Transcript Diapositivo 1 - IDEC | Consulting, Training, High

MODULE 2 - Integrated Pollution Prevention and Control
PART A – Council Directive 96/61/EC
Project
ETIV – EMAS TECHNICAL IMPLEMENTATION
AND VERIFICATION
Prepared by:
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MODULE 2 - Integrated Pollution Prevention and Control
PART A – Council Directive 96/61/EC
This project has been funded with support from the European
Commission. This publication reflects the views only of the
author, and the Commission cannot be held responsible for any
use which may be made of the information contained therein.
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PART A – Council Directive 96/61/EC
Council Directive
96/61/EC
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PART A – Council Directive 96/61/EC
 Introduction to IPPC:
 What is IPPC:
• Council Directive 96/61/EC
• Fundamental purpose
− introduction of an integrated system of pollution prevention
and control
• Main aims
− minimise environmental pollution,
− encourage efficient energy,
− assure efficient waste management,
− prevent environmental accidents and limit their
consequences,
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• Main aims (cont.)
− assure restoration of site condition and elimination of
pollution risks.
• Implementation of a permit-to-operate process
• “Best Available Techniques” - the elementary base of the permit
system
• BAT Reference Documents – information exchange on Best
Available techniques
• Local BAT – consideration of the technical characteristics of the
installation, its geographical location and the local environmental
conditions
• Reviewing and updating BAT and granted permits
• Public participation and information
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 IPPC versus EMAS:
• Common elements:
– Aiming at preventing and reducing industrial effects on the
environment
– Stressing importance of monitoring effects and reducing
impacts
– Integrated approach
• EMAS requires compliance with regulatory requirements
(including IPPC)
• EMAS facilitates the application of IPPC
• EMAS environmental management system, provides assurance
of competence and performance.
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 IPPC Addressees:
• Industrial installations
• Agricultural installations
• Others
 IPPC Coverage:
• Previously existent 15 Member States
• Recently joined countries
 IPPC Players:
• The European Commission, Member States governments and
national authorities,
• Industrial operators,
• The Information Exchange Forum
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 IPPC Players (cont.)
• Technical Working Groups,
• The European IPPC Bureau,
• The IPPC Experts Group,
• The IMPEL network,
• The European Pollutant Emission Register Committee
• The public.
 IPPC Basis
• EU environmental commitments
− Priority to intervention at source
− Prudent management of resources
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PART A – Council Directive 96/61/EC
•

EU environmental commitments (cont.)
−
Compliance with the polluter pays and pollution
prevention principles,
−
Sustainable balance between human activity and socioeconomic development,
−
Balance between natural resources and regenerative
capacity of nature,
−
Promotion of sustainable production.
Expected Achievements
•
Protection of the environment as a whole,
•
High level of environmental protection,
•
Promotion of clean technologies and good management
practices,
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PART A – Council Directive 96/61/EC


Expected Achievements (cont.)
•
Continuous improvement and innovation,
•
Redress of imbalances,
•
Dissemination of techniques and technology,
•
Simplify and centralize permit concession systems,
•
Promote public participation and information.
IPPC Regulation and Obligations

