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TEXTILE MANUFACTURING PROCESS
Rerouting rope-guides, which determine the route fabrics take through dyeing machines, reduced water use by 6.2% on average for 5 dye recipes. Counter-current washing, where wastewater is recycled from the last wash step to the next, reduced consumption by 50-80% compared to normal flow washing and showed decreasing pollution concentrations from the first to last wash tanks. Both techniques provide simple, effective ways to minimize water and wastewater in textile dyeing and finishing.
TEXTILE MANUFACTURING PROCESS
- 1. TEXTILE MANUFACTURING PROCESS Presentedby: Vishal Kumar Kushwaha (141050004)
- 2. Textile Manufacturing isone of the Largest Industrial Consumers of Water • “Environmental Technology Best Practice Program, guide Code EG98, Water Use in TextileDyeing and Finishing” states that; the water consumption is: 150-200 kg/kg of product
- 3. Reducing the waterconsumption REDUCE WASTEWATER GENERATED & INCREASE THE COST EFFECTIVENESS. In the Guide called as “A Step Towards Cleaner Production”, Susan Barclay and Chris Buckley states that; Within any process, there are five main aspects that should be taken into account when considering the implementation of waste minimisation. • raw materials used and other input materials such as water • the type of technology, • the manner is which the process is executed, • the products that are formed, and • the wastes and emissions that are generated.
- 4. The Textile MillStudied The Textile Mill studied; • is one of the major mills in Turkey • has a capacity of 20 000 ton denim fabric per year • includes Cotton Fiber Production, Dyeing, Sizing and Finishing 8
- 5. The Textile MillStudied The production is 24 hours a day & 3 shifts/day The water consumption of 2000 m3 /day Chemical consumption of 1000 ton/month Over 100 chemicals used It has own WWTP and Co-generation Units 9
- 6. COTTON FIBER PRODUCTION DYINGPROCESSES WEAVING FINISHING PROCESSES 150-200 kg of water/kg of product SIZING PROCESSES
- 7. Dyeing Machineincludes the equipment which is used for preparation and softening processes. The flow chart for Dyeing Processes in the Mill; Preparation Pre-Washing Dyeing Back-Washing Water consumed in these processes is; about 40 % of the total water used through this whole production line of the Mill Softening
- 8.
- 9. WATER CONSUMPTION REDUCTION STUDY PROCESSREVIEWING DETERMINING THE WATER USAGE IN DYING PROCESS ASSESSMENT OF THE WATER CONSUMPTION REDUCTION OPTIONS ASSESSMENT OF TECHNICAL FEASIBILITY OF CHOSEN OPTIONS Through out the study;
- 10. Brain stormswith the managers of the selected Textile Mill / Site Visits Literatural Reviews European Integrated Pollution Prevention and Control (IPPC) Reference Document on Best Available Techniques (BAT) for the Textiles Industry was accepted as main reference document. WATER CONSUMPTION REDUCTION STUDY
- 11. Rerouting theRope-Guide Counter-Current Washing in Back-washing
- 12. What is Rope-Guide? •Different Dyeing recipes exist for Different Denim Products. • Each recipe has its own application method in the Textile Mill. • There are four Dyeing Machines in the Mill, which includes; Preparation, Pre-washing, Dyeing and Back-washing Units in different numbers of their application tanks. •Therefore, there are some differences of applications of different Dyeing recipe. • To adjusting the following Dyeing recipe application to the Dyeing machine, Rope-Guide is used in the Mill.
- 13. Prepara tion Tank Pre- wash ing 1 Pre- wash ing 2 Pre- wash ingN Dyein g 1 Dyein g 2 Dyein g N Back- washi ng 1 Back- washi ng 2 Back- washi ng N Route of Rope-Guide (Dyeing Recipe A) Water Flow New Route of Rope-Guide (Dyeing Recipe B) • Rope guide is fixed to the rope which will be going through the Dyeing processes, and it determines the route of the rope which will be dyed. • ReroutingRerouting is to change the route of the rope-guide in an environmental friendly way, which provides reduction of water consumption.
