Design and development of composite nonwoven filter for

pre-filtration of textile effluents using nano technologyUnder the guidance of

Dr.J.P.Singh & Dr. Devendra prasadUPTTI Kanpur

&Dr. Anurag Shrivastava

DMSRDE KanpurBy

Vivek Kumar Sharma

Department of Textile TechnologyUttar Pradesh Textile Technology Institute Kanpur

ABSTRACT• “Waste Water filtration as a global challenge

for textile dyeing industry in the present time and Nanofibre filtration as an advanced solution”

• This project discusses a Cleaner approach for minimization of waste particle in dyeing effluents with good flux permeability.

• The removal of stuff by Nanofibre (polyethersulfone) film coated over nonwoven needle punched fabric (Polyester) was evaluated for reactive dye. Results showed that membrane treatment is a promising advanced treatment option for pollution control for textile industry effluents

introduction• Textile industry is one of the major industries in the world and

plays a major role in the economy of country

• About 200 L of water are used to produce 1 kg of textile.

• The waste water produced during this process contains large amount of dyes and chemicals containing trace metals such as Cr, As, Cu and Zn which are capable of harming the environment and human health.

• The textile waste water can cause haemorrhage, ulceration of skin, nausea, skin irritation and other health issues.

Intro......................• The effluent water discharged from the textile industries undergoes

various physio-chemical processes such as flocculation, coagulation and ozonation followed by biological treatments for the removal of nitrogen, organics, phosphorous and metal.

• The whole treatment process involves three steps: primary treatment, secondary treatment and tertiary treatment.

• The primary treatment involves removal of suspended solids, most of the oil and grease and gritty materials.

Intro......................• The secondary treatment is carried out using

microorganisms under aerobic or anaerobic conditions and involves the reduction of BOD, phenol and remaining oil in the water and control of color.

• The tertiary treatment involves the use of electro dialysis, reverse osmosis and ion exchange to remove the final contaminants in the wastewater.

Intro......................• So if the prefiltration of textile effluent is good the other

next process results will go even better.• Important characteristics for achieving high performance

UF and MF are high flux in combination with desired selectivity and low fouling.

• We all know that non woven fabric is mostly used for filtration process of air and water for her messing structure and applying the Nanofibre over it is give control the pore size and give even better filtration results.

Filter method (why filtration)

• Various conventional methods are being used to treatment effluents, including biological methods, physic-chemical treatment (coagulation and flocculation), adsorption, ion-exchange and chemical treatment with oxidizing agents.

• But limitation of all these methods, however, is that-1. Total colour removal is not achieved.2. Chemical by -products are introduced3. A sludge management’s problem is also a limitation arising from the use of chemicals.4. Thus the water quality produced does not meet the requirement for textile reuse.5. Biological treatment – because of low bio degradability of most dye and chemicals used in

textile industry, their biological treatment by the activated sludge process does not always achieve great success.

6. Coagulation-flocculation treatment- generally used to eliminate organic substance, but the chemicals used in this process have no effect on the elimination of soluble dye stuffs.

7. Although this process effectively eliminates insoluble dyes, its value is doubtful because of the cost of treating the sludge and the increasing number of restrictions concerning the disposal of sludge.

Filter method (why filtration)

• Advantage of Membrane based process- • Process using membrane provide very interesting

possibilities for the separation of hydrolyzed dye-stuff and dyeing auxiliaries that simultaneously reduce coloration and BOD/COD of the waste water.

• Membrane based processes provide appealing possibilities of separating hydrolysed dye stuff and dyeing auxiliaries, thereby reducing colouration and COD removal.

• No specific temp is required for process.• No sludge formation in process.

PES Nanofibre

• PES was selected as the Nanofibre membrane material due to its high thermal and chemical resistance also its appropriate mechanical properties.

LITERATURE REVIEW

Fig show

A) Size comparison of electro spunNanofibre;B) Electro spunNanofibre compared to a normal human hair.

{Fig from- Microfiltration Membranes via Electro spinning of Polyethersulfone Solutions research will done by M. Sc. BintasanKwankhao}

Production Techniques(Nanofibre)

The main processing techniques for preparation of polymer Nanofibre.

• Drawing,• template synthesis, • phase separation, • self-assembly and • electro spinning. .

Production Techniques(Nanofibre) Electro-Spinning

• Electro spinning is a novel production technique of continuous ultrafine fibers (with diameters of 10 μm down to 10 nm) based on forcing a polymer melt or solution through a spinnerets with an electrical driving force. The main advantages of this technique are relatively easiness (easy to setup), high speed, low cost of the process, high versatility allowing control over fiber diameter, microstructure and arrangement and vast materials selection.

Fig 1

Fig 2

Parameter Investigation• Conversion process of polymer solution into Nanofibre through

electro spinning is affected by several different parameters including: Parameter Effect on fiber morphology

Viscosity (polymer solution) ↑

Fiber diameter ↑ (from beads to beaded fibers to smooth fibers)

Surface tension ↑ Number of beaded fibers and beads ↑ Solution conductivity ↑ Fibers diameter ↓ Evaporation of solvents↑ Fibers exhibit micro texture (pores on fiber

surfaces) Applied voltage ↑ Fiber diameter ↓ initially,

Spinneret to collector distance ↑

Fiber diameter ↓ (beaded morphologies occur if the distance between the capillary and collector is too short

Humidity ↑ Fiber diameter ↓ (pores on fiber surfaces), then fiber diameter ↑

Flow rate ↑ Fiber diameter ↑ (beaded morphologies occur if the flow rate is too high)

Figure 2.3:A) Beaded electrospunnanofibers

Figure 2.3:B) Porous Nanofibre

Applications

Needle Punched Fabric• Needle punching is the oldest method of producing nonwoven products. • Needle punched fabrics finds its applications as blankets, shoe linings,

paper makers felts, coverings, heat and sound insulation, medical fabrics, filters and geotextiles.

Basic Principle -

Working principle of Needle punching Machine

Experimental Part

1. Preparation of nonwoven material2. Coating of Nanofibre over Nonwoven material3. Preparation of wastewater4. Filtration

Preparation of nonwoven material• In this project we manufacture nonwoven by regenerated

round shaped polyester fibre (staple length 51mm and fineness 1.5 denier) by UPTTI lab model machine (model- Trytex) with two different weight sample of 130 and 195 gsm.

Sr. No.

Parameters Sample A(20 gram fibre)Each 3 Sample

Sample B(30 gram fibre)Each 3 Sample

1 Sample Size 10x25 inch 10x25 inch2 Weight of sample 20 gm 30 gm3 GSM of sample 130 1954 Pore size 50-300 50-3005 Thickness 2.1 mm (approx) 3.5 mm (approx)

Machine parameter1 Feed mm /Stroke 10 102 Punches /min 35 35

Preparation of Nanofibre• Polyethersulfone (PES) (Mw= 58000 and density of 1.37 g/cm3) was

from DMSRDE lab. As the sub layer of the membrane a technical polyester non-woven was used. The chemical structure of PES and DMF is shown in figure. The solvents N,Ndimethylformamide (DMF) were obtained from DMSRDE lab.

Polyethersulfone (PES) N,Ndimethylformamide

Different Solution viscosity -

. PES (%) Viscosity (Pa s)

9 0.10

15 0.52

22 1.82

Electro spinning conditionsSr. No. Parameter PES nanofibrous

Membrane(first)

PES nanofibrousMembrane

(Second)

PES nanofibrousMembrane

(third)

1 PES Concentration 15wt% 15wt% 15wt%

2 Applied voltage 20 kV 20 kV 20 kV

3 Feed rate 25 micro lt/min 25 micro lt/min 25 micro lt/min

4 Spinning distance 25 cm 25 cm 25 cm

5 Collection time 2 h 3 h 5 h

6 outer diameter of theinjector

15 mm 15 mm 15 mm

Photo image of nanofiber membranes obtained by electros pining from 15% PES in DMF using the conditions, i.e., a spinneret-to-collector distance of 25 cm, an applied voltage of 20 kV, a flow rate of 25 μL/min, a spinneret diameter of 0.8 mm, stationary substrate set-up and Aluminium foil served as the substrate.

Photo image of nanofiber

Composite Membrane

No of sampleSr. No. Sample no. Non woven sample Nanofibre layers

According fibre weight (grams)

According Spraying time (hours)

1 S1 130 2

2 S2 130 3

3 S3 130 5

4 S4 195 2

5 S5 195 3

6 S6 195 5

Waste water Preparation• Preparing a waste water Sample with Medium shade Using

Salt Concentration 20g/l Nacl, 8g/l Na2CO3 & Dye 50 mg/Lit.

Method of filtration

1. Due to non woven fabric character the pore size will deform in pressure and force applied so the minimum tension will give better pore size.

2. The sample volume will filtered is 250 ml solution.

Result & DiscussionFLUX PERMEABILTY

• Flux Permeability through WaterSr. No.

