Resource efficiency
Sanko Tekstil: Sanko Tekstil operations under the Project scope include yarn production, dyeing and recycling facilities.
Sanko Tekstil recycles post- and pre-consumer textile materials for yarn production. Today’s yearly capacity of 80k tons will be scaled up to 200k tons/year by the end of 2024. The new recycling facility in Gaziantep will meet the growing circularity need of the textile market and enhance Sanko Tekstil’s recycled fiber engineering. Around 30 percent of cotton fibers are recycled. Sanko Tekstil’s target is to produce yarns with up to 100 percent recycled fiber content with open-end spinning technology. The expansion of spinning capacity is planned to be increased from 250 to 400 tons/day. Pet bottle recycling unit produces polyester flakes and chips which can be melt spun into fibers. The solar PV installation is expected to replace 20 percent of the electricity demand. Sanko Tekstil cooperates with Turkish cotton farmers and ginners in organic and regenerative cotton farming and owns about 100 hectares of farmland for experimenting organic cotton farming and increasing harvesting efficiency.
The “Smart Factory” initiative was started two years ago for the digitization of management and control of productivity, energy use, and quality. The energy intensity of the new line is expected to be around 10 percent below the industry average of approximately 3.50-4.00 kWh/kg. Sanko Tekstil commits to meeting EDGE or LEED certification criteria in the greenfield ring spinning mill in Gaziantep.
Super Film: Super Film’s existing Gaziantep plant produces BOPP, BOPET and cast PP films with approximately 140,000 tons/year capacity production.
Electricity which is used in production, air conditioning, and lighting is supplied from the national grid. The total annual consumption of the existing plant is 72,202,670 kWh in 2022. Natural gas and coal are used for heating systems, the total annual consumption of the plant is 328,820 m3 and 12,919 tons, respectively, in 2022. The thermal oil heater with the fluidized bed combustion system utilizes 0-10 mm fine coal and circulates 90 tons of thermal oil at 250 0C in a closed system. As part of the continual improvement principle of ISO 50001, Super Film’s Gaziantep plant has developed a robust energy management initiative which has produced over 150 implemented improvements in energy efficiency since 2016 (close to 10 percent energy efficiency improvement), with more than 50 under implementation. Energy efficiency projects include the replacement of the chiller, heat recovery, condensate cleaning system, replacement of old motors and pumps with energy efficient ones, extrusion melt isolation etc.
The greenfield plant in Kirklareli will have 60,000 tons annual production capacity of BOPP. The plant utilizes Best Available Technology (BAT) from leading vendors (the main supplier is Bruckner) including the use of recycled PET plastic to boost material circularity, reducing the need for virgin PET. Super Film cooperates with resin producers, converters, and FMCG (Fast Moving Consumer Goods) companies to develop recyclable solutions and higher use of recycled content. The new BOPP line is estimated to consume 15 percent less energy than the existing facility in Gaziantep. Natural gas will be used for heat generation. Electricity consumption is estimated at 55,000,000 kWh and will be supplied by the national grid.
Super Film commits to meeting EDGE or LEED certification criteria in the greenfield plant in Kirklareli.
Cimko: The upgraded WHR plant, alternative fuel arrangements (e.g., waste tires, used oils, refuse derived fuel from textile and pulp industries, WWTP dewatered sludge) with mechanical waste feeding systems, and energy efficiency measures (ceramic ball usage, cement mechanical dispatch system) will reduce the total amount of primary fuel (coal) needed in cement production, while the solar PVs will reduce the amount of grid electricity used. Cimko has reported its target to reach 60 percent use of alternative fuels by 2030 in its Narli plant. Operation of existing RDF facility located in the Narli plant has direct impact of reduction of the current fossil fuels use. The RDF facility has operational license which includes criteria for waste acceptance with the minimum calorific value of waste and maximum concentration levels of specific pollutants.
Cimko has also its water-saving initiative which aims at minimizing the water use. For instance, in its Narli plant, 54,000 m3/year of water is saved by harvesting stormwater for cooling purposes of cement mills.
Green House Gas (GHG) emissions
The project’s total carbon footprint, direct (Scope 1) and indirect (Scope 2) emissions, is estimated to reach 2.71 million tons of CO2-eq annually. The majority of the project emissions will come from cement production (i.e., Cimko Narli plant), corresponding to 2.64 million tons of CO2-eq annually. It will be followed by the emission of 35,750 tons of CO2-eq at Sanko Tekstil and 34,000-ton CO2-eq at Super Film’s Kirklareli plant, annually. The new textile recycling plant in Gaziantep will be emitting 4,930 tons of CO2-eq annually.
Majority of emissions of Cimko’s Narli plant emissions, ca. 69 percent, will be non-energy process emissions occurring in the clinker production process. For the rest of the facilities, electricity use is the dominant source of emission. Thanks to energy efficiency improvements in Cimko’s Narli plant and solar PV plant installations in various capacities at the project facilities; annual net emissions of the project will be negative, -121,300 tons of CO2-eq.
The companies will continue monitoring their direct GHG emissions in accordance with the internationally recognized methodologies, also where required expanding the monitoring scope to include indirect emissions. Verified reports and the annual carbon footprint of the project facilities will be shared with IFC in the annual monitoring report (AMR).
Air Emissions
Sanko Tekstil’s Gaziantep and Adiyaman textile facilities use electricity for production and heating purposes.
Super Film’s Gaziantep plant performs monitoring of air emissions (COx, NOx, SOx, PM (Particulate Matter), and VOCs from adhesive tape unit) in line with the environmental permit. Monitoring results for 2023 indicates compliance with the local regulations and the applicable WBG EHS Guideline values. Coal-burned boiler stack has an active online emission monitoring system and connected to the MoE’s portal as required by the local regulation (Regulation on the Control of Industrial Air Pollution, 3 July 2009).
Greenfield plant of Super Film in Kirklareli will use natural gas (4,550,000 tons/year) and electricity from the grid and is required to apply for an emission permit before operations start, as per the local regulation. The company reported that according to the EPC contractor’s guarantee, emissions will comply with local regulations and WBG EHS General Guideline values.
Air pollution control system for the cooler and bag filters for the cement mills and kiln are effectively operated at the Cimko’s Narli plant. Closed clinker stock halls prevent dispersion of dust. A continuous air emission monitoring system has been installed at the rotary kiln’s main stacks. Cimko’s Narli plant obtained A-class emission permission from the relevant government authorities. In addition to continuous monitoring of air emission of kiln stacks, periodical air emission and ambient air quality monitoring are performed by accredited laboratories. Review of the available monitoring results of air emissions and ambient air quality indicates compliance with the national legal requirements and WBG EHS Guidelines for Cement and Lime Manufacturing (2022) values.
Cimko is planning to increase the use of alternative fuels up to 60 precent comparing with the current 20 percent. Hence, when the project achieved use of 60 percent alternative fuels, as per ESAP item #4, Cimko will submit to IFC the results of burning test and if necessary, implement technically and financially feasible process and emission control measures to achieve compliance of air emission levels with the national legal requirements and WBG EHS Guidelines for Cement and Lime Manufacturing (2022).
Water and Wastewater
For Sanko Tekstil’s and Super Film’s greenfield plants, water will be supplied from the municipal network. Water will be used only for cleaning purposes and domestic consumption. Process stages of Sanko Tekstil do not include considerable water use except for the dyeing unit. State of art dying equipment led to less water usage, eventually achieving full water circularity as mentioned above in the resource efficiency section.
Water for the Cimko operations is sourced from groundwater wells within the plant premises and continuously monitored at regular intervals via analyses performed by an accredited laboratory. As per the circular letter issued by the MoE, the company performed a field analysis of watershed geometry. Cimko started to use the water collected within the watershed's boundaries for watering concrete roads after the physical treatment.
In all facilities, process and domestic wastewater is pretreated in onsite chemical and/or biological treatment plants before discharge to sewer systems which are connected to municipal or industrial wastewater treatment plants. Effluent quality is monitored, and results indicate compliance with the local effluent discharge limits to sewage systems.
All existing plants are equipped with drainage systems that collect stormwater run-off separately and discharge to the municipality stormwater network.
Solid waste management and hazardous materials
Sanko Tekstil, Super Film and Cimko have hazardous and non-hazardous waste management procedures including a system of appropriate sorting, handling, storage, and disposal which are consistent with applicable legal requirements and objectives of PS3.
During the site visits to three project companies’ selected facilities, proper implementation and practices were observed in line with IFC WBG EHS General Guidelines. Wastes are segregated and stored in temporary storage areas with proper containment (110 percent coverage capacity. MSDSs (Material Safety Data Sheets) were translated into Turkish, and emergency absorbents were observed to be readily available in all required areas. Hazardous waste is stored separately from non-hazardous waste in special labeled containers and disposed to licensed companies authorized by regulatory agencies. Domestic waste is collected by municipality and disposed of to the municipality landfill. The companies have waste reduction/recycling/reusing targets. For example, Cimko has recycled 97 percent of non-hazardous waste, and reused 74.6 percent of hazardous waste for energy.
Super Film’s greenfield facility in Kirklareli will not have any process waste. All process losses will be reused in the production. Packaging materials will be sent to a recycling facility. Repairment and maintenance workshop waste and waste oils will be stored in a temporary storage area with containment and will be disposed of by licensed companies in line with local legislation (Regulation on the control of hazardous waste Official Gazette. 25755, 14 March 2005). Outdoor areas will be asphalted, and spill kits will be readily available on the site. The company will prepare a hazardous and non-hazardous waste management plan as required by law.
Noise
Sanko Tekstil and Super Film are located in industrial zones and have not significant outdoor noise sources. Cimko reported measured values of noise emissions and vibrations for both the cement facility and adjacent quarry in Narli. All measured values are within the local regulatory limits.
Quarry sites Closure & Rehabilitation
Cimko has a quarry site EHS management plan including a quarry site closure and rehabilitation action plan as per the recovery of nature and rehabilitation requirement of Mining Regulation No 32040. Cimko will review and revise the quarry sites closure and rehabilitation plan to ensure its compliance with WBG EHS guidelines for Construction Materials Extraction and Good International Industry Practice (GIIP), to meet the objectives of physical, chemical, and ecological habitat integrity and including estimated timelines and cost (ESAP item #5).