Study On Reducing Water Consumption In Textile

Total Textile Process at a Glance

IntroductionWater is very important resources in our Ecology. We use this resource

in different purposes. In textile, water is a part & parcel component

without this nothing can be dyed properly. We use a huge quantity of

water in dyeing section. As a result waste water is increased makes

water pollution and thus the amount of this vital resources is reduced.

Batch Dyeing50%

Preparation27%

Finishing13%

Boilers10%

Usage of Water In Textile

Batch Dyeing Preparation Finishing Boilers

Pie Graph Of Water Uses In Textile

Water Resources are limited and we need to handle them

reasonably and responsibly. The environmental impact of textile

production is considerable due to the vast quantity of water

required and the variety of chemicals used that generates waste.

Therefore, Water consumption Should be reduced in textile.

Why Water Consumption Should be Reduced ?

Bio-Scouring Method

Solvent Dyeing

Air Dyeing

Plasma Dyeing

Enzyme Dyeing

Compressed & Pressurized CO2 Dyeing

Methods Of Reducing Water Consumption

In bio- scouring process only one bath is used before the actual dyeing starts, whereas in conventional process a minimum of 5 baths are used. This leads to a total 4 bath saving. Considering an MLR of 1:7, the total amount of water that will be saved is about 28 liters for every Kg. processed. For a unit doing a 30 Mt. of bleaching every day, the amount of water that will be saved is 840,000 Liters per day. On annual basis the amounts comes to be 306600,000 liters of water.

Bio-Scouring Method

With pectinases(enzyme) have shown promise in replacing the traditional alkakine scouring treatment. Some auxiliaries’ suppliers have introduced an enzymatic process to remove hydrophobic and other non-cellulosic components forn cotton. The new bio-scouring process operates at mils pH conditions over a broad temperature range and can be applied using equipment such as jet machines. It is claimed that, due to a better bleach ability of enzyme-scoured textiles, bleaching con be carried out with reduced amounts of bleaching chemicals and auxiliaries. Bio-scouring enzymes actually make the substrate more hydrophilic (which could explain better bleach ability), but they are not able to destroy wax and seeds which are therefore removed in the subsequent bleaching process. There is no need for the use of caustic soda in enzymatic scouring. So this process reduced pollution loads, high TDS, BOD and COD in the effluent.

Working Procedure Of Bio-Scouring

Bio-Scouring

A solvent dye is a dye soluble in organic solvents. It is usually used as a solution in an organic solvent. Solvent dyeing is a dyeing process carried out from a continuous non-acqueous phase. Here solvent is used as dyeing media. But water may be added to assist dyeing process. Since the introduction of hydrophobic fibers like cellulose acetate in 1920’s solvent have been considered for Dyeing because it was not possible to dye such Fibres with ionic dyes and water.

Solvent Dyeing Method

Some solvents of chlorinated hydrocarbons of aliphatic series posses most of the mentioned requirements and hence are being used as solvents are extensively used such as –

1. Tri-chloro Ethylen (TCE).2. Per-chloro Ethylen (PCE).3. Methyl Chloroform (MC).

All three solvents are almost equally suitable but tri-chloroethylene has very high stability to decomposition and hence isomers preferable.

Types of Solvent Used in Textile Processing

Air Dye technology manages the application of color to textiles without the use of water.[1] It was developed and patented by Colorep, a California-based sustainable technology company.[2] The process of making textiles can require several dozen gallons of water for each pound of clothing.[3] The Air Dye process employs air instead of water to help the dyes penetrate fibers, a process that uses no water and requires less energy than traditional methods of dyeing, The technology works only on Synthetic material and is currently available only in the United States.

Airflow Dyeing Method

Airflow Dyeing Machine

Super Cretical Fluid Dyeing Machine

EvaporateCurve

GasSuper Cretical Fluid Dyeing Machine

AirDye® Technology

AirDye Solids AirDye Singles AirDye Wovens AirDye Contrast

AirDye Solids dyes both sides of a fabric a single color.

AirDye Singles prints one side of fabric while leaving the other side undyed.

AirDye Wovens simulates dyed woven jacquard and dobby weave.

AirDye contrast dyes opposite sides of fabric two different colors.

Print-to-Solid AirDye Imprints Print-Contrast Print-Squared

Print-to-Solid prints one side of fabric and dyes the other.

AirDye Imprints dyes or prints an image or logo on fabric.

Print-Contrast prints opposite sides of fabric with different designs.

Print-Squared prints opposite sides of fabric with the same design.

1. Water and Chemical (Disperse agent, Leveling agent, and RC agent) is needlessness

2. Drain treatment and Dryer is needlessness

3. CO2 is possible for recovery use (Recovery Rate 96%)

4. From these merits, we can say that Super- critical Dyeing and Treatment contributes to the environmental damage and it is not influenced by water resources.

