N. Patel Chemist 9427680746 -

32. Vinod Denim Pvt. Ltd. Mr. Mitesh P. Patel Laboratory Chemist 9726085333 -

33. Anand Textiles Mr. Anand Shah Partner 9327070081 [email protected]

34. Pran Textiles Mr. Surendra ETP Supervisor 9374053888 -

35. The Real Honest Textile Mr. Salim Partner 9898593556 [email protected] 36. Blue Blends (I) Ltd. Mr. Utkal Patel Environment Officer 9879759155 [email protected]

37. Komal Texfab Pvt. Ltd. Mr. Suresh Bagrecha Director 9824023144 [email protected]

38. Soma Textiles Mr. Hardik Shah - 9825038115 -

39. Mangal Textiles Mr. P. L. Shah General Manager 9879203901 -

40. GIZ_MSME Umbrella Mr. Laurin Wuennenberg Intern 8130839769 [email protected]

Page | 17

Programme

41. Weizmann Ltd. Mr. Jivan Ranka - 9825083300 -

42. Shree Jagdamba Textiles

Pvt. Ltd. Mr. Hiren Engineer 9925012773 [email protected]

43. Green Environment Services

Co-operative Society Limited Mr. Deepak Davda CEO 9909907178 [email protected]

44. Arrow Clothing Mr. Bharat Shah Director 9825038440 [email protected]

45. Denifine Line Mr. Kamlesh Electrical Engineer 9998223394 [email protected]

46. Aggarwal Dyeing & Printing

Works Mr. Sanjeev Aggarwal Proprietor 9328679636 [email protected]

47. Chamaria Fashion Pvt. Ltd. Mr. Lalit Chamaria Director 9375867335 -

48. Gopi Synthetics Mr. Jairam Patel General Manager 9879204915 -

49. Shankar Textile Mills Mr. Sanjay Paul Production Manager 9879204915 -

50. Vishal Fab Pvt. Ltd. Mr. Tushar Bhatt Manager 9825801001 [email protected]

51. Aakar Textile Mr. Yasin Devdiwala Partner 9825031752 [email protected]

52. Shalin Textile Mr. Haroon Devdiwala Partner 9825033075 [email protected]

53. Sinhal Brothers Mr. Puroshottam Das Manager 9909003961 -

54. Shyam Corporation Pvt. Ltd. Mr. Amit Patel Manager 9723670596 -

55. Kamal Processors Mr. Farukh Manager 9925229595 -

56. Kajal Textiles Mr. Pappu Director 9825016971 -

57. Rinkoo Processors Mr. Manoj Garg Director 0825247400 -

58. Bajaj Processors Mr. Nitin Manager 9374079810 -

59. Shree Rang Fabrics Pvt. Ltd. Mr. Nivant Patel Owner 9825319282 [email protected] 60. Nandam Exim Ltd. Mr. Praveen Gupta Deputy General

Manager 9825342539 [email protected]

61. Nandam Exim Ltd. Mr. Rajesh Shalin - - -

62. Jay Ambey Mr. Dau Manager 9374688652 -

Page | 18

63. Swan Energy Ltd. Mr. D. N. Bhatt Chief Engineer 9824469506 [email protected]

64. 3 E Incorporation Mr. Lalit Sanghvi Technical Advisor 932706605 [email protected]