Initial Concepts
•
Best Available Techniques
−
Best - most effective in achieving a high level of
environmental protection,
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•
•
Best Available Techniques (cont.)
−
Available - those developed on a scale which allows
implementation, under economically and technically
viable conditions,
−
Techniques - technology used and the way the
installation is designed, built, maintained, operated
and decommissioned.
BAT Reference Documents
−
Produced, for each sector covered by the Directive,
by the European IPPC Bureau,
−
Do not set any legally binding standards, solely
providing reference information
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•
Permit Requirements
−
Emission limit values, equivalent parameters or
technical measures based on BAT,
−
General binding rules if the regulator adopts them,
−
Temporary derogations when the regulator approves
rehabilitation plans,
−
Conditions for protection of the soil and ground,
−
Guaranties of appropriate management of wastes,
−
Requirements to minimize long-distance or
transboundary pollution
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•
Permit Requirements (cont.)
−
Measurement methodology, frequency, and evaluation
procedures of releases monitoring,
−
Obligation to report to the competent authority the
monitoring data,
−
Conditions to guarantee environmental protection during
start-ups, accidents, malfunctions, definitive cessation,
etc,
−
Any others the regulator may find necessary to prevent
pollution and achieve an high level of environmental
protection.
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 Operators Obligations
• Take all preventive measures against pollution through the
application of BAT,
• Do not cause significant pollution,
• Avoid waste production,
• If waste is produced, is recovered or disposed of, avoiding
impact on the environment,
• Use energy efficiently,
• Take necessary measures to prevent accidents and limit their
consequences,
• Upon cessation, take measures to avoid pollutions risks and
return the site to a satisfactory state
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 Operators Obligations (cont.)
• Comply with environmental quality standards other EU
Directives or domestic regulations.
 Permit Application Stage
In making permit applications operators need to include adequate
descriptions of:
• The installation and its activities,
• All the materials used,
• The energy used or generated,
• The sources of emissions,
• The nature and quantities of foreseeable emissions,
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 Permit Application Stage (cont.)
• The effects of the emissions on the environment,
• The technology and other techniques used for preventing or
reducing emissions,
• Proposed releases monitoring schemes,
• The measures for preventing and recovering of waste
generated,
• The actual condition of the site of the installation (site report),
• Any further measure planed to comply with the operator’s
obligations,
• A non-technical summary of all the above points.
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 Permit Application Stage (cont.)
With the descriptions operators shall:
• Provide enough information for the authority to determine the
permit conditions,
• Satisfy the authority that everything has been anticipated so
as to comply with the operator’s obligations,
• Assure the authority that competence and management skills
exist so as to guarantee compliance with the permit
conditions.
 Operation Stage
• Regular reports
− Periodically report to the regulator the monitoring data.
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 Operation Stage (cont.)
• Extraordinary reports
− Report to the authority any incidents or accidents affecting
the environment.
• Notifications
− Inform the authority of any planned changes in the
installation or operations.
• Assistance to the authorities on:
− Inspections,
− Samples,
− Information gathering.
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 Operation Stage (cont.)
• Compulsory modifications
− Apply for a new permit when planed changes are
considered significant,
− Accept new permit conditions resulting from permit
revisions, updates or new legal provisions.
• Assure compliance of all permit requirements
 Closure and Surrender Stage
• Apply to Surrender the Permit
− Include a site report
• Elimination of pollution risks
• Site restoration if needed
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 Member States Obligations
• Set up the national legal framework to give effect to the Directive,
• Designate authorities to report to the commission the
implementation of the Directive,
• Determination of permit applications,
• Consultation on permit applications
− Public consultation,
− Consultation of competent authorities,
− Transboundary Consultation.
• Checking and enforcing compliance,
• Review and update permits,
• Keep update on BAT developments,
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 Member States Obligations (cont.)
• Create and maintain public registers on:
− Permit applications,
− Permits granted and eventual alterations,
− Emissions monitoring data
• Report to the Commission on:
− The implementation of the Directive,
− The principal emissions and sources responsible,
− The ELVs adopted and the BAT from which they where
derived.
• Designate authorities responsible for Exchange of Information
Activities
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 Obligations of the European Commission
• Organize and publish exchange of information on best
available techniques, associated monitoring and
developments in them,
• Create and maintain an inventory of the principal EU
emissions and the sources responsible.
 IPPC Work Program and Timeframe
• In 1997, IMPEL, the Member States informal network of
authorities was created,
• The dead line for the national transposition of the Directive
expired on 30 October 1999,
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 IPPC Work Program and Timeframe (cont.)
• From October 1999, the IPPC regime should have been
applied to all new installations,
• The IPPC regime should have also been applied to existing
installations that had carried out changes involving significant
impact on humans or the environment,
• The final deadline for all other existing installations to apply
BAT and meet all requirements of the Directive is October
2007
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 IPPC Work Program and Timeframe (cont.)
• Every three years, and for the first time within 18 mouths
from the date the Directive came into force, Member States
will send, to the Commission, data on ELVs adopted and the
BAT from which they derived,
• The Commission established an Information Exchange
Forum and started exchange of information on BAT in 1997,
• All first-edition BREFs are expected to be ready by the end
of 2005,
• Revision of BREFs was expected to start in 2003,
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 IPPC Work Program and Timeframe (cont.)
• In the year 2000 the Commission lays down the
obligations of Member States and the Commission on the
implementation of a European Pollutant Emission
Register,
• Every three years, starting in June 2003 with data on
emissions 2001, Member States will report to the
Commission information on emissions.
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 CONCLUSION
• IPPC Directive is expected to:
− Drive industry towards more sustainable production
patterns,
− Promote industrial innovation and modernization,
− Contribute to economical and social cohesion,
− Bring fair competition to the internal market,
− Promote world-wide dissemination of techniques and
standards, etc.
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PART B
MODULE 2
PART B
REFERENCE DOCUMENT ON THE
GENERAL PRINCIPLES OF MONITORING
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DOCUMENT STATUS

IPPC directive, means the council directive 96/61/EC
MONITORING DEFINITION

Monitoring - Systematic surveillance of the variations of a
certain chemical or physical characteristic of any
- emission
- discharge
- process parameter, etc.,
…based on repeated measurements in accordance with fixed
procedures, to provide information that can lead to better
decision-making about an industrial operation.
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Monitoring issues to consider in setting IPPC permits

Permit writers are recommended to take into account the
following seven considerations when establishing optimized
permit monitoring conditions:







Why” monitor?
Who carries out the monitoring?
“What” and “How” to monitor
“How” to express ELVs and Monitoring results
Monitoring timing considerations
How to deal with uncertainties
Monitoring requirements to be included with Emission
Limit Values (ELVs) in Permits
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DIFFERENT APROACHES TO MONITORING
 OBJECTIVES
 Operator’s
 optimising a process;
 auditing;
 quality control;
 occupational health and safety.
 Authorities
 compliance checking;
 environmental reporting;
 assessing charges;
 quantifying the performance of BATs.
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DIFFERENT APROACHES TO MONITORING
OBJECTIVES
Monitoring programmes cover:
 Controlled emissions of waste gas and airborne
particulate to air via chimney stacks;
 Controlled discharges of waste water via sewers to
and from effluent treatment plants;
 Controlled disposal of solid waste to landfill sites;

Controlled discharges of waste water via sewers to
and from effluent treatment plants;

Controlled disposal of solid waste to landfill sites;

Controlled disposal of solid and liquid wastes,
including organic, to incinerators;
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
Process raw material inputs (e.g. trace contaminants and
operating conditions (e.g. process temperature, pressure and
flow rate);

Fugitive releases to air, water and land; being those that are not
coming from a defined point but rather from a number of
widespread points;

Energy efficiency and water consumption;

Noise and odour nuisances;

In addition, receiving environments (e.g. ambient air, grass, oil
surface and ground waters) may be monitored.
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 Emission Sources:
– Identification of the suitable priority level of monitoring of
different releases taking into account:
 the nature, scale of the operation, and variations in the
process and emissions;
 resources available for monitoring.
– Quantification of the total emission, and not measure only
some individual points very accurately or only the big point
sources;
– Importance of exceptional emissions (disturbance and
accidental situations, such as start up and shutdowns).
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 Parameter Value:




Directly measured;
Indirectly measured by using surrogate parameters;
Calculated by emission factors, extrapolation of other
values, etc.
Monitoring Technique (depend on the use of):
 Fixed (in-situ or on line) continuous reading instruments;
 Portable discontinuous reading instruments;
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 Laboratory analysis of samples taken by fixed, in-situ, on-line
time or flow proportional samplers;
 Laboratory analysis of spot samples;
 Calculations based on surrogate measurements of flow rates,
raw material, contaminants, temperature, pressure etc.

