Cotton textile processing waste generation and effluent treatment


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Cotton textile processing waste generation and effluent treatment

  1. 1. The Journal of Cotton Science 11:141–153 (2007) 141, © The Cotton Foundation 2007 TEXTILE TECHNOLOGY Cotton Textile Processing: Waste Generation and Effluent Treatment B. Ramesh Babu*, A.K. Parande, S. Raghu, and T. Prem Kumar ABSTRACT countries are demanding biodegradable and ecologi- cally friendly textiles (Chavan, 2001). Cotton provides This review discusses cotton textile process- an ecologically friendly textile, but more than 50%ing and methods of treating effluent in the textile of its production volume is dyed with reactive dyes.industry. Several countries, including India, have Unfortunately, dyes are unfavorable from an ecologi-introduced strict ecological standards for textile cal point of view, because the effluents generated areindustries. With more stringent controls expected heavily colored, contain high concentrations of salts,in the future, it is essential that control measures and exhibit high biological oxygen demand/chemicalbe implemented to minimize effluent problems. oxygen demand (BOD/COD) values.Industrial textile processing comprises pretreat- In dyeing textiles, ecological standards are strictlyment, dyeing, printing, and finishing operations. applied throughout processing from raw materialThese production processes not only consume selection to the final product. This has become morelarge amounts of energy and water, but they critical since the German environmental standardsalso produce substantial waste products. This regarding dye effluents became effective (Robinson etmanuscript combines a discussion of waste pro- al., 1997). The main challenge for the textile industryduction from textile processes, such as desizing, today is to modify production methods, so they aremercerizing, bleaching, dyeing, finishing, and more ecologically friendly at a competitive price, byprinting, with a discussion of advanced methods using safer dyes and chemicals and by reducing costof effluent treatment, such as electro-oxidation, of effluent treatment/disposal. Recycling has becomebio-treatment, photochemical, and membrane a necessary element, not because of the shortage ofprocesses. any item, but because of the need to control pollution. There are three ways to reduce pollution: (1) use ofT he textile dyeing industry consumes large quantities of water and produces large volumesof wastewater from different steps in the dyeing new, less polluting technologies; (2) effective treat- ment of effluent so that it conforms to specified dis- charge requirements; and (3) recycling waste severaland finishing processes. Wastewater from printing times over before discharge (Sule and Bardhan, 1999),and dyeing units is often rich in color, containing which is considered the most practical solution.residues of reactive dyes and chemicals, and requires The objective of this review is to discuss theproper treatment before being released into the various processing stages in the textile industry andenvironment. The toxic effects of dyestuffs and other the methodologies adopted for treating textile waste-organic compounds, as well as acidic and alkaline water. A variety of water treatment techniques (Tablecontaminants, from industrial establishments on 1) are discussed from an environmental point ofthe general public are widely accepted. Increasing view. Conventional and novel techniques discussedpublic concern about environmental issues has led include electro-oxidation, biological treatment, pho-to closure of several small-scale industries. tochemical processing, ion-exchange, and a variety Interest in ecologically friendly, wet-process- of membrane textile techniques has increased in recent yearsbecause of increased awareness of environmental TEXTILE OPERATIONSissues throughout the world. Consumers in developed The textile industry comprises a diverse and fragmented group of establishments that produce and/or process textile-related products (fiber, yarn, B. R. Babu*, A.K. Parande, S. Raghu, and T. P. Kumar, Central Electrochemical Research Institute, Karaikudi 630006, and fabric) for further processing into apparel, home Tamil Nadu, India. furnishings, and industrial goods. Textile establish-*Corresponding author: ments receive and prepare fibers; transform fibers
  2. 2. BABU ET Al.: TExTIlE PROCESSING AND EFFlUENT TREATmENT 142Table 1. Possible treatments for cotton textile wastes and their associated advantages and disadvantages Processes Advantages Disadvantages References Biodegradation Rates of elimination by oxidizable Low biodegradability of Pala and Tokat, 2002; substances about 90% dyes Ledakowicz et al., 2001. Coagulation– Elimination of insoluble dyes Production of sludge Gaehr et al., 1994. flocculation blocking filter Adsorption on Suspended solids and organic Cost of activated carbon Arslan et al., 2000. activated carbon substances well reduced Ozone treatment Good decolorization No reduction of the COD Adams et al., 1995; Scott and Ollis, 1995. Electrochemical Capacity of adaptation to different Iron hydroxide sludge Lin and Peng, 1994; Lin and processes volumes and pollution loads Chen, 1997. Reverse osmosis Removal of all mineral salts, High pressure Ghayeni et al., 1998. hydrolyzes reactive dyes and chemical auxiliaries Nanofiltration Separation of organic compounds of Erswell et al., 1998; Xu et al., low molecular weight and divalent ----- 1999; Akbari et al., 2002; Tang ions from monovalent salts. and Chen, 2002. Treatment of high concentrations Ultrafiltration– Low pressure Insufficient quality of the Watters et al., 1991; Rott and microfiltration treated wastewater Mike, 1999; Ciardelli