65. Mayank Textile Mr. Amrish Supervisor 9925430063 -

66. M. G. Textile Mills Mr. Harish - 9825743947 -

67. Vinay Overseas Pvt. Ltd. Mr. Munir Saiyed General Manager 9879213200 -

68. Prem Processors Mr. Pradeep General Manager 9374645650 -

69. Mahak Synthetic Mr. Venkatesh Chemist 8866687812 [email protected]

70. Kedmawala Textile Mr. Ashish Agarwal Director 9377519727 -

71. V. R. Poly Fab Mr. Deepak Jain Director 9825031602 -

72. Anjali Synthetics Mr. Mahavir Director 9925207500 -

73. Anjali Fabrics Mr. Bhavesh B. Director 9099040957 -

74. ATPA Mr. Sripal Executive Secretary 9824371717 -

75. Asarwa Mills Mr. Sohaib Manager 9824430087 -

76. Blue Blends (I) Ltd. Mr. Ajit Ranke General Manager 9376110918 -

77. Mahalaxmi Fabric Mills Mr. Kothari President 9825010315 -

78. XH2O Solutions Mr. Varun Bhuta Marketing 9898875757 -

79. Rankas Tex Feb (P) Ltd. Mr. Prakash General Manager 9727765623 -

Page | 19

Annexure III

Presentations

1

Page 1

Theme Introduction on

“Environment Friendly Techniques in Textile Sector”

Lalit Sharma

GIZ, Indo German Environment Partnership Programme

13/03/2013 13/03/2013 Page 2

Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH

 A public-benefit enterprise of the German Government [German Federal Ministry for Economic Cooperation and Development]

 Supports the German Government in the field of international cooperation for sustainable development.

 GIZ is also engaged in international education work around the globe.

 GIZ currently operates in more than 130 countries worldwide and has over 16,000 staff.

Page 3 Programme

Owners

Key Stakeholders

Cooperation Partners

MoEF

Ministry of Urban Development

Ministry of Housing &

Urban Poverty Alleviation

Ministry of Consumer Affairs,

Food & Public Distribution

GIZ

CPCB

Urban Local Bodies

Training Institutions Civil Society Industries & Ind.

Associations Key Implementation

Partners

BMZ DEA

Department of Pharmaceuticals (MoC&F)

GIDC

APIIC Karnataka

SPCB

State NGOs Governments

Page 4

SID - Activities/Locations

Pollution control, Environmental planning/monitoring /management

Eco Industrial Development

Env. Labs, Hazardous waste management etc.

National Environmental Protection Training &

Research Institute Eco Industrial Development Industrial Disaster Risk Management Eco Industrial Development

KSPCB GIDC

DoPharma (MoC&F)

DMI

MoEF Relocation of

polluting electroplating industries (Eco Electroplaters

Park) ^EPMFAT

Resource efficiency in industries Disaster Risk

Management

Page 5 13/03/2013

GIZ in India

 Germany has been cooperating with India by providing expertise through GIZ for more than 50 years.

 Focus on the following areas:

»Energy - Renewable Energy and Energy Efficiency

»Sustainable Urban and Industrial Development

»Natural Resource Management

»Private Sector Development

»Social Protection

»Financial Systems Development

Page 6 13/03/2013

Indo German Environment Partnership (IGEP) Programme

Thrust Area: 

Sustainable Industrial Development Planning of  New Industrial 

Parks & 

Investment Zones

Waste Water  Management Environment  

Friendly   Techniques (Pulp & Paper, 

Textiles)

2

Page 7 13/03/2013

Cooperation Activities in Gujarat

 Planning of new industrial parks –co-operation with GIDB, GIDC

 Waste water management –cooperation with VWEMCL

 Environment friendly techniques in pulp & paper sector and textiles sector –cooperation with industries and industries associations

 Capacity building of GPCB to promote state-of-the-art environmental management and pollution control in the state of Gujarat –cooperation with GPCB

 Cooperation with GCPC

Page 8 13/03/2013

Textile Sector

 Identify the environmental issues related to pulp & paper sector (perspectives of the industry, regulatory agencies, people, government...)

 Highlight the immediate need of the sector in order to do their business in sustainable manner

 Identify best available environment-friendly technologies and techniques (most effective – e.g. reduces pollution, allows implementation - technically feasible, economically)

 Demonstrate the use in selected pulp & paper industries

 Develop an up-scaling strategy and supportive policy documents/instruments

SME-EPT

Page 9

Sector Introduction – Textile

13/03/2013

Distribution of Textile Factories in India (State wise) Total Textile Industries – 16104 nos. (Annual Survey of India)

Source: CRISIL report on

“Enhancing Competitiveness of Indian Manufacturing Industry: Assistance in Policy Making, 2009”

