Processing Today December 2018

U n ve i l i n g i n d u s t r y b e s t p r a c t i c e s

Knit & Woven Dyeing & Finishing D e ce m ber 2018

A Textile Today Initiative l Published with Volume 11, Issue 12 l Pages 79 to 96

CHT’s organIQ BLEACH, a smart alternative to potassium permanganate for denim fabric bleaching

CPB dyeing saves 50% water of Robintex Group

Knit & Woven Dyeing & Finishing

“Transfar Chemicals is in the global platform with a vision of ethical and sustainable business”

U n ve i l i n g i n d u s t r y b e s t p r a c t i c e s

Biolase APC – a combined bio-scouring & bio-polishing enzyme

by Raas Biotech

Global Leader in the Manufacturer of Dyestuffs and Intermediates

Liyuansol Classic for Cellulose Liyuansol BLF Series for Better Lightfastness Liyuansol HS Series for Deep Shade along with excellent RFT Liyuansol FL Series for Top Lightfastness (PLF)

We are on our way-

Address: House-11 (5th Floor), Road-07, Sector-12, Uttara Model Town, Dhaka-1230 Tel: +88 01713 027506, +88 01708 539402 Email: dndchem@yahoo.com, info@dndchem.com

Room - 501, Unit-7, Oceanwide International SOHO Town, Huaihai Road, Jianghan District , Wuhan City, Hubei Province, 430000, China Tel: 0086-27-88185025 | Fax: 0086-27-88185276

Viyellatex Group, the first Bangladeshi knit fabric manufacturer achieves bluesign® certificate FT Research Team Viyellatex Group is the world’s first knit composite manufacturer became bluesign® system partner.

It received bluesign® certificate as the very first Bangladeshi apparel manufacturer on 29 November at Le Meridien, Dhaka.

The Viyellatex Group is composed of a variety of operational and functional units such as spinning, knitting, dyeing, washing, printing, embroidery, and stitching, all based in the greater Dhaka area. It supplies knit and woven garments, mainly t-shirts and shirts, for top European and American brands, including Puma, Calvin Klein, and Tommy Hilfiger etc.

Recently Textile Today visited

Bangladesh Textile Today |

Viyellatex to know the details about the accomplishment.

The vision of Viyellatex Group is ‘to be the most regarded company’.

They are committed to a cleaner and greener environment. In fact, they drive the business with a responsibility to the society as a corporate body. It is conscious about sustainability issues from the very beginning of its business journey so they took sustainable initiatives towards ensuring social and environmental prosperity.

David Hasanat, Chairman of Viyellatex Group stated, “From the beginning of the establishment of Viyellatex Group in 1996 we entered into a partnership and

Volume 11, Issue 12

collaboration agreement with Huntsman Textile Effects. After the time being we almost used 90-95% complied products as we committed to becoming an environment-friendly organization.

Moreover, we hired a consultant from Germany in 2009 to continue the growth. By 2010, we were almost ready to be 100% complied factory as Viyellatex Group placed a strong emphasis on sustainability by minimizing energy usage, adopting waste and water recycling, and using only organic materials and environmentally compliant chemicals and dyes.”

“By the late of 2018, we achieved the bluesign® recognition. But the achievement was not so easy

81

Figure 2: David Hasanat, Chairman of Viyellatex Group.

because the bluesign® criteria are very stringent to maintain.

However, we were successful as we have a policy of using better raw material for production.” bluesign® frequently assess the company to make sure the criteria set by bluesign® are maintained.

A mutually agreed roadmap guarantees the continuous improvement. Every organizational body can be benefited by their global expertise and guidance.

There are a lot of tangible and intangible benefits as well who are using bluesign® approved products.

David Hasanat urged the factory owners to use better chemistry to fulfill today’s needs, which is given if inputs and products comply with the bluesign® criteria so that Bangladesh as a country can have a better image as a sustainablefocused nation to produce a safer product for the end consumer. He expressed his expectation to grow all together in a sustainable way.