and Ranieri, 2001; Ghayeni et al., 1998.into yarn, thread, or webbing; convert the yarn into Man-made Man-made Raw wool,fabric or related products; and dye and finish these filament fibers staple fibers cottonmaterials at various stages of production (Ghosh and Texturizing Fiber preparationGangopadhyay, 2000). The process of converting raw fibers into fin- Yarn formationished apparel and non-apparel textile products is Warping Spinningcomplex, so most textile mills specialize. There islittle difference between knitting and weaving in the Slashingproduction of man-made cotton and wool fabrics Knitting Knitting(Hashem et al., 2005). Textiles generally go throughthree or four stages of production that may include Weavingyarn formation, fabric formation, wet processing, andtextile fabrication. Some of the steps in processing Wet Preparation processingfibers into textile goods are shown in Figure 1. A listof some wastes that may be generated at each level De-sizingof textile processing are provided in Table 2. Desizing. The presence of sizing ingredients in Bleaching Mercerizingthe fabric hinders processes, such as dyeing, printing,and finishing. For example, the presence of starch can Dyeing,hinder the penetration of the dye into the fiber, which printingnecessitates removal of starch prior to dyeing or print-ing. Starch is removed or converted into simple water- Finishingsoluble products either by hydrolysis (by enzymaticpreparations or dilute mineral acids) or by oxidation (by Figure 1. A flow diagram for various steps involved in pro-sodium bromide, sodium chlorite, etc.) (Batra, 1985). cessing textile in a cotton mill. In general, about 50% of the water pollution isdue to waste water from desizing, which has a high be recovered by distillation for use as a solvent orBOD that renders it unusable. The problem can be fuel, thereby reducing the BOD load. Alternatively,mitigated by using enzymes that degrade starch into an oxidative system like H2O2 can be used to fullyethanol rather to anhydroglucose. The ethanol can degrade starch to CO2 and H2O.
  3. 3. JOURNAl OF COTTON SCIENCE, Volume 11, Issue 3, 2007 143 Electro-oxidation on RuO2/Ti or PbO2/Ti elec- were a biomass concentration of approximately 0.5trodes is an effective method for the treatment of mg/ml N (5 mg/ml volatile suspended solids), 20starch effluent. An anaerobic plate-column reactor °C, an HRT of 30 h, and a TOC-loading rate of 0.8capable of retaining high concentrations of biomass g/l/day. A removal efficiency of dissolved organicwas studied using a synthetic wastewater that con- carbon exceeding 90% was realized. At the endtained starch. The total organic carbon (TOC)-load- of the treatment, the removal efficiency reacheding rate, hydraulic retention time (HRT), and tem- a steady-state value of 98%, at which the biomassperature were kept constant. The initial conditions concentration in the reactor was 2.3 mg/ml N.Table 2. List of some of the waste materials generated at each level of cotton textile processing Process Air emissions Wastewater Residual wastes Fiber Little or no air emissions Little or no wastewater Fiber waste; packaging waste; hard preparation generated generated waste. Yarn spinning Little or no air emissions Little or no wastewater Packaging waste; sized yarn; fiber generated generated waste; cleaning and processing waste. Slashing/sizing Volatile organic compounds BOD; COD; metals; cleaning Fiber lint; yarn waste; packaging waste, size waste; unused starch-based sizes. Weaving Little or no air emissions Little or no wastewater Packaging waste; yarn and fabric generated generated scraps; off-spec fabric; used oil. Knitting Little or no air emissions Little or no wastewater Packaging waste; yarn and fabric generated generated scraps; off-spec fabric. Tufting Little or no air emissions Little or no wastewater Packaging waste; yarn and fabric generated generated scraps; off-spec fabric. Desizing Volatile organic compounds BOD from water-soluble sizes; Packaging waste; fiber lint; yarn waste; from glycol ethers synthetic size; lubricants; cleaning materials, such as wipes, rags biocides; anti-static and filters; cleaning and maintenance compounds wastes containing solvents. Scouring Volatile organic compounds Disinfectants and insecticide Little or no residual waste generated. from glycol ethers and residues; NaOH; detergents; scouring solvents fats; oils; pectin; wax; knitting lubricants; spin finishes; spent solvents Bleaching Little or no air emissions Hydrogen peroxide, sodium Little or no residual waste generated. generated silicate or organic stabilizer; high pH Singeing Small amounts of exhaust Little or no wastewater Little or no residual waste generated. gasses from the burners. generated. Mercerizing Little or no air emissions High pH; NaOH. Little or no residual waste generated. generated. Heat setting Volatilization of spin finish Little or no wastewater Little or no residual waste generated. agents applied during generated. synthetic fiber manufacture. Dyeing Volatile organic compounds Metals; salt; surfactants; Little or no residual waste generated. toxics; organic processing assistance; cationic materials; color; BOD; sulfide; acidity/ alkalinity; spent solvents. Printing Solvents, acetic acid from Suspended solids; urea; Little or no residual waste generated. dyeing and curing oven solvents; color; metals; heat; emissions; combustion BOD; foam. gasses; particulate matter. Finishing Volatile organic compounds; BOD; COD; suspended solids; Fabric scraps and trimmings; contaminants in purchased toxics; spent solvents. packaging waste. chemicals; formaldehyde vapor; combustion gasses; particulate matter. Product Little or no air emissions Little or no wastewater Fabric scraps. fabrication generated. generated.
