Reducing water and energy consumption in chemical industry by sustainable production approach: a pilot study for polyethylene terephthalate production

Alkaya, Emrah
Demirer, Göksel Niyazi
In this study, a polyethylene terephthalate manufacturing plant was subjected to environmental performance evaluation and analyses/benchmarking of water consumption. The objective was to determine processes/practices where significant water and related energy saving potential was present. Based on evaluations and analyses, a technology change was realized in heat transfer systems from water-to air-cooled process. As a result of the applications, soft cooling water consumption of the company was reduced by 46.7% which corresponds to water saving of 151,428 m(3)/year. Moreover, 117,848 kWh/year of energy was saved due to electricity saving in electric motors of pumps of heat transfer systems as well as pumps/fans of cooling towers. Owing to the improved energy efficiency, total carbon emissions of the company was reduced by 69,530 kg CO2/year. Auxiliary material consumption was also reduced since the maintenance requirements of heat transfer pumps were minimized. The total cost saving was 104,905 $/year, while the payback period was calculated as 6 months. This study was conducted to be used as a successful model to increased water and energy efficiency in manufacturing industries based on systematic environmental performance evaluations and benchmarking. Furthermore, it could serve as a building block in Turkey for the integration of cleaner and sustainable production approach into national agenda which is currently being structured by the European Union harmonization efforts of this country.


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The aim of this study was to investigate water conservation and reuse opportunities in a soft drink/beverage manufacturing company. Water use analysis and benchmarking were carried out to determine the areas and processes where significant water saving potential is present. Based on evaluations, water recycling and reuse practices were realized in cooling systems. As a result of applying these practices, the total specific cooling water demand of the company was reduced from 14.4 to 1.2 m(3)/m(3) product or...
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The objective of this study was to investigate the climate change adaptation opportunities of six companies from different sectors through resource efficiency and sustainable production. A total of 77 sustainable production options were developed for the companies based on the audits conducted. After screening these opportunities with each company's staff, 19 options were selected and implemented. Significant water savings (849,668 m(3)/year) were achieved as a result of the applications that targeted reduc...
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The present study was undertaken as the first plant scale application and evaluation of Best Available Techniques (BAT) within the context of the Integrated Pollution Prevention and Control/Industrial Emissions Directive to a textile mill in Turkey. A "best practice example" was developed for the textile sector; and within this context, BAT requirements for one of the World's leading denim manufacturing textile mills were determined. In order to achieve a sustainable wastewater management; firstly, a detail...
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Ozturk, Emrah; KÖSEOĞLU, Hasan; KARABOYACI, Mustafa; YİĞİT, Nevzat Özgü; Yetiş, Ülkü; KİTİŞ, Mehmet (2016-12-01)
Cleaner production assessment studies were carried out according to the Integrated Pollution Prevention and Control and Industrial Emission Directive in a cotton/polyester fabric finishing-dyeing textile mill, located in Denizli, Turkey. Following detailed on-site process evaluation, environmental performance of the mill was evaluated. Data of the material flow and the energy consumption in all processes was collected. Mass-energy balances and specific input and output values based on the production process...
Citation Formats
E. Alkaya and G. N. Demirer, “Reducing water and energy consumption in chemical industry by sustainable production approach: a pilot study for polyethylene terephthalate production,” JOURNAL OF CLEANER PRODUCTION, pp. 119–128, 2015, Accessed: 00, 2020. [Online]. Available: