Indian textile industry environment issue ppt, nitra

1I I T DelhiDec.7,2002

INDIAN TEXTILE INDUSTY-ENVIRONMENTAL ISSUES

Prof.R.B.CHAVAN

DEPT. OF TEXTILE TECHNOLOGY

INDIAN INSTITUTE OF TECHNOLOGY

HAUZ-KHAS, NEW DELHI


PRESENT PAPER

STRUCTURE OF TEXTILE INDUSTRY

PROBLEMS

IMPACT ON ENVIRONMENT

POLLUTION CONTROL STRATEGY

GERMAN BAN

RESPONSE OF MINISTRY OF TEXTILES

TO COPE WITH GERMAN BAN

Dec.7,2002 I I T Delhi 3

Decentralized Sector

TEXTILE INDUSTRY IN INDIA

NATURAL FIBRES / FABRICS

MAN-MADE FIBRES / FABRICS

Organized Sector(Mills)

Spinning Composites Handloom Powerloom Khadi

WOOL

JUTE

SILK

COTTON

RAYONCellulose / viscose

BLENDED(Synthetic + Natural)

SYNTHETIC(Nylon, PET, PAN)


11

33

0

10

20

30

40No

. of S

pind

les in

m

illio

n

Spinning Capacity

1951 1997

2.1

1.24

0

0.5

1

1.5

2

2.5

No.

of L

oom

s in

lakh

s

weaving Capacity

1951 1997


Share of Cloth Production

1990's

6%

74%

20%

1950's

70%

20%

10%

Organized Sector

Power Loom

Handloom


INDIAN TEXTILE INDUSTRY AND ITS PROBLEMS

ONE OF THE OLDEST AND SINGLE LARGEST INDUSTRIAL SECTORS SHARE OF TEXTILE PRODUCTION IN 50S ORGANIZED SECTOR >75%

DENCENTRALIZED POWERLOOM 25%

PRESENTLYORGANIZED SECTOR 6%

BALANCE POWERLOOME, HANDLOOM, HOSIERY


DIFFICULT PHASE 60S AND 70S

OBSOLETE MACHINERY LACK OF MAINTENANCE LACK OF MODERNIZATION LOW PRODUCTIVITY LOW CAPACITY UTILIZATION STAGNANT DOMESTIC MARKETS SAGGING EXPORTS

WIDE SPREAD SICKNESS


EMERGING TRENDSEMERGENCE OF SYNTHETIC AND

BLENDED FABRICS

PHENOMENAL EXPANSION OF SPINNING

RAPID EXPANSION OF DECENTRALIZED POWERLOOM SECTOR

BROUGHT SICKNESS COMPOSIT ORGANIZED SECTOR

LARGE NUMBER OF MILLS WENT BANKRUPT

2/3 OF THEM WERE COMPOSIT MILLS


NATIONALIZATION (1967)

SETTING UP OF NATIONAL TEXTILE CORPORATION (NTC)

MAIN OBJECTIVE: EMPLOYMENT RELIEF TO THOUSANDS OF WORKERS

PRODUCTION OF CONTROLLED CLOTH

EXPERIMENT MISERABLY FAILED

MANY NTC MILLS CLOSED DOWN


NEW TEXTILE POLICY (1980)

OBJECTIVE: DEVELOP HARMONIOUSLY

MILL, POWERLOOM AND HANDLOOM SECTORS

RECOGNITION OF LACK OF MODERNIZATION AS MAIN CAUSE OF SICKNESS

750 CRORE AS TEXTLE MODERNIZATION FUNDS IN 1986


SHIFT IN PRODUCTION PATTERN 1987 GLOBAL INCREASE IN COTTON

PRICES SPINNING THOUGH TECHNOLOGICALLY

ADVANCED, LABOUR INTENSIVEDEVELOPED COUNTRIES PREFERRED

TO BYU YARN FROM DEVELOPING COUNTRIES

LED TO YARN EXPORT GROWTH IN INDIA FROM 1987 ONWARDS

5% YARN EXPORT IN 1990 INCREASED TO 22% IN 1997


LIBERALIZATION

DE-LICENSING OF TEXTILE INDUSTRY

(1991)

IMPORT OF MODERN MACHINES TO SET UP NEW UNITS

IMPROVEMENT IN YARN QUALITY

INDIA BECAME GLOBAL PLAYER IN

YARN EXPORTS


COLLAPSE OF YARN EXPORTS

IN 1990 70% EXPORT TO QUOTA COUNTRIES 30% TO NON-QUOTA COUNTRIES

AFTER LIBERIZATION INCREASE IN PRODUCTION STAGNANT QUOTA EXPORTS SHOT UP IN NON-QUOTA EXPORS 80% DROP IN QUOTA EXPORTS 20% UNINTENTIIONAL EXPORT DEPENDENCE

ON NON-QUOTA COUNTRIES


COLLAPSE OF YARN EXPORTS

IN 1997

CURRENCY CRISIS IN SOUTH EAST ASIAN COUNTRIES

SEVERE EFFECT ON EXPORTS

EXPORT BELOW COST

DUMP EXPORT QUALITY YARN IN DOMESTIC MARKET

CRIPPLING EFFECT ON TEXTILE INDUSTRU

HUGE OVERSUPPLY POSITION

SUNRISE INDUSTRY BECAME SUNSET INDUSTRY


WTO REGIME

MEMBER OF WTO

SIGNATORY TO GATT( GENERAL AGREEMENT ON TRADE AND TARRIF)

END OF ATC (AGREEMENT OF TEXTILES AND CLOTHING) BY DECEMBER 2004.

END OF QUOTA ERA

TO FACE THE GLOBAL COMPETITION

LIMITED TIME FOR

INDUSTRY RESTRUCTURE

IMPROVED QUALITY PRODUCTS AT COMPETITIVE PRICE


NEED OF THE HOUR

MODERNIZE TO COMPETE GLOBALLY

WITHSTAND CHEAPER IMPORTS FROM CHINA, PAKISTAN AND OTHER SOUTH-EAST ASIAN COUNTRIES

TECHNOLOGY UPGRADATION FUND SCHEME (TUFS)

Rs 25 000 CRORE FOR MODERNIZATION

5% RE-IMBERSEMENT OF INTEREST CHARGED BY FINANCIAL INSTITUTIONS

IN OPERATION FOR FIVE YEARS FROM APRIL 1999 – MARCH 2004


INDIA IS FIRST COUNTRY TO HAVE CONSTITUTIONAL PROVISION FOR ENVIRONMENT PROTECTION.

NO SPECIFIC ENVIRONMENTAL NORMS FOR TEXTILE SECTOR

INDUSTRY SPECIFIC STANDARDS EXIST STRINGENT ENVIRONMENTAL LEGISLATION POORLY EMFORCED JUDICIARY HAS TO INTERVENE TO ENFORCE

ENVIRONMENTAL POLICIES JUDICIARY HAS GOT ITS OWN LIMITATIONS AND CAN

NOT ACT AS ENFORCING AGENCY. MAKING LAW ONLY DOES NOT HELP ENVIRONMENT IS A SOCIAL RESPONSIBILITY DESIRABLE COMPLIENCE SHOULD COME VOLUNTARILY

FROM INDUSTRY AND NOT BY POLICING

ENVIROMENT LEGISLATION


IMPACT ON ENVIRONMENTINDUSTRIAL ACTIVITY IS ASSOCIATED WITH

POLLUTIONEXTENT VARIESCONCEPT: TO KEEP POLLUTION LEVEL AS

LOW AS POSSIBLEANOTHER DIMENSION: SOCIAL

ACCOUNTABILITY STANDARDS SAS 1800NO CHILD LABOURMINIMUM LABOUR WAGESPROVISION OF HYGIENIC CONDITIONS AT

WORK PLACECOMPLIANCE WITH GERMAN BAN INTRODUCED

IN 1996


Input / output analysis of Textile Finishing Processes

Textile Auxiliaries

Dyes

Base chemicals(e.g. acid, Alkali, sodium chloride)

Textile EnergyNatural Fibres; 10-20 MJ/kgSynthetic Fibres: 5-50 MJ/kg

Water60-360 l/kg textile

Polluted Air

Water Effluent

WasteSewage sludge:

60-70 g/kg textile

Wet Processing (pre-treatment,

dyeing, printing,

finishing.)

AIR EMMISSION SOURCES

FOUR GENERAL CATEGORIES

OIL AND ACID MISTS

SOLVENT VAPOURS

ODOUR

DUST AND LINT


OIL AND ACID MISTS

MOST COMMON SOURCE IS STENTER

EVAPORATION OF SPINNING OILS, PLASTICIZERS, AND VOLATILE FINISHING AGENTS

ACID MISTS (CORROSIVE)