Monitoring technique phases:
 Preparation;
 Generation;
 Evaluation.
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PREPARATION

Setting up a measurement strategy, determining:
 Which objectives;
 Frequencies (risk-based approach);
 Process conditions;
 Duration;
 Measurements protocols (tools, standards
procedures).
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GENERATION

Depends on the:
 Information needed and specific situation;
 Direct (difficult, inaccurate, or excessive costly) or
indirect (process deep knowledge) measurement;
 Calculation or estimation or extrapolation.
EVALUATION

Calculation of the concentration, accounting:
 Operating conditions of the stream (temperature,
pressure,…);
 Statistical treatment to reduce the amount of data;
 Interpretation in the light of the objectives.
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ENVIRONMENTAL PERMIT /
MONITORING PROGRAMME /REPORTING OBLIGATION
TECHNICAL AND PRACTICAL
REQUIREMENTS
ENVIRONMENTAL MANAGEMENT SYSTEM
POLLUTER DATA PRODUCTION CHAIN
NOISE
VIBRATION
7
1 VOLUME
WASTE
2-5 CONTINUOS ANALYSIS
WASTEWATER
2
3
4
5
SAMPLE
SAMPLE
SAMPLING
PRE –
ANALYSIS
TREATMENT
TREATMENT
REPORTING
EMISSIONS
TO THE AIR
HEAT
6
DATA PROCESSING
EMISSIONS SOURCE TO BE MONITORED
QUALITY SISTEMS
RELIABILITY
ASSESSMENT
EXCEPTIONAL EMISSIONS
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Factors affecting the monitoring:

Flow/amount measurement;

Sampling;

Sample pre-treatment;

Sample treatment;

Sample analysis;

Data processing;

Reporting.
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FLOW MEASUREMENT accuracy has a major impact on the total
load emission results:



For waste gas flow the error can hardly be less than 5%,
normal errors of 10% are often found;
For waste water discharge an error of  5% has been
recommended to be;
For determination of the amount of solid waste, including
sludge is usually made by multiplying the density and
volume of the containers.
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SAMPLING must be:

Representative in the time and also in space.

The sample to the laboratory should represent all that it
has been discharge during , for example, a day of work
(time representativeness);

or if a material is being monitored, the portion of
sample should represent the thousands of tonnes that
are being introduced in the plant (space
representativeness)
The sampling should be carried out with no change in
the composition of the sample. There are parameters
in a sample that should be determined, or somehow
preserved, in situ as their value may change with the
time.

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The complexity is increased as the sample :
 May range from a few grams up to thousands of tonnes;
 May include substances that can vary widely in their nature;
 Is homogeneous or heterogeneous;
 Can be solid, gaseous or liquid.
Factors to be indicated:

The location should be such that:
 material is well mixed;
 same defined points;
 flow can be measured or known;
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Factors to be indicated:

The location should be such that:
 material is well mixed;
 same defined points;
 flow can be measured or known;
 not difficult to reach;
 no personnel risk regarding safety hazards (care of

inhaling or contacting toxic substances or receiving hot
discharges).
The frequency is decided on a risk basis taking into account:
 variability of the flow;
 composition of the flow;
 magnitude of the variability with respect to limit;
 unacceptable values.
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The sampling method and/or equipment:

The type of sampling:
 automatic time;
 flow proportional;
 manual spot.

The size of individual samples and bulking arrangements
to provide composite samples;

The type of sample e.g. sample for single or multiple
determinant analysis;

The personnel in charge of taking the samples should be
skilled.
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Label attached to the sample:

All previous characteristics;

A unique sample identification number assigned from a
sequentially number register ;

Date and time of sampling;

Sample preservation;

Process relevant details;

References to measurements made at the time when
the sample is taken.
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SAMPLE PRE-TREATMENT

To preserve the value of the parameters, while storage
and transporting of the sample:
 keeping the sample at a suitable temperature
(typically at 4ºC);
 adding certain chemicals to fix the composition.

Pre-treatment of the sample must be carried out
according to the analysing programme.

Clearly documented in the sample label.
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SAMPLE TREATMENT
Reasons for sample treatment:

Concentration:
 carried out when the concentration of the compound
is too low to be detected by analysis method.

Elimination of impurities:
 added to the sample during the sampling procedure.

Elimination of water:
 indicate if the resulting data are referred to dry basis
or wet basis.
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
Homogenisation:
 different
results from sedimented and nonsedimented wastewater sample; composite samples
should be well mixed.

Dissolution:
 improve performance of the analytical method.

Elimination of interference:
 compounds that increase or decrease the reading of
the determinant of interest.
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SAMPLE ANALYSIS
• Different methods can give variable results of the sample.
The analytical method to be used is depending on a number
of factors, including:
•
suitability;
•
availability;
•
economy.
• National or international standards should be used.
• Laboratory carrying out the analysis could be accredited
under appropriate standards, e.g. EN4500.
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REPORTING
From the large amount of data generated when a
parameter is monitored, a summary of the results over a
certain period of time is to be presented to the relevant
authorities.
Averages can either be peak of an hour values or averages
of a calendar day, monthly or annual averages.
Basis on which data should be reported:
Test environmental and technical performances of
processes and (gas) cleaning techniques - hourly average,
but when peak concentrations are very important, the
average time has to be reduced; emissions expressed as
mg/m3;
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General compliance checking or the BAT-performance use “emission relevant parameters” (ERP`s);
Actual burden to the local environmental - emissions
expressed kg/h;
Emissions registration purpose - parameters expressed as
tonne/year;
Comparing process performances - express emissions as
kg/tonne of product.
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PARTICULATES
Procedures for monitoring particulates are different from
those of sampling other parameters, mainly because
particulates are an inhomogeneous suspension in the gas
stream.
A preliminary test should be done to check the suitability of
the sampling plane.
Velocities and temperatures are measured in a number of
points to test homogeneity.
The number of sampling points and the distribution of them
is very important, and it recommended that the number of
points is not less than 4, with two perpendicular sampling
lines.
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The duration of the sampling depends on a number of
factors, including the concentration of particules and the
accuracy of the weighing.
To ensure representativeness of the sample, providing the
wide range of particle size, it is necessary to sample
isokinetically.
Equipment includes:

sharp sampling nozzle;

sampling flow rate measure;

a particle separator (a cyclone, a filter or both).
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GASES
Continuous gas monitors classification:

Extractive systems - the gas is extracted from the
stack continuously along a sampling line, transported
and conditioned before entering the analyser unit.
The sampling point should be selected so that it is
representative of the gas stream;

In-situ systems - The measuring cell is the duct
itself; they are based on a beam of a certain
wavelength that crosses the duct and it is attenuated
proportionally to the concentration of the compound.
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Aspects of a manual monitoring gas:
 Sampling time;
 Sampling time/contamination level;
 Flowrate control;
 Stability of the sample;
 Parameters to measures while sampling.
Devices of the equipment sampling:
 Flow measurement device to calculate exact
the
volume of the flow sample;
 Pump to extract the sample;
 Sample collector (absorption by solutions; adsorption on
fine solids; cooling techniques; sample bags; personal
sampler pumps, …).
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INTRODUCTION
Flow measurement is of great importance in order to
calculate loads of pollutants to the receiving waters (error
of <5% has been recommended; open and closed
channels).
Aspects to taken into account:

sampling method;

nature of the sampler;

conservation of the sample.
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SAMPLING METHOD
Situations respecting industrial discharge :

Effluent has a constant compositions over the day - a
single sample can do;

Composition varies but the flowrate is constant composite a sample by putting the same quantity every
certain time, ex. every hour;

Flowrate and composition varying - samples for the
composite sample can be proportional to the flowrate;

Parameters that change with time, for example the pH measure periodically the value in the discharge. Since
the value cannot be average should not be measured in
a composite sample.
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PART B
NATURE OF THE CONTAINER
Types of suitable container materials for sampling purpose:

Borosilicate glass;

Plastic containers;

Stainless Steel containers.
CONSERVATION OF THE SAMPLE
There are compounds that must be determined in-situ.
Others must be preserved until the moment of analysis by:
 low temperature;
 adding chemical reactants.
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PART B
SAMPLING POINT
Sewage samples can be taken from the source point before
being mixed with other sewage and/or discharge into the
river.
Sufficient space in order to set up automatic sampling
equipment.
Take samples on an outflow proportional or time
proportional basis at the sewage treatment plant inlet and
outlet.
General considerations to account:

Indicate for any sample aspect, colour, odour, etc.;

Take several samples, during the day, at night, different
seasons, etc.;
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PART B

If a composite sample is taken, the sampling will be proportional to
the flowrate;

Carry out some in-situ determinations;

Transport the samples cooled, so that temperature is kept low.
DIFFERENT LOCATIONS OF THE SAMPLING POINT IN A PIPE
(a)
Block
Valve
To Sample System
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PART B
DIFFERENT LOCATIONS OF THE SAMPLING POINT IN A PIPE
(b)
To Sample System
Block
Valve
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PART B
DIFFERENT LOCATIONS OF THE SAMPLING POINT IN A PIPE
(c)
Block
Valve
To Sample System
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PART B
SAMPLING OF SOLID MATERIAL
Automatic samplers - movement of a collecting device, with
a cutter, through a stream of material as it falls from a
conveyor or a pipe;
Manual sampling:

dry solid - made by coning and quartering.
SAMPLING FOR CHEMICAL ANALYSIS
Minerals
Combustible
Materials
1 Kg<1.7 mm
0.5 Kg<1 mm
250 g subsample
50 g subsample
Pulverise for 5 min
(<0.075)
Crush for 2 min
20 g subsample
10 g subsample
Split for analysis
Split for analysis
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PART B
SAMPLING OF WET (PULP) MATERIAL
Automatic samplers - a pneumatically operated piston is
immersed directly into the pipeline preferably in vertical flow,
with the piston in the “open” or “closed” position;
Manual sampling - material homogeneous in the storage
vessel.
LEVEL OF UNIFORMITY
For non-homogenous materials it is necessary to have
several sampling points in order to obtain a representative
sample.
WASTES
The type of container, the amount of sample required and
the number of subsamples needed, is depending on the size
of the container (<200 litres or >200litres).
The type of analysis and the objectives of the monitoring
also affect the sampling method for wastes.
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PART B
SOIL
Properly formulated spatial sampling designs are an
important aspect of any contaminated soil monitoring.
Number of sampling points for success in locating a
contaminated area depends:
 sampling pattern chosen;
 size of the area;
 shape of the area.
Preliminary investigation:
 site history;
 potentially contaminates uses;
 neighbouring land uses;
 hydrology;
 geology;
 site reconnaissance.
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Initial working plan covering:
 likely contaminants;
 sources;
 present spatial distribution;
 potential for migration;
 initial sampling strategy.
Sampling strategy includes:

number of sampling points;

location on the site;

number of samples;

depth profile at each sampling point.
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PART B
ENERGY
Energy sources can be classified as fuels and electricity.
Different industry energy requirements:

consumption of fuels as raw material;

consumption of fuels as fuel and power (energy use).
Total consumption of energy as fuel and power is the sum of
fossil fuel and electricity.
Unit for measure fossil fuel - tons of oil equivalent (toe).
Unit for measure electricity - GWh - in order to sum them,
quantities of electricity are converted into toe ( 0.23 ktoe per
GWh).
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NOISE
Most important characteristics:

intensity, expressed as decibels (dB) in a scale
logarithmic, that means that an increase of 20dB
means that the level has increased 100 times;

frequency.
The sonometer is the most used device for measuring
noise.
Possible ways to monitoring industrial noise:

measuring at several points surrounding the plant;