82

campaign, there is a possibility of increased difficulty for not using safe materials. Along with that, out of 17 goals from SDG 2030, there are many which are very specific about the environment, workers’ safety, hazardous chemicals, responsible sourcing etc. These areas are exactly on which the bluesign® system focuses.”

bluesign® frequently assess the company to make sure the criteria set by bluesign® are maintained.

A mutually agreed roadmap guarantees the continuous improvement.

Every organizational body can be benefited by their global expertise and guidance. There are a lot of tangible and intangible benefits as well who are using bluesign® approved products.

“The bluesign® system guarantees the application of sustainable ingredients in a clean process at which end stands a safely manufactured product. As a result, the textile industry manages the natural resources soundly and responsibly, reduces water and air emissions, improves its wastewater treatment, saves the cost of production by optimized use of resources and generally reduces its ecological footprint,” he added.

Shahan Reza, Country Relation Manager, Bangladesh of bluesign® highlighted the importance of bluesign® and said, “By the end of 2019, because of the DETOX

Shahan Reza further mentioned, “bluesign® has over 560 system partners globally, out of which more than 50% are manufacturers.

We are happy that Viyellatex Group has taken the right decision

Bangladesh Textile Today |

Volume 11, Issue 12

at the right time. Our global team was happy to work with them as from the beginning Viyellatex Group were very supportive and prompt on taking appropriate actions. They have taken bluesign® certification for seven of their products. Viyellatex Group will be able to use the bluesign® approved logo for these products from now on.”

Shahan Reza further added about the system: “bluesign® performs production site EHS/ OHS assessment including material and processes, does an evaluation of all emissions, implements and qualifies chemical management, benchmark cost savings through resource consumption and environmental performances, provides training and guidance on regulations and chemical management. It also performs reassessment within 3 years to make sure continuous improvement of the overall situations.”

Figure 3 (L-R): Shahan Reza, Country Relation Manager (Bangladesh), Walter Streitler, Head of Customer Relation Asia, bluesign®; Abdur Rashid, Country Manager, Bangladesh, SGS Group.

bluesign® has the largest database of safe chemicals and safe raw materials, i.e. fabric, fiber, accessories etc. which are authenticated and guaranteed.

The world is getting more and more concern regarding the

impact of using hazardous materials and new regulations are coming up every day. Partnering with bluesign® may have a positive impact not only on the country’s image and business but also for the future generation.

Contact with bluesign® personnel in Bangladesh - shahan_reza@bluesign.com

Do you want to be a Join the Foundation Training on

Factory Skills Development (FSD) & become the future leader as Fabric Technologist

FSD Courses

Certified Fabric Technologist

Options

Date

Time

Textile Fibre, Yarn & Fabric

Mandatory

16th,23rd February & 2nd, 9th March

Knitting & Knit Processing

Mandatory

25th January, 1st, 8th, 10th February

9.00 AM- 1.00 PM

Weaving & Woven Processing

Optional

1st, 8th, 15th & 22nd March

9.00 AM- 1.00 PM

Quality Assurance

Optional

12th, 19th, 26th & 29th January.

9.00 AM- 1.00 PM

Denim Development & Manufacturing

Optional

18th, 25th January,1st & 2nd February

4.00 PM- 8.00 PM

Apparel Supply Chain Management

Optional

22th, 29th March ,5th & 12th April.

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Transforming Human Capital

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Sustainable Processing

CPB dyeing saves 50% water of Robintex Group FT Research Team Ecological sustainability demands are constantly rising, especially with regard to the consumption of water and energy. Cold Pad Batch (CPB) dyeing is one of the most economical and environmentally friendly approaches in the textile industry. With the vision of cleaner production and sustainability, a Bangladesh-Germany joint venture factory Robintex Group introduced CPB dyeing in Bangladesh for the first time. They started CPB in mass production from 2017 in Narayangonj factory.

Robintex placed its stenter, straighter, compactor and all other dyeing finishing machines from Germany. Foreign experts help maintain the groups dyeing standards and develop its local expertise as well. It has the most contemporary sample dyeing machine also.

Many methods are used for dyeing cotton with reactive dyes, but the CPB method is relatively more environment-friendly due to high dye fixation and non-requirement of thermal energy owing to low bath ratio (M: L = 1:1) required for the process. It is a widely used technique for the semi-continuous dyeing process.