Page 10 13/03/2013

Sector Introduction – Pulp & Paper

Source: UNIDO and CRIS Analysis 54%

17%

7%

6%

3%

3% 3%

3% 1%

1%

1% 1%

Textile Clusters In India

Power loom Readymade Garments Hosiery Coir & Coir Products Jeans Garments Textile Processing Garments Shoddy Yarn Silk Cotton Spinning Cotton Cloth Weaving Cotton Mills

Page 11 13/03/2013

Legal & Regulatory Related Core Issues

 In order to meet the standards set by the Pollution Control Boards, textile production unitshave to make large investments in technology up gradation and expertise.

 Government of India runs the Skill Updation Programme through the Textile Committee,it has to be seriously taken.

Resource Efficiency Related Core Issues

 Training to Industries on resource efficiency and cleaner production.

 Knowledge sharing platformto improve though sharing.

 R & D activitiesin cooperation with industries.

Page 12 13/03/2013

Available Solutions - Overview

1. Identification of Core issues

 Process Related

 Pollution Control Related

 Legal / Regulatory Related

 Resource Efficiency Related 2. Identification of Pilot Projects

3. Pilot Project Implementation and Case Study Generation

 Careful use of raw and process materials (Good House Keeping / Cleaner Production)

 Replacement of raw and process material (Eco-Substitutes)

 Change of technology (Best Available Technologies) 3. Dissemination within Sector

 Web based

 Through Associations / Institutes

3

Page 13

Concluding Session - Questions

13/03/2013

•Issues in Textile Sector in India for Improved Environmental Performance ?

Government policies & support Instruments required for supporting Textile Sector ?

•Scope of BAT for Textile Sector ?

13‐03‐2013

1

Units are facing difficulties in operating secondary ETP, particularly for maintaining MLSS.

Due to space constrain, new technology with minimum land area for treatment is required.

Concept of waste water recycling at various stages.

Detail guideline with specific quality and the processes, where it can be re-use/recycle.

Units carrying out mercerizing operation should install Caustic Recovery Plant or any other source where it can be used

Use of modern technology for washing at various stages to reduced water consumption.

Optimum/ Eco friendly use of colorant with specific criteria.

Feasibility of common ESP for steam boiler (capacity between 5 TPH to 10 TPH) and Thermic fluid heater.

Up gradation of APCM with TFH( whether bag filters can be provided)

Auto feeding fuel system into Boiler (capacity 3 TPH or more) as well as Thermic Fluid Heater irrespective of fuel

Feasibility of utilization of Fly Ash in Bricks manufacturing at common level

3/13/2013

1 Environmental Policies, Standards and 

Regulatory Aspects in Textile Industries 

D.S. Kharat

Sr. Environmental Engineer 

Central Pollution Control Board Delhi

February 28, 2013

Content of presentation

• Figures and Facts related to sector at national  level 

• Environmental issues 

• Existing environmental standards, regulatory  aspect and policies if any.  

Textile Industry in India…

• Installed capacity: 43.13 million spindles & 

52,000 looms

• Woven cloth production: 88,745 lakhs meters

• Knitted cloth production: 3,40,100 tonnes

• Consumption of dyes : 6,01,225 tonnes

(17 % in composite sector)

• Consumption of chemicals : 24,36,412 tonnes

& 13,20,643 KL 

Source: Census of Textile Power Processing, Ministry of Textiles, Government of India,2001 Annual Report, Ministry of Textiles (2011‐12) 

Textile Industry in India

State/UT

Composite mills

Semi composite/

processing units Total

Andhra Pradesh 54 54

Assam 1 1 2

Bihar 4 4

Delhi 61 61

Gujarat 17 506 523

Haryana 1 74 75

Himachal Pradesh 4 4

Jammu & Kashmir 1 2 3

Karnataka 8 33 41

Kerala 3 11 14

Madhya Pradesh 3 9 12

Maharashtra 27 222 249

Orissa 1 1 2

Punjab 4 378 382

Rajasthan 2 30 32

Tamil Nadu 2 739 741

Uttar Pradesh 4 76 80

West Bengal 8 32 40

Puducherry 1 4 5

Total 83 2,241 2,324

Consumption of main chemicals 

Dyes ( % of fabric)