- 14. 5 dyeingrecipes (X, Y, Z, W, U) in different dyeing machines Application Frequency within the period of the study: 30% of the number of the total dyeing recipe Rerouting is applicable Rerouting alternatives were determined and application conditions were examined and application was achieved. Water saving was determined. The effect of varying dyeing time was observed. The duration of dyeing can be changed between 165 min and 1000 min. Rerouting the Rope-Guide Materials and Methods
- 15. Dying Tank used as washingtank Washing Tank Washing Tank Fresh water feeding tank Q Q/3 Q/3Q/3 Dying Tank used as washing tank Washing Tank Washing Tank Fresh water feeding tank Q Q/2 Q/2 Fresh water Dying Machines 3 and 4 Dying Machines 1 and 2 Q Q/2 Q/2 q
- 16. According todata obtained from the facility; for the three months, in which the rerouting has taken place, the percentage of those types of dyeing recipes are determined as 30 % of the total production. Preparation, dying, washing and softening processes are defines “rope dyeing processes” by the facility. Amount of consumed water in rope dyeing process(L) Washing water consumption (new method) (L) Washing water consumption (old method) (L) Difference (L) Reduction in total (X,Y,Z,W,U) water consumption (%) X 110872 56000 63800 7800 7,0 Y 93479 25000 40600 15600 16,7 Z 265683 41000 51000 10000 3,8 W 156767 85500 93300 7800 5,0 U 163750 92000 99800 7800 4,8 Total 790551 299500 348500 49000 6,2 Rerouting the Rope-Guide Reduction in Water Consumption
- 17. March-April-Mai total wateruse for rope dying processes Amount of consumed water (L) March 42475000 April 28191000 Mai 31736000 Total 102402000 Rerouting the Rope-Guide Reduction in Water Consumption Water consumed in three months for X,Y,Z,W,U type dyings (30% of total consumption) can be calculated as follow; 102402000 L * 0.3 = 30720600 L Water reduction amount in three months is equal to 30720600 L * 0.062 = 1,904,677 L
- 18. Within theselected five specific type of dying the effect of the method was investigated. By investigating this effects, it was obviously seen that water saving can be achieved. The effect of duration of dying on water saving was also investigated: when there is an additional freshwater feeding tank to the washing tank there is not significant effect of duration of dying on the water saving percentage. Rerouting the Rope-Guide Conclusion
- 19. • The moreimportant consideration is to achieve the required washing efficiency by using less amount of rinsing water. • The counter-current washing principle is the most common and efficient one among those techniques.
- 20. Counter-current washing isoften practiced by introducing raw water into the last wash of the washing series. The wastewater is then circulated from the last step to the next preceeding step and so on up the line. The cleanest product is washed with the cleanest water and and the most contaminated product is washed with dirtiest water. The system leads to huge savings in water use. Material Flow Water Flow
- 21. Typical water savingsobtained by counter-current washing Number of washing tank Water saving (%) 2 3 4 5 50 67 75 80 Source:(US EPA, 1995) Since preparation and dying processes are typically continuous, counter-current washing can be used to great advantage for water conservation in washing processes. The principle of counter-current washing in textile industry is simple and usually not expensive or difficult to implement.
- 22. Filtrate System Savingin water (%) Direct counter-current 50-80 Split flow counter-current 40-65 Source: Sillanpää, 2005 •Sillanpää states that the one of the developed techniques is the split flow counter current washing which is the variation of counter-current washing. •Because the various reasons for each industry, the counter-current washing was modificated and called as split flow counter current washing Product Flow Fresh water Wastewater Washin g 2 Washin g 1 Washin g 3 Washin g 4 Wastewater Wastewater