Engr. Muhammad Mahiuddin, Executive Vice President of Robintex Group said, “Environmental responsibility is best achieved in cold pad-batch application since no salt and steam is required, the rate of dye fixation is at ambient temperature is high. It’s also a cost-effective process with a very high level of reproducibility.”

Robintex is using ERBATECH machine from Germany which runs on average 40m/min and user-friendly. ERBATECH padder

Bangladesh Textile Today |

Figure 1: Robintex is the successful implementer of CPB dyeing in Bangladesh.

has Nip dyeing system, so tailing problem is eliminated. Their production capacity is 20 ton per day. They are using nip pad where dyes are picked up instantly. There has no chance for hydrolyzed. A uniform dye quality is achieved with even color absorbency and colorfastness. In pad batch dyeing, qualities like high shade reliability and repeatability are common. This is because of the high reactivity of dyes with rapid fixation rate and stability.

process instead of bio polishing from a sustainability aspect.

Because bio polishing requires a huge amount of water and chemicals and finally decreases the strength of the fabric. At the same time, they practice drying and finishing on stenter machine to eliminate the process.

Behind the story of a successful pioneer, Muhammad Mahiuddin shared, “We are using the same type of machinery for pretreatment, dyeing, and washing for a continuous process. Our In the pretreatment process, machine and chemical suppliers Robintex is using the singeing have supported Comparison of consumtion values us during the installation. It 70 l/kg 5.0 kg/kg 0.40 kWG/kg must require to be the same nature of all dyeing process, 28 l/kg 1.8 kg/kg 0.18 kWG/kg otherwise, perfect dyeing couldn’t be achieved.

Some factories installed Water Steam Electricity Consumption Consumption Consumption machinery (Without stenter) (Without stenter) before us but Exhaust dyeing CPB dyeing they did not take Figure 2: Comparison between exhaust and CPB dyeing’s the risk of mass consumption values (as provided by Robintex).

Volume 11, Issue 12

85

Sustainable Processing

production. In here, now we are the successful pioneer of CPB dyeing.”

a strong alternative than the conventional exhaust dyeing. Where salt in the effluent is an issue CPB dyeing should be the method of choice, hence less TDS in ETP. These benefits contribute to the sustainable development of the entire textile industry,” Mahiuddin further added.

A report showing that Cold Pad Batch dyeing technology achieves 13% carbon savings and over 50% water savings in fabric manufacturing compared with the conventional processes using exhaust dyeing.

Robintex has been awarded “The best works friendly knit factory” by the government of Bangladesh. It’s most advanced and dynamic Figure 3: Engr. Muhammad Mahiuddin, Executive Vice President of ERP backed inherent Robintex Group. system figures out the most efficient economy alternative dyeing methods to CPB Compared to traditional exhaust of scale in which cost optimization, like exhaust method are expensive dyeing methodology, CPB dyeing timely delivery, global standard, due to the requirement of thermal technology consumes less water, appropriate technology, skilled energy for dye fixation. energy, and chemical. It also human resource and all together, has the capability of continuous “I believed that improved the maximum benefits to the production. The reduced dyeing environmental impact, resource valued customers head for the auxiliary concentration leads to efficiency savings and the higher optimal harmony. minimize the waste effluent. The quality of CPB-dyed fabric present The CPB procedure is simple since the only step involved in the passage of fabric through the dye bath and squeezing through the dyeing padder with subsequent batching for twelve hours.

Do you want to be a

Certified Apparel Manufacturing Technologist

Join the Foundation Training on

Factory Skills Development (FSD) & become the future leader as Apparel Manufacturing Technologist.

Factory Skills Development Courses

Option

Date th

Lean Manufacturing

Mandatory

Product Development

Mandatory

8

Time

February

9.00 AM-5.00 PM

15th, 17th February

4.00 PM- 8.00 PM

11th, 18th, 25th & 27th January th

th

th

th

Industrial Engineering

Optional

29

Quality Control & Inspection

Optional

12th, 19th, 26th & 29th January.