Sample Classification Filtered Volume Time

Non-Woven(GSM)+ Nano Fibre Time For Spreading (Hours)

ml Second

A. Without SampleFor Apparatus Flux Permeability

250 10.56

B. With Sample1 130+2 250 11.202 130+3 250 11.823 130+5 250 14.104 198+2 250 15.455 198+3 250 18.566 198+5 250 21.77

Result & DiscussionFLUX PERMEABILTY

Flux Rate = Flow Rate/Area of Membrane = 81.81/0.002828 = 28981.86 L/m2/hr

Flow Rate = total volume/total time (l/hr) = 250ml/11 sec = 250*60*60/11*1000 (l/hr) =81.81 Lit/hour

Sr. No. Sample Classification Flow Rate Flux RateNon-Woven(GSM)+ Nano Fibre Time For

Spreading (Hours)Lit/hour L/m2/hr

A. Without SampleFor Apparatus Flux Permeability

81.81 28981.86

B. With Sample

1 130+2 78.26087 27673.572 130+3 76.14213 26924.373 130+5 63.82979 22570.654 198+2 58.25243 20598.455 198+3 48.49138 17146.886 198+5 41.3413 14618.56

Flow Rate

Without Sample 130 GSM + 2 Hour

130 GSM + 3 Hour

130 GSM + 5 Hour

198 GSM + 2 Hour

198 GSM + 3 Hour

198 GSM + 5 Hour

0

10

20

30

40

50

60

70

80

90

Flow Rate (Lit/Hour)

Flux rate

Without Sample 130 GSM + 2 Hour

130 GSM + 3 Hour

130 GSM + 5 Hour

198 GSM + 2 Hour

198 GSM + 3 Hour

198 GSM + 5 Hour

0

5000

10000

15000

20000

25000

30000

35000

Flux rate (L/m2/h)

Result & DiscussionFLUX PERMEABILTY

• Flux Permeability through Waste Water

Sr. No.

Sample Classification Filtered Volume Time Flow Rate Flux Rate

Non-Woven(GSM)+ Nano Fibre Time For Spreading (Hours) ml SecondLit/hour L/m2/hr

A. Without SampleFor Apparatus Flux Permeability 100 12 81.81 28981.86

B. With Sample

1 130+2 100 25 14.4 5091.938

2 130+3 100 28.45 12.65 4474.462

3 130+5 100 33.44 10.76 3806.772

4 198+2 100 45.56 7.901 2794.083

5 198+3 100 48.78 7.380 2609.644

6 198+5 100 55.12 6.531 2309.478

130 GSM + 2 Hour 130 GSM + 3 Hour 130 GSM + 5 Hour 198 GSM + 2 Hour 198 GSM + 3 Hour 198 GSM + 5 Hour0

2

4

6

8

10

12

14

16

Flow Rate( lit/Hour)

flow rate of different type of sample through dyeing waste water

130 GSM + 2 Hour 130 GSM + 3 Hour 130 GSM + 5 Hour 198 GSM + 2 Hour 198 GSM + 3 Hour 198 GSM + 5 Hour0

1000

2000

3000

4000

5000

6000

Flux rate (L/m2/h)

flux rate of different type of sample through dyeing waste water

Comparison flux rate of different type of sample through

dyeing waste water and fresh water

130 GSM + 2 Hour 130 GSM + 3 Hour 130 GSM + 5 Hour 198 GSM + 2 Hour 198 GSM + 3 Hour 198 GSM + 5 Hour0

5000

10000

15000

20000

25000

30000

Comparison flow rate of different type of sample through dyeing waste water and fresh water

130 GSM + 2 Hour 130 GSM + 3 Hour 130 GSM + 5 Hour 198 GSM + 2 Hour 198 GSM + 3 Hour 198 GSM + 5 Hour0

10

20

30

40

50

60

70

80

90

Chart Title

Axis Title

UV RESULTS

Company DMSRDE[Detailed Information]Creation date 11/3/2016 4:42 AMData array type Linear data arrayHorizontal axis Wavelength [nm]Vertical axis AbsStart 800 nmEnd 200 nmData interval 1 nmData points 601

[Measurement Information]Instrument name spectrophotometerModel name V-630Serial No. B187161148Accessory USE-753Accessory S/NB187161148 Cell length 10 mmPhotometric mode AbsMeasurement range 800 - 200 nmData interval 1 nmUV/Vis bandwidth 1.5 nmResponse MediumScan speed 200 nm/minChange source at 340 nmLight source D2/WIFilter exchange StepCorrection Baseline