  4. 4. BABU ET Al.: TExTIlE PROCESSING AND EFFlUENT TREATmENT 144 Cornstarch waste is easily degraded by treatment by stretching it or holding it under tension. The mate-in a mixed activated sludge system. The bio-kinetic rial acquires the desired properties of luster, increasedcoefficients were calculated from the two-level ac- strength, dye uptake, and increased absorbency. Thetivated sludge operational processes using influent large concentrations of NaOH in the wash water can beCOD concentrations and four values of solid reten- recovered by membrane techniques. Use of ZnCl2 as antion time. The results indicate that the effluent COD alternative method leads to an increase in the weight ofis related to the influent COD concentration. It is also fabric and in dye uptake, and allows easy recovery ofproportional to the product of the influent COD and NaOH. moreover, the process is ecologically friendlythe specific growth rate. A multiple-substrate model and does not require neutralization by acetic or formicwas developed to predict the effluent COD under acid (Karim et al., 2006).variable influent COD concentrations (Bortone et Bleaching. Natural color matter in the yarnal., 1995). There was no sludge-bulking problem imparts a creamy appearance to the fabric. In orderapparently because of high dissolved oxygen (DO) to obtain white yarn that facilitates producing paleconcentrations, a buffered system, and a balanced and bright shades, it is necessary to decolorize theC:N:P ratio; however, the critical DO concentration yarn by bleaching. Hypochlorite is one of the oldestat which the sludge volume index began to rise in- industrial bleaching agents. The formation of highlycreased as the food for microorganism (F/m) ratio toxic chlorinated organic by-products during theincreased. A cost analysis was provided for a hypo- bleaching process is reduced by adsorbable organi-thetical wastewater plant with a flow rate of 300m3/ cally bound halogen (AOx).day (Vanndevivera and Bianchi, 1998). Synthetic Over the last few years, hypochlorite is beingsizing formulations based on polyvinyl acrylic (PVA) replaced by other bleaching agents (Rott and minke,and acrylic resins, instead of starch, are expensive. 1999). An environmentally safe alternative to hypo-Considering the cost of effluent treatment, the cost chlorite is peracetic acid. It decomposes to oxygen andof synthetic sizing formulations is negligible. Today, acetic acid, which is completely biodegradable. One ofadvances in nano-filtration and ultra-filtration tech- the advantages of peracetic acid is higher brightnessniques allow recovery and reuse of PVA (meier et values with less fiber damage (Rott and Minke, 1999).al., 2002; Yu et al., 2001). Recently, a one-step preparatory process for desizing, Compared with reverse osmosis, nanofiltra- scouring, and bleaching has helped to reduce thetion is less energy intensive and can be used for the volume of water. The feasibility of a one-step processtreatment of various industrial effluents (Meier et for desizing, scouring, bleaching, and mercerizing ofal., 2002). moreover, a higher retention of dyes and cotton fabric followed by dyeing with direct dyes hasother low molecular weight organic compounds (MW: been discussed by Slokar and majcen (1997).200–1000) is achievable by nanofiltration. The salt- Cooper (1989) suggested an economical andrich permeate can be reused in the preparation of dye pollution-free process for electrochemical mercer-baths, which minimizes the amount of wastewater that ization (scouring) and bleaching of textiles. Theneeds to be processed. The basic problems involved process does not require conventional caustic soda,in any membrane-based process are a drop in flux and acids, and bleaching agents. The treatment is carriedmembrane fouling. To overcome this problem and out in a low-voltage electrochemical cell. The baseto achieve a high quality separation, combinations required for mercerization (scouring) is produced inof various separation methods have been adopted in the cathode chamber, while an equivalent amountrecent years (Pigmon et al., 2003; Abdessemed and of acid is produced in the anode chamber, which isNezzal, 2002; Dhale et al., 2000; xu et al., 1999). used for neutralizing the fabric. Gas diffusion elec- Mercerization. In order to impart luster, increase trodes simultaneously generate hydrogen peroxidestrength, and improve dye uptake, cotton fiber and for bleaching. With a bipolar stack of electrodes,fabric are mercerized in the gray state after bleaching. diffusion electrodes can be used as anode or cathodeEssentially, mercerization is carried out by treating cot- or both. The process does not produce hydrogenton material with a strong solution of sodium hydroxide bubbles at the cathode, thereby avoiding hazards(about 18–24%) and washing-off the caustic after 1 to involving the gas (lin and Peng, 1994).3 min, while holding the material under tension. Cot- An electrochemical treatment was developed forton is known to undergo a longitudinal shrinkage upon the treatment of cotton in aqueous solution contain-impregnation with this solution. This can be prevented ing sodium sulphate. In this technique, the current