Apparel Supply Chain Management

Optional

Product Planning & Control

Optional

22

March, 5 , 12

nd

th

th

, 29 th

& 15 th

March & 5 , 12 th

th

5 , 11 , 18 , 20

April.

th

January

April

9.00 AM- 1.00 PM 9.00 AM- 1.00 PM 9.00 AM- 1.00 PM 9.00 AM- 1.00 PM 4.00 PM- 8.00 PM

Partcipants have to take 4 courses from above 6 for being Certified Apparel Manufacturing Technologist.

Contact:  House-25A, Lake Drive Road, Sector 7, Uttara, Dhaka 1230, Bangladesh.  +88 02 55093682 |  +88 01734211085 |  info@textiletoday.com.bd  h t t p : // t ra i n i n g .t ex t i l e t o d ay.c o m . b d

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Sustainable Processing

CHT’s organIQ BLEACH, a smart alternative to potassium permanganate for denim fabric bleaching FT Research Team Bleaching jeans in an environmentally friendly way is always a challenge for denim manufacturers. The CHT Group has developed the organIQ BLEACH System as an alternative to potassium permanganate (KMnO4). organIQ BLEACH is the first patented purely organic bleaching agent for denim materials by which jeans bleaching becomes innovative. It is an effective and reproducible jeans treatment with advantages for the environment.

Why organIQ BLEACH The organIQ BLEACH system is a completely biodegradable bleaching agent for denim.

Potassium permanganate can be completely replaced in the spraying procedure. In case of an application with fog system, stonewash, and chlorine bleaches, all can be replaced with cold treatments, extremely low water consumption and least wastewater pollution.

Advantages of organIQ BLEACH A big ecological advantage of the organIQ BLEACH system is the good biodegradability of the bleaching agent in comparison to potassium permanganate (KMnO4).

• The pure organic bleaching agent •F ree from heavy metal, chlorine, and AOX •C ompletely biodegradable (> 99% in compliance with OECD 301B) • Without persistent components

organalQ BUFFER AL [g/l] 140

122 114

120

105 100

93 82

80

72 62

60

52 42

40

32 20

20

10

00 0

25

45

50

75

90

120 140 180 125 150 175 organlQ BLEACH T [g/l]

100

potassium permanganate (KMnO4) is the most used bleaching procedure worldwide, most reliable and proven bleaching procedures for denim fabrics but still, it is not that environmentfriendly in many ways like•M anganese is a heavy metal and non-biodegradable.

•P otassium permanganate (KMnO4) belongs to the hazardous substances, which pose a great risk for the environment due to the high fish toxicity.

• In many countries, there are strict regulations or even obligatory to take into account that any misuse of KMnO4 is avoided.

•C MR classification for KMnO4 under evaluation at ECHA (European Chemical Agency).

Reference: CLP Annex VI, No. 025:-022-00:-9 organIQ BLEACH spray application The organIQ BLEACH system has three parts, main part is BLEACH

• No risk for the environment •N o soiling of wastewater with heavy metals

18

250

270

275

300

T, BUFFER AO works as activator and organIQ ASSIST works as spray amount indicator. organIQ BLEACH T alone in solution is water-clear, which is why organIQ ASSIST is added in spray application to make it visible. organIQ ASSIST has no affinity to fibers, so it can be easily rinsed out and also completely biodegradable (according to OECD 301B). organIQ BLEACH + fog application The combination of modern technologies such as organIQ + fog application leads to ecological washing results with maximum efficiency means protection of resources.

These technologies are based on an extremely fine distribution of the product in the form of fog in the washing machine. A very homogeneous distribution and a very low liquor pick-up are obtained. This provides water and product saving process.

19

16 14 12

SAVINGS 31.6 %

15

13

10 8

• No need of neutralization

SAVINGS 66.7 %

6

5

4

Threats of potassium permanganate

2 0 CONVENTIONAL Bathas

88

220 225

20

•N o necessity of a where-used list according to valid legal requirements

The spray application with

200

CONVENTIONAL

FOG (organlQ + CORE) Steps FOG (organlQ + CORE)

Bangladesh Textile Today |

Volume 11, Issue 12

Sustainable Processing

Biolase APC – a combined bio-scouring & bio-polishing enzyme by Raas Biotech Desk Report To reduce chemical, water, time & energy consumption.

RAAS biotech brings groundbreaking revolution in knit pre-treatment and enzyme process. It offers a combined bio scouring and enzyme process by a single product called Biolase APC that eliminates using of seven pre-treatment chemicals. The combined process considerably reduce chemical, water, time and energy consumption in the knit dyeing process.

This Malaysia based company is renowned for manufacturing enzymes and auxiliaries, operating a business in Bangladesh for the last 10 years. Biolase APC offers a combined bio scouring and enzyme process that eliminates seven to eight chemicals like, Sequestering Agent, Anti Creasing agent, Caustic Soda, Peroxide, Stabilizer, Peroxide killer, and enzyme.

of Companies Limited.

In fabric dyeing industry maintaining the cost of sustainability is quite a big issue as the dyeing process uses many hazardous chemicals and to neutralize them a huge amount of ETP chemical is needed. Biolase APC is an enzyme-based product so it is totally biodegradable so the process releases minimum TDS on ETP thus minimize the usage of ETP chemical.

“We choose Biolase APC as it needs less process time, less water and saves a significant amount of energy for fabric processing, because as a part of sustainability practice we always try to implement the 3R process (Reduce, Reuse, Recycle).

This also allows less TDS on ETP as the product is enzyme based biodegradable” Imtiaz Uddin Topu, GM, Fabrics, Hams Garments Limited.

The dyeing industry is facing rising process cost as the price of energy and material goes up, Biolase APC is the demand of time as it saves overall 35% of energy consumption. We are getting a very good response from the dyeing industry as this product meeting their demand.

“In recent days the cost of business has been increased significantly. We are always looking for the product and process that could reduce the cost as well as maintain the quality.

Biolase APC has significantly reduced the fabric pre-treatment and enzyme cost as it needs less chemical, water, energy & time,” Engr. Kawsar Alam Sikder, COO, Textile Division, Asrotex Group one of the users of Biolase APC told.

Generally, the knit pre-treatment & enzyme process takes 3.30 hours while Biolase APC only takes 1.30 hours to complete the process and delivery more production as it saves time.

In this fast fashion arena, the manufacturers are in a hustle to meet the shorter shipment date.

Companies have set up R&D department to innovate process and ideas to enhanced production efficiency to deliver more production within the time bound.

“Our dyeing production per day has been increased after using Biolase APC. Generally, it takes 3.30 hours, but Biolase APC only takes 1.30 hours for souring & enzyme” Mohammed Ashraful Hossain (Shimul), General Manager, Knit Dyeing Division, Shovon Group

90

Rasheedul Islam CEO, Aux & Hue

Biolase APC becomes widely accepted and reliable to popular Bangladeshi knit dyeing and finishing factories like HAMS Group, NAZ Bangladesh Ltd, Asrotex Group, Crony Group, Libas Textile, Model De Capital, Shovon Knitwear, Unity Fabric, Rising Group, Anontex Group, Mascom Composite Ltd, Rony Textile, Ibrahim Knit Composite, Fatullah Dyeing and many more companies.

“The dyeing industry is facing rising process cost as the price of energy and material goes up, Biolase APC is the demand of time as it saves overall 35% of energy consumption. We are getting a very good response from the dyeing industry as this product meeting their demand” Rasheedul Islam, CEO, Aux & Hue (Local agent of Raas Biotech) expressed.

Bangladesh Textile Today |

Volume 11, Issue 12

Needle free space dyeing, No more yarn breakage

Steamer

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Exclusive Interview

“Transfar Chemicals is in the global platform with a vision of ethical and sustainable business” Founded in 1986, Transfar Group is a private enterprise group with diversified businesses. Transfar Chemicals is an important part of the Group’s five largest utility transmission platform, with more than 12000 employees and annual sales of over USD 1.2 billion. Based on its global production and supply network, it is actively pushing forward its internationalization strategy by building wide international market networks in APAC, America, Europe, the Middle East, and Africa. It has also established strategic partnerships with some wellknown multinational companies including BASF and Shell.