- 23. Reasons for usingsplit flow counter current washing The company uses cotton as raw material. According to Textile Sector Environmental Report; in opposition of dying of synthetic raw materials, counter-current washing applications are not common in cotton dying. The cotton fiber pollution is the main reason for that. For the last washing tank, from which water is sent to the previous, the cotton fiber pollution is minimum. Therefore using filter is a solution and does not create a clogging problem. But for the washing tanks before the last tank, the fiber pollution is a problem, because the cotton lets its fiber in a suspended situation in these tanks at most. For this reason, it is thought that the filter clogging would be a big problem if direct counter-current washing were applied. Product Flow Fresh water Wastewater Washin g 2 Washi ng 1 Washin g 3 Washin g 4 Wastewater Wastewater Filter
- 24. 3 dyeing recipes(A, B, C) were selected. Two methods of washing was applied. Normal Flow Washing (old system) Split flow counter current washing (new system) F<Q where the product quality is said to be the same. Water saving was determined. Analysis of wastewater characteristics for water from each washing tank was done to compare with literatural truth. Samples from each washing tanks were taken after the retention time was exceed. Counter-Current Washing in Textile Industry Materials and Methods Product Flow Fresh water WW 2 1 3 4 WW WW WW Product Flow Fresh water ww 21 3 4 ww ww Filter Q F F/3 F/3 F/3 Q/4 Q/4 Q/4 Q/4
- 25. Counter-Current Washing A Typerecipe Product Flow Fresh water ww Washin g 2 Washin g 1 Washin g 3 ww ww 300 L/min 100 L/min 100 L/min 100 L/min 2 3 Product Flow Fresh water Washin g 1 Washin g 2 Washin g 3 ww ww Filter 185 L/min 92,5 L/min 92,5 L/min a b c Flow diagram for new system washing of dying type A Flow diagram for old system washing of dying type A • Each washing tank is 1000 L • 500 min washing period •Retention time is 10 minute for each tank • Flowrate of freshwater is 300 L/min •Each washing tank is 1000 L •115 min washing period • Retention time is 10.8 for first two and 5.4 min. •Flowrate of freshwater is 185 L/min 1
- 26. Counter-Current Washing B Typerecipe Flow diagram for new system washing of dying type B Flow diagram for old system washing of dying type B • First washing tank is 1600 L, where others are 1000 L. • 330 min washing period •Retention time is 30 min for first tank where it is 18 min for others. • Flowrate of freshwater is 275 L/min •First washing tank is 1600 L, where others are 1000 L. •330 min washing period • Retention time is 39 min for first tank and 24.3 min for 2,3,4 and 6 min for WT 5. •Flowrate of freshwater is 165 L/min Product Flow Was hing 2 Waste water Was hing 4 Was hing 3 Waste water Waste water 275 L/min 55 L/min 55 L/min 55 L/min 1 1 2 3 Waste water Was hing 1 Waste water Was hing 5 4 5 55 L/min 55 L/min Product Flow Fresh water Washin g 2 ww Washin g 3 ww Washin g 5 Filter 165 L/min 41,25 L/min Washin g 1 ww Washin g 4 ww 41,25 L/min 41,25 L/min 41,25 L/min a b cdef
- 27. Counter-Current Washing C Typerecipe Flow diagram for new system washing of dying type C Flow diagram for old system washing of dying type C • First washing tank is 1600 L, RT =30.7 minutes • the other WT 1600 L with RT=19.2 minutes • 330 min washing period • Flowrate of freshwater is 260 L/min •First washing tank is 1600 L, where others are 1000 L. •115 min washing period • Retention time is 47 min for first tank and 29.6 min for 2,3,4 and 7.5 min for WT 5. •Flowrate of freshwater is 135 L/min Product Flow Was hing 2 Wastew ater Was hing 4 Was hing 3 Wastew ater Wastew ater 260 L/min 52 L/min 52 L/min 52 L/min 1 2 3 Wastew ater Was hing 1 Wastew ater Was hing 5 4 5 52 L/min 52 L/min Product Flow Fresh water Washin g 2 ww Washin g 3 ww Washin g 5 Filter 135 L/min 33,75 L/min Washin g 1 ww Washin g 4 ww 33,75 L/min 33,75 L/min 33,75 L/min a b cdef
- 28. Counter-Current Washing A Typerecipe Results for each tank in dying type A, old system Dying Type A Old System Washing Tank 2 (2) Washing Tank 3 (3) TSS (mg/L) 196 44 TDS (mg/L) 2348 1760 Color (Pt-Co) 6920 3320 Turbidity(NTU) 690 389 Alkalinity (mg/L CaCO3) 870 680 COD (mg/L) 1002 400 Conductivity (s/cm) 3470 2760 pH 11,1 10,62 Results for each tank in dying type A, new system Dying Type A New System Washing Tank 2 (c) Filter Inlet (Washing tank 3) (a) TSS (mg/L) 322 34 TDS (mg/L) 5198 882 Color (Pt-Co) 9060 2515 Turbidity(NTU) 726 354 Alkalinity (mg/L CaCO3) 1874 310 COD (mg/L) 1372 264,5 Conductivity (s/cm) 8660 1221 pH 11,8 9,5 Pollution concentration is less in last washing tanks for new system where it is more in 2nd washing tank.
