List of Acronyms BOD Biological Oxygen Demand CAPMAS Central Agency for Public Mobilization and Statistics CO Carbon Monoxide COD Chemical Oxygen Demand EMS Environmental Management System O&G Oil and Grease SIC Standard Industrial Classification SM Self-Monitoring SMS Self-Monitoring system SO Sulfur Oxides x TDS Total Dissolved Solids UHT Ultra High Temperature WWTP Wastewater Treatment Plant µm Micro meter 10-6 m VOCs Volatile Organic Compounds NO Nitogen Oxides x CFCs Chloro-fluoro carbon MHUUC Ministry of Housing, utilities and urban Communities CP Cleaner Production Eop End-of-pipe P2 Pollution Prevention HACCP Hazardous Analysis& Critical Control Point CIP Clean in Place Table of Contents 1. Introduction 1 1.1 Preface 1 2. Description of Industry 3 2.1 Raw Materials, Chemicals and Other Inputs 3 2.1.1 Raw Material for the Following Textile Substances 3 2.1.2 Chemicals for the Following Wet Processes 3 2.1.3 Water 4 2.2 Production Operations 4 2.2.1 Spinning Industry 4 2.2.2 Fabric Formation Industry 10 2.2.3 Finishing Industry 16 2.2.4 Garment Industry 23 2.2.5 Man-made Fiber Industry 26 2.3 Service Units 36 2.3.1 Boilers 36 2.3.2 Water Treatment Units 36 2.3.3 Cooling Towers 37 2.3.4 Laboratories 37 2.3.5 Workshops and Garage 37 2.3.6 Storage Facilities 38 2.3.7 Wastewater Treatment Plants 38 2.3.8 Cotton Dust Scavenging Unit 39 2.3.9 Restaurants, Washrooms and Housing Complex 39 2.4 Emissions, Effluents and Solid Wastes 39 2.4.1 Air Emissions 39 2.4.2 Effluents 40 2.4.3 Solid Wastes 41 2.5 Noise Pollution 41 3. Environmental and Health Impacts of Pollutants 42 3.1 Impacts of the Main Pollutants on Health 49 3.2 Impacts of the Main Pollutants on Environment 50 3.3 Impact of the Main Solid Wastes 51 3.4 Impact of Noise 51 3.5 Impacts on Ambient Environment 51 3.6 Summary of the Emissions and their Degree of Pollution Impact 51 4. Egyptian Laws for Maximum Limits of Pollutants 56 4.1 Maximum Limits of Air Pollutants 58 4.2 Pollutant Effluents 61 4.3 Concerning Work Environment 62 4.3.1 Noise Pollution 62 4.3.2 Emissions in Work Environment 63 4.4 Concerning Hazardous Materials and Waste. 64 ﺃ 4.5 The Environmental Register 64 5. Pollution Abatement In the Different Textile Industries 65 5.1 Pollution Abatement in Spinning 65 5.1.1 Pollution Abatement in Cotton Spinning 65 5.1.2 Pollution Abatement in Wool Spinning 65 5.2 Pollution Abatement in Fabric formation industry 66 5.2.1 Pollution Abatement in Weaving 66 5.2.2 Pollution Abatement in Knitting 66 5.2.3 Pollution Abatement in Nonwoven Fabrics 67 5.2.4 Pollution Abatement in Tufting 67 5.3 Pollution Abatement in Wet Processes 67 5.3.1 Purchasing Policy for Raw Materials 67 5.3.2 Pollution Abatement in Desizing 68 5.3.3 Pollution Abatement in Scouring 68 5.3.4 Pollution Abatement in Bleaching 69 5.3.5 Pollution Abatement in Mercerizing 70 5.3.6 Pollution Abatement in Dyeing 70 5.3.7 Pollution Abatement in Printing 73 5.3.8 Pollution Abatement in Finishing 74 5.4 Pollution Abatement in Garment Industry 76 5.5 Pollution Abatement in Man-made Fiber Manufacturing 76 5.6 Noise Pollution Abatement 78 6. Industrial Inspection 79 7. Inspection Planning at the Inspectorate Level 80 7.1 Activities Related to the Textile Industry 80 7.2 Providing Information about the Facility 80 7.3 Providing Required Personnel, Equipment and Method of 81 Inspection 8. Preparation for Filed Inspection 82 8.1 Gathering and Reviewing of Information 82 8.2 Preparation of the Inspection Plan 82 8.3 Preparation of the Required Checklists 83 8.4 Legal Response for any Violation of the Law 4/1994 83 9. Performing the Field Inspection 84 9.1 Starting the Field Visit 84 9.2 Proceeding with the Field Visit 84 9.2.1 Inspection of Production Lines of Different Textile 85 Subsectors 9.2.2 Inspection of Service Units 91 9.2.3 Effluent Analysis 91 9.3 Ending the Field Visit 92 10. Conclusion of the Field Inspection 93 10.1 Preparing the Inspection Report 93 ﺏ 10.2 Supporting the Enforcement Case 93 10.3 Following-up Compliance Status of Violating Facility 93 Annex (1) Assessment of Dyes Annex (2) Inspection Checklist for a Textile Facility ﺝ 1. Introduction This manual has been prepared to guide the industrial inspector to carry out his work in the textile industry regarding the environmental pollution caused by the different sources in the different subsectors of this industry. The information in this manual introduces the inspector to the technical knowledge of the different production lines of textile manufacturing; spinning, weaving, knitting, finishing, garment manufacturing and man-made fiber manufacturing. This technical information helps the inspector to know the possible pollution due to air emissions, wastewater and solid waste, and the health impact due to the different pollutants. The manual also provides the relevant data from the Egyptian Environmental Law, number 4 of 1994 and its executive regulation, regarding the permissible limits of air pollutants and noise data are given from the regulation of Ministry of Housing, law 44/2000 regarding the specifications of industrial wastewater to be discharged to public sewage system. These limits and specifications provide the inspector with the basis to judge the facility compliance to environmental laws. The manual also provides the inspector with information about a number of proposals for pollution abatement which may be applied in the different textile processes to minimize the pollution due to air emissions in the working environment and the pollution in the facility wastewater to be discharged to surface water or to public sewage system. Because of the continuous development in the textile industry, regarding the types of raw material, the types of chemicals used and the type of technology of the process, the types of pollutants and their concentrations are also liable to change. This justifies that this manual is subjected to the updated when the situation necessitates the needs of alterations 1.1 Preface The textile industry is considered one of the greatest industries in Egypt regarding the number of labor, the value of exports, and the value of local production. The Egyptian textile industry comprises 31 public sector companies and about 3500 private sector and joint venture companies. The availability of the high quality Egyptian cotton represents a great support in the international competition for the Egyptian textile products especially the extra fine quality. The textile industry is the fifth largest source of foreign earnings, after oil, remittances, tourism and Suez Canal earnings. The public sector dominates nearly 100% of the spinning, 70% of weaving, 40% of knitting and 30% of the finished goods. The private sector currently dominates the market in terms of knitted fabrics and manufactured garments. The exports of the textile industry represent about 43% of the total Egyptian industrial exports. The largest share of the textile exports is that for cotton yarns. Other exports also a cotton for grey fabrics, finished fabrics, and manufactured garments, which are obtaining an increasing share of total exports of the present time. The textile industry causes pollution to the environment through air emissions, effluents and solid waste. the liquid wastes tend to dominate over air emissions and solid wastes in terms of severity of environmental impacts. Wastewater resulting from various washing operations contains substantial pollution load represented in organic matter and suspended matter such as fibers and grease. This wastewater also contains 1 alkaline and toxic chemicals, which if discharged into aquatic bodies can cause lowering of dissolved oxygen, damage to aquatic life and expose downstream water users to possible toxic effects. The wet processes in the textile industry use large volumes of water that generate large volumes of wastewater containing a wide variety of chemicals used throughout processing. The major source of pollution in the dry processes, such as cotton spinning, weaving, knitting ,..etc., is the cotton dust, lint, and particulates which have pollution and health impact in the working environment and affect the respiratory system. Another important source of pollution in both the dry and wet textile processes is the noise, especially when high speed machines are used such as ring spinning machines, winding machines, air-jet looms, ..etc. the textile production lines usually contain a large number of machines in each stage, so that the pollution load is expected to be great and needs much effort to control to keep it as low as possible. 2 2. Description of Industry The textile industry deals with fibrous materials in a form depending on the type of process, chemicals and other inputs, as shown in the following . 2.1 Raw material, chemicals and other inputs tables (1-11) presents the different processes, the raw materials and products from each process and the related pollution sources. 2.1.1 Raw material for the following textile subsectors Cotton Spinning Raw cotton fibers, man-made fibers with specifications similar to cotton, or blends of cotton and man-made fibers. The raw fibers are supplied in bales. Wool Spinning Raw wool fibers, man-made fibers with specifications of wool, or blends of wool and man-made fibers. The raw fiber material is supplied in bales. Weaving Cotton yarns, woolen yarns, man-made yarns, blended yarns, textured yarns, stretch yarns, …etc. Knitting Cotton yarns, woolen yarns, man-made yarns, blended yarns, textured yarns, stretch yarns, …etc. Nonwoven Man-made fibers, wool fibers, or blends Tufting Acrylic yarns, polypropylene yarns, blended yarns with the wool-type. Garment Woven or knitted fabrics, from cotton, wool, man-made fibers, blends of natural and man-made fibers, interlining fabric and lining fabric, buttons, zebs, …etc. 2.1.2 Chemicals for the following wet processes Sizing Polyvinyl alcohol, carboxymethyl Cellulose, oils, waxes, adhesives, urea, diethylene glycol, ..etc. Desizing Enzymes, Sulpheric acid, detergents and alkali Scouring Sodium hydroxide, Sodium Carbonate, surfactants, chlorinated solvents Bleaching Hypochlorite, hydrogen peroxide, acetic acid. Mercerization Sodium hydroxide, surfactants, acid, liquid ammonium Dyeing Dyestuffs, auxiliaries, reductants, oxidants Printing Dyes (acids or alkalis), pigments, kerosene, binders, ammonia, xylenes. Chemical finishing Formaldehyde, phosphorus, ammonia, silicone, fluorocarbon resins, toluene, zircon salts, ..etc. 3 2.1.3 Water The textile industry includes many wet processes within the production operations, such as sizing, scouring, desizing, bleaching, dyeing, finishing, …etc. These wet processes consume large amounts of water which are estimated to be at a rate of 200 liters/ kg of product. So, water is an important input to the textile industry. The required characteristics of the input water may need to treat the water in a special plant to remove hardness from water before being used in the wet processes. 2.2 Production operations The textile industry covers the following different production processes and service units: Production Processes Service units Spinning Boilers Cotton spinning (and blends) Cooling towers Wool spinning (and blends) Laboratory Fabric formation Mechanical and electrical workshop Weaving Garage Knitting Storage facilities Nonwoven Water treatment plant for water to be used in production units Tufted carpet Finishing Wastewater treatment plant Preparation for finishing (singeing, Scavenging system for cotton dust bleaching, …etc.) Dyeing Printing Chemical finishing Garment manufacturing Man-made fiber manufacturing Viscose production Nylon production Polyester production 2.2.1 Spinning Industry Tables (1 &2) presents the different processes, the raw materials and products for each process and the related pollution sources. The two main technologies for spinning are explained in the following: 4