  5. 5. JOURNAl OF COTTON SCIENCE, Volume 11, Issue 3, 2007 145density was controlled between two electrodes. At treatment wastewater from the dyeing and finishingthe cathode, water is reduced to hydrogen and base, process (Chen et al., 2005).while at the anode it is oxidized to oxygen and acid. measures adopted for the abatement of pollutionFavorable results on mercerization (scouring) and by different dyes are 1) use of low material-to-liquorelectrochemical sanitation of unmercerized (grey) ratios, 2) use of trisodiumcitrate (Fiebig et al., 1992),cotton have been reported (Naumczyk et al., 1996). 3) replacement of reducing agent (sodium hydro- Neutralization. According to Bradbury et al. sulphite) with a reducing sugar or electrochemical(2000), replacement of acetic acid by formic acid for reduction (maier et al., 2004), and 4) use of suitableneutralization of fabric after scouring, mercerizing, dye-fixing agents to reduce water pollution loads.bleaching, and reduction processes is effective, eco- Padma et al. (2006) first reported the conceptnomical, and environment-friendly. The procedure of totally ecologically friendly mordents or naturalalso allows a sufficient level of neutralization in a mordents during dyeing with natural dyes. Deo andshort period of time, needs low volumes of water, Desai (1999) were the first to point out that naturaland results in low levels of BOD. dye shades could be built-up by a multiple dip Dyeing. Treatment of fiber or fabric with chemi- method that renders natural dyeing more pigments to impart color is called dyeing. The Dyeing of natural and synthetic fibers with naturalcolor arises from chromophore and auxochrome dyes has been the subject of several studies. Devel-groups in the dyes, which also cause pollution opment of ecologically friendly non-formaldehyde(Azymezyk et al., 2007). In the dyeing process, water dye fixative agents for reactive dyes was recentlyis used to transfer dyes and in the form of steam to reported (Bechtold et al., 2005; Sekar, 1995).heat the treatment baths. Cotton, which is the world’s Printing. Printing is a branch of dyeing. It ismost widely used fiber, is a substrate that requires a generally defined as ‘localized dyeing,’ i.e. dyeinglarge amount of water for processing. For example, that is confirmed to a certain portion of the fabric thatto dye 1 kg of cotton with reactive dyes, 0.6–0.8 constitutes the design. It is really a form of dyeing inkg of NaCl, 30–60 g of dyestuff, and 70–150 l of which the essential reactions involved are the same aswater are required (Chakraborty et al., 2005). more those in dyeing. In dyeing, color is applied in the formthan 80,000 tonnes of reactive dyes are produced of a solution, whereas in printing color is applied inand consumed each year. Once the dyeing opera- the form of a thick paste of the dye. Table 3 shows thetion is over, the various treatment baths are drained, pollution loads for a printing and finishing operationincluding the highly colored dye bath, which has (50 polyester/50 cotton). The fixation of the color inhigh concentrations of salt and organic substances. printing is brought about by a suitable after-treatment ofThe wastewater must be treated before reuse. Co- the printed material (El-molla and Schneider, 2006).agulation and membrane processes (nanofiltration orreverse osmosis) are among processes suggested for Table 3. Pollution loads for printing and finishing operations for 50% polyester/50% cotton blend fabrictreatment of this water; however, these treatmentsare effective only with very dilute dye baths. Dye Biological Total pH oxygen dissolvablebaths are generally heavily polluted. For example, Process demand solidswastewater produced by reactive dyeing contains per 1000 kg of producthydrolyzed reactive dyes not fixed on the substrate Printing(representing 20 to 30% of the reactive dyes applied Pigment 6–8 1.26 5.0 0.13 2.5on an average of 2 g/l). This residual amount is (woven goods)responsible for the coloration of the effluents, and Pigment 6–8 1.26 5.0 0.13 2.5cannot be recycled. Dyeing auxiliaries or organic (knot goods)substances are non-recyclable and contribute to the Vat dye 10.0 21.5 86 25 34high BOD/COD of the effluents. (woven goods) membrane technologies are increasingly being Vat dye 10.0 21.5 86 25 35used in the treatment of textile wastewater for the (knit goods)recovery of valuable components from the waste Resin finishing 6–8 - - - 22stream, as well as for reusing the aqueous stream. A (woven goods)number of studies deal with application of various Resin finishing flat 6–8 6.32 25 12 17.3pressure-driven membrane filtration processes in the curing (woven goods)
  6. 6. BABU ET Al.: TExTIlE PROCESSING AND EFFlUENT TREATmENT 146 Textile fabric printing produces hydrocarbon Among the products that are used in textile finish-effluents that must be removed before they reach ing, the most ecologically friendly ones are formalde-the atmosphere. limits on emissions will become hyde-based cross-linking agents that bestow desiredmore restrictive in the future, which makes cleaning properties, such as softness and stiffness that impartexhausts an environmental necessity. In India, a ma- bulk and drape properties, smoothness, and handle,jority of textile printing units prefer to use kerosene to cellulosic textiles. It can also lead to enhancedin printing because of the brilliant prints and ease of dimensional stability. A free surface characteristic ofapplication. In India alone, about 122 million liters the fabric shows the evolution of un-reacted form-of kerosene is released into the atmosphere annually aldehyde. This obviates the use of formaldehyde induring printing, drying, and curing. The resulting the product and liberation of chemical products, andpollution of the atmosphere and wastage of hydro- results