5. 43% of energy reduction is possible.

Low liquor ratio based dying machine

Plasma, as a very reactive material, can be used to modify the surface of a certain substrate (typically known as plasma activation or plasma modification), depositing chemical materials (plasma polymerisation or plasma grafting) to impart some desired properties, removing substances (plasma cleaning or plasma etching), which were previously deposited on the substrate (Pane, et al 2001).

Plasma Dyeing Method

Plasma technology is a surface-sensitive method that allows selective modification in the nm-range. By introducing energy into a gas, quasi-neutral plasma can be generated consisting of neutral particles, electrically charged particles and highly reactive radicals. If a textile to be functionalized is placed in a reaction chamber with any gas and the plasma is then ignited, the generated particles interact with the surface of the textile. In this way the surface is specifically structured, chemically functionalised or even coated with nm-thin film depending on the type of gas and control of the process.

Principle of plasma processing

Various application of plasma in textile.

APPLICATION MATERIAL TREATMENT

Hydrophilic finish PP, PET, PE Oxygen plasma, Air plasma

Hydrophobic finish Cotton, P-C blend Siloxane plasma

Antistatic finish Rayon, PETPlasma consisting of dimethyl silane

Reduced felting Wool Oxygen plasma

Crease resistance Wool, cotton Nitrogen plasma

Improved capillarity Wool, cotton Oxygen plasma

Improved dyeing PET SiCl4 plasma

Improved depth of shed

Polyamide Air plasma

Bleaching Wool Oxygen plasmaUV protection Cotton/PET HMDSO plasma

Flame retardancyPAN, Cotton, Rayon

Plasma containing phosphorus

There are many different ways to induce the ionization of gases.

i)Glow discharge

ii)Corona discharge

iii)Dielectric Barrier discharge

iv)Atmospheric pressure plasma technique.

Various plasma technologies used in textile

# Products that can bring the desired effect using fewer amount of chemical

# Solutions that increase the efficiency of a process resulting in saving water and energy, as well as time and costs

What BASF offers

Eco-efficient Solutions Cyclanon® XC-W New: After-soaping agent for reactive-dyed cellulose fibers. Compared to the conventional process, it considerably shortens the processing time, saving both water and energy.

Helizarin® ECOSOFT Printing System: Eco-efficient pigment printing solution that significantly reduces the consumption of water and energy compared to reactive printing due to its shorter processing time.

Water-friendly enzymes enter the fashion world

China is one of the world’s largest textile producing countries, contributing a sizable portion of the estimated 9 million tons of knitwear manufactured globally every year. With the production of 1 ton of cotton knitwear consuming what corresponds to the daily water usage of 600–700 urban Chinese people, the Chinese government recently intervened in an attempt to improve this use of resources. As of 2011, new legislation caps the maximum water consumption by textile plants at 100 tons of fresh water per ton of cotton knitwear. A life cycle assessment (LCA) reveals that enzymes can help manufacturers to overcome this challenge.

Clear benefits of using enzymes

Chinese manufacturer Esquel has performed several trials incorporating Novozymes’ enzyme-based solution known as elemental textiles. In the LCA, for the concept in use Esquel reported savings of 30 m3 (or 30 tons) of water per ton of knitted fabric in just a single bleaching process when substituting enzymes for chemicals.

Eco-efficient Solutions Cyclanon® XC-W New: After-soaping agent for reactive-dyed cellulose fibers. Compared to the conventional process, it considerably shortens the processing time, saving both water and energy.

Helizarin® ECOSOFT Printing System: Eco-efficient pigment printing solution that significantly reduces the consumption of water and energy compared to reactive printing due to its shorter processing time.

As water is a viatl resources but it is poluued by different ways day by day. As a textile related persion it is our concern to minise the water consumption in textile sector to save the water resources from being polluted. We have already discussed about the some methods to reduce the use of water in textile sector

Reducing Water Consumption

• Evolution or revolution?– Right first time– Best available technology – Re-cycling – Liquid carbon dioxide– Marginalisation of cotton (Kyoto style targets)– Product labelling based on facts not hype

Summary

• Water ‘use’ is not always an issue

• Pollution is the major issue

• Energy use associated with water use is a major issue

• Focus on industry not domestic

• Best practice could halve water consumption in dyeing

1. Yarn Manufacturing TechnologyLink : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808

2. Fabric Manufacturing TechnologyLink : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605

3. Garments Manufacturing TechnologyLink : http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126

3. Wet processing TechnologyLink : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404

4. Fashion-Design-and-TechnologyLink : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts

My Facebook Textile related Pages

http://www.textilelab.blogspot.com (Visit )