sustainable and eco friendly alternatives in textile wet
TRANSCRIPT
Sustainable and Eco Friendly
Alternatives in Textile Wet Processing
area - ATIRA Developments
Sarika Singh, Dr. Md.S Rahman, B S Parikh
Ahmedabad Textile Industry’s Research Association
P O Ambawadi Vistar, Ahmedabad
Date: 01/03/2013
Fibre
1. Spinning Waxes/Oils
2. Sizing Starch, Binder,
Lubricants, PVA etc
3.Weaving
Fabric
4. Fabric Preparatory Process
5. Dyeing /Printing Dyes, Soda Ash, Caustic
Soda, Sodium chloride/Glauber Salt,
Soap etc
* In Knits Manufacturing, sizing is not done.
Textile Manufacturing process
Textile Wet Processing
• Singeing
Removal of hairiness
• Desizing
Removal of sizing ingredients
• Scouring
Removal of Oils, Lipids, Waxes and Pectin from substrate.
• Hypo Bleaching (optional)
Decolorizes coloring matter
• Peroxide Bleaching
Decolorizes coloring matter
• Mercerization
Dimensional stability, Absorbent
• Dyeing / Printing Coloration
Chemicals used in conventional
Preparatory processes • Singeing
• Desizing
In oxidative – Hydrogen peroxide, Caustic soda, Wetting
agent, Sequestering agent, Peroxide Stabilizers etc.
In Enzymatic - Enzymes, Wetting agents, Acetic Acid.
• Scouring–Caustic soda, Wetting agent, Sequestering
agent,
• Hypo Bleaching -Sodium Hypochlorite
• Peroxide Bleaching- Hydrogen peroxide, Caustic soda,
Wetting agent, Sequestering agent, Peroxide Stabilizers
etc
• Mercerization- Caustic Soda, Acids
Environment Scenario
Conventional wet-processing requires use of salts & alkalis, which results in increase in pollution load in terms of T.D.S, color, C.O.D. and heavy metals.
Most important environmental issue facing manufacturing business in India is development of “Green or Environment Friendly” technologies/products.
ATIRA’s developed processes
• Singeing : Can be opted.
• Desizing
In oxidative – Hydrogen peroxide, Caustic soda,
Wetting agent, Sequestering agent, Peroxide
Stabilisers etc.
In Enzymatic - Enzymes, Wetting agents, Acetic
Acid.
• Scouring–Caustic soda, wetting agent,
Sequestering agent.
• Hypo Bleaching-Sodium Hypochlorite
• Peroxide Bleaching- Hydrogen peroxide, Caustic
soda, Wetting agent, Sequestering agent, Peroxide
Stabilizers etc
• Mercerization- Caustic Soda, Acids
Chemicals used in ATIRA’s Developed
process •Desizing cum scouring
Enzymes, Wetting agents, Acetic acid
•Peroxide Bleaching-
Hydrogen peroxide ( 60 % reduction in qty)
Wetting agent, Sequestering agent, Peroxide
Stabilizers (60 % reduction in qty) , Caustic
Soda (90% reduction in qty) etc
(All chemicals are used in significantly less
quantity)
•Mercerization- Caustic Soda, Acetic Acid.
Benefits to ETP
Quality of fabric produced is similar to conventional one.
Contribution to Total Suspended Solids: In conventional process, 7-8 % fibre loss In enzymatic process-2-3 % fibre loss Fibres ( going to ETP) which is
considered as Total Suspended Solids (TSS) will be reduced up to 5% considering Fiber loss only.
Benefits to ETP
Less times of neutralization, less TDS
Almost neutral process, Less Wash
Off water.
Enzymes are Bio-degradable , less
load to ETP Reduced waste-water volume and
pollutant load, reduces cost of Waste-water treatment
Reactive Dyeing
Conventional
Dyes
Sodium
chloride /
Glauber salt
Soda ash
Sodium
Hydroxide
Soap
ATIRA Process
Dyes
Sodium
chloride /
Glauber salt
Soda Ash (70%
less qty)
Sodium
Hydroxide
Soap
Water used in exhaust pretreatment
Dyed fabrics
ATIRA’s Process Conventional
Process
13 baths of each 500 ltrs
and 6 of each 500 ltrs
rinses
Total water : 10,500 lts
for lots of 400-500 kgs
fabric
10 baths of each 500 ltrs
and 4 of each 500 ltrs
rinses
Total water : 7000 lts for
lots of 400-500 kgs fabric
water saving
by 20-25 %
The waste dye liquor & 1st wash off collected are tested :
Sample
Description
Results
pH TDS
(mg/L)
COD
(mg /L)
BOD
(mg/L)
Waste Dye
liquor
Control 10.09 25946 1248 541
Trial 10.20 5686 392 127
1st Post wash
Control 8.61 1438 344 110
Trial 8.39 1348 40 <10
Standard Methods for the Examination of Water & Waste Water, 21st edition, prepared & published by APHA-AWWA-WPCF, USA & BIS method
Results
High productivity: Due to no reaction time
for salts & less neutralization due to very
low alkali in dyeing process, less times is
required for dyeing
Benefits to ETP are more in terms of Total
suspended solids, total dissolved solids,
COD, BOD etc
Developed process are economical due to
less use of chemicals & auxiliaries.
Thank You…..
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