Parameters-

UV RESULTS

Absorption Value

UV VALUE Main Sample 130 GSM+ 2 Hours

130 GSM + 3Hours

103 GSM + 5Hours

198 GSM + 2 Hours

198 GSM + 3 Hours

198 GSM + 5 Hours

800 1.71591 0.520248 0.490538 0.460582 0.343146 0.281131 0.109926

799 1.71545 0.519843 0.49034 0.45977 0.343158 0.281105 0.110076

700 1.63816 0.482494 0.462668 0.393183 0.320951 0.273147 0.106418

600 1.5975 0.462997 0.446871 0.367181 0.307864 0.26762 0.108035

500 1.72512 0.601857 0.61504 0.501424 0.446751 0.423599 0.300661

462 4.48165 2.59514 2.95018 2.43993 2.39472 2.36918 2.60564

461 7 2.69383 3.03568 2.53488 2.49018 2.46368 2.68427

401 7 3.22102 3.06696 2.9293 2.88693 2.83693 2.57948

400 7 7 7 7 7 7 7

Graph between absorption and UV Value-Main sample(dyeing waste water)

200 300 400 500 600 700 8001

2

3

4

5

6

7A

bs

UV Value

Main Sample

130 GSM & 198 GSM sample absorption in different UV value (comparison)

200 300 400 500 600 700 800

0

1

2

3

4

5

6

7

8A

bs

UV Value

Main Sample 130 gsm+ 2 hours 130 gsm + 3hours 130 gsm + 5 hours 198 gsm +2 Hours 198gsm+3 hours 198 gsm +5 hours

CONCLUSION• Flux Permeability

1. Result Show that the flux permeability value and permeate flux will decrease simultaneously according to thickness of nonwoven fabric and also Nanofibre.

2. 198 GSM non woven fabric permeate flux will lower than 130 GSM fabric.

3. As increasing the Nanofibre spraying time the permeate flux intensity will also decrease will so that the cleaner approach will go higher In both 198 and 130 GSM type non woven fabric.

4. The decreasing of permeate flux in both type of fabric will simultaneously

CONCLUSION• UV Results

1. Results Show that the ion and other particle concentration will decrease in all filtered sample from main sample.

2. The UV results show that the 198 GSM fabric filtered sample with different Nanofibre layer will give better filtered result in comparison to 130 GSM fabrics.

3. In 198GSM &130 GSM nonwoven fabric 2, 3 AND 5 hours Nanofibre spreading will give better results as the time of spreading will increase.

CONCLUSION• The textile wastewater treatment by membrane processes presents some limitations such as

membrane fouling which causes a rapid flux decline. In fact, the membrane processes efficiency can be affected by membrane pore blocking or/and cake formation. In order to limit the effect of membrane fouling caused by plugging particles in textile effluent, a combination between two membrane processes was studied. 

• The Use of Pre-treatment is able to reduce the effect of fouling on next filtration process.

• In conclusion, after the analysis of results of determination UV Results we have to say that the particle removal efficiency will go better as the pre treatment of textile waste water if we use the this filter as the pre filter for ultra filtration or Nano filtration. Because the pore size of Nanofibre is generally in the range of 1-2 micron.

•  • We know that the main disadvantage of member filtration is fouling and fluxpermiabilty. If we

use this type of membrane is prefilter of nanofilter or ultra filtration the fouling of membrane will automatically decrease because the some partial will automatically removed by prefilter and the rapid flux decline will also decrease.

Acknowledgement• It gives me immense pleasure to express my deep sense of gratitude & whole hearted thanks to

my college authority & DMSRDE authority for giving me opportunity to work on this project.

• I am thankful to Dr. D.B.Shakyawar (Director, U.P.T.T.I) & Dr. Anurag Shrivastava Sc-“G” (Joint Director & Head-Department of Technical Textile, DMSRDE) in this regard.

• I am immense grateful to Dr. J.P.Singh (Project Guide) Dr. K. Mukophadhyaya Sc-“F”- (Head- Department of Nano materials DMSRDE) & Dr. Debmalya Roy Sc-“E”- (Department of

Nano materials DMSRDE) for his valuable guidance, generous advice, critical observations & benevolent approach which all our work & exercise to achieve something worthwhile & satisfactory from a technical point of view.

• I am also like to thank to all DMSRDE Lab Staff & weaving lab staff- UPTTI for their immense support in the lab.

• Last but not the least we also acknowledge the direct indirect effort & support of all the members of UPTTI & DMSRDE for their continuous co-operation during project duration & making this learning experience a truly successful one