in considerable reduction in the amount ofcarbon products is colossal. Air-laden kerosene is formaldehyde during the cross-linking reaction thatharmful to human beings, as well as to the flora and leads to toxicity and stream pollution. Generation offauna, in the neighborhood. Therefore, it is impera- formaldehyde during vacuum extraction has been usedtive that as much kerosene as possible is recovered in the storage of resin-finished fabrics and garments.from the exhaust pipes of the printing industry. The formaldehyde resin used as a cross-linking agent Zachariah (1995) developed a process for the is a pollutant and a known carcinogen. much effortrecovery of thin kerosene vapor. In this process, the has been expended in the search for a substitute forpercentage of recovery of kerosene from the printing formaldehyde (Hashem et al., 2005).drier was 78.5%, and the total percentage of recovery Since the late 1980s, there has been an increase inof kerosene consumed for the preparation of print the demand for easy-care, wrinkle-resistant (durablepaste was 58.8%. press), 100% cotton apparel. Formaldehyde-based The most common chemical in reactive dye chemical finishes, such as dimethylol dihydroxyeth-printing is urea, which leads to a high pollution load. ylene urea and its etherified derivative with lowerA number of attempts have been made to limit or formaldehyde concentrations, are used to impart ease-eliminate the use of urea in the print paste to reduce of-care characteristics and durable-press properties toeffluent load. Geeta et al. (2004) developed a urea-free cotton apparel. They are cost-effective and efficientprocess in which caprolactam, PEG-400, and PEG- (Hashem et al., 2005). The free formaldehyde on the600 partially or completely replaced urea in the dyeing finished fabric is a major drawback given the adverseand printing of reactive dyes on cotton fabrics. Cap- effects of formaldehyde, which ranges from a strongrolactam in many reactive dyes can fully replace urea, irritant to carcinogenic. In addition, washing the ap-while PEG-400 and PEG-600 replaced approximately parel pollutes the washing liquor. Because of its carci-50% of the dyes required for fixation. Other substitutes nogenic properties, the concentration of formaldehydefor urea include glycerin, cellosolve, sorbitol, polycar- allowed in the workplace air space is limited to 0.1boxylic acid, PEG-200, and PEG-4000. ppm. Furthermore, worker health must be monitored Printing is mainly done by a flat or rotary screen, in the textile industry when formaldehyde is used.and after every lot of printing some residual paste is This is strictly stated in recent actions by federalleft in the wastewater. This can be reused for printing of regulatory agencies in most industrialized countries.similar shades by adding new stock. Recently, screen- The restrictions have sprouted renewed interest in non-free printing methods, such as ink-jet printing and formaldehyde textile finishing substances in the cottonelectrostatic printing, have been developed that make textile industry (El-Tahlawya et al., 2005). moreover,use of an electronic control of color distribution on formaldehyde-based finishing is energy-intensive. Afabric. Screen-free printing methods are attractive for variety of cellulose cross-linking agents, such as poly-pollution mitigation (lukanova and Ganchev, 2005). carboxylic acids, have been investigated to provide Finishing. Both natural and synthetic textiles are non-formaldehyde easy-care finishing.subjected to a variety of finishing processes. This is Natural polymeric substances, such as natural oildone to improve specific properties in the finished and wax, have been used for water-proofing; however,fabric and involves the use of a large number of textiles made from natural fibers are generally morefinishing agents for softening, cross-linking, and wa- susceptible to biodeterioration compared with thoseterproofing. All of the finishing processes contribute made from synthetic fibers. Products, such as starch,to water pollution. protein derivatives, fats, and oils, used in the finishing
  7. 7. JOURNAl OF COTTON SCIENCE, Volume 11, Issue 3, 2007 147or sizing bath can also promote microbial growth. An neutralization step BOD: 290 mg/l; neutralizationideal anti-bacterial finish should 1) not support growth COD: 830 mg/l; dyeing step BOD: 500 mg/l; dyeingof bacteria or fungi on the cloth, 2) be effective over step COD: 1440 mg/l; soaping step BOD: 310 mg/l;the lifetime of the treated sample, 3) be durable against soaping step COD: 960 mg/l). Because aquatic or-wash and bleaching, 4) pose no risk of adverse dermal ganisms need light in order to develop, any deficitor systemic effects, 5) have no detrimental influence in the light reaching the aquatic life due to wateron fabric properties, such as yellowing, handle, and coloration results in an imbalance in the ecosystem.strength, 6) be compatible with colorants and other moreover, river water meant for human consumptionfinishes, such as softeners and resins, and 7) have low that is colored will increase treatment costs. Obvi-environmental impact of heavy metals, formaldehyde, ously, when legal limits are specified (although notphenols, and organic halogens. in all countries), they are justified. There are few anti-bacterial fibers. There are a Table 4. Composition of cotton textile mill wastenumber of antibacterial chemicals are available (Son etal., 2006; Singh et al., 2005; El-Tahlawya et al., 2005), Characteristics