SCOPE OF WATER RECOVERY

IN TEXTILE PROCESSING
EFFLUENT
DR. SURENDER KUMAR
NITRA
GHAZIABAD
IN THE HIRARCHY OF HUMAN NEEDS, CLOTHING HAS THE
SECOND TOP MOST PRIORITY NEXT TO FOOD.

DEMAND OF FABRICS IN THE WORLD IS EVER INCREASING
DUE TO POPULATION GROWTH.

TEXTILE INDUSTRY IS A MAJOR USER OF WATER STARTING
FROM RAW NATURAL FIBRES LIKE WOOL, COTTON, SILK
ETC OR MANMADE FIBRES PRODUCTION UPTO GARMENT
MANUFACTURING.

INTRODUCTION
OVERALL CONSUMPTION OF WATER FOR COTTON TEXTILE
MILL IN INDIA WHERE SPINNING, WEAVING, PROCESSING
AND FINISHING OPERATIONS ARE CARRIED OUT UNDER
ONE ROOF IS IN THE RANGE 120 TO 280 LITERS PER KG.
OF THE PRODUCT.

IN A DYEING AND FINISHING PLANT ON AN AVERAGE 100
LITRES OF WATER IS CONSUMED FOR EVERY KG OF
CLOTH PROCESSED


TOTAL TEXTILE PRODUCTION IN INDIA DURING THE LAST
TWO FINANCIAL YEAR
S.
No
Finan-
cial
Year
Total yarn production
Million Kg.
Total fabric (in organised
Sector) prodn. Million sq.
Meter
Cotton Blended Synthe-
tic
Cotton Blended Synthe-
tic
1 2002-
03

2177 585 319 1019 263 214
2 2003-
04

2120 590 341 968 253 212


SORUCE : ANNUAL REPORT YEAR 2001-2002 AND 2003-2004,
MINISTRY OF TEXTILE, GOVT. OF INDIA
WATER CONSUMPTION PATTERN IN
TEXTILE MILLS
SNO.



1.


2.

3.

4.

5.


6.


7.


NAME OF PROCESS



BLEACHING AND
FINISHING

DYEING

PRINTING

BOILERS

HUMIDIFICATION IN
SPINNING

HUMDIFICATION IN
WEAVING

SANTITARY, DOMESTIC
ETC.
TOTAL WATER
CONSUMPTION
%AGE


38

16

8

14

6


9


9





PERCENT SHADE INTENDED I.E. LIGHT, MEDIUM OR DARK
SHADE

TYPE OF MACHINE USED IN THE PROCESS