Recently, TANATEX Chemicals, a global leader in specialist textile chemicals become the part of Transfar Chemicals Co. LTD. Michael Zhou, President of Transfar Chemicals Group, who has the versatile knowledge and a huge experience in this industry gave an interview altogether with Youlin Fu, Vice President; Shengpeng Wang, Technical Center Director and Bruce Liu, Senior Sales Manager with Textile Today Research Team recently. Through this conversation, many domestic and global issues came out with solutions.

Textile Today: Earlier Transfar Chemicals was a Chinese based company but now it expressed itself as a global company by taking the full share of Tanatex Chemicals, a Netherlands based company. What actually thrived it to go in the global platform?

Michael Zhou: Transfar Chemicals is in the global platform with a vision of ethical and sustainable

92

is the biggest step to coming up to the form of internationalization. But it is really important to understand the global market.

Textile Today: Recently Chinese Ministry of Ecology and Environment (MEE) shut down many chemical factories in China, how does it affect the business? And what are your strategies to cope with the new Chinese regulations?

Michael Zhou President of Transfar Chemicals Co. Ltd.

business. First of all, we studied about the global market for such a long time and then we are here now and purchased Tanatex Chemicals which we are considering as an important move for Transfar Chemicals to be a global company.

China has been a key player in the textile industry for all of the time but except China, there are many more markets of textile auxiliaries and chemicals. This is the first reason why we are in the global platform. Again, we already have more than 30 years of experience and we have almost all chemical solution for a dye-house. Precisely, our strength actually thrived us to go in the global platform and we are committed to sharing our ideas and experiences to all of the customers for providing a better solution. So, this is the second reason for the globalization of our company. Then coming up to Tanatex Chemicals, which

Michael Zhou: Changing MEE policy definitely affecting the whole chemical business in China, in the greater angle it is actually dominating the world chemical business. It has two impacts, one is negativeit is affecting the customer collaboration, another impact is positive- this policy of Chinese ministry will accelerate the transformation of our customers from the low end product order to high end product order which actually will make the scope to develop the economy and improve the products structure better than anytime. So, we want to provide continuous solutions by improving our service and product structure according to the customers demand. We also want to provide some clean chemicals and that is the low emission chemicals which will be the energy saving product. Some more services we are providing as to reduce the emission of the chemicals and about the proper use of these chemicals. Now we are thinking of differentiating the chemicals from the wastewater, which are very necessary for the dyeing factories.

This is how we are reshaping us in a better way though we were always conscious.

Bangladesh Textile Today |

Volume 11, Issue 12

Exclusive Interview

Textile Today: Do you think Chinese policy on the environment will cause many dyeing mills to shift to countries such as India, Bangladesh, and Southeast Asia?

How does this trend impact the whole value chain?

Michael Zhou: Actually, before the policy changing chemical industries started to shift from China to other countries. So, policy-changing is not the only reason behind shifting.

Transformation is a manufacturing habit as different countries opened a new market. So, production factories location inspired the chemical manufacturers in some points. However, in China, we have an integrated supply chain, which is very important for upgrading the product structure and design to a certain level, which is the best for this continuous marketing system. I think, in future due to this type of change in the supply chain, Chinese chemical manufacturers will pay more attention to develop their ability of garments design, fashion etc. which can really make the impact on the trend of shifting in other countries very well.

Textile Today: We know Transfar has a huge products variation. Please share your products range and what new products you are going to bring in the Bangladeshi market.

Michael Zhou: Actually, we have a long range of products for various industries including textile. We are providing different types of products mainly knit dyeing dyes and chemicals, as we know that Bangladesh is very strong for knit processing. So, we are focusing right now in this segment and our products are structured in the same focus. But we are also concerned that Bangladesh woven sector is booming gradually and we have also planned for that.

We are also developing some energy saving low emission products and we want to introduce some functional products in Bangladesh market.

We also noticed that the Bangladesh

Bangladesh Textile Today |

Figure 2: (R-L) Shengpeng Wang, Technical Center Director; Youlin Fu, Vice President; Bruce Liu, Senior Sales Manager, and Amit Sarker, Technical Engineer of Transfar International Group.

government has some special policies like ‘tax-free policy’. In that case, we are developing some high solid content products and hopefully, we would be able to work here more intensively in the future.

