Färbungsprozess_Salzgehalt und Wasser

8/14/2019 Frbungsprozess_Salzgehalt und Wasser

1/19

THE STORY OFSALT & WATER

IN MAKINGA T-SHIRT


2/19

PRODUCT PROCESS

COTTONCULTIVATION &

GINNING

YARN SPINNING

GREY FABRIC KNITTING

DYED & FINISHED

FABRIC

DYEING &

FINISHING

USE OF

SALT &

WATER

T-SHIRTCUTTING , STITCHING

& FINISHING

T-SHIRT MAKING PROCESS


3/19

INPUT OUTPUT OVERVIEW FOR

DYEING

DYEING & FINISHING

ENERGYWATERCHEMICAL INPUTSDyestuffs

SALT Basic Chemicals

Auxiliaries

Electricity

Boiler Fuel

Genset Fuel

OTHERS ITEMS

RAW MATERIALS PRODUCTS

Grey Fabric Dyed &

Finished

Fabric

WASTE WATER GAS EMISSIONS SOLIDWASTE WASTE HEAT Boiler

Genset

Packing

Containers

Raw Materials

Sludge

Ash

Boiler

Genset

Dryers

Effluent

Packing

Lub oil-grease

Accessories

Concentrated Waste Water

with Salt

Wash Water


4/19

THE SCENARIO OF

SALT & WATER USAGEn The Whole of Europe is discharging about

200 Million Kilogram of Salt every year in

Textile Dyeing

n The Whole of Tirupur is discharging about80 Million Kilograms of Salt every year in

Textile Dyeing


5/19

35 litres200 gramsColouredT-Shirt

15 litresNilWhite

T-Shirt

Water Used

To make

One T-Shirt

Salt Used

To make

One T-Shirt

T-Shirt

SALT & WATER USED IN MAKING

ONE T-SHIRT


6/19

n To recover 95% of Water for reuse

from Textile Dyeing Waste Water= 111 Million litres / annum

n To recover 90% of Salt for reuse from

Textile Dyeing Waste Water= 4,50,000 Kgs / annum

Objectives ofSalt & Water Recovery Plant

at PREM , Tirupur, India


7/19

The Need

SWITCHER-PREM

SUSTAINABLE DEVELOPMENT

PROGRAMME

AS PART OF

THEIR CORPORATE SOCIAL

RESPONSIBILITY


8/19


9/19

Treatment Scheme

Segregation at Source

Dye Effluent Wash Effluent

Pre Treatment

Multiple Evaporator

Salt Crystallizer

Primary, Secondary &

Tertiary Treatment

Reverse Osmosis

Plant

2 stage water recovery

Recovered Water

for Reuse

Concentrated

RejectRecovered Salt

For Reuse


10/19

Technology of Salt Recovery

n During the Dyeing Process, Glaubers Salt will be usedinstead of Common Salt because it is purer and easierto recover for Reuse

n The concentrated Dye Effluent with Glaubers Salt ispre treated to remove colour

n It is passed through Multiple Evaporators and getsconcentrated

n The concentrated solution is chilled in VacuumCrystallizer and the Glaubers Salt is crystallized

n The crystallized Glaubers Salt is centrifuged and takenfor Reuse in the Dyeing Process


11/19


12/19

Capital Cost of the Project

Glaubers Salt Recovery Plant Rs. 158 lakhsWith

Multiple Evaporators, Crystallizer

Centrifuge, Structure etc.

Water Recycling Plant Rs. 200 lakhsWithPrimary Treatment Plant,

Secondary Bio Reactor,

Tertiary Treatment Plant,

Two Stage Reverse Osmosis Recycling Plant

TOTAL PROJECT COST Rs. 358 lakhs

USD 8,00,000


13/19

The Cost & The Benefits

Inputs Required for Operation

Electrical Power

Steam Energy

Chemicals & Consumables

Man power

Cost of FundsBenefits

Value Recovered Salt

Value of Recovered Water


14/19

COST OF OPERATION

FOR SALT RECOVERYn Every Kilogram of Recovered Salt Costs

Rs. 8 more than the cost of buying the Salt

uThis means Every T-Shirt cost goes up

by Rs. 2.00

uTherefore for 2.50 Million Coloured

T-Shirt / annum, it will cost the Company

by Rs 5.00 Million = USD 1,13,600


15/19

COST OF OPERATION

FOR WATER RECOVERYn Every Kilo litre of Recovered Water costs Rs. 30

more than the cost of procuring Water

u Every White T-Shirt cost goes up by Rs. 0.45

costing the Company annually for2 Million T-Shirts = Rs 0.90 Million = USD 20,400

u Every Coloured T-Shirt cost goes up by Rs. 1.05

costing the Company annually for

2.5 Million T-Shirts = Rs 2.62 Million = USD 59,500


16/19

THE FINAL COST OF

SALT & WATER RECOVERYn The Total annual Additional Cost of

Salt & Water Recovery

= Rs. 8.00 Million = USD 1,80,000n This means finally every T-Shirt costs more

by Rs. 1.77 = USD 0.04


17/19

Benefits of this Projectfor the Company

n Meeting the statutory requirements

n Using Glaubers Salt gives better Dyeing Results

n Using Recovered Water gives enhanced Dyeing

Performance in terms of Fastness, Uniformity,Reproducibility and less rejection

n Tackles the Water Shortage problem

n A major step in achieving Zero Liquid Effluent

Discharge

n Satisfying the requirements of SWITCHER &

PREM GROUPS Corporate Social Responsibilities


18/19

Benefits of this Projectfor the Environment

n Stops discharging several thousand tons Salt on the

land and water receivers and hence the increase in

the salinity is prevented

n Several thousand tons of salt is Recovered and

Reused

n Stops discharging several million litres of Effluent

n Stops drawing and using several million litres of

water from the nature

n

A major step in implementing SustainableDevelopment Concept


19/19

Documents

Färbungsprozess_Salzgehalt und Wasser