NaCl or Na₂SO₄

( g/L)

Soda ash ( g/L)

Dye fixation time (Minutes)

≤ 0.10 10 10 30

0.11 – 0.30 20 10 30

3.1 - 0.50 30 10 45

0.51 – 1.00 45 15 45

1.01 – 2.00 60 15 45

2.01 – 4.00 30 20 60

> 4.00 90 20 60

Effluent Treatment Technology for  Textile Industries

• Chemical treatment

• Biological treatment (Anaerobic/Aerobic) 

• Activated carbon adsorption 

• Oxidation (Ozonation/Chlorination)

• Concentration 

‐ Membrane filtration: UF/NF/RO

‐ Evaporation: 

Multiple effect evaporation Mist evaporation

Mechanical Vapour recompression 

• Crystallization 

3/13/2013

2 Issues relating to textile industry

• Data base 

‐ In case of small units, data at national level is  inadequate. 

• Process efficiency

‐ Water and chemical consumption in industries  with old machinery may be high. 

• Trained manpower  

‐Adequate training to manpower engaged in  operation of ETP/CETPs can improve efficiency of  these treatment facilities. 

Water pollution aspect

Input  Operation/potential  source 

Cotton cultivation

Water, Fertilizer Insecticides Pesticides 

Effluent

•High volume (100  l/kg)

•Residual dyes

•BOD/COD

•Dissolved solids

•Heavy meats Water contamination

Spinning   weaving

Effluent, BOD/COD 

•Desizing

•Scouring

•Mercerising

•Bleaching

•Dyeing

•Printing

•Finishing

•Measures 

•ETP/CETP

•Recovery of salt

•Recovery of water

•ZLD

•Low salt dyes

•Salt less dyeing Cotton bales

Water Sizing agents

Water  Alkali Acid Bleaching agents Salt Dyes Surfactants etc.

Wet processing 

Fugitive emission aspect

Operation/potential  source 

Sizing Spinning/weaving

Finishing Printing  Scouring

Singeing 

Dyeing

VOC, formaldehyde vapors Solvent, emission from curing

‐ Exhaust gases Scouring solvent, VOC VOC

Lint 

Solid waste aspect

• Solid waste from spinning mills

‐Cotton mills: 2‐4 % of raw fibre weight 

‐Woolen mills: 3‐6 % of raw fire weight 

Hazardous waste aspect

• Primary ETP Sludge

‐Quantity of sludge (Cotton) = 0.60‐ 1.20 kg/m³of  effluent 

‐Quantity of sludge (Manmade fibre)  =  0.4‐0.6  kg/m³of effluent 

• Treatment & disposal of hazardous waste

‐ 28 Nos. of TSDF sites   

‐ 13 Nos. of Incinerators 

‐ Cement is kiln is also an option   

Remediation of degraded soil/ground  water  

• Discharge of coloured and TDS bearing effluent  without adequate treatment can degrade receiving  environment such as river, ground water and soil. 

• Pali Rajasthan: Discharge of textile industry effluents in  Bandi River at Pali, Rajasthan affected about 10,000 ha  of land (1993).

• Tirupur, Tamil Nadu: Ground water quality in Noyyal River basin near Tirupur, Tamil Nadu is contaminated  due to the discharge of effluents by textile dyeing  industries located at Tirupur (2006).  

• Remediation of ground water/soil has not taken place. 

3/13/2013

3

Effluent Discharge Standards notified under the  Environment (Protection) Act, 1986

Parameter Concentration not to exceed mg/l,

except pH

pH 5.5‐9.0

Total suspended solids 100

Boi‐chemical oxygen demand (BOD) 30 Chemical oxygen demand (COD) 250

Total residual chlorine 1

Oil an d grease 10

Total chromium as Cr 2

Sulphide as S 2

Phenolic compounds as C6H5OH 1 Note:

1. Where the treated effluent is discharged into municipal sewer leading to treminal treatment plant, the BOD  may be relax to 100 mg/l and COD to 400 mg/l.

