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Research Detail

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Md. Sazzadul Haque
Corresponding author:
Department of Civil and Environmental Engineering, North South University, Dhaka, 1229, Bangladesh

Nazmun Nahar
Corresponding author:
Department of Civil and Environmental Engineering, North South University, Dhaka, 1229, Bangladesh

Sayed Md. Sayem
Corresponding author:
Department of Civil and Environmental Engineering, North South University, Dhaka, 1229, Bangladesh

In the industrial sector of Bangladesh there is a lack of standardized mechanisms to account for water incorporating both efficiency and sustainability. With the growing number of textile industries that rely heavily on groundwater, there is a desperate need for efficient water management at the process level as well as groundwater conservation for safe manufacturing operations. This current study particularly emphasizes on the groundwater withdrawal and use in different units of the wet processing facility of a textile industry. Two years’ operational water use data was utilized to develop “Sustainable Industrial Water Projection (SIWP)” tool for water management for the studied textile which also estimates the potential groundwater volume that can be conserved. Moreover, energy and economic benefits are analyzed through the saving in electricity associated with the pumping cost of groundwater abstraction and softwater production in water treatment plants.

  Conservation, Groundwater depletion, Industrial water, Processing facility, Textile industry, Groundwater abstraction, Water management tool
  Rupganj area under Narayanganj district, Bangladesh
  00-00-2009
  00-00-2009
  Crop-Soil-Water Management
  Water management, Groundwater

To establishes a functional relationship between the input and output of the wet processing facility,  and to better quantify the distribution of water among different units and finally promotes conservation of groundwater.

General information about the textile industry: A textile industry located at Rupganj area under Narayanganj district (about 26.0 km away from Dhaka City) was selected for the current study. This industry began its journey to the RMG sector in 2009. The industry manufactures both woven (shirts, women wear, pajama or trousers) and knitted (tee shirts, polo shirts, knit and infant wear) fabrics. The total area of this manufacturing industry is approximately 30,000 m2 and it has nearly 12,000 staffs. The average daily production and embroidery capacity is recorded as 150,000 and 110,000 pcs per day,1 respectively. Moreover, the industry’s knitting and dyeing capacity is of 25 tons per day, respectively. The textile industry produces different types of knit fabrics such as single jerky, interlock, pique, drop-needle, french terry and lacquered knit. In order to manufacture such fabrics, the industry uses cotton, polyester, viscose, organic cotton and mixed composition of cotton (i.e., poly cotton, poly viscose, etc.). Like other textile industries of Bangladesh, this industry uses both yarns and raw fabrics as the raw material. Typically, in the textile manufacturing facility, imported yarn is first turned into raw fabric through warping followed by the weaving. After completion of weaving, raw fabric is used in dyeing followed by the procedures such as singeing, desizing, scouring, bleaching and mercerizing. After completion of the dyeing process, the prepared fabric goes through finishing and finally the “finished fabric” is produced shows the typical processes used by the RMG sector of Bangladesh in manufacturing finished fabrics. Water consumption details: The most water-intensive facility of textile industry is its wet processing unit. In this unit, water is used for dyeing, washing, printing, finishing and other processes depending on the industry’s production pattern, equipment and nature of dyes used. Water is mainly treated as a solvent for the processing of chemicals, washing and rinsing medium, and also utilized in ion exchange, boiler operation, cooling facilities, steam drying, pressing and cleansing processes. To supply the fresh water in the wet processing unit, textile industries use both surface and groundwater as the principal sources. In some instances, rainwater harvesting system has been introduced for the supplementary supply of water. The studied industry uses groundwater as the main source of water and extracts water using three deep wells with three submersible pumps to fulfill the daily production and domestic consumption demand. The daily groundwater abstraction capacity of the submersible pumps is about 6,240 m3 and the extracted groundwater is reserved in the underground raw water reservoir with a tank capacity of 6,500 m3. Reserved raw water cannot be used directly in the wet processing unit due to the hardness (i.e., Ca++, Mg++) of the raw water, which is further softened through three water treatment plants (WTPs). The three water treatment plants have a capacity of 60 m3/h (WTP-1), 80 m3/h (WTP-2) and 100 m3/h (WTP-3), respectively. The generated softwater is supplied to the underground softwater reservoir which has a tank capacity of 6,500 m3 and used in the industry’s wet processing facilities including dyeing, washing, finishing, and other utilities. Since no recycling is performed, the used chemical-loaded softwater is then supplied to the industry’s effluent treatment plant (ETP) and treated wastewater is discharged to the nearby government-maintained canal. Data collection and analysis: Daily water consumption data for different processes of the wet processing facility for the years of 2018 and 2019 were collected. This raw data includes daily groundwater abstraction, water use in different wet processing units, domestic use, receiving wastewater volume in the ETP and daily discharge amount of treated effluent. The data were arranged in a database that shows the daily records of water abstraction and use in different processes for each month of a year. A sample of the received raw data is given in Appendix A. Prior to developing the water management tool, the received daily data were processed and a new database was created for the groundwater abstraction, softwater production, and water use in different wet processing units. The data processing involved identification and removal of erroneous data and replacement of ‘missing’ data using linearly projected values based on past records.

  Water Resources and Industry 25 (2021) 100145
  https://doi.org/10.1016/j.wri.2021.100145
Funding Source:
1.   Budget:  
  

An effective water management solution can be achieved across the textile industries using better knowledge about the water usage in different facilities of the manufacturing process. The SIWP tool has demonstrated its efficient accounting capability. The techniques that have been used in developing the tool demonstrate the minimization in groundwater over extraction and ensure groundwater conservation (156,763 m3 groundwater per year) together with energy saving and economic viability (i.e., 13,367 KWh and 153,173 BDT annual savings from pumping operation and electricity cost, respectively). Thus, the current study will serve as a prospective step towards meeting the “greener concepts” of the textile industries of Bangladesh as the development of the SIWP tool is embedded with the goal of sustainable production and consumption. The techniques that have been employed in this study to prepare the SIWP tool can be used for other textile industries of Bangladesh. The SIWP tool is cost effective and has shown significant potential in solving the ongoing problem of groundwater table decline in Dhaka city. Future studies can incorporate a comprehensive water usage details for a cluster of textile industries and develop separate SIWP tools for each industrial cluster. Furthermore, the SIWP tool can be used in assessing the performance of sustainable development goals (SDGs) in terms of water consumption in production and energy saving across the textile industrial settings of Bangladesh.

  Journal
  


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