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Frontiers of Environmental Science & Engineering

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ISSN 2095-221X(Online)

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Front. Environ. Sci. Eng.    2024, Vol. 18 Issue (8) : 103    https://doi.org/10.1007/s11783-024-1863-9
Assessment of the implementation status of best available techniques for cleaner production in the textile industry
Mehmet Eren Yaman1, Emrah Ozturk2(), Ulku Yetis3, Mehmet Kitis1
1. Department of Environmental Engineering, Suleyman Demirel University, Isparta 32260, Turkey
2. Department of Environmental Protection Technologies, Isparta University of Applied Sciences, Isparta 32200, Turkey
3. Department of Environmental Engineering, Middle East Technical University, Ankara 06800, Turkey
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Abstract

● The compliance status of 488 BATs was investigated in the Turkish textile sector.

● Full-scale BAT implementation ratios (IR) were evaluated under 17 headings.

● It was found that 37% of the BATs was already implemented full-scale.

● 63% of BATs was potentially to be implemented and not projected to be implemented.

● It was found that 60 BATs had lower IR values (0%–43%).

The draft Integrated Pollution Prevention and Control (IPPC) regulation mandates compliance with best available techniques (BATs) for textile manufacturers. A study in Turkish textile facilities, covering 56 units across four sub-sectors, assessed the status of 488 BATs through on-site visits and surveys. The aim was to gauge the sector’s adherence to BATs. The findings revealed that 37% of surveyed BATs were fully implemented, rising to 88% when considering potential future implementations. This suggests a strong industry inclination toward adopting BATs for cleaner production and competitiveness. The study highlighted significant BAT-related investments in the textile sector, driven by environmental concerns, regulations, customer demands, resource efficiency, competition, and cost-benefit considerations. However, the study results also indicated that there is still much work to do for the implementation of some BATs. It was found that 60 BATs had lower implementation ratios (IR: 0%–43%). Lower IR values for these BATs are mainly due to factors like specificity, high costs, long payback periods, operational difficulties, limited expertise, space constraints, customer requirements, quality concerns, operational issues, and sector-specific challenges. The study recommends similar assessments in other European industrial sectors to evaluate compliance with mandatory BATs outlined in the Industrial Emissions Directive. The insights from this study on the Turkish textile sector can serve as a valuable guide for future evaluations.
Keywords Best available techniques (BAT)      Cleaner production      Green Deal      Integrated Pollution Prevention and Control (IPPC)      Textile sector     
Corresponding Author(s): Emrah Ozturk   
About author:

#usheng Xing, Yannan Jian and Xiaodan Zhao contributed equally to this work.]]>
Issue Date: 30 May 2024
 Cite this article:   
Mehmet Eren Yaman,Emrah Ozturk,Ulku Yetis, et al. Assessment of the implementation status of best available techniques for cleaner production in the textile industry[J]. Front. Environ. Sci. Eng., 2024, 18(8): 103.
 URL:  
https://academic.hep.com.cn/fese/EN/10.1007/s11783-024-1863-9
https://academic.hep.com.cn/fese/EN/Y2024/V18/I8/103
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
General measures 18 BATs with the highest IR
BAT2 Training programs to raise awareness about the environment 89
BAT5 Adopting better practices in maintenance and cleaning activities 86
BAT6 Organizing technical training to raise awareness of employees and strengthen the technical infrastructure 82
BAT7 Choosing machines that provide resource efficiency in the selection of machines, devices and equipment 89
BAT11 Following new technologies and developments related to the sector 91
BATs with the least IR
BAT1 Establishing an environmental management system (EMS) 34
BAT10 Using process-based monitoring systems and/or conducting cleaner production-efficiency studies periodically 46
BAT12 Establishing an efficiency and/or sustainability unit 25
BAT13 Preparation and effective use of necessary procedures to implement a cleaner production policy specific to the facility 38
Products produced and their quantities 5 BATs with the highest IR
BAT21 Ensuring appropriate conditions for storing and storing raw materials 82
BAT22 Monitoring raw material losses in production processes and taking precautions against raw material losses 77
BAT23 Preferring substances that can provide resource efficiency (increase production performance and improve product properties) in the selection of raw materials and chemicals 84
BATs with the least IR
BAT19 Preferring in the selection of fiber raw materials, the environmental effects of the fiber in the previous production stages taken into account and the one with the least environmental impact 43
BAT20 Establishing procedures that provide supplier control in raw material selection 52
Chemical use 27 BATs with the highest IR
BAT24 Optimizing the recipes applied in production, taking into account environmental impacts 71
BAT25 Applying and storing all chemical substances in accordance with the instructions given in the Substance Safety Data Guides (MSDS) 86
BAT26 Preventing all chemical spills, controlling and cleaning the area if a spill occurs, and preventing chemical spills from mixing with the receiving environment and sewage system 79
BAT29 The use of the chemical with the least risk, in cases where the use of chemicals is essential in the selection and use of chemicals 84
BATs with the least IR
BAT32 Applying a dry process to remove iron from the fabric before bleaching, especially in pre-treatment and dyeing processes, when using complexing agents 13
BAT40 Use of polyether/polyester or polyether/polycarbonates, special polyol esters and special sterically hindered fatty acid esters as an alternative to conventional preparation additives containing mineral oil 23
BAT42 Calculation of substrate-based emission factors in textile finishing regularly (at least once a year) and especially before using a new recipe or changing compounds of an existing recipe 18
Tab.1  Current BAT implementation status regarding general measures, produced products and chemical use
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Water resources and water supply 18 BATs with the highest IR
BAT59 Increasing washing efficiency 66
BAT62 Developing and effectively implementing procedures to prevent water losses 63
BAT63 Increasing washing efficiency by using water-efficient elements (water spray heads, spray nozzles, etc.) in facility and equipment cleaning, thereby saving water and reducing the amount of wastewater 63
BAT68 Determination of water quality standards requirements for each water consumption points 61
BATs with the least IR
BAT52 Establishing a monitoring system to monitor water consumption 34
BAT61 Characterization of discrete wastewater streams and evaluation of water/material recovery and reuse opportunities 23
BAT66 Reducing liquor ratios by using an airbag system in high-temperature (HT) dyeing machines in the dyehouse unit 21
Process water preparation systems 7 BATs with the highest IR
BAT72 Determination of regeneration frequencies depending on raw water quality or determination with a hardness sensor 45
BAT74 Optimizing rinse times after regeneration 59
BATs with the least IR
BAT69 Reuse of sand filter backwash water before water softening in appropriate areas 16
BAT73 Determination of regeneration frequencies using online hardness sensors 13
Tab.2  Current BAT implementation status regarding water resources, water supply and process water preparation systems
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Energy supply, distribution and use 18 BATs with the highest IR
BAT82 To prevent steam losses, complete steam insulation in machines 70
BAT83 Insulation of pipes, valves, tanks and machines to minimize energy losses 73
BAT84 Optimizing boiler rooms with practices such as reusing steam condensates 71
BATs with the least IR
BAT76 Establishing an energy management system 25
BAT86 Establishing a cogeneration system (may be advantageous for some facilities) 16
BAT87 Utilization of cold water and air obtained by using an absorption cooling system in cogeneration in the required processes 4
BAT93 Evaluation of alternative/renewable energy sources (solar energy for water heating or hot oil production, etc.) 11
Steam production and distribution 64 BATs with the highest IR
BAT95 Carrying out boiler cleaning as often as necessary 79
BAT96 Carrying out regular boiler checks (if there is more than one boiler, consecutive boiler checks) 79
BAT147 Ensuring full functionality of steam traps in steam distribution systems 79
BAT148 Preventing steam leaks in steam distribution systems 79
BAT152 Closing the valves in the steam line for long periods when there is no work in the relevant unit in the business 77
BATs with the least IR
BAT110 Providing heat recovery from flash steam 18
BAT127 Using recovery (exchanger type air preheater) and regenerative burners (with recovery burner, the combustion air can be preheated using the heat in the flue gas) 13
BAT135 Using online monitoring-control systems for important energy flows and combustion processes in the facility 16
BAT142 Installation of flue gas isolation dampers in facilities with more than one boiler 14
Tab.3  Current BAT implementation status regarding energy supply, steam production and distribution
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Electricity usage 17 BATs with the highest IR
BAT159 Controlling and monitoring electricity usage 71
BAT164 Shutting down when there is no work or the machines are at a standstill 82
BAT168 Using variable speed drives to reduce the load on fans, compressors and pumps 73
BAT170 Avoiding the use of engines with higher power than necessary 80
BAT171 Installing capacitors in the alternating current circuit to reduce the size of reactive power 75
BATs with the least IR
BAT158 Establishing an Energy Management System 23
BAT160 Monitoring electrical energy consumption on the basis of machines or processes 46
BAT161 Conducting process-based energy audits and identifying potential savings points 48
BAT162 Documentation of the production procedures and using by employees to prevent energy loss 43
BAT169 Elimination of unnecessary drying processes (that do not pose a risk on product quality) in the production flow by process modification/optimization 45
Tab.4  Current BAT implementation status regarding electricity usage
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Compressed air systems 15 BATs with the highest IR
BAT176 Preventing compressed air leaks 82
BAT177 Optimizing compressor capacity 77
BAT182 Preventing compressor pressure from increasing excessively 80
BATs with the least IR
BAT179 Optimizing compressor inlet air temperature 36
BAT181 Installation of the compressor system on the north facade 39
BAT186 Establishing a compressor monitoring system and monitoring load distributions 29
Humidification, ventilation and air conditioning systems 11 BATs with the highest IR
BAT190 Preventing excessive energy consumption by determining optimum conditions for humidity and temperature within the facility 52
BAT191 Using variable speed and frequency drivers in air conditioning systems 45
BAT196 Preventing excessive energy consumption by ensuring optimum conditions for humidity and temperature within the facility 54
BATs with the least IR
BAT192 Reducing the condensing temperature (decreasing by 1 oC reduces annual cooling costs by 2%–4%) 23
BAT193 Preventing the formation of non-condensable gas in the condenser to reduce the condensation temperature 25
BAT195 Increasing the evaporation temperature (If the evaporation temperature is increased by 1 oC, annual cooling costs decrease by 2%–4%) 23
Tab.5  Current BAT implementation status regarding compressed air and HVAC systems
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Pre-treatment processes 120 BATs with the highest IR
BAT245 Using automatic equipment to control bath volume and temperature in batch-operating machines 89
BAT249 Using water flow control devices and automatic shut-off valves in continuously operating machines 89
BAT251 Investigating the possibilities of combining different operations in one step 78
BAT252 Increasing washing efficiency 78
BAT258 Appropriate collection, storage and disposal of textile waste for reuse 89
BATs with the least IR
BAT210 Recovery of sizing chemicals from desizing wastewater by membrane filtration 0
BAT260 Conducting process-based energy audits and identifying potential savings points 0
BAT273 Controlling and monitoring energy consumption 0
BAT308 Characterization of discrete wastewater streams and evaluation of water/material recovery and reuse opportunities 0
Dyeing and printing processes 58 BATs with the highest IR
BAT321 Use of dyes that have high adhesion to fiber 64
BAT322 Using auxiliary chemicals that will not prevent the dyes from adhering to the fiber at a high rate 61
BAT333 Selecting the machines most suitable for the lot sizes to be processed 61
BAT345 Avoiding the use of dangerous carrier 63
BAT346 Instead of organic carriers containing chlorine, use of carriers containing benzylbenzoate and N-alkylphthalimide groups, which do not contain chlorine groups, cause less odor problems in the operation and have low volatility 59
BATs with the least IR
BAT327 Reuse of dyeing wastewater after treatment 2
BAT328 Reuse of washing wastewater after dyeing by membrane filtration 0
BAT329 Reuse of washing wastewater after dyeing by adsorption 2
BAT371 Making the printing paste feeding system more efficient and automating in flat printing machines 4
BAT372 Reducing the paste remaining on the template by modifying the squeegees in flat printing machines 5
Finishing processes 41 BATs with the highest IR
BAT405 Use of easy-care products that do not contain formaldehyde or have reduced formaldehyde content (< 0.1% formaldehyde content in the formulation) that create cross-linking during final treatments 50
BAT407 Optimizing passage speeds in stenters 55
BAT410 Removing excess water remaining on the fabric before drying by using effective squeezing processes and thus reducing the energy need for drying where technically possible 50
BAT413 Adapting appropriate material preparation procedures 52
BAT416 Preventing spills as a result of overflow 65
BATs with the least IR
BAT386 Reusing rinse water in technically possible processes without purification 11
BAT387 Reusing the rinse water as process water after combining it with similar wastewater streams and after treatment 9
BAT388 Evaluation of the use of relatively clean washing/rinsing wastewater for cleaning purposes 11
BAT389 Reuse of finishing wastewater in other processes 7
BAT390 Neutralization of finishing wastewater with alternative methods instead of sulfur/citric acid 7
Tab.6  Current BAT implementation status regarding pre-treatment, dyeing-printing and finishing processes
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Wastewater streams and wastewater treatment systems 39 BATs with the highest IR
BAT427 Reuse of cooling water (It is possible to recycle the cooling water that does not come into contact with the product in a closed circuit and transfer the used water to a tank and reuse it in the process) 45
BAT428 Separate collection and reuse of cooling water (Cooling water that does not come into contact with the fabric/yarn can be collected in a tank and used in processes that require hot water such as dyeing, bleaching, washing. For example: condenser-cooling water, heat exchanger water, water from compressors, etc.) 43
BAT429 Preventing contamination risks by checking coils and cooling water quality 45
BATs with the least IR
BAT443 Membrane processes (Pressure membrane processes used in the treatment of textile wastewater are microfiltration (MF), ultrafiltration (UF), nanofiltration (NF) and reverse osmosis (TO)) 0
BAT444 Treatment and reuse of textile wastewater with membrane processes (Wastewater originating from the textile industry can be treated with membrane processes, respectively, following balancing and neutralization works, and the purified water taken from the RO or NF output can be directly used back in the textile industry production processes) 0
BAT445 Treatment with membrane bioreactors (MBR) (With the MBR system, which is a combination of aerobic biological treatment and membrane process, the treatment of textile wastewater with high and complex pollution can be achieved with very high efficiency) 0
BAT446 Membrane bioreactor (MBR) + Nanofiltration (NF) (One of the best techniques for the purification and reuse of textile wastewater is the purification of MBR effluent in the NF process. In this composite membrane configuration, the purified water at the NF outlet can be reused within the facility) 0
BAT447 Treatment of wastewater with approximately 60% water recovery (Activated sludge + adsorption + sedimentation + flocculation/precipitation/flotation + sand filtration + activated carbon filtration + RO) 0
BAT450 Treatment with ozonation + activated sludge system (In the treatment system where ozonation and activated sludge are used together, the effluent COD value can be reduced to 50 mg/L) 0
BAT455 Activated sludge system + powdered activated carbon + sand filter implementation (The exit water COD value can be reduced to 20 mg/L and a good color removal efficiency can be achieved) 0
Tab.7  Current BAT implementation status regarding wastewater streams and wastewater treatment systems
BAT category Number of BAT BAT code BAT description Current BAT IR (%)
Prevention and control of waste gas emissions 12 BATs with the highest IR
BAT465 Determination of air pollutant sources and their emissions 70
BAT467 Preventing chemical substances from spilling and evaporating and causing air pollution 71
BAT470 Using fuels that will create less waste gas emissions and have high calorific value 68
BATs with the least IR
BAT462 Controlling particle emissions using aqueous washing systems 45
BAT468 Controlling volatile organic compounds (VOCs) in emission sources at the source using methods such as concentration, aqueous washing and thermal combustion 3 38
BAT469 Determining Determining and periodically monitoring air emission sources in the facility 43
Prevention and control of noise generation 9 BATs with the highest IR
BAT474 Maintenance and replacement of old equipment 70
BAT479 Use of personal protective equipment to prevent employees from being affected by indoor noise 75
BATs with the least IR
BAT472 Noise insulation to reduce noise in the weaving unit 20
BAT473 Noise insulation to reduce noise in the spinning unit 13
Prevention and control of solid waste generation 9 BATs with the highest IR
BAT480 Separate collection of solid waste 86
BAT484 Appropriate collection, storage and disposal of textile waste for reuse 88
BATs with the least IR
BAT483 Expired (lost function) activated carbon used for solvent recovery during wool pre-treatment should be disposed of as hazardous waste or sent to specialized companies for regeneration 15
BAT488 Use of waste in regenerated yarn production 38
Tab.8  Current BAT implementation status regarding waste gas emissions, noise and solid wastes
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