2. The quantity of effluent (liter per kilogram of product) shall not exceed 100, 250 and 80 in composite cotton  textile industry, composite woolen textile industry and textile processing industry, respectively

Hazardous waste disposal standards 

Class/Limit Contaminants 

Class A/ Concentration limit: 50 mg/kg Arsenic and arsenic compounds Cadmium and cadmium compounds Chromium (VI) compounds Mercury and Mercury compounds Inorganic cyanide compounds Class B/ Concentration limit: 5, 000mg/kg Chromium (III) compounds

Cobalt compounds Copper compounds Lead and Lead compounds Nickel compounds Class C / Concentration limit: 20, 000 mg/kg Sulphides

Zinc compounds Acid amides Class D/ Concentration limit: 50, 000 mg/kg Total Sulphur

Inorganic acids Nitrides

Eco‐mark Standards, IS:15651 (2006)

S No. Parameter Requirement  mg/kg (ppm), Max

Baby Clothing Close to Skin Outer Wear

i) Free and releasable formaldehyde 20 75 300

ii) Extractable heavy metals by artificial acidic sweat:

a) Antimony (Sb) b) Arsnic (As) c) Lead (Pb) d) Cadmium (Cd) e) Mercury (Hg) f) Chromium

Total g) Cobalt (Co) h) Copper (Cu) i) Nickel (Ni)

5 0.2 0.2 0.1 0.02 0.1 1.0 25.0 1.0

10 1.0 1.0 0.1 0.02 2.0 4.0 50.0 4.0

10 1.0 1.0 0.1 0.02 2.0 4.0 50.0 4.0

iii) Pentachlorophenol (PCP) 0.05 0.5 0.5

(iv) 2,3,5,6 Tetra‐cholorophenol (TeCP) 0.05 0.5 0.5

v) Orthophenyl phenol (OPP) 0.5 1.0 1.0

vi) Organo‐tin compounds a)Tributyltin (TBT) b) Dibutyltin (DBT)

0.5 1.0

1.0 1.0

1.0 1.0

vii a)Pesticides  (Sum parameter) 0.5 1.0 1.0

viii Banned Pesticide Nil Nil Nil

Ix x

Banned aryl amines from azo days pH of aqueous extract

30.0 4.0‐7.5

30.0 4.0‐7.5

30.0 4.0‐7.5

CETP Scheme 

• Common Effluent Treatment Plant (CETP)  scheme is operated  by the Ministry of Environment and Forests, Government of  India for financial and technical support to SSI industries  located in clusters. 

• Under the scheme assistance up to 25 % of total cost of the  CETP is provided as a grant to the CETP society on the  condition following condition: 

‐ The State Government will give a matching contribution (up  to 25 %)

‐ The remaining 50 % of cost is to be met by equity  contribution by the industries and loan from financial  institution. 

• Under the scheme 90 CETPs have been constructed. (682.57  MLD installed capacity) 

Thanks 

1

DOB 1

Statutory Compliance in Industries

Prepared by : R.N.CHAREL.

Mainly there are two types of statutory Laws applicable to the industry for safety and welfare of Laboures.

Safety Laws (Factory Laws) & Welfare Laws (Labour Laws)

Factory laws Focuses about the safety, Health and Environment aspect, while Labour Laws concentrated towards welfare and social security measures.

