DoingMore withLess - unescap.org II.pdf · A holistic program working for the long-term competitiveness and environmental sustainability of the textile wet processing sector-Washing,

DoingMorewithLess

PaCT II

May 5, 2019

Background

A holistic program working for the long-term competitiveness and environmental sustainability of the textile wet processing sector-Washing, Dyeing and Finishing units

Program Objective

Addressing high water, energy, and chemical use through the adoption of industrial best

practices throughout the supply-chain

PaCT Partners

A Collaborative Effort

PaCT PillarsWorking within and beyond factory gates

Awareness Raising

Step 1 Step 3

Basic CP Assessments Targeting the low-hanging fruitsInstalling water and/or gas meters, Improving

Insulation, Installing trigger nozzles, Maintaining steam traps and systems, Replacing T-8 bulbs

with energy efficient lights (T-5/LED), etc.

Step 2

In-depth CP Assessments Targeting the Advanced Technologies

Recovering salts and caustic, Installing economizers, Recovering Heat from processes, etc.

Factory EngagementDoing more with less

Factory engagement (cont’d)

Awareness building

663

In-depth Cleaner Production

91

Basic Cleaner Production

173

In depth CP

Improving Efficiency of

Delivery of Utilities

Reducing Demand For Water, Energy, Chemicals in Wet

Processing and Finishing

Reducing Volume of Effluent

Improving Efficiency of ETP Treatment

Other Areas of Factory

Process Time

• Dyehouse Processes• ≈4-5 hrs to 12 -13 hrs

• Time is closely linked to Electricity• <Time = > Capacity

• Many expansion plans in place before optimising current installed capacity

• Lab to bulk• ≈ 60% to 85%

• Bulk to bulk• ≈ 70% to 95%

• Sometimes ~ 20% of water and energy is spent on corrections

• RFT is not always well recorded or defined in factories

Lab to Bulk Right First Time

• Total Investment – US$ 2.3m

• Cost Savings – US$ 3.8m/yr

• Payback Period - < 1 Year

Caustic Recovery Plant

• Total Investment - US$ 312, 500

• Cost Savings – US$ 146,000/yr

• Payback Period - 2.5 Years

Salt Recovery Plant

Factories implemeted In-depth CP reduced water consumption from

169 L/kg to 133 L/kg, a 21% reduction

0

50

100

150

200

250

300

350

400

450

16 11 7 38 26 8 5 18 3 36 32 17 14 19 4 6 37 35 20 39 21 28 46 12 47 22 33 30 29 49 23 25 44 51 1 9 34 43 2 10 50 42 13 40 15 48 27 52 41 45 24 53 31

Before PaCT (L/kg) After PaCT (L/kg) Average before PaCT (L/kg) Average after PaCT (L/kg)

Factories Implemented In-depth CP reduced energy consumption from

19.1 kWh/kg to 15.6 kWh/kg - a 19% reduction

0

5

10

15

20

25

30

35

40

45

50

32 34 40 21 5 12 25 4 20 24 9 36 14 31 39 8 22 47 33 6 23 37 18 16 48 28 27 13 11 15 19 44 41 38 7 1 35 46 42 2 3 50 26 10 43 29 49 45 17 30

Before PaCT (kWh/kg) After PaCT (kWh/kg) Average before PaCT (kWh/kg) Average after PaCT (kWh/kg)

Fakir Apparels Ltd.PaCT suggested 50 recommendations in utility,

dyehouse, and ETP

Total Investment - $ 177, 000

Cost Savings - $ 208, 620/year

Payback Period - 10 months

Succ

ess

Sto

rie

s o

f P

aCT

Inte

rve

nti

on

s

2.9

7.8

13.4 14.4

18.4

0

2

4

6

8

10

12

14

16

18

20

31 December,2014

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative Water Savings(Million m3/year)

Target - 15 Million

597,485

1,108,954 1,232,361

1,783,792

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

2,000,000

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative Energy Savings (MWh/year)

Target - 1,250,000

64,000

169,400188,238

275,346

0

50,000

100,000

150,000

200,000

250,000

300,000

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative GHG emission reduction (tonnes CO2 /year)

Target - 225,000

Program Achievements (cont’d)

4.66.7

10.6 10.7

15.9

0

2

4

6

8

10

12

14

16

18

31 December,2014

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative Wastewater Reduction (Million m3/year)

Target - 12 Million

12

18.8

28.4 2931.4

0

5

10

15

20

25

30

35

31 December,2014

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative Investments facilitated (Million USD)

Target - 32 Million

2.6

4.7

7.7

9.9

12.4

0

2

4

6

8

10

12

14

31 December,2014

30 June, 2015 31 December,2015

30 June, 2016 31 December,2016

Cumulative Expected Annual Savings (Million USD/year)

Target - 9 Million

Program Achievements (cont’d)

Program Achievements (cont’d)

✓ $200m Green Financing instrument;

✓Reduced use of hazardous chemicalsfrom policy reform;

✓ Increased uptake of green machineryfrom policy reducing tariff on greenmachinery

850

940

0

200

400

600

800

1000

2013 2014 2015 2016 2017Imp

ort

in

US

D M

illi

on

Trend in import value of 52 machineries

Business-as-usual(USD million)

Actual totalimport (USDmillion)

Program Achievements (cont’d)

Textile Technology Business CenterFirst ever knowledge hub for the Bangladesh textile industry

• Established in partnership with BGMEA • Offers reliable and comprehensive range of services• Access to specialized information• Capacity building through workshops and expert training programs,

worker training program• B2B linkages with a strong network of technology suppliers, factories,

and financial institutions and banks• Facilitating investments in resource efficiency technologies

To date TTBC has…

176 members

120 factories

56 technology suppliersUS $860,000 investment facilitated

Thank you…