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Green textile production: a chemical minimization and substitution study in a woolen fabric production

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Abstract

This study aimed to decrease chemical costs and increase productivity and environmental performance by applying various practices for chemical minimization and substitution in an integrated textile mill producing woolen textile fabric. Detailed on-site process investigations and data collection studies were carried out in the mill. Process-based specific auxiliary chemical and dyestuff consumptions were calculated. Process and composite wastewater samples were collected at different periods and analyzed. The chemical loads of wastewaters were also calculated. The specific dyestuff and auxiliary chemical consumptions of the mill were compared with the data of a similar textile mill in the literature and the Integrated Pollution Prevention and Control (IPPC), Textile Best Available Techniques Reference (BREF) document. Thus, the chemical saving potential of the mill was evaluated. A detailed chemical inventory study was also carried out in the mill. The material safety data sheets (MSDSs) of 371 chemicals were examined in terms of biodegradation ratio, toxicity, and micropollutant content. As a result, 23 chemicals were proposed to be replaced with environmentally friendly substitutes. A total of 10 minimization and substitution practices were identified for the mill according to the investigation and analysis results. After the implementation of the suggested practices, reductions of 15–32 and 13–37% are estimated to be achieved in total chemical consumption and chemical oxygen demand (COD) load of wastewater, respectively. The potential payback periods of the suggested practices were calculated to range between 4 and 36 months. The employed methodology and the findings of this study may be useful for similar textile mills, stakeholders, and regulators. This study may also provide a road map to the textile industry for their sustainable and green production applications.

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Funding

This study was conducted as a part of the project entitled “Increasing energy and chemical efficiency in dyeing and finishing process by cleaner production approach in the woolen textile industry” funded by the Scientific and Technological Research Council of Turkey (TÜBİTAK), TEYDEB Project No. 3150964.

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Authors and Affiliations

  1. Department of Environmental Protection Technologies, Isparta University of Applied Sciences, 32510, Isparta, Turkey

    Emrah Ozturk

  2. R&D Department of Yünsa, Cerkezkoy, Tekirdağ, Turkey

    Nazlı Caglar Cinperi

  3. Department of Environmental Engineering, Suleyman Demirel University, 32260, Isparta, Turkey

    Mehmet Kitis

Authors
  1. Emrah Ozturk
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  2. Nazlı Caglar Cinperi
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  3. Mehmet Kitis
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Correspondence to Emrah Ozturk.

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Responsible Editor: Philippe Garrigues

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Highlights

• A chemical minimization and substitution study was carried out in a textile mill.

• A chemical inventory study was conducted for 371 dyestuff and auxiliaries.

• Chemical replacement was suggested for 9 dyestuff and 14 auxiliary chemicals.

• Ten minimization practices were determined to reduce chemical consumption.

• Chemical and COD load was estimated to be reduced by 15–37 and 13–37% after the implementation of minimization practices, respectively.

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Ozturk, E., Cinperi, N.C. & Kitis, M. Green textile production: a chemical minimization and substitution study in a woolen fabric production. Environ Sci Pollut Res 27, 45358–45373 (2020). https://doi.org/10.1007/s11356-020-10433-8

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  • DOI: https://doi.org/10.1007/s11356-020-10433-8

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