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Water Saving Processes for Textile Production (WASATEX)

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The WASATEX project uses an innovative combination of well-tested technologies in water treatment that allows the re-use up to 90% of water treated with Wasatex technology, in any part of the industrial processes.  This allows a significant savings in water itself, in costs associated to its discharge and to incoming water. A further reduction of environmental impact is due to a lower consumption of natural resources to heat the incoming water (because the re-used water has a temperature of 30°C against 15°C of well water), with a consequent fewer gaseous emissions and a cost saving related to fuel.For the execution of the Wasatex project was chosen the production plant in Osjek- Croatia of group Benetton Tekstil (the Benetton group production and distribution branch for Croatia), which currently re-uses in production processes only 5-10% of water, treated only with a biological plant and standard clarifier.However, the system has substantial potential of exploitation, addressing the needs of the textile industry, and being re-adaptable to other water intensive productions such as paper, tannery or the agro-food sector.

Benefits

  • Through recycling of treated water for industrial processes, it is possible to obtain a Net Saving cost of about 42%, mainly due to a reduction in the consumption of primary water and natural gas
  • The reduction of environmental impact is summarized in a water conservation of 64% and a lower production of C02 of 50% due to lower demand of natural gas for heating water
  • Aslo using of recycled water facilitates dyeing and finishing, as well as the replicability of the dyeing processes
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Results

  1. 90% of water reuse: The main objective of Wasatex is to save water. Consumption is immediately reduced: the plant used 1,600 m3/day of water of which only 10.5% was coming from recovery treatments. Today the percentage of reused water rose to about 62%, or 1,000 m3/day. About 1000 m3/day leass water is drawn from the well. Potentially the plant can reach a level of water reuse of 90%.
  2. Less energy: Saving water also saves energy related to its heating thereby reducing CO2 emissions. The recycled water has an average temperature of 30° C, against a well water temperature of 15° C; you will get an energy saving since the boiler will heat the water up to the operating temperature, starting from a temperature of 30° C instead of 15° C.
  3. Less CO2 equivalent: Whereas CO2 emissions of natural gas burned amount to 2,276 g / Nm3 and that now there is a reduction of natural gas consumption of 949 Nm3 / day, the CO2 emissions will be reduced by approximately 2160 kg CO2 / day, equal to 648 tons of CO2 / year.
  4. Less running costs, sustainability pays off: With the new plant savings related to operating costs will reach almost 400,000 €/year.
  5. Using recycled water is not only good to the environment because the Second Life water has chemical characteristics that facilitate dyeing and finishing, as well as the replicability of the processes:
  • It is technically perfect and stable. There are seasonal variations in the characteristics of the water in salt content; This avoids dyeing recipes adjustments throughout the year, ensuring colour replicability,
  • The yarns and fabrics colors are more stable, both to rubbing and to light and thanks to the absence of salts are more brilliant,
  • Dyeing processes use less chemicals such as soaps, sequestrants and equalizers,
  • Less re-dyeing processes are needed due to shade variations caused by water quality.
  • We can therefore say that fibres subject to processes suffer less from aggressive chemicals and are therefore softer and have more resistant colours.
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Partners and coordinator

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Contact

ASPEL SRL
Via Albano Seguri 6
46100 Mantova
Italy
Contact point: 
Name: 
Diego Cornacchia

Budget

In brief

Sector:
Water
Duration:
01/07/2014 to 31/12/2016
Contract number: 
ECO/13/630322

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