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Pollution Prevention and Waste Management
  • Air Pollutant Discharge Management
  • Wastewater Discharge Management
  • Waste Management

FENC established air pollutant reduction plan in 2018 and devoted ongoing efforts in treating pollutants created during the production process through pollution prevention and control equipment.

The Company examines existing facilities and reviews the production process on a regular basis. The boilers and exhaust system also undergo regular inspection to ensure all emissions are within regulatory requirement.

In November 2018, China International Import Expo was held in Shanghai. The event took place during winter, a period when smog reached the peak. Hence, the local government placed stringent control over corporate air pollutants. OPSC and FEIS responded to the government mandate and carried out annual maintenance in November. In the case of severe air pollution, the plant temporarily discontinues operations that are prone to generate dusts, and reduces transport vehicles by half to reduce air pollutant.

In 2018, Taiwan and China amended regulations governing the discharge of NOx. The amended Boiler Air Pollutant Emissions Standards stipulates that the NOx concentration of all existing boilers must be capped under 100ppm prior to July 2020. The amended Shanghai Emission Standard of Air Pollutants for Boilers requires that NOx concentration for boilers must be lower than 50ppm before September 2020. To comply with the regulatory requirements, all production sites modified the production process and added equipment to lower NOx emission. Hsinpu Chemical Fiber Plant and Kuanyin Chemical Fiber Plant invested approximately NT$120 million to install Selective Catalytic Reduction (SCR) System for denitrification. SCR allows NOx and ammonia to mix through a special catalyst, and converts the mixture into innocuous nitrogen and water. The system is expected to reduce 70% of NOx in the coal water slurry. The 4 sets of equipment were fully installed in 2018 and the 6 sets in Hsinpu Chemical Fiber Plant are expected to be installed by 2020. Hukou Mill plans to replace oilfired boiler with electric steam humidification system, which will reach zero NOx and SOx emission.Construction is planned to commence in 2019.

Regulations governing production tail gas are increasingly stringent in China. In 2018, OTIZ installed 2 regenerative thermal oxidizers, which decompose volatile organic compounds (VOC) into water vapor and CO2 with approximately 95% removal efficiency. FEDZ is expected to add the 4th smoke purification system for the forming machine to reduce VOC with 90% removal efficiency. Two additional sets will be installed in 2019.

►Air Pollution Emission in 2018

►Air Pollution Emission 

Unit: metric tons
Business Petrochemical Polyester Textile Total
Year 2016 2017 2018 2016 2017 2018 2016 2017 2018 2016 2017 2018
Type
NOX 167  161  131  750  854  713  34  26  10  952  1,041  854 
SOX 123  125  56  153  153  162  284  284  219 
VOC 87  103  108  339  324  349  16  20  443  447  464 
Particulate Pollutan 113  38  46  23  21  19  138  61  68 
Total 380  391  299  1,356  1,369  1,271  80  73  37  1,816  1,833  1,607 

Note:

  1. Only gases emitted are listed.
  2. Particulate matter pollutants include PM, dust and smog.
  3. The data includes four types: actual measured values, annualized sample values, calculate values, and permitted amounts of emissions. Actual measured values come from Hsinpu Chemical Fiber Plant (NOx, SOx, particulate pollutant), Kuanyin Chemical Fiber Plant (NOx, SOx, particulate pollutant), FEFC, the second plant of OPTC (VOC, particulate pollutant), OPSC (NOx, SOx), WHFE, FEIW, FEDZ and FEAZ; annualized sample values are from OPSC (VOC), Kuanyin Dyeing and Finishing Plant, FEIS and FEAV; calculated values are from the first plant of OPTC, the second plant of OPTC (NOx, SOx), Hsinpu Chemical Fiber Plant (VOC), Kuanyin Chemical Fiber Plant (VOC), Hukou Mill, Neili Texturizing Plant and FEIZ; permitted amounts of emissions are from OTIZ.

In 2018, emission of air pollutants decreased significantly with 12% reduction comparing to the previous year, and 15% decrease per metric ton of air pollutants (equivalent of 0.05 kg/ton). The decrease in emission is universal across all business units, and so is pollutant emission per unit of production. Reduction from the Petrochemical Business is mainly attributed to the second plant of OPTC, which adopted an eco-friendly production process. The move reduced air pollutants significantly. Reduction from the Polyester Business is contributed greatly by Kuanyin Chemical Fiber Plant, which installed denitrification system and reduced NOx as a result. Kuanyin Dyeing and Finishing Plant switched from oil-based ink to water-based ink, which reduced VOC emission and tremendously reduced air pollutants for the Textile Business. The closing of FEIZ also contributed to the decrease in air pollutants.

►Air Pollution Emission per Unit of Production

Unit: KG / metric ton of product

Note:The Textile Business does not include FEAZ and FEAV.

FENC has comprehensive guidelines and operational procedure in place for wastewater treatment. Pollutants are treated according to the procedure with regular testing on wastewater quality to endure regulatory compliance on effluent water quality. The Company also obtains industrial wastewater discharge permit in accordance with regulatory procedures prior to discharging treated wastewater into water bodies where discharge is permitted. In addition, we strengthen wastewater recycling to increase the volume recycled and truly fulfill the recycling and reuse of resources. The wastewater from FENC is not utilized by other organizations, and there was no occurrence of leakage in 2018.

In 2018, Hsinpu Chemical Fiber Plant started constructing separated sewage system. Rainwater and wastewater are collected through separate pipes, which reduce wastewater discharge. The project is expected to be completed in 2019, reducing wastewater discharge by 109,500kL/year. FEIS installed oil water separator, which divides the mixture of oil and water into separate compounds. The pure water separated from the oil may be recycled and reused with condensed water, which also reduces wastewater discharge. The system began operating in 2017. In 2018, wastewater discharge reduced by approximately 29,700kL. Kuanyin Dyeing and Finishing Plant asked the suppliers to provide toxin-free solvent in 2018, making it easier to treat wastewater and increase the volume of recycled water that can be reused.

Wastewater Management

Wastewater Sites and Volume

Unit: 1,000 kL
Business Production 
Site 
Wastewater Volume Wastewater Treatment Method and Discharge Location
2016 2017  2018
Petrochemical OPTC 2,571  2,179  3,023  Wastewater goes through biotreatment (deep shaft aeration and anaerobic treatment) within the plant. Once the water quality meets the effluent standards, it is discharged into Shulin River and Dajyue River.
OPSC 1,347  1,423  1,463  Wastewater is treated within the plant until meeting the required standards, and then discharged through the municipal pipelines to Fengxian District East Wastewater Treatment Plant. Once fully treated, the wastewater is discharged into the Hangzhou Bay.
Polyester Hsinpu Chemical Fiber Plant 1,025  907  1,082  Wastewater goes through biotreatment within the plant. Once meeting effluent standards, it is discharged into Fengshan River.
Kuanyin Chemical Fiber Plant 439  394  430  Wastewater goes through biotreatment within the plant. Once meeting effluent standards, it is discharged into Shulin River.
FEFC  99  98  97  Industrial and domestic wastewater goes through biotreatment (contact oxidation) and sedimentation within the plant. Once the water meets the effluent standards, it is discharged into Shulin River.
FEIS 651  669  650  Wastewater is treated within the plant until meeting the required standards, and then discharged through the municipal pipelines to Fengxian District East Wastewater Treatment Plant. Once fully treated, the wastewater is discharged into the Hangzhou Bay.
WHFE 12  13  13  Treated in the wastewater treatment facility within the plant first, the wastewater then goes through the municipal wastewater treatment facility. Once fully treated, the wastewater is discharged into the Yangtze River.
Textile Kuanyin Dyeing and Finishing Plant 545  497  485  Wastewater is treated in house, discharged to the wastewater treatment plant in the industrial park for further treatment, and then discharged into Shulin River.
Neili Texturizing Plant 110  63  45  The plant obtains the permission to discharge wastewater directly into the drainage ditch within the plant, which connects to Taoyuan Canal.
Hukou Mill 74  72  62  Wastewater goes through biotreatment (oxidation and aeration) within the plant and then discharged into Desheng River.
OTIZ 138  239  368  Wastewater is treated within the plant until meeting the required standards, and then discharged through municipal pipelines to Hedong Wastewater Treatment Plant. Once fully treated, the water is discharged to the Jing-Hang Grand Canal.
FEIZ 11  25  - FEIZ has closed down in 2018.
FEIW 73  70  63  The wastewater goes through Wuxi municipal sewage pipelines to the wastewater treatment facility. Once treated, the water is discharged into the Jing-Hang Grand Canal.
FEDZ 2,474  1,965  1,498  Wastewater is treated within the plant until meeting the required standards, and then discharged through municipal pipelines to Hedong Wastewater Treatment Plant. Once fully treated, the water is discharged to the Jing-Hang Grand Canal.
FEAZ 93  88  85  Wastewater is treated within the plant until meeting the required standards, and then discharged through municipal pipelines to Chengnan Wastewater Treatment Plant. Once fully treated, the water is discharged to the Jing-Hang Grand Canal.
FEAV 76  71  74  The wastewater is treated at the treatment center within the industrial park and then discharged to Saigon River.
Total  9,739 8,773  9,438  

Note: 

  1. The difference between wastewater discharge and withdrawal are mainly attributed to evaporation at the cooling tower. There is also loss of water during the production process.
  2. There is no significant impact from wastewater discharge on the water bodies and related habitat.
  3. Wastewater at OPSC includes wastewater from the manufacturing process, domestic wastewater, lab wastewater and wastewater from the cooling tower; wastewater at Hsinpu Chemical Fiber Plant, FEFC and FEIS is from the manufacturing process, cooling tower, domestic wastewater and cleaning water; wastewater at WHFE and FEDZ is from the manufacturing process, domestic wastewater and lab wastewater; wastewater at Kuanyin Dyeing and Finishing Plant, OTIZ and FEIZ is from the manufacturing process and domestic wastewater; wastewater at OPTC and Kuanyin Chemical Fiber Plant is from the manufacturing process and the cooling tower; wastewater at Neili Texturizing Plant, Hukou Mill, FEIW, FEAZ and FEAV is from domestic wastewater.
  4. Calculation of wastewater at Hukou Mill also includes the Biomedical Business Unit of Oriental Resources Development Limited.

Wastewater Volume per Unit of Production

Unit: kL/metric ton of product

 

Note:The Textile Business does not include FEAZ and FEAV.

The 2018 discharge is higher than the previous year mainly due to increase in production capacity at OPTC and higher production at OTIZ. Increased water consumption during the production process led to increase in wastewater. An analysis of the increase in wastewater per unit of production in Taiwan indicates that the main contributing factor is product restructuring at Hsinpu Chemical Fiber Plant and OPTC.

FENC established waste reduction goals in 2018 and reinforced waste management. We continue to introduce new production process and equipment to reduce waste from the very beginning. Meanwhile, the Company strives for raising the percentage of reused recycled waste in the manufacturing process. All waste treatments meet regulatory requirements, including the permit application, quantity reported, the hiring of qualified professional waste management companies for waste disposal. The guiding principle for waste management is “classification for reduction; converting waste into earnings; transforming earnings into valuables”. Production units strictly enforce waste classification. Procurement Department sells waste with monetary value to external organizations, which will then recycle or reuse the waste. Those without monetary value will be handled by waste management companies with proper qualifications. We scrutinize these companies with stringent standards, inspecting the waste disposal randomly with GPS tracking. However, rising waste treatment costs and lower return have made recycling disincentivizing for these companies. Hence, FENC tackles waste reduction from the source and fully implement waste classification to reduce waste. The Company works with R&D to develop alternatives for waste materials that cannot be reintroduced into production cycle. All hazardous waste is stored in designated sites and then processed by qualified companies. FENC also conducts random checks by following the waste collecting trucks to ensure compliance.

In recent years, an emphasis on wastewater treatment led to increase in sludge. Hence, the Company initiated a series of sludge reduction projects. In 2015, Hsinpu Chemical Fiber Plant led the way by introducing the sludge drying system. Sludge drying system reduces the moisture content in sludge. Seeing remarkable results, OTIZ and Kuanyin Chemical Fiber Plant also installed the system in 2016 and 2017, respectively. The newly installed system, once in operation, reduces the moisture content in sludge down to 25-40%, which would reduce waste treatment costs by NT$12.24 million per year. In 2018, FEDZ installed 2 sludge dryers with plate and frame filter press, which may reduce the moisture content in sludge down to 70-75% through high-pressure dewatering, and lower sludge discharge by 45%. Kuanyin Chemical Fiber Plant installed upflow anaerobic sludge bed in 2018, which reduces sludge in wastewater through organic redux reaction with microorganisms.

All production sites continue to optimize waste management and actively promote waste classification and recycling. Hsinpu Chemical Fiber Plant has designated Wednesdays as the recycling day to help employees develop the habit of waste classification. FEIW focused on kitchen waste in 2018 and commissioned professional waste management companies with qualifying credentials to handle kitchen waste, and ensure that the entire process is harmless to the environment. FEAV introduced the waste management system, which aims to classify waste for data management, analysis and query. The system is set to begin in 2019.

►Type of Waste and Percentage of Recycling and Reuse in 2018

►Data of Waste

Unit: metric tons
    2016 2017 2018
General
Business
Wastes
Manufacturing
Process
Wastes
 Recycling and Reuse 75,263  79,140  80,194 
 Energy Uses 207  8,334  5,939 
 Incineration 8,854  5,700  6,046 
 Landfilling 339  475  1,089 
 Other Treatment Methods 871  1,151  1,581 
 Subtotal 85,534  94,791  94,849 
 Domestic
Wastes
 Recycling and Reuse 2,417  2,397  3,055 
 Energy Uses 340  340  368 
 Incineration 1,102  1,369  1,374 
 Landfilling 365  352  333 
 Other Treatment Methods 110  110  110 
 Subtotal 4,334  4,568  5,240 
 Total General Business Wastes 89,868  99,368  100,089 
Hazardous
Business
Wastes
 Recycling and Reuse 2,538  3,860  3,702 
 Energy Uses  413 
 Incineration  872  1,267  774 
 Landfilling 
 Other Treatment Methods 66  109  22 
 Total Hazardous Business Wastes 3,476  5,236  4,911 
 Total 93,344  104,594  105,000 

Note:Recycling and reuse includes recycling and reuse by the plants, selling of waste materials, and recycling by commissioned contractors.

►Waste Volume per Unit of Production

Unit: KG/metric ton of product

Note:The Textile Business does not include FEAZ and FEAV.

The volume of waste generated in 2018 is close to the previous year. Waste generated per unit of production decreased by 3% (the equivalent of 0.7kg/ton) comparing to 2017. The percentage of recycled and reused waste out of total waste increased by 1% in 2018.

 Collaboration with Supply Chain, Turning Recycled PET Shrink Film into Imitation Wood Products

FENC produces PET shrink film, which is then further processed by the downstream printing houses. Typically, the scraps from the printing houses are incinerated. In order to create new values for customers and help them reduce waste, Hsinpu Chemical Fiber plant provided an alternative for the manufacturer of imitation wood products by using recycled PET shrink film. The Company also provided technological support on recycling.

This project started in 2016. With multiple testing on the product, the effortsfinally came to fruition when the Company successfully developed imitation wood made with recycled PET shrink film. The hardness of this product is superior to that of other plastic materials. In 2018, the Company successfully produced imitation wood flooring that is used in the vicinity of Zaociao Railway Station in Miaoli County using. The project required 15 metric tons of recycled PET shrink film. It is estimated that demand for recycled PET shrink film in 2019 will reach 300 metric tons.

The recycle and reuse technology, which is a core to FENC, is applied in this project. In addition to solving waste treatment issues for customers, this technology brought new business opportunities for the manufacturers of imitation wood. This project is the quintessential exemplification of circular economy, creating win-win for FENC and its partners.

 

 Optimization of Waste Recycling System

At Kuanyin Chemical Fiber Plant, scraps and PET chips that do not meet quality standards are treated and remanufactured. In 2018, Kuanyin Chemical Fiber Plant replaced the single screw extruder with twin-screw and added the vacuum system. This adjustment increased processing capacity by more than 3 times, which increased production efficiency. The adjustment also increased the recycled waste by 5,100 metric tons per year, reduced energy consumption by 563,000 kWh per year, and decreased GHG emission by 312t-CO2e per year.

Note: The emission factor for the calculation of GHG emission of electricity is 0.554 t-CO2e/1,000 kWh

 

 Installing Modified Upflow Anaerobic Sludge Bed

In 2018, Kuanyin Chemical Fiber Plant installed modified upflow anaerobic sludge bed (UASB) to treat wastewater. The anaerobic organism turns the organic materials in the wastewater into methane and CO2, which reduces the total organic compounds. Different from the activated sludge process, which utilizes aerobic organism, the anaerobic organism does not require aeration. The process requires less energy and generates less sludge. Methane produced during the process can also be captured and reused. During the year 2018, one UASB was added to Kuanyin Chemical Fiber Plant, and the system treated 98,600 kL of wastewater per year, reducing approximately 120 metric tons of sludge per year.

 

 

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