DURING WOOL CARBONIZATION

VOLATILIZATION OF ORGANIC ACIDS LIKE ACETIC ACID


SOLVENT VAPOURS

INCLUDE LARGE NUMBER OF TOXIC

CHEMICALS

KEROSENE OR MINERAL TURPENTINE

OIL

FORMALDEHYDE

CARRIERS FOR POLYESTER DYEING

CHLOROFLUORO HYDROCARBONS


ODOUR

ASSOCIATED WITH

OIL MIST OR SOLVENT VAPOURS

SULPHUR DYEING

BLEACHING WITH SODIUM

HYPOCHLORITE


DUST AND LINT

PRODUCED DURING

SPINNING AND WEAVING

CARPET SHEARING

CAUSE RESPIRATORY DISEASES


EFFLUENT CHARACTERISTICSTEXTILE EFFLUENTS GENERALLY ARE

COLOURED

HIGH BOD

HIGH TDS

HIGH RATIO BETWEEN BOD AND COD

RATIO OF 1:2 TO 1:3 INDICATES GOOD BIODEGRADABILITY

IN WOOL RATIO 1:5 INDICATING DIFFICULT BIODEGRADABILITY DUE

TO GREASE CONTENT


DETERGENTS AND

SURFACTANTS RISK TO AQUATIC LIFE

HEALTH RISK TO LARGE POPULATION IF DISCHARGED IN RIVER USED FOR DRINKING


METAL POLLUTANTS

METAL COMPLEX DYES

CHROMIUM SALTS USED FOR

SULPHUR DYE OXIDATION

CHROME DYEING OF WOOL

• MORDANTS FOR NATURAL

DYES


ORGANIC WASTES

SIZES

VARIOUS ORGANIC SOLVENTS AND ACIDS


CLASSIFICATION OF TEXTILE

WASTES

HARD TO TREAT

HAZARDOUS OR TOXIC

DISPERSIBLE

• HIGH VOLUME


HARD TO TREAT WASTES

COLOURS

METALS

PHENOL

TOXIC ORGANIC COMPOUNDS

PHOSPHATES

NON-BIODEGRADABLE SURFACTANTS

TOXIC TO AQUATIC LIFE


TOXIC WASTES

SUB GROUP OF HARD TO TREAT

WASTES

METALS

CHLORINATED SOLVENTS

BOILER CHEMICALS


DISPERSIBLE WASTES

PRINT PASTES

COATING CHEMICALS

UNUSED PROCESS CHEMICALS

HIGH VOLUME WASTES

WASH WATER FROM • PREPARATORY

• DYEING

• PRINTING

• EXHAUSTED DYEBATHS


POLLUTION CONTROL

STRATEGIES CLEANER PRODUCTION

TECHNIQUES

• END OF PIPE TREATMENTS


CLEANER PRODUCTION TECHNIQUES

WASTE MINIMIZATIONHIGHEST PRIORITY FOR REDUCTION IN WASTE

WATER COUNTER CURRENT WASHING OPERATIONS OPTIMUM USE OF PROCESS CHEMICALSSUBSTITUTION OF TOXIC CHEMICALS BY ECO

FRIENDLY CHEMICALSGOOD HOUSE KEEPINGRECOVERY OF CHEMICALS SUCH AS SIZE, CAUSTIC

SODA, DYES AND GREASEREPLACEMENT OF HIGH BOD CHEMICALS BY LOW

BOD ONESUSE OF LOW LIQUOR RATIO DYEING EQUIPMENTSIMPROVED PRODUCTION PROCESSES TO ELIMINATE

AND REDUCE WASTE AS MUCH AS POSSIBLE


CLEANER PRODUCTION TECHNIQUES

END OF PIPE TREATMENTS

SEGREGATION AND SEPARATE TREATMENT OF SPECIFIC EFFLUENT STREAM IS MORE EFFICIENT COMPARED TO

COMBINED AND COMPLEX EFFLUENTS

SUCH STRATEGY PROVIDE OPPORTUNITY TO

RE-USE WATER

RECOVER CHEMICALS

• REDUCE SIZE OF TREATMENT PLANT

EFFLUENT TREATMENT

COMMON PROCESS

PRIMARY SETTLING

FLOCULATION/CHEMICAL COAGULATION

BIOLOGICAL TRETMENT

SECONDARY PHYSICAL ADSORPTION

TERTIARY TREATMENT IF NECESSARY


SLUDGE TREATMENT AND DISPOSAL

FORMATION OF LARGE QUANTITIES OF

SLUDGE DURING

BIOLOGICAL TREATMENT

SUBJECT SLUDGE TO AEROBIC

DIGESTION

DEWATER BY CENTRIFUGE

DISPOSE OFF TO LAND FILL


SOLID WASTES

INCLUDE

CANS

REJECTED FABRIC PIECES

CART AWAY TO LAND FILL OR

INCINERATE ON OR OFF SITE

DURING INCINERATION ADEQUATE AIR

POLLUTION CONTROL MEASURES


AIR EMMISSION CONROL

OIL MISTS AND VOLATILE ORGANIC CARBON (VOC)

MORE DIFFICULT TO CONTROL

CONTROL THE APPLICATION OF SPINNING

OILS AND FINISHING AGENTS

PROPER AIR DUCTING

INSTALLATION OF MIST ELIMINATORS

CONDENSATION OF VAPOURS BY COOLING THE

CONTAMINATED AIR


MANAGING AND AUDITING RESOURCE CONSUMPTION

RESEARCH ASSOCIATIONS DEVELOPED MANUFACTURING NORMS FOR

DESIRABLE USAGE OF RESOURCES SUCH AS WATER, LABOUR, ELECTRICITY AND COMMON CHEMICALS

NORMS NOT IMPOSED LEGALLY

ACT AS GUIDELINES

MEMBERMILLS ARE ENCOURAGED TO FOLLOW THESE NORMS

RECORD OF SIMPLE MATERIAL BALANCE

WORTH EXAMINING THE RECORD OF STORE KEEPER AND PROCESSING DEPRTMENTS TO TRACK LOSSES OF EXPENSIVE AND/OR HAZARDOUS CHEMICALS DURING HANDLING AND PROCESSING


MANAGING AND AUDITING RESOURCE CONSUMPTION

• ASSESSMENT AT INTERVALS THE PERFORMANCE

OF EFFLUENT TREATMENT PLANT AND AIR

POLLUTION CONTROL EQUIPMENTS

IT IS NECESSARY TO EMPLOY A FULL TIME

PROFESSIONAL ENVIRONMENTAL TEAM OR TRAIN

SENIOR STAFF AND WORKERS TO UNDERTAKE

ENVIRONMENT MONITORING AND AUDIT TASKS

COMMITMENT BY TO MANAGEMENT TO

ESTABLISH SOUND ENVIRONMENT MANAGEMENT

SYSTEM

THIS WOULD ALSO IMPROVE THE PRODUCTIVITY

AND PROFITABILITY OF THE ORGANIZATION


SIMPLE OPTIONS

IMPROVED HOUSEKEEPINGBETTER EQUIPMENT MAINTENANCEOPTIMIZATION OF VARIOUS PROCESS

SEQUENCESTHE MANAGERS MUST HAVE BASELINE

DATA FOR SIMILAR OPERATIONA IN OTHER INDUSTRIES

COMPARE AND INTERPRET THE RESULTS WITH OPEN MIND

ALLOW DISCUSSION BETWEEN STAFF AND ENCOURAGE TEAM MEMBERS TO BRING FORWARD INNOVATIVE IDEAS

EVALUATE THE IDEAS FROM TECHNICAL AND ECONOMIC PERSPECTIVE


POLICY MANAGEMENT BY GOVT OF INDIA

GERMAN BAN AND GOVERNMENT RESPONSE

• RECOGNITION THAT NUMBER OF DYES AND CHEMICALS ARE HAZARDOUS

• AFFECT THE CONSUMER HEALTH

• CAUSE IRREPARABLE DAMAGE TO ENVIRONMENT

• GERMANY IMPOSED BAN ON THE USE OF AZO DYES

BASED ON CARCINOGENIC AMINE

• ABOUT 300 AZO DYES SUSPECTED TO BE CARCINOGENIC HAVE BEEN WITHDRAWN

• ENVIRONMENTAL PERMISSIBILITY NORMS FOR

HAZARDOUS CHEMICALS ARE AVAILABLE FROM

VARIOUS INTERNATIONAL ORGANIZATIONS


ECO STANDARDS AND ECO LABLES CONCEPT OF ECO FRIENDLY TEXTILES IS

PROMOTED BY ECO STANDARDS AND ECO LABLES

ECO LABLES ARE BASED ON ENVIRONMENT

FRIENDLY NORMS FOR VARIOUS CHEMICALS STIPULATED ON THE BASIS OF CRADLE TO GRAVE APPROACH

USE OF ECO LABLES IS VOLUNTARY IN

NATURE


ECO STANDARDS AND ECO LABLES

CHEMICALS CONSIDERED FOR ECO NORMS

FORMALDEHYDE

TOXIC PESTICIDES

PENTACHORO PHENOL

HEAVY METAL TRACES

CARCINOGENIC AZO DYES

HALOGEN CARRIERS

CHLORINE BLEACHING


EFFORTS MADE BY GOVERNMENT OF INDIA

REGULATORY MEASURES

• PROHIBITION ON THE USE OF BANNED DYES

• EVOLUTION OF ECO STANDARDS AND LOGO FOR ECO FRIENDLY TEXTILES


EFFORTS MADE BY GOVERNMENT OF INDIA

DEVELOPMENTAL MEASURES• ORGANIZATION OF EDUCATIVE SEMINARS,

WORKSHOPS FOR THE AWARENESS OF ECO FRIENDLY CONCEPTS

• ASSISTANCE TO INDUSTRY FOR THE SECURING ISO 9000 AND EMS 14000 CERTIFICATION

• FINACIAL ASSISTANCE THROUGH TUFS FOR MODERNIZATION

• MASSIVE PROGRAMME ON SETTING ECO TESTING FACILITIES

•

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