This document discusses various methods for water conservation in textile processing, which can reduce effluent volume and treatment costs. Key methods mentioned include improving housekeeping to fix leaks, installing water meters, reusing cooling and washing water through countercurrent flow systems, and optimizing chemical usage. Case studies show that these measures have successfully reduced fresh water consumption by up to 40% and lowered biochemical oxygen demand in effluent.

1. WATER CONSERVATION REDUCED TOTAL EFFLUENT VOLUME EASY TO HANDLE REDUCED VOLUME EFFLUENT FOR TREATMENT SAVINGS IN COST OF EFFLUENT TREATMENT PLANT SAVINGS IN OPERATION COST POSSIBLE TO ACHIEVE 25% WATER CONSERVATION IN SOME CASES

2. COMMON SOURCES OF WATER WASTAGE POOR HOUSE KEEPING EXCESSIVE USE OF WATER IN WASHING OPERATION POOR HOUSE KEEPING BROKEN AND MISSING VALVES UNATTENDED LEAKAGES FROM PIPES AND HOSES HOUSE KEEPING MEASURES PLUGGING LEAKAGES CHECKS ON RUNNING TAPS INSTALLATION OF WATER METERS OR LEVEL CONTROLLERS ON MAJOR WATER CARRYING LINES

3. EXCESSIVE USE OF WATER IN WASHING OPERATION INEFFICIENT WASHING MACHINES EXCESSIVE LONG WASHING CYCLE USE OF FRESH WATER AT ALL POINTS OF WATER USE

4. SOME MEASURES FOR WATER CONSERVATION REUSE OF COOLING WATER IN SOME MACHINES WATER IS PASSED THROUGH COOLING COILS FOR REDUCTION IN BATH TEMPERATURE SUCH COOLING WATER BECOMES HOT AND IN MAJORITY OF CASES ALLOWED TO GO TO DRAIN MEASURES COLLECT COOLING WAETR IN TO SEPARATE TANK RECYCLE THE COOLING WATER OR CONNECT THE TANK TO MAIN WATER LINE TO ACHIEVE RECYCLING

5. COUNTER CURRENT FLOW OF WASHING CHEMICALPROCESSING SEQUENCE (TYPICAL FOR COTTON) DESIZE SCOUR MERCERISE BLEACH DYE PRINT FINISH SEVERAL WASHES ARE ESSENTIAL AFTER EACH PROCESS SEQUENCE

6. WASHING CONTINUOUS BATCH WISE CONTINUOUS WASHING RANGE COUNTER CURRENT FLOW WASHING LEAST CONTAMINATED WATER FROM THE FINAL WASH COMPARTMENT IS REUSED IN THE LAST BUT ONE COMPARTMENT AND SO ON UNTILL THE WASH WATER REACHES THE FIRST WASH COMPARTMENT WHERE IT IS FINALLY DRAINED

7. COUNTER CURRENT WASHING IS BUILT IN TO THE PROCESS FLOW SHEET OF NEW TEXTILE MILLS COUNTER CURRENT FLOW WASHING SYSTEM CAN ALSO BE IMPLEMENTED IN A MILL WHERE IT IS NON EXISTANT

8. COUNTER CURRENT FLOW WASHING IN BATCH WISE OPERATION BATCHWISE WASHING OPERATION AFTER DESIZING, SCOURING AND BLEACHING IN KIER OR J-BOX IS CARRIED OUT IN ROPE FORM REUSABLE WATER IS COLLECTED IN A COMMON SUMP (UNDER GROUND TANK) PUMP THE COLLECTED WATER FROM SUMP TO APPROPRIATE WASHING MACHINE COUNTER CURRENT FLOW WASING SAVES CONSIDERABLE QUANTITY OF WATER THUS REDUCING EFFLUENT VOLUME

9. POINTS TO REMEMBER BEFORE IMPLEMENTING COUNTER CURRENT FLOW WASHING SYSTEM IT IS ADVISABLE TO FIND OUT EXPERIENCE OF THE UNIT WHICH HAS IMPLEMENTED THE SYSTEM IN TERMS OF OPERATIONAL DIFFICULTY EFFECTIVENESS OF SYSTEM PRODUCT QUALITY

10. IF DECIDED TO IMPLEMENT THEN REMEMBER PIPES IN THE PLANT ARE PROPERLY COLOUR CODED TO INDICATE FRESH WATER LINES AND USED WATER LINES TRAINING SHOULD BE GIVEN TO OPERATOR TO EXPLAIN THE REVERSE WATER FLOW MAKE SURE THAT WATER TREATMENT PLANT FUNCTIONS AT THE REQUIRED EFFICIENCY BECAUSE OF INCREASED EFFLUENT CONCENTRATION DUE TO REDUCED VOLUME

11. CASE STUDIES FOR WATER CONSERVATION RECOVERY AND REUSE OF WATER IN TEXTILE MILL IN MUMBAI ( STUDY BY BOMBAY TEXTILE RESEARCH ASSOCIATION) A DIAGNOSTIC STUDIES WERE UNDERTAKEN TO EXAMINE THE CONSERVATION AND REUSE OF WATER IN WET PROCESSING

12. MEASURES SUGGESTED REDUCED RATE OF WATER SUPPLY TO WASHING MACHINES COUNTER CURRENT FLOW OF WASHING WATER ON OPEN SOAPER, MERCERISING MACHIINE, J-BOX etc. APPLICATION OF STATIC WASHES IN JIGGERS IN PLACE OF OVER FLOW WASHES RECYCLING OF WATER USED FOR WASHING OF BLANKET ON PRINTING MACHINE

13. BULK TRIALS FOR SUCH CONSERVATION AND REUSE MEASURES WERE CARRIED OUT FOR PROCESSING OF NUMBER OF FABRIC VARIETIES

14. TOTAL FRESH WATER CONSUMPTION BEFORE SURVAY 1,83,350 lit/day AFTER SURVAY 1,10,950 lit/day WATER SAVING ~ 73,000 lit/day WATER COST Rs. 60 / 10,000 lit SAVING Rs. 420 / day ANNUAL SAVING ~ Rs.1,50,000

15. CASE STUDY REUSE OF WASTE WATER FROM DYEING (BINNY TEXTILES, CHENNAI) SUCCESSFULLY REPLACED THE USE OF FRESH WATER BY EQUIVALENT VOLUME OF HARD TO TREAT DYEING WASTE WATER FOR QUENCHING OF HOT ASH FROM BOILER HOUSE 520kg/day REDUCTION IN BOD CONTENT OF EFFLUENT WATER IT WAS CONFIRMED THAT THERE WILL BE 20 % REDUCTION IN BOD CONTENT OF EFFLUENT

16. CASE STUDY REUSE OF WASTE WATER FROM SIZING (BINNY TEXTILE CHENNAI) TO AVOIDE SPONTANEOUS COMBUSTION,FRESH WATER IS USED FOR WETTING COAL IN THE YARD. THE COAL WETTING IS CARRIED OUT BY HIGH ORGANIC STRENGTH WATER FROM SIZING OPERATION. NET SAVING IS A TOTAL ELIMINATION OF WASTE WATER FORM SIZING. REDUCTION IN BOD LOAD IN EFFLUENT WATER ~ 25%.

17. OPTIMISATION OF CHEMICAL USAGE CAREFUL REVIEW OF THE USE OF VARIOUS PROCESS CHEMICALS REVEALS THAT IT IS POSSIBLE TO REDUCE THE AMOUNT OF PROCESS CHEMICALS BY 20 - 25 %