modelling in a computer measuring periodically the
intensity at different sources.
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ODOUR
The basic system to assess odours is based in the
human nose (they are in contact with different
concentrations of the substance). It is recommended a
number between 2 and 15.
Odours can be assessed for two reasons:

determination of threshold concentration;

determination of the intensity of an odour.
Attributes to monitoring:

intensity;

penetration capacity;

quality;

acceptability.
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ODOUR
Scale points:
0 No perception
1 Very weak perception
2 Weak perception
3 Easy perception
4 Strong perception
5 Irresistible perception
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PART B
SELF-MONITORING
Self-monitoring involves
measurements of
the
permit
holder
making
process conditions
process releases
environmental levels
… and reporting the results to the regulatory authority in
accordance with laws, regulation or permits.
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Role of the operator:
1. Obligation to be aware of the emissions and their
impacts on the environment;
2. Carries out monitoring of process and emission
treatment plant conditions, emissions and impacts of
the emissions;
3. Obligation to react in non-compliance situations;
4. Responsibility for the measurements and the reliability
of the results;
5. Obligation to report the authority in accordance to the
monitoring programme;
6. Responsibility for all pollution abatement costs which
include also monitoring costs.
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PART B
Role of the authority:
1. Inspections;
2. Intercalibration;
3. Control samples;
4. Control of data production chain.
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PART B
Module 2 Part B contents concerns the Reference Document on “The
General Principles of Monitoring”, BREF code MON.
The key issues and the following topics are potentially important:
 The parameters (ELVs or equivalent) to be monitored depend on
the production chain processes, raw materials and chemicals used
in the installation.
 The production of monitoring data need to be performed according
to either standards or method-specific instructions and consists of
the following steps:
flow measurements
sampling
storage, transport and preservation of the sample
sample treatment
sample analysis
data processing
reporting of data.
 The responsibility for monitoring is generally divided between the
competent authorities and operators (“self monitoring”).
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PART B
Under other perspective the topics are presented in
the following items:







deciding monitoring frequency
data generation
data handling and processing
quality assurance/quality control
surrogate parameters
fugitive emissions
efficiency of raw material, energy and water
consumption
 noise monitoring
 odour monitoring
 emergency monitoring
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PART C - BREF FOR THE TEXTILE INDUSTRY
MODULE 2
PART C
Reference Document On Best Available
Techniques For The Textile Industry
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PART C - BREF FOR THE TEXTILE INDUSTRY
INTRODUCTION
TXT BREF covers the industrial activities specified in section 6.2
of Annex I of the IPPC Directive 96/61/EC, namely: “Plants for
pretreatment (operations such as washing, bleaching,
mercerisation) or dyeing of fibres or textiles where the treatment
capacity exceeds 10 tonnes per day”.
THE TEXTILE INDUSTRY
Is one of the longest and most complicated industrial chains in
manufacturing industry.
Is composed of a wide number of sub-sectors, covering the entire
production cycle from the production of raw materials (man-made
fibre) to semi-processed (yarn, woven and knitted fabrics with
their finishing processes) and final products (carpets, home
textiles, clothing and industrial use textiles).
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APPLIED PROCESSES AND TECHNIQUES
The “finishing processes” (pretreatment, dyeing, printing,
finishing and coating, including washing and drying) and
others processes such as spinning, weaving, knitting, etc.,
they may have a significant influence on the environmental
impact of the subsequent wet processing activities.
Raw materials
 Fibres
 Natural
 Origin animal (raw wool)
 Origin vegetable (raw cotton fibre)
 Origin Mineral (asbestos)
 Chemical (man-made)
 Natural polymer fibres (viscose)
 Synthetic polymer fibres
 Inorganic polymer (glass)
 Organic polymer (polyester )
 Chemicals and auxiliaries
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APPLIED PROCESSES AND TECHNIQUES
Fibre preparation:
 Natural fibres
 Wool
 Cotton and flax
 Silk
Yarn manufacturing
 The wool spinning process
 The cotton spinning process
 Environmental issues
Cloth production
 Woven textiles
 Knitted textiles
 Textile floor-coverings
 Non–Woven textiles
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APPLIED PROCESSES AND TECHNIQUES
Pretreatment
 Pretreatment processes should ensure:
 the removal of foreign materials from the fibres in
order to improve their uniformity, hydrophilic
characteristics and affinity for dyestuffs and
finishing treatments
 the improvement of the ability to absorb dyes
uniformly (which is the case in mercerising)
 the relaxation of tensions in synthetic fibres (without
this relaxation of tension, unevenness and
dimension instabilities can occur).
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APPLIED PROCESSES AND TECHNIQUES
Dyeing
 General principles of dyeing
 Dyeing processes
 Dyeing can be carried out in batch or in
continuous/semi-continuous mode.
 Both continuous and discontinuous dyeing involve
the following steps:
 preparation of the dye
 dyeing
 fixation
 washing and drying.
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APPLIED PROCESSES AND TECHNIQUES
Printing
Printing processes
A typical printing process involves the following steps:
 colour paste preparation, Printing, fixation, aftertreatment
Printing technology
Can be used different machines for printing fabrics:
 Flat-screen printing; Rotary-screen printing;
 Roller printing; Jet printing .
Environmental issues
Emission sources typical of printing processes are:
 printing paste residues
 waste water from wash-off and cleaning operations
 volatile organic compounds from drying and fixing.
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APPLIED PROCESSES AND TECHNIQUES
Finishing
 Finishing processes may involve
 treatments mechanical/physical
 treatments chemical
Coating and laminating textiles
 consist of a textile substrate combined with a thin, flexible
film of natural or synthetic polymeric substances.
Washing
 Washing with water
 Important factors in washing are:
 water characteristics
 choice of soaps and detergents
 hydromechanical action
 temperature and pH
 rinsing stage.
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APPLIED PROCESSES AND TECHNIQUES
Drying
 Drying is necessary to eliminate or reduce the
water content of the fibres, yams and fabrics
following wet processes.
 Drying, in particular by water evaporation, is a
high-energy consuming step (although overall
consumption may be reduced if re-use/ recycling
options are adopted).
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KEY ENVIRONMENTAL ISSUES FOR TEXTILE SECTOR
Emissions of environmentally non-friendly chemicals
 The use of more environmentally friendly chemicals and
processes is a feature of developments in this sector.
 An example is the case where dye exhaustion is poor and
reductions in the amount of chemical and colour emitted is
possible by increasing the affinity of the dye to the fabric by
changing some auxiliary chemicals.
Waste water
 Water use is a major issue from the knock-on effects of high
water use in terms of increased emissions. Persistent organic
pollutants that are included in several action lists may be
present in wool and cotton processing effluents. The
discharge of AOX is a potential problem if chlorine is used
during processes.
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KEY ENVIRONMENTAL ISSUES FOR TEXTILE SECTOR
Bleaching and dyeing
 A major problem has been the use of chlorine compounds in
bleaching of fibres and fabrics, chlorine reacts with organic
materials and produces some persistent organic compounds.
Similarly the emission of highly coloured effluents can cause
significant colouring of controlled waters even after treatment
in a sewage treatment works.
Water treatment (BOD and COD)
 Most processors discharge via a municipal treatment works, in
some cases Installations have their own wastewater treatment
plant. In either case, confirmation that the more persistent
substances are broken down remains an issue. Residual
colour in the effluents after treatment is also an issue for this
sector.
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KEY ENVIRONMENTAL ISSUES FOR TEXTILE SECTOR
VOCs from coating and solvent scouring
 The significance will vary considerably between installations.
Releases associated with energy use
 The industry is a major energy user. There remain significant
opportunities for reduction of emissions caused by energy use
and choice of energy source (CO2, SOx, NOx, etc. contributing
in particular to global warming and acidification).
Accident risk
 Apart from the normal process and spillage risks, many older
sites will have insecure drainage systems that will need
attention.
Noise
 There are noise sources that should be addressed.
Long distance and transboundary pollution
 Persistent organic pollutants have been identified as potential
long range pollutants.
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KEY ENVIRONMENTAL ISSUES FOR TEXTILE SECTOR
Monitoring
 The residual organic constituents of the effluent are
generally not known in detail, so it is hard to monitor.
Analysis of the constituents of the effluent will be a key
issue and direct toxicity testing may be appropriate for
processes that discharge to controlled waters.
Solid waste recovery, recycling and disposal
 Sludge to land is a major issue. An assessment of the
options for the recovery or disposal of wool grease and
fibres from sludge is likely to be needed. Solid waste is
also produced in the form of packing materials, yarn, fabric
and cones.
Site restoration
 Many installations will have been operating on the same
site for many years. There may well be ground
contamination.
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WOOL SCOURING SECTOR
Emission and consumption levels

Wool scouring with water leads to the discharge of an effluent
with a high organic content and variable amounts of micro
pollutants resulting from the pesticides applied on the sheep.
Techniques to consider in the determination of BAT:


General good management practices
 Range from staff education and training to the definition of
well-documented procedures for equipment maintenance,
chemical storage, handling, dosing and dispensing.
Use of integrated dirt removal/grease recovery loops
 Allows water and energy savings and a valuable by-product
is obtained, along with a significant reduction of the organic
load sent to the effluent treatment plant.
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WOOL SCOURING SECTOR

Use of integrated dirt removal/grease recovery loops
combined with evaporation of the effluent and incineration of
the sludge,
 With full recycling of the organic load sent to the water
and energy, additional environmental benefits are
achieved in terms of water savings and amount of solid
waste to be disposed of.

Wool scouring with organic solvents
 Avoids the use of water in the actual cleaning process.
 This has beneficial implications for the downstream
processes where the wool is finished.
 Reduced energy consumption.
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PART C - BREF FOR THE TEXTILE INDUSTRY
WOOL SCOURING SECTOR
Best Available Techniques
 Generic BAT
 Technology by it self is not sufficient; it needs to go together
with environmental management and good housekeeping.
Management of an installation that uses potentially polluting
processes requires the implementation of many of the
elements of an Environmental Management System (EMS).
 Process-integrated measures for unit processes and operations
 Wool scouring with water
 BAT is to use recovery loops for grease and dirt.
 Wool scouring with organic solvent
 Scouring with organic solvent is determined as BAT,
provided that all measures are taken to minimise fugitive
losses and prevent any possible contamination of
groundwater arising from diffuse pollution and accidents.
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CARPET INDUSTRY SECTOR
 Wool and wool-blend carpet yarn dyehouses
 Integrated carpet manufacturing companies
Best Available Techniques
 Generic BAT
 See in wool scouring sector
 Process-integrated measures for unit processes and
operations
 See in textile finishing sector
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TEXTILE FINISHING SECTOR
Emission and consumption levels
 A large percentage of the total emission load from textile
industry activities is attributable to substances that are
already on the raw material before it enters the finishing
mill (impurities and associated materials for natural fibres.
preparation agents, spinning lubricants, etc.).
 These substances are usually removed from the fibre
during the pre-treatment process before colouring and
finishing.
Techniques to consider in the determination of BAT:
 General good management practices
 See in wool scouring sector
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TEXTILE FINISHING SECTOR
 Selection and substitution of chemicals used
 The substitution of the harmful substances is often an available
option to reduce the environmental impact of a process.
 For example:
 Surfactants
 Complexing agents
 Antifoaming agents
 Pre-treatment
 Water-soluble synthetic sizing agents such as PVA,
polyacrylates and CMC can be recovered from washing liquor
by UF and re-used in the process.
 Hydrogen peroxide is now the preferred bleaching agent for
cotton and cotton blends as a substitute for sodium hypochlorite.
 The rinsing water after the mercerising treatment can be
recycled in the process after being concentrated by evaporation.
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TEXTILE FINISHING SECTOR
 Dyeing
 Well-known PES dyeing carriers can be avoided by dyeing
under high-temperature conditions.
 The use of non-carrier dyeable PES fibres, such as PTT
polyester fibres.
 Pre-reduced sulphur dyestuffs
 The use of sodium silicate in pad-batch dyeing of cellulosic
fabrics can be avoided…
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TEXTILE FINISHING SECTOR
 Printing
 Minimising the volume of the printing paste supply system
has major effects in reducing printing paste losses in
rotary-screen printing.
 Screens, buckets and the print paste feed systems need
careful cleaning before being used for new colours.
 The use of digital techniques avoids printing paste residues
at the end of each run.
 Urea can be substituted in some cases.
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TEXTILE FINISHING SECTOR
 Finishing
 In addition, various techniques are available for reducing
energy consumption in stenter frames.
 In easy-care treatments, emissions of formaldehyde can be
significantly reduced with low-formaldehyde or
formaldehyde-free products.
 Minimisation of emissions in the application of mothproofing
 Washing
 Water & energy conservation in bath washing and rinsing;
 Water & energy conservation in bath washing and rinsing;
 Use of fully closed-loop installations for fabric washing
(scouring) with organic solvent
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TEXTILE FINISHING SECTOR
Best Available Techniques
 Generic BAT
 See in wool scouring sector
 Process-integrated measures for unit processes and
operations(Textile finishing and carpet industry)
 Pre-treatment
 Removing knitting lubricants from fabric
 BAT is to do one of following:
- Select knitted fabric that has been processed using water-soluble
and biodegradable lubricants instead of the conventional mineral oilbased lubricants
- Carry out the termofixation step before washing and treat the air
emissions generated from the stenter frame by dry electrofiltration
systems that allow energy recovery and separate collection of oil.
- Remove the non-water soluble oils using organic solvent washing.
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TEXTILE FINISHING SECTOR
 Desizing
BAT is to do one of the following:

select raw material processed with low add-on techniques and
more effective bioeliminable sizing agents combined with the
use of efficient washing systems for desizing and low F/M
waste water treatment techniques to improve the
bioeliminability of the sizing agents

adopt the oxidative route when it is not possible to control the
source of the raw material.

combine desizing/scouring and bleaching in one single step.
recover and re-use the sizing agents by ultra filtration.
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TEXTILE FINISHING SECTOR

Bleaching
BAT is to:
 use hydrogen peroxide bleaching as preferred bleaching
agent combined with techniques for minimising the use
of hydrogen peroxide stabilisers, or using
biodegradable/bioeliminable complexing agents
 use sodium chlorite for flax and bast fibres that cannot be
bleached with hydrogen peroxide alone.
 limit the use of sodium hypochlorite only to cases in
which high whiteness has to be achieved and to fabrics
that are fragile and would suffer depolymerisation.
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
Mercerising
BAT is to either:
 recover and re-use alkall from mercerising rinsing water
 or re-use the alkall-containing effluent in other preparation
treatments.
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TEXTILE FINISHING SECTOR

Dyeing
 Dosage and dispensing of dye formulations
BAT is to do all the following:
 reduce the number of dyes (one way to reduce the number of
dyes is by using trichromatic systems)
 use automated systems for dosage and dispensing of dyes, only
considering manual operation for dyes that are used infrequently
 in long continuous lines where the dead volume of the
distribution tine is comparable with the volume in the padder, give
preference to decentralised automated stations that do not premix
the different chemicals with the dyes before the process and that
are fully automatically cleaned.
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TEXTILE FINISHING SECTOR

Printing
 Process in general
BAT is to:
 reduce printing paste losses in rotary screen printing
by:
 minimising the volume of printing paste supply
systems
 recovering printing paste from the supply system
at the end.
 recycling residual printing paste.
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TEXTILE FINISHING SECTOR

Printing
 Process in general
BAT is to:
 reduce water consumption in cleaning operations by a
combination of:
 start/stop control of cleaning of the printing belt
 re-use of the cleanest part of the rinsing water from the
cleaning of the squeegees, screens and buckets
 re-use of the rinsing water from cleaning of the printing belt
 Use digital ink-jet printing machines for the production of short
runs for flat fabrics, when product market considerations
allow.
 Use digital jet printing machines for printing carpet and bulky
fabrics, except for resist and reserve printing and similar
situations.
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Finishing
 Process in general
BAT is to:
 minimise residual liquor by:
 using minimal application techniques (e.g.
foam application, spraying) or reducing volume
of padding devices
 re-using padding liquors if quality is not
affected
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Finishing
Process in general
BAT is to:
 minimise energy consumption in stenter frames
 using mechanical dewatering equipment to reduce water
content of the incoming fabric
 optimising exhaust airflow through the oven, automatically
maintaining exhaust humidity between 0.1 and 0.15 kg
water/kg dry air, considering the time taken to reach
equilibrium conditions
 installing heat recovery systems
 fitting insulating systems
 ensuring optimal maintenance of the burners in directly
heated stenters
 use low air emission optimised recipes.
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Washing
BAT is to:
 substitute overflow washing/rinsing with drain/fill methods
or "smart rinsing" techniques.
 reduce water & energy consumption in continuous
processes by:
 installing high-efficiency washing machinery
according to the principle
 introducing heat recovery equipment
 when halogenated organic solvent cannot be avoided,
use fully closed-loop equipment.
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Waste water treatment
 Waste water treatment follows at least three different
strategies:
 central treatment in a biological waste water
treatment plant on site
 central treatment off site in a municipal waste water
treatment plant
 decentralized treatment on site (or off site) of
selected, segregated single waste water streams
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Waste water treatment
 All three strategies are BAT options when properly
applied to the actual waste water situation. Well-accepted
general principles for waste water management and
treatment include:
characterizing the different waste water streams
arising from the process.
segregating the effluents at source according to their
contaminant type and load, before mixing with other
streams. This ensures that a treatment facility receives
only those pollutants it can cope with. Moreover, it
enables the application of recycling or re-use options
for the effluent allocating contaminated waste water
streams to the most appropriate treatment
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PART C - BREF FOR THE TEXTILE INDUSTRY
TEXTILE FINISHING SECTOR

