An environmental strategy for medium scaled synthetic leather manufacturing facility

Abstract

Environmental friendly production through industries has become one of the most favorable necessities in recent years due to gradually increasing environmental concerns. It is a fact that the old manufacturing facilities, which are the initial step of environmental pollution, are lack of environmental technologies. By taking this into consideration, in this study, the effects of a medium scale synthetic leather facility on the environment were evaluated before and after the application of the proposed strategy to show the improvements in water consumption, waste generation, energy consumption, and the emissions. The results of the study showed that the implementations of the proposed strategy minimized the effects of the focused synthetic leather facility on the environment. In the facility, the dye preparation unit was separated from the process line to prevent of extra water consumption and indoor pollution. In line with energy audits the water leakage points were determined and the facility’s conventional taps were replaced with the photocell basin taps to reduce the water consumption for the domestic usage. All of these improvements in the water consumption systems led to a 38,5 % reduction of in the water consumption rates. In order to minimize energy consumption, energy audits were started by the facility. The audits determined energy consumption and energy loss points and captured a picture of the operations which caused waste in energy. The major energy consuming equipment and their energy efficiencies were identified. Lightning systems were supported by multiple glazing windows and mercury containing fluorescent lighting replaced with energy saving LED lighting, or high-pressure sodium or ceramic metal bulb lighting. All of these energy audits and the improvements enabled a reduction from 812.574kwh/year to 569.963kwh/year and led to a 30% reduction in the energy consumption rates. The synthetic leather facility had no waste management plan and all types of wastes were collected together. In order to separate collection of the hazardous wastes and non-hazardous wastes, waste management plan and a separate collection were put into practice at the facility. Through the waste management policy; the waste was collected based on its type. The reuse of waste in production cycles as secondary raw material was started. Waste was disposed of by licensed companies, and waste management training for employees were also given in the synthetic leather facility. Both the generation of the waste itself as well as effects of the disposed waste on the environment were minimised. While the synthetic leather facility’s emission measurement results did not exceed the limit values, the odour level was high throughout the facility. The VOC emissions were creating this pervasive odour. Furthermore, indoor air emissions were at the harmful level according to occupational health and safety. The synthetic leather facility did not have a ventilation system or effective emission collection system. The door and window systems were the only source of ventilation. The facility’s emissions were not under control. For controlling the system emissions and reducing the low – value VOCs; waste gas collection and combustion systems, and the new ventilation systems were installed. Since these improvements, the synthetic leather facility does not have any reduction in the waste gas, but indeed, it started to prevent high level of indoor air pollution. Another result is that the facility has had huge odour reduction efficiency approximately 78%. When the by-pass stack flue gas and combustion system analysis results are compared, there is an emission reduction efficiency of around 98%. After the all emission systems’ improvements, waste gas emissions and their effect on environment have been brought under control.