Textile Today: Transfar Chemicals Co. Ltd. is now in the global platform along with its ideas, products, and surveys. So, what is Transfar Chemicals doing to establish ZDHC and sustainability in the textile industry?

Michael Zhou: From very beginning, Transfar Chemicals is committed and actively working for sustainability. ZDHC is one of the important commitment of our company’s roadmap and from 2014, we have associated with ZDHC. To ensure ZDHC and sustainability in the textile industry, it is very important to work all the parties in the supply chain to keep the environment safe. Of course, it is not only our responsibility, brands and manufacturers should also take responsibility. To comply with the ZDHC and sustainability standard, we are structuring our product carefully. Not only ZDHC, there are other bodies to ensure the environmental safety and we are actively working with them also.

Transfar Chemicals acts as the secretariat of Subcommittee on Textile Auxiliaries of National Technical Committee on Dyestuff of Standardization Administration of China and is a National Work Safety Standardization Grade

Volume 11, Issue 12

2 Enterprise. We are also an important member of the Textile Supply Chain Green Manufacturing Industry Innovation Alliance and other organizations. Our labs are certified by CNAS (China National Accreditation Service for Conformity Assessment).

In addition, Transfar Chemicals passed the certification of bluesign®, a Swiss certification for textiles impact on the environment and goes onto the supplier list of internationally known enterprises such as H&M. Textile Today: As we have already seen that Transfar Chemicals expanded its business in the global platform. So, how is your business growth in Bangladesh and does Transfar Chemicals has any expansion plan in Bangladesh based on the global promotion plan of an international company?

Michael Zhou: Actually, we have a different strategy and plans for the different countries based on the market situation. We are very proud to say that in Bangladesh we have a very good response from our customers. Our yearly growth is 20% which is satisfying and also in Bangladesh yearly sales volume is about 30 million RMB. In the question of expansion in Bangladesh, we are still researching on our customers and their feedbacks and assessing the prospects of the Bangladesh textile industry, we will take the decision.

93

Steam Management

Forbes Marshall solution for recovering condensate and flash steam FT Research Team Steam is an essential source of power for an industry especially when it is textile industry. Often it is seen in the factory the misuse of steam which is a direct waste of money! There is already pressure on the manufacturers that how to save money. Recovery of condensate and flash steam could save a huge amount for the industrialists and Forbes Marshall has a special solution for it.

Forbes Marshall is a leader in process efficiency and energy conservation for process industry for more than seven decades.

Innovative solutions, knowledge, reliable products and global presence in more than 50 locations made them a trusted partner. They are the manufacturer of the widest range of steam engineering and control instrumentation products including - Steam Boilers (Gas/ Oil/Solid Fuel fired), Exhaust Gas Boilers (EGB), Temperature & Pressure Control System, Condensate Recovery System, Steam Traps, Zero Leakage Piston Valves, Flow meters (for every application), almost everything related to steam and control instrumentation.

What is condensate?

Condensate is the result of steam transferring a portion of its heat energy, known as latent heat, to the product or equipment being heated. As steam loses heat and it turns back into the water, it contains 20% energy of the total steam.

This condensate water has a temperature equal to that of steam and it is basically distilled water, which is ideal for use as boiler feed water.

94

Illustrations: Benefits of Condensate Return High Feedwater temp.

Reduced fresh water

High efficency with better boiler health

Reduced Blowdown

Condensate Return

Recovering condensate reduces the fuel bill Returning condensate to the boiler feed water tank raises the feed water temperature, improving the steam to fuel ratio. This cuts the fuel consumption thereby reducing the fuel bill.

Illustration: Consider, 1 kg of feed water to be converted to steam at 5 bar g.

So, improvement of feed water temperature by recovering condensate from 30 to 90 deg C will give 10% fuel savings.

Case-1

Case-2

A Feed Water Temp.