Valuesbut they are man-made. There are many natural plant pH 9.8–11.8products that are known to slow down bacterial growth. Total alkalinity 17–22 mg/l as CaCO3Anti-bacterial properties have been detected in chemi- BOD 760–900 mg/lcals extracted from the root, stem, leaves, flowers, fruits, COD 1400–1700 mg/land seeds of diverse species of plants (Kannan and Total solids 6000–7000 mg/lGeethamalini, 2005). Sachan and Kapoor (2004) used Total chromium 10–13 mg/lnatural herbal extracts for developing bacteria-resistantfinishes for cotton fabric and wool felting. Years ago, Raw waste H2SO4wool was treated with chlorine, hypochlorite, and sul- Na3Po4furyl chloride. Bio-polishing using cellulose enzymes Primary Neutral- Settlingis an environmentally friendly method to improve soft Equalization ization Coagulation tank Basin tankhandling of cellulose fibers with reduced piling, less tankfuzz, and improved drape (Thilagavathi et al., 2005). EFFLUENT TREATMENTS Effluent Secondary High rate settling trickling tank filter Dyes in wastewater can be eliminated by vari-ous methods. The wastewater from the dye house isgenerally multi-colored. The dye effluent disposedinto the land and river water reduces the depth of Sand dryingpenetration of sunlight into the water environment, bedwhich in turn decreases photosynthetic activity anddissolved oxygen (DO) (Table 4). The adverse ef- Figure 2. A flow diagram for treatment of cotton textile mill waste.fects can spell disaster for aquatic life and the soil.Figure 2 shows a flow diagram for treatment of Softened watercotton textiles, and the water and COD balance are Dyes + axillaries To laminatingdepicted in Figure 3. many dyes contain organic Yarn preparation Dyeingcompounds with functional groups, such as carbox-ylic (–COOH), amine (–NH2), and azo (–N=N–) Knittinggroups, so treatment methods must be tailored to the Equalization dischargechemistry of the dyes. Wastewaters resulting from Washingdyeing cotton with reactive dyes are highly polluted agents Washingand have high BOD/COD, coloration, and salt load.For example, this ratio for Drimaren HF (a cellulosic Knitting oilproduct from Clariant Chemicals, India) is constant To finishingand around 0.35 for each dyeing step (bleaching step Softened waterBOD: 1850 mg/l; bleaching step COD: 5700 mg/l; Figure 3. Activites involving water in textile processing.
  8. 8. BABU ET Al.: TExTIlE PROCESSING AND EFFlUENT TREATmENT 148 marrot and Roche (2002) have given more than Biological treatments. Biological treatments100 references in a bibliographical review of textile reproduce, artificially or otherwise, the phenomenawastewater treatment. Treatment operation and deci- of self-purification that exists in nature. Self-purifica-sion structure are shown in Figure 4. The physical tion is the process by which an aquatic environmentmethods include precipitation (coagulation, floccula- achieves the re-establishment of its original qualitytion, sedimentation) (lin and Peng, 1996; Solozhenko after pollution. Biological treatments are differentet al., 1995; lin and liu, 1994; mcKay et al., 1987), depending on the presence or absence of oxygenadsorption (on activated carbon, biological sludges) (Bl’anquez et al., 2006). ‘Activated sludge’ is a(Pala and Tokat, 2002), filtration, or reverse osmosis common process by which rates of elimination bymembrane processes (Ghayeni et al., 1998; Treffry- oxidizable substances of the order of 90% can beGoatley et al., 1983, Tinghui et al., 1983). realized (Pala and Tokat, 2002). Because of the low biodegradability of most of the dyes and chemicals Desizing Ultrafiltration used in the textile industry, their biological treatment Reuse by the activated sludge process does not always achieve great success. It is remarkable that most of Mercerization Electrolysis (recovery of NaOH) these dyes resist aerobic biological treatment, so ad- Bleaching sorbents, such as bentonite clay or activated carbon, are added to biological treatment systems in order to Dyeing eliminate non-biodegradable or microorganism-toxic organic substances produced by the textile industry Activated Electrochemical treatment & (Pala and Tokat, 2002; marquez and Costa, 1996; carbon recovery of process chemicals Speccia and Gianetto, 1984). Resin Oxidative chemical treatment, or sometimes the Evaporator use of organic flocculants (Pala and Tokat, 2002), Reusable water is often resorted to after the biological treatment (ledakowic et al., 2001). These methods, whichFigure 4. Electrochemical treatment and recovery of chemi- cals from the textile effluent. only release effluents into the environment per legal requirements, are expensive (around €2.5/kg for Azo dyes constitute the largest and the most polyamide coagulant: a factor 10 compared withimportant class of commercial dyes used in textile, mineral coagulants).printing, tannery, paper manufacture, and photogra- Biological aerated filters (BAF) involve thephy industries. These dyes are inevitably discharged growth of an organism on media that are held station-in industrial effluents. Azo dyes have a serious ary during normal operation and exposed to aeration.environmental impact, because their precursors and In recent years, several BAF-based technologiesdegradation products (such as aromatic amines) are have been developed to treat wastewater. Effluentshighly carcinogenic (Szymczyk et al., 2007). Numer- from textile industry are among wastewaters thatous biodegradability studies on dyes have shown are hard to treat