The Textile Industry
and Climate Change mitigation
The textile industry requires various productive processes. This is due to the
wide variety of raw materials and treatment options available, which lead to
a great variety of end products.
The industry has high energy requirements throughout all stages of the
production process. The treatments vary. Some, such as melt spinning,
require refrigeration; and others, such as dyeing, desizing and scouring need
heat. Thus, energy consumption plays a central role in many key stages of
the process.
The textile business is involved with climate change by virtue of its
considerable energy consumption. To meet its energy demand, the sector
resorts to two distinct types of energy sources: indirect emission sources
(electricity) and direct emission sources (natural gas, cogeneration and
diesel fuel).
Reduction in greenhouse gas emissions associated with energy consumption
can be achieved by various means, the main ones being: energy efficiency,
the rational use of energy consumption, and cogeneration.
This brochure proposes possible mitigation measures for the various
productive processes of the textile industry.
Emissions reduction strategies
Improve energy efficiency to reduce emissions.
--Oriented towards both direct and indirect emissions
--Special attention to the processes with the greatest energy consumption,
such as heat generation, as they have a greater impact on climate change
Emissions mitigation alternatives in the textile industry
Preparation of the Fibre
-- Measures:
Fat recovery systems by means of decantation
or hot water centrifuge equipment
Energy consumption minimisation systems , by means
of sealing degreasing
winches or vats and optimisation of mechanical
water extraction.
-- Advantages:
Reuse of wool fat as a by-product
Reduction in the level of dirt and facilitation of the
subsequent rinsing tasks.
Water and energy savings
Fabric Production
-- Measures:
Substitution of traditional lubricants in the
manufacturing of knitted fabric with self-emulsifying
oils
Substitution of adhesives with polyacrylates
in the sizing process prior to the manufacture of
woven fabric
-- Advantages:
Elimination of oils and adhesives with water
at low temperatures and without auxiliary agents
Use of smaller amounts of glue to obtain the same
effectiveness
Reduction of the washing temperature with lower
energy consumption
Subsequent bleaching and scour ing in a single step
Reduced water and energy consumption
Printing
-- Measures:
Printing with pigments
-- Advantages:
Reduction of the process to 2 phases without
additional consumption
Pretreatment
-- Measures:
Application of the oxidative method for
eliminating sizing agents
Enzymatic scouring by substituting chemical
agents with enzymes
Recovery of sizing agents by ultrafiltration
Use of the Flash Steam and Pad Batch systems
to perform desizing, scouring and bleaching in
a single step.
-- Advantages:
The oxidative method allows for efficient and
uniform degradation of the desizing agents
The enzymes selectively attack the impurities
that need to be removed, they reduce the
working temperature, processing time, loss in
the weight of fabric and consumption of the
subsequent load.
The amount of energy consumed by the
ultrafiltration phase is less than that required
for the production of new desizing agents.
The Flash Steam and Pad Batch systems allow
for the simultaneous performance of distinct
productive processes.
In general, energy consumption and economic
costs are reduced.
DyEing
-- Measures:
Continuous dyeing of the polyester with vat
colouring in a single step
Post-treatment to the polyester dye by means
of a reducing agent to avoid baths after the
dyeing bath.
Econtrol alternative process to traditional
continuous and semi-continuous dyeing of
cellulose fabrics
Use of liposomes as auxiliary agents in
wool dyeing
Post-treatment with enzymes in the dye to
achieve more efficient extraction of the
colouring agents.
Optimisation of the equipment in the dyeing
baths by sealing covers and doors
Optimisation of winch dyeing
Optimisation of jet dyeing by means of
Soft-flow systems.
Use of the Jet-Overflow system
-- Advantages:
Dye bath at low temperatures
Greater diffusion of the colouring agent
Reduction of temperature and steam losses
Usage of lower bath ratios
Reduction in processing time
Reduction in energy consumption
Finishes and finishing agents
-- Measures:
Minimisation of energy consumption in the stenter
by mechanical extraction of the water, air-water
heat exchanger and thermal insulation.
-- Advantages:
Energy savings of up to 70%
20% reduction in heat losses
Washing
-- Measures:
Water and energy savings in the
continuous washing and rinsing by means of
automatic stop valves, counter-current flow and
heat recovery systems.
-- Advantages:
Improve the process efficiency and energy savings
Case study:
El-Nasr (Egipt)
(Source: MedClean -27)
El-Nasr is one of the biggest public sector textiles factories in Egypt. Its main activities
are as spinning, weaving and wet processing. With this production, volume their main
environmental problem was the large amount of energy involved in all the processes.
To try to resolve this situation, and in the context of a SEAM project, an environmental audit
was carried out, the results of which identified problems related to poor energy management.
General measures to reduce emissions
-- Improve insulation of the steam and hot water network.
-- Install counter-current flow washes and rinses to improve efficiency.
-- Install automatic shut-off valves in the laundering chains in order to control
and optimize water flow.
-- Thermal energy recovery and reuse of wash water from the rubbing of spinning
and dyeing liquids.
-- Optimization of chemical use through the substitution of some new products such
as enzymes, new sizing agents, new lubricants, dyes, reagents, and so on.
results
All measures put in place proved to be easy to install and represented low or no
cost to the company. A satisfactory energy conservation and fuel savings of 5%
was attained. This contributed to the report, in a short period of time, to the return of
the cost of the improvements and significant benefits for the company.
Investment cost and amortization
Regional Activity Center for Cleaner Production (CP/RAC) - Dr. Roux, 80 - 08017 Barcelona (Spain) Tel. +34 93 553 87 90 - Fax. +34 93 553 87 95
www.cprac.org