Statutory Laws in Industries

Factory Laws : (Safety)

1. Indian Electricity Act – 1910 2. Indian Boiler Act – 1923 3. Factory Act – 1948 etc.

Labour Laws : (Welfare)

1. Workmen Compensation Act - 1923 2. Payment of wages Act -1936 3. Provident Fund Act

4. Industrial Dispute Act - 1947 5. Indian Trade Union Act - 1926

DOB 3

Laws Administered in Boiler Directorate

Directorate of Boiler has to follow the Central Boiler Act and regulation rules and State Boiler rules for the purpose of ensuring safety of public and property

1. Indain Boilers Act 1923 2. Indian Boiler Regulation 1950 3. Gujarat Boilers Rules 1966 4. Gujarat Economiser Rules 1968 5. Boiler Operation Engineers Rules 2011 6. Boiler Attendant Rules 2011

Formulation of Boiler Act

2 Evolution Of Boiler,

 Boiler came in service in India near 1820, W.P. of the boiler was restricted to 65 PSI at that time to avoid explosion. Boiler were every where in India around 1900’s

 We know that boilers have a great potential for causing Loss of life and damage to property because steam generating water at elevated pressure and temp. is highly explosive in nature and explodes When its suddenly exposed to atmospheric conditions due to Failure of Boilers, such explosions causes destruction of life and property around boilers.

 There fore Laws are made to ensure proper design, construction and maintenance of boilers and there by avoid boiler explosions.

 But, We must know background and brief histories of formation of Act and for enacting Act.

 The History of initial Boilers Acts is quiet interesting to know about it. So, I would like to say that,

 What was the situation before boiler Act Formation?

 How did Indian boilers Act came in to Force in whole India?

 1840-1850 : started industrialization

 Before : 1860:-There were no any boiler laws during British India – No statutory binding on boiler owner.

– They had their own safety rules of their own interest

 In December – 1863, A serious boiler explosion was occurred in Calcutta, which took A lives of 13 people. After that accident,

 First boiler legislation in India was introduced as the Bengal Act-1864 for boiler inspection.

 In 1869, The Bombay code was introduced inline with Bengal Act after two Fatal accident in Bombay ( in 1868-1869 period) Then, Boiler legislation were introduced one by one in other provinces like Madras, Barma etc. During the next 40 years.

 In 1872 : A small boiler Act passed in Ahmedabad city only after Fatal accident in 1871-1872.

 In 1882 : The boiler explosion Act passed by the British parliament

 In 1919 : 7 different Acts or codes were functioning in different provinces area of the country, Every province had adopted a different definition of a boiler.

In such a way, boiler played most vital role acting as heart in the industries, But the boilers were found to met with Frequent accident due to faulty design, construction, materials and operation causing Losses of lives and properties.

To control and check the reoccurrence of such accident, separate Acts and rules were framed in some parts of India Hence, Govt. of India decided to introduce a uniform standard through out the British India for the inspection of Boilers for which a boiler Laws committee constituted in Nove-1920.

 1920 : Boiler Law committee set up by Govt.of India for common rules/regulation s in whole India.

 Boiler Law Committee – President : Mr. Ascoli, I.C.S

– Members : (1) Mr. R.P. Adams, O.B.E, A.M.I.E, C.I.B., Bengal

 (2) Mr. D.R. Macin tosh, C.I.B., Bombay

 The Committee commenced its tour on the 25th Nove. 1920 in different provinces of India ( They visited all the provinces)

 They were returned to Delhi on the 20th Feb.1921.

 On 10/3/1921, The committee submitted details report with draft Act on the basis of that report,

3

 The Indian Boiler Act-1923 came in to force in whole India on 23/2/1923

 With Aims to provide for safety of life and property from the danger of explosion of boilers during use.

 It is matter of pride for us that, The subject “Boiler” is included in the seventh schedule under the concurrent list of the constitution of India , Hence boiler Act is so older than constitution of India

 In 1924 The IBR were framed to have uniform Engg.standard in the whole country I.B.R.-1924 came in to force in respect of material, design, construction, registration, method of determining person working pressure, Method of preparing a boiler for examination, Ensuring the safety of person working inside the boiler, prescribing forms etc.

 In 1937 : Central Boiler Board was formed

 After that with the industrialization of our country and getting independent in the 1947, The I.B.R-1950 was framed in 27 Sept.1947

 I.B.R-1950 is not a standard or specifications

 I.B.R-1950 is the technical part of boiler Laws containing design, materials, construction inspection, testing etc.

