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Pollution Prevention in the Textile Industry

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Pollution Prevention in the Textile Industry POLLUTION PREVENTION IN THE TEXTILE INDUSTRY DEVELOPED BY: U.S. EPA/SEMARNAP POLLUTION PREVENTION WORK GROUP DECEMBER 1996 CONTENTS Sheet 1 of 2 Section Page PURPOSE OF THIS MANUAL ..................................................................................................... vi INTRODUCTION............................................................................................................................vii SECTION I GOALS AND BENEFITS OF POLLUTION PREVENTION..................................I-1 What is Pollution Prevention? ...........................................................................................I-1 Other Environmental Management Strategies..................................................................I-4 Pollution Prevention Goals................................................................................................I-4 Benefits of a Pollution Prevention Program ......................................................................I-4 Developing a Pollution Prevention Program .....................................................................I-9 SECTION II GENERAL POLLUTION PREVENTION OPTIONS AND COMMON PRACTICES.........................................................................................................II-1 Impact of Pollution Prevention on Company Expenses...................................................II-1 Design for Environment....................................................................................................II-1 Housekeeping ..................................................................................................................II-2 Inventory Control ..............................................................................................................II-2 Reduce Packaging Waste................................................................................................II-3 Establish an On-Site Recycling Program.........................................................................II-4 SECTION III POLLUTION PREVENTION IN THE TEXTILE INDUSTRY ..........................................................................................................III-1 Introduction......................................................................................................................III-1 Chapter 1 THE TEXTILE INDUSTRY......................................................................III-2 Overview of the Textile Industry..............................................................III-2 Textile Processes....................................................................................III-2 Textile Process Waste Streams..............................................................III-3 Chapter 2 POLLUTION PREVENTION OPTIONS FOR THE TEXTILE INDUSTRY ..............................................................................................III-7 Organization of this Chapter ...................................................................III-7 Process 1—Yarn Formation....................................................................III-8 Process 2—Fabric Formation ...............................................................III-12 Process 3—Fabric Preparation.............................................................III-17 CONTENTS Sheet 2 of 2 Section Page Process 4—Dyeing................................................................................III-31 Process 5—Printing...............................................................................III-52 Process 6—Final Finishing ...................................................................III-58 Process 7—Product Fabrication ...........................................................III-65 SECTION IV CASE STUDIES ..................................................................................................III-1 CASE STUDY NO. 1—Dyeing and Finishing .................................................................IV-1 CASE STUDY NO. 2—Textile Manufacturing ...............................................................IV-4 CASE STUDY NO. 3—Screen Printing ..........................................................................IV-6 CASE STUDY NO. 4—Knitting, Dyeing, and Finishing ..................................................IV-9 CASE STUDY NO. 5—Nylon Hosiery Manufacturing.................................................. IV-11 CASE STUDY NO. 6—Acrylic Yarn Production........................................................... IV-13 CASE STUDY NO. 7—Spun Cotton Yarn Manufacturing ........................................... IV-15 CASE STUDY NO. 8—Textile Processing .................................................................. IV-17 CASE STUDY NO. 9—Textile Manufacturing ............................................................. IV-19 CASE STUDY NO. 10—Textile Manufacturing ........................................................... IV-20 CASE STUDY NO. 11—PVC-Coated Fabric Finishing ............................................... IV-22 CASE STUDY NO. 12—Textile Processing and Washing.......................................... IV-24 CASE STUDY NO. 13—Preparation, Printing, and Finishing ..................................... IV-27 GLOSSARY................................................................................................................................. G-1 BIBLIOGRAPHY...........................................................................................................................B-1 Appendix ADDITIONAL SOURCES OF INFORMATION Attachment A INFORMATION ON ACCESSING POLLUTION PREVENTION INFORMATION CLEARINGHOUSES B SURVEY FIGURES Figure Page I-1 POLLUTION PREVENTION STRATEGIES .....................................................................I-2 I-2 WASTE MANAGEMENT HIERARCHY............................................................................I-6 I-3 POLLUTION PREVENTION PROGRAM .......................................................................I-11 III-1 FLOW DIAGRAM OF TYPICAL TEXTILE PROCESS ...................................................III-4 III-2 STEAM TEXTURIZING SYSTEM.................................................................................III-10 III-3 WATER REUSE STRATEGIES IN CONTINUOUS AND BATCH-TYPE BLEACHING..................................................................................................................III-21 III-4 CAUSTIC RECOVERY SYSTEM .................................................................................III-23 III-5 COUNTERCURRENT WASHING ON A SOAPER RANGE ........................................III-24 III-6 POLYVINYL ALCOHOL (PVA) RECOVERY SYSTEM ................................................III-26 III-7 ULTRAFILTRATION LOOP SYSTEM ..........................................................................III-27 III-8 CONTINUOUS-SOLVENT-SCOURING RANGE .........................................................III-30 III-9 LOW-LIQUOR-RATIO DYEING....................................................................................III-37 III-10 CONTINUOUS-DYEING RANGE .................................................................................III-42 III-11 INDIGO DYE RECOVERY SYSTEM ............................................................................III-44 III-12 PROCESSING SAVINGS AND COSTS ASSOCIATED WITH ULTRAFILTRATION OF INDIGO DYES ......................................................................III-45 III-13 REDUCTION OF DYEBATH RATIO BY USING A VOLUME DISPLACER.................III-48 III-14 DYEBATH RECONSTITUTION PROCESS .................................................................III-49 III-15 TRANSFER PRINTING OF DISPERSE DYES ............................................................III-55 III-16 MECHANICAL SHRINKING OF FABRIC ....................................................................III-62 III-17 CHEMICAL FOAM APPLICATION SYSTEM ...............................................................III-63 FIGURES Figure Page III-18 WET-ON-WET FABRIC FINISHING ............................................................................III-66 III-19 ALTERNATIVE APPLICATION METHODS FOR INDUSTRIAL COATINGS..............III-67 III-20 MICROEMULSION SPRAYING AND CENTRIFUGAL EXTRACTION OF MOTHPROOFING FINISH............................................................................................III-68 TABLES Table Page I-1 EXAMPLES OF SOURCE REDUCTION OPTIONS ........................................................I-3 I-2 WASTE MANAGEMENT STRATEGIES THAT ARE NOT POLLUTION PREVENTION ...................................................................................................................I-5 III-1 COMPONENTS OF TEXTILE WASTEWATER .............................................................III-5 III-2 TYPICAL COST AND SAVINGS FOR DYEBATH REUSE..........................................III-51 III-3 SYSTEMS FOR DYEBATH REUSE.............................................................................III-51 PURPOSE OF THIS MANUAL This manual provides an overview of the pollution prevention and recycling options that are available in the textile industry. This report is intended only to assist the user in his or her preliminary research and development of pollution prevention options. Each company is responsible for identifying, evaluating, and implementing pollution prevention options that are appropriate to its specific situation. By compiling and distributing this manual, EPA and SEMARNAP are not recommending the use of any particular processes, raw materials, products, or techniques in any particular industrial
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