satisfactorily, because their com-that azo dyes are not prone to biodegradation under positions are highly variable. The strong color isaerobic conditions (O’Neill et al., 2000; Basibuyuk most striking characteristic of textile wastewater. Ifand Forster, 1997). These dyes are either adsorbed or unchecked, colored wastewater can cause a signifi-trapped in bioflocs, which affects the ecosystem of cantly negative impact on the aquatic environmentstreams, so they need to be removed from wastewater primarily arising from increased turbidity and pol-before discharge. Removal of dyes from wastewater lutant concentrations.can be effected by chemical coagulation, air flotation, Coagulation–flocculation treatments. Coagu-and adsorption methods (malik and Sanyal, 2004; Se- lation–flocculation treatments are generally used toshadri et al., 1994). These traditional methods mainly eliminate organic substances, but the chemicalstransfer the contaminants from one phase to another normally used in this process have no effect on thephase without effecting any reduction in toxicity. elimination of soluble dyestuffs. Although this pro-Therefore, advance oxidation is a potential alternative cess effectively eliminates insoluble dyes (Gaehr etto degrade azo dyes into harmless species. al., 1994), its value is doubtful because of the cost
  9. 9. JOURNAl OF COTTON SCIENCE, Volume 11, Issue 3, 2007 149of treating the sludge and the increasing number of and floatation. Electro-coagulation is an efficientrestrictions concerning the disposal of sludge. process, even at high pH, for the removal of color Adsorption on powdered activated carbon. and total organic carbon. The efficiency of the pro-The adsorption on activated carbon without pretreat- cess is strongly influenced by the current density andment is impossible because the suspended solids duration of the reaction. Under optimal conditions,rapidly clog the filter (Matsui et al., 2005). This decolorization yields between 90 and 95%, and CODprocedure is therefore only feasible in combination removal between 30 and 36% can be achieved.with flocculation–decantation treatment or a biologi- Ozone treatment. Widely used in water treat-cal treatment. The combination permits a reduction ment, ozone (either singly or in combinations, suchof suspended solids and organic substances, as well as O3-UV or O3-H2O2) is now used in the treatmentas a slight reduction in the color (Rozzi et al., 1999), of industrial effluents (Langlais et al., 2001). Ozonebut the cost of activated carbon is high. especially attacks the double bonds that bestow Electrochemical processes. Electrochemical color. For this reason, decolorization of wastewatertechniques for the treatment of dye waste are more by ozone alone does not lead to a significant reduc-efficient than other treatments (Naumczyk et al., tion in COD (Coste et al., 1996; Adams et al., 1995).1996). Electrochemical technology has been applied moreover, installation of ozonation plants can entailto effectively remove acids, as well as dispersed additional costs (Scott and Ollis, 1995).and metal complex dyes. The removal of dyes fromaqueous solutions results from adsorption and deg- MEMBRANE PROCESSESradation of the dye-stuff following interaction withiron electrodes. If metal complex dyes are present, Increasing cost of water and its profligate con-dye solubility and charge are important factors that sumption necessitate a treatment process that isdetermine the successful removal of heavy metals. integrated with in-plant water circuits rather than asIn order to maximize dye insolubility, pH control a subsequent treatment (machenbach, 1998). Fromis crucial (Chakarborty et al., 2003; Vedavyasam, this standpoint, membrane filtration offers potential2000; Nowak et al., 1996; Calabro et al., 1990). Con- applications. Processes using membranes provideventional methods involve generation of secondary very interesting possibilities for the separation ofpollutants (sludge), but sludge formation is absent hydrolyzed dye-stuffs and dyeing auxiliaries thatin the electrochemical method (Ganesh et al., 1994). simultaneously reduce coloration and BOD/CODElectrochemical treatment and recovery of chemicals of the wastewater. The choice of the membranefrom the effluent are shown in Fig. 4. In this process, process, whether it is reverse osmosis, nanofiltration,the recovery of metals or chemicals is easily carried ultrafiltration or microfiltration, must be guided byout. At the same time, the following environmental the quality of the final product.advantages are realized; emission of gases, solid Reverse osmosis. Reverse osmosis membraneswaste, and liquid effluent are minimized. have a retention rate of 90% or more for most types The use of an electrolytic cell in which the dye of ionic compounds and produce a high quality ofhouse wastewater is recirculated has been described permeate (Ghayeni et al., 1998; Treffry-Goatley et(lin and Chen, 1997; lin and Peng, 1994). The ad- al., 1983; Tinghui et al., 1983). Decoloration andvantage of this process seems to be its capacity for elimination of chemical auxiliaries in dye houseadaptation to different volumes and pollution loads. wastewater can be carried out in a single step by re-Its main disadvantage is that it generates iron hy- verse osmosis. Reverse osmosis permits the removaldroxide sludge (from the iron electrodes in the cell), of all mineral salts, hydrolyzed reactive dyes, andwhich limits its use. Electro-coagulation has been chemical auxiliaries. It