 The Indian Boiler Act –1923 and regulations and rules there under were made to ensure proper design, manufacture, operation and maintenance of boilers. IBR-1950 is an exhaustive manufacturing code, Thus proper design of a boiler provides inbuilt safety to a boiler.

This inbuilt safety to a boiler is ensured by through checking of design and vigorous inspections during the course of manufacture. Now, Let us discuss the act by knowing about sailent features

 Back ground

 Scope of the Act/its application

 Definition

 Machinery of execution

 Important section of the Act and its provisions

 Penalties

This Act is perhaps one of the smallest Act containing 34 sections.

 These Includes

 Extent of an Act

 Definition

 Application of Act

 Limitations of Act

 Power of limit extent

 Machinery for executing of Act

 Prohibition of use of boiler

 Requirments for registration and statutory in use boiler inspection

 Certificate of Boiler

 Revocation of certificate

 Alteration, Renewals to boiler

 Duty of Boiler owner at examination of boiler

 Production of certificates

 Transfer of certificates

 Power of Entry

 Report of accident

 Appeals

 Finality of orders

 Penalties for non compliance

 Prosecution

 Authority for making regulation

 Power of central Govt.

 Power of state Govt.

 Penalty for breach of rules and regulations

 Recovery of fees

 Applicability to the Govt. Boilers

 Exemptions from operation of the Act

Definition of Boiler:-

Old Definition :Boiler means any closed vessel exceeding 22.75 Litres in capacity which is used expressly for generating steam under pressure and includes any mounting or other fittings attached to such vessel which is wholly or partly under pressure when steam is shut off;

But with time and technology, the provisions of the Indian Boiler Act-1923 have been amended in December- 2007 by the Central Government. Hence New Boiler Act (Amendment) 2007 has been in forced for implementation in whole of India. The important amendments in the said Act are as under:

Section-1:

From the title “Indian Boilers Act-1923” the word “Indian” will be omitted.

Section-2(a):

The definition of “Accident” is amended so as to cover death or injury of a person or damage to the property.

Section-2(b):

New definition of Boiler:

The following are the new features of definition of boiler.

Boiler means a pressure vessels

* In which steam is generated for use external to itself by application of heat.

* Which is Wholly or partly under pressure when steam is shut off

* Following pressure vessels not include

* Having capacity less than 25 Litres.

(Such capacity being measured from the Feed check valve to the main steam stop valve)

* With design and working gauge pressure less than 1 Kg/Cm² OR

* In which water is heated below 100°C.

Definition of Boiler has been amended as under.

Boiler means a pressure vessels in which steam is generated for use external to itself by application of heat which is wholly or partly under pressure when steam is shut of but does not include pressure vessel:

(i) With capacity less than 25 Liters. Such capacity being measured from the feed check valve to main steam stop valve.

(ii) With less than 1 Kg/Cm² design and working gauge pressure OR (iii) In which water is heated below 100°C.

But it is to clarified by the C.B.B after consultation with Ministry of Low by Letter dtd.01/01/2010.

If a pressure vessel falls in any one of the clauses (i),(ii), and (iii) of sub Section (2) of Section 3 of the Boiler (Amendment) Act-2007 then it is not to be treated as a Boiler.

Section-2(cb):-

A person recognized to perform duties similar to those of a boiler inspector will be designated as “Competent Person”.

Section-2(ccd):-

Institution will be recognized as Inspecting Authority for inspection and certification of manufacturing activities in addition to the State Inspectorates.

Section-2(d)

The definition of “Owner” is amended to include the person processing the boiler disregarding its use.

Section-2(f)(ii):

Pipe exceeding 254mm internal diameter with steam pressure not exceeding 1 Kg/Sq.cm (gauge) is now excluded from the definition of “Steam Pipe”.

Section-3: Limitation of Application This Act shall not apply to:

* Boilers belonging to or under control of the railways.

* Boiler belonging to Steam ships.

* Boiler belonging to or under control of the Army, Navy, or Air force.

A Sterilize disinfector used in Hospitals or Nursing homes having does not exceed one hundred litres in capacity.