- 29. Counter-Current Washing B Typerecipe Results for each tank in dying type B, old system Results for each tank in dying type B, new system Dying Type B Old System (1) (5) TSS (mg/L) 206 26 TDS (mg/L) 13456 688 Color (Pt-Co) 8600 4750 Turbidity(NTU) 360 543 Alkalinity (mg/L CaCO3) 3300 220 COD (mg/L) 3740 238 Conductivity (s/cm) 17850 969 pH 12,03 9,75 Dying Type B New System 1 (f) 5 (a) TSS (mg/L) 546 22 TDS (mg/L) 24134 558 Color (Pt-Co) 22300 935 Turbidity(NTU) 1709 209 Alkalinity (mg/L CaCO3) 6960 178 COD (mg/L) 4823 102 Conductivity (s/cm) 30400 893 pH 12,17 9,08
- 30. Counter-Current Washing C Typerecipe Results for each tank in dying type C, old system Results for each tank in dying type C, new system Dying Type C Old System (1) (5) TSS (mg/L) 54 35 TDS (mg/L) 2688 908 Color (Pt-Co) 2280 1330 Turbidity(NTU) 138 282 Alkalinity (mg/L CaCO3) 1150 440 COD (mg/L) 511 125 Conductivity (s/cm) 4200 1366 pH 11,12 10,18 Dying Type C New System 1 (f) 5 (a) TSS (mg/L) 108 14 TDS (mg/L) 3592 632 Color (Pt-Co) 2860 715 Turbidity(NTU) 251 94 Alkalinity (mg/L CaCO3) 1548 240 COD (mg/L) 650 87 Conductivity (s/cm) 6470 954 pH 11,81 9,48
- 31. Counter-Current Washing Reduction inWater Consumption Old System water consumption (L/min) New System water consumption (L/min) Reduction in water consumption (%) Type A 300 185 38 Type B 275 165 40 Type C 260 135 48
- 32. All theprocesses in the Textile Mill were investigated to identify the water conservation opportunities. As well as the Literatural Review, after some site visits to the facility the processes were detected and the possible changes especially related to the water consuming processes were determined. Possible water use reduction techniques were detected. The techniques were applied in the facility. Conclusion for the Presentation
- 33. The waterconservations obtained through the techniques of “Rerouting the Rope-Guide” and “Split Flow Counter Current” were determined in the application base. For counter-current washing, the washing water were analysed to compare the character of it, with the literatural knowledge. Future Work: Determination of the total effect of this water conservation applications on the water consumption of the facility. Conclusion for the Presentation
- 34. Thank You foryour Attention and Interest on Cleaner Production !!! VISHONAL
Editor's Notes
- #2 Welcome to all! First let me introduce myself. I am Vishal Kumar Kushwaha, and studing in VJTI,Mumbai.
- #3 According to literatural information a huge amount water is consumed in this sector.
- #5 This study has been conducted on one of the major textile mills in Turkey (with a capacity of 20,000 tons of denim fabric per year). The processes applied in the factory are cotton fiber production by spinning, fiber dyeing, sizing and finishing.
- #6 The production in the factory continues for 24 h/day with 3 shifts/day. The water consumption of the factory is about 2000 m3/day and the chemical consumption is approximately 1000 ton/month. Over 100 textile chemicals including dyestuffs and auxiliaries are used in the wet processes in the factory. And the company has its own wwtp and co-generation units.
- #11 From the beginning to the end of the study there have been organized a lot of site visits to the factory. The process was reviewed. And also participation of the workers and managers of the factory was achieved.
- #12 Throughout some techniques which are mentioned in BAT Reference documents and literature, also the techniques which are possible and specific to the process of the mill, two techniques are applied. Rope: consist of a number of Cotton fibers.
- #13 ForeRope guide is fixed to the rope which will be going through the Dyeing processes.
- #15 After selection of the dyeing recipe, rerouting alternatives were determined.
- #18 The total effect of rerouting the rope-guide on the total water consumption of the factory will be calculated.
- #23 As well as the counter current washing there are some different applications in industry. One of them is which silenpaa states.
- #24 Environmental Technology Program for Industry, 1998 Let’s look at the figures below, which represents the old washing system and new washing system split flow counter-current washing application in this company. As you see in Figure 4, there is a need for a filter system for counter flow washing water.