40˚C

46˚C

B

Amount of energy in feed water

40 kCal

46 kCal

C

Steam at 5 bar g contains

658 kCal/kg

D

GCV of fuel (Natural Gas)

8700 kCal/m3

E

Amount of fuel required to produce steam, (C-B)/D

0.071 m3

0.070 m3

Table: As a rule of thumb, every 60C rise in feed water temperature saves 1% on the fuel bill.

In textile industries, there is an opportunity to recover the maximum condensate water as boiler feed water where the makeup water requirement will be negligible.

Higher feed water temperature increases the boiler output The capacity of a boiler is stated in ‘from & at’ rating which shows the amount of steam in kg/hr. which the boiler can create ‘from

Bangladesh Textile Today |

Volume 11, Issue 12

Steam Management

Oxygen & othet gases to vent

FORBES MARSHALL SULUTION OF CONDENSATE RECOVERY SYSTEM Although Flash Steam is 10~15% in mass but it Flash Steam Return connais 50% of total condensate return Condensate Deaerator Return

Cold Make up water

High Pressure Steam

Flash Vessel (FV) Pump Exhaust

Steam Trap Returned Condensate contains 20% energy of steam

Motive Steam or air supply

Reservoir Condensate Recovery System Comprises: 1. Pressure Power Pump Unit (PPPU) Pressure Power [for pumping condensate to FWT] Pump Unit (PPPU) 2. Flash Vessel (FV) [to separate flash steam from condensate] 3. Deaerator Head [for proper mixing of condensate, flash & makeup water]

& at’ 100 deg C, at atmospheric pressure. Thus, the close the feed water temperature to 100 deg C, the closer the output generated to rated capacity.

Across most of the plants the feed water temperature is rarely maintained 100 deg C. Mostly it is ambient or slightly higher than ambient. This leads to a poor steam to fuel ratio and lowers the boiler capacity.

The following formula helps to calculate the steam output from the boilerSteam output = Boiler rating (kg/ hr. x [A / (B-C)] Where, A = Specific Enthalpy of Evaporation at atmospheric pressure = 540 kCal/kg

90

Here, 500C rise in temperature in feed water increases the steam generation- 757 kg/hr.

Flash steam contains almost 50% energy Flash steam is low-pressure steam created when hot condensate water is released from a high pressure to a lower pressure within a steam system. It can be released through steam trap or blow through.

Recovering flash steam is as important as recovering condensate water. Although flash steam is very less (8~10%) in mass but it contains about 40~50% energy of the total condensate.

The following formula helps to calculate the flash steam-

C = Specific Enthalpy of Feed Water Illustration:

If, Condensate load is 3000 kg/hr.

For a 10 ton/hr. capacity boiler, at 9 bar g operating pressure

Steam Pressure is 6 bar g Flash Pressure is 0.5 bar g

Feed Water Temperature

40˚C

90˚C

% Flash Steam = 10% = 300 kg/hr.

Max. steam generation capacity

8,667 kg/hr.

9,424 kg/hr.

Flash steam should be recovered to the feed water tank or it can be used in somewhere else.

96

100

Float Trap

% of Flash Steam = [(Enthalpy of Fluid * steam press. – Enthalpy of Fluid * Flash Press.) / (Enthalpy of Vapor * Steam Press. - Enthalpy of Fluid * Flash Press.)]

B = Specific Enthalpy of Steam at operating pressure

Feed Water Tank (FWT)

Other benefits are•C ondensate water is free from TDS (total dissolve solid) and it reduces the requirement of blowdown thereby curtailing blowdown losses.

•C ondensate does not need to undergo water treatment and thus saving water treatment cost.

•R ecovering condensate reduces the cost for oxygen scavenging chemicals, since the improved temperature reduces the amount of dissolve oxygen mostly.

•U sing Flash Condensing Deaerator Head helps to mix the condensate & flash steam with makeup water and reduce the oxygen and other gases from the feed water.

Forbes Marshall has a complete solution for condensate & flash steam recovery system with their Pressure Powered Package Pumping Unit (PPPPU) which is one of the most efficient way of recovering condensate. It does not need any storage and electrical pump. More than 350 installations of Forbes Marshall Condensate Recovery Units are there in different textile industries in Bangladesh.

Bangladesh Textile Today |

Volume 11, Issue 12