Waste water treatment
 All three strategies are BAT options when properly applied
to the actual waste water situation. Well-accepted general
principles for waste water management and treatment
include:
 avoiding the introduction of waste water components
into biological treatment systems when they could
cause malfunction of such a system
 treating waste streams containing a relevant nonbiodegradable fraction by appropriate techniques
before, or instead of, a final biological treatment.
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EMERGING TECHNIQUES
 Enzyme catalysed finishing processes
 Enzymes are proteins that act as biocatalysts activating and
accelerating chemical reactions which would otherwise normally
need more energy. Their excellent substrate selectivity allows
more gentle process conditions compared to conventional
processes. Enzymes are present in bacteria, yeasts and fungi.
 Some enzymes, such as the amylases in the desizing process,
have been widely applied for a long time; other enzymes are still
the object of investigations.
 Plasma technology
 A plasma can be described as a mixture of partially ionised
gases. Atoms, radicals and electrons can be found in the
plasma. The electrons in low temperature plasmas are able to
cleave covalent chemical bonds, thereby producing physical and
chemical modifications of the surface of the treated substrate.
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

Electron-ray treatment
 Electron-rays start free-radical initiated polymerisation reactions
that can then be used for coating, lamination and for graft copolymerisation reactions on textiles pre-coated with monomers
or pre-polymers.
Use of supercritical CO2 in dyeing processes
 CO2 dyeing of PES and PP fibre is already developed on an
industrial scale, however the application of this technique on
wool, PA and cotton is still problematic doe to the polar nature
of the dyestuffs used to colour these fibres.

CO2 dyeing of PES and PP can be carried out under optimal
isothermal and isobaric conditions at 120 and 300ºC. Dye
uptake and fastness properties are very similar to water dyeing.
Nevertheless some precautions need to be taken.
 Excess dye dissolved in the dyeing medium must be extracted
with fresh supercritical CO2 at the end of the dyeing cycle.
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

Ultrasonic treatments
 Ultrasonic treatments improve the dispersion of dyestuffs
and auxiliaries and enhance their ability to emulsify and
solubilise.
 This allows improved liquor homogenisation, which then
results in higher bath exhaustion and level dyeing
properties. In addition, ultrasounds produce a de-aeration
effect in the liquor and on the fabric, which is normally
obtained by adding special auxiliaries (de-aerating
agents). .
Electrochemical dyeing
 Vat and sulphur dyeing involves both a reducing and an
oxidising step, which are carried out with chemical
oxidants and reducing agents. An attractive alternative
technique is to reduce and oxidise the dye by means of
electrochemical methods.
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
Alternative textile auxiliaries

Complexing agents

The use of polyasparginic acid as a substitute for
conventional dispersing and complexing agents is
under study.

Cross-linking agents

Polycarbonic acids can be used as an alternative to
N-methylol-based cross-linking agents, which are
responsible for formaldehyde emissions.

Biopolymers

Besides cellulose, chitin, the main structural
component of crustacean shells (crabs, lobster, etc.)
and insects, is the second main biopolymer. Its
deacetylated derivative, chitosan, which is easier to
handle due to its higher solubility, is increasing in
importance.
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Fuzzy logic

The application of fuzzy logic in the textile industry is
the object of a number of research projects. Two
examples are reported concerning the control of the
sizing process and the control of the condensation
reaction of cross-linking agents.
On-line monitoring

Process control by on-line monitoring enhances operation
liability in the direction of "right first time production".


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PART C - BREF FOR THE TEXTILE INDUSTRY
SUMMARY

Module 2 Part C contents concerns the Reference Document on
“Best Available Techniques for the Textiles Industry”, BREF code
TXT.

These contents comprise information, valuable for all textiles
industries, although IPPC Directive only namely:
“Plants for pretreatment (operations such as washing, bleaching,
mercerisation) or dyeing of fibres or textiles where the treatment
capacity exceeds 10 tonnes per day”.

The textile chain begins with the production of harvest of raw fibre,
and it involves single and integrated processes to produce textiles
and carpets using animal, synthetic and mixtures of fibres. The
process stages mainly include: fibre preparation; fibre treatment;
pre-treatment before colouring; dyeing and printing; finishing and
washing.
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Revision of key environmental issues and BAT for each sector
Water use is a major issue and organic pollutants are present in
wool and cotton processing effluents;
Substitution of environmentally non-friendly chemicals and
avoidance of emissions;
For bleaching and dyeing the discharge of AOX is a potential
problem if chlorine is used during processes and similarly the
emission of highly coloured effluents (BAT includes the use
hydrogen peroxide preferentially, reduce the number of dyes and
reduce liquor ratio);
In wastewater treatment (COD and BOD), residual colour in the
effluents after treatment is also an issue for this sector unless
additional treatment is carried out (tertiary treatments following the
biological treatment process; combined biological physical and
chemical treatments with the addition of powdered activated
carbon; ozonation of recalcitrant compounds);
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




Heat, VOC recovery and visible plume suppression imply an
assessment of an heat recovery system and fitting insulating
system and plume suppression;
Fugitive losses of VOCs from coating and solvent scouring must
be minimise;
Releases associated with energy use are important since the
industry is a major energy user. There remain significant
opportunities for reduction of emissions caused by energy use and
choice of energy source (CO2, SOx, NOx, etc. contributing in
particular to global warming and acidification);
Accident risk are related with unsecured drainage systems;
Noise sources should be addressed;
Persistent organic pollutants have been identified as potential long
distance and transboundary pollutants;
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
On Solid waste recovery, recycling and disposal, sludge to land is
a major issue and an assessment of the options for the recovery
or disposal of wool grease (BAT is to implement dirt
removal/grease recovery loops) and fibres from sludge is likely to
be needed. Solid waste is also produced in the form of packing
materials, yarn, fabric and cones.
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