must be noted that higher thesuccessfully used to treat textile industrial wastewa- concentration of dissolved salt, the more importantters. The goal is to form flocs of metal hydroxides the osmotic pressure becomes; therefore, the greaterwithin the effluent to be cleaned by electro-dissolu- the energy required for the separation process.tion of soluble anodes. Three main processes occur Nanofiltration. Nanofiltration has been ap-during electro-coagulation; electrolytic reactions at plied for the treatment of colored effluents from thethe electrodes; formation of coagulants in the aque- textile industry. A combination of adsorption andous phase and adsorption of soluble or colloidal pol- nanofiltration can be adopted for the treatment oflutants on coagulants; and removal by sedimentation textile dye effluents. The adsorption step precedes
  10. 10. BABU ET Al.: TExTIlE PROCESSING AND EFFlUENT TREATmENT 150nanofiltration, because this sequence decreases con- (Al-malack and Anderson, 1997), as well as forcentration polarization during the filtration process, subsequent rinsing baths. The chemicals used inwhich increases the process output (Chakraborty et dye bath, which are not filtered by microfiltration,al., 2003). Nanofiltration membranes retain low- will remain in the bath. Microfiltration can also bemolecular weight organic compounds, divalent used as a pretreatment for nanofiltration or reverseions, large monovalent ions, hydrolyzed reactive osmosis (Ghayeni et al., 1998).dyes, and dyeing auxiliaries. Harmful effects ofhigh concentrations of dye and salts in dye house CONCLUSIONSeffluents have frequently been reported (Tang andChen, 2002; Koyuncu, 2002; Bruggen et al., 2001; Waste minimization is of great importance inJiraratananon et al., 2000; xu et al., 1999; Erswell decreasing pollution load and production costs. Thiset al., 1988). In most published studies concerning review has shown that various methods can be ap-dye house effluents, the concentration of mineral plied to treat cotton textile effluents and to minimizesalts does not exceed 20 g/l, and the concentration pollution load. Traditional technologies to treatof dyestuff does not exceed 1.5 g/l (Tang and Chen, textile wastewater include various combinations2002). Generally, the effluents are reconstituted with of biological, physical, and chemical methods, butonly one dye (Tang and Chen, 2002; Koyuncu, 2002; these methods require high capital and operatingAkbari et al., 2002), and the volume studied is also costs. Technologies based on membrane systemslow (Akbari et al., 2002). The treatment of dyeing are among the best alternative methods that can bewastewater by nanofiltration represents one of the adopted for large-scale ecologically friendly treat-rare applications possible for the treatment of solu- ment processes. A combination methods involvingtions with highly concentrated and complex solutions adsorption followed by nanofiltration has also been(Rossignol et al., 2000; Freger et al., 2000; Knauf et advocated, although a major drawback in directal., 1998; Peuchot, 1997; Kelly and Kelly, 1995). nanofiltration is a substantial reduction in pollutants, A major problem is the accumulation of dis- which causes permeation through flux.solved solids, which makes discharging the treated It appears that an ideal treatment process foreffluents into water streams impossible. Various satisfactory recycling and reuse of textile effluentresearch groups have tried to develop economically water should involve the following steps. Initially,feasible technologies for effective treatment of dye refractory organic compounds and dyes may be elec-effluents (Karim et al., 2006; Cairne et al., 2004; trochemically oxidized to biodegradable constituentsRott and Mike, 1999). Nanofiltration treatment as an before the wastewater is subjected to biologicalalternative has been found to be fairly satisfactory. treatment under aerobic conditions. Color and odorThe technique is also favorable in terms of environ- removal may be accomplished by a second electro-mental regulation. oxidation process. microbial life, if any, may be Ultrafiltration. Ultrafiltration enables elimi- destroyed by a photochemical treatment. The treatednation of macromolecules and particles, but the water at this stage may be used for rinsing and wash-elimination of polluting substances, such as dyes, is ing purposes; however, an ion-exchange step maynever complete (it is only between 31% and 76%) be introduced if the water is desired to be used for(Watters et al., 1991). Even in the best of cases, the industrial processing.quality of the treated wastewater does not permitits reuse for sensitive processes, such as dyeing ACKNOWLEDGEMENTof textile. Rott and minke (1999) emphasize that40% of the water treated by ultrafiltration can be The support of the Director of the Central Elec-recycled to feed processes termed “minor” in the trochemical Research Institute, Karaikudi- 630 006,textile industry (rinsing, washing) in which salinity India, is gratefully not a problem. Ultrafiltration can only be used asa pretreatment for reverse osmosis (Ciardelli and REFERENCESRanieri, 2001) or in combination with a biologicalreactor (mignani et al., 1999). Abdessemed, D. and G. Nezzal. 2002. Treatment of primary Microfiltration. microfiltration is suitable effluent by coagulation adsorption-ultrafiltration for reuse. Desalination 152:367-373.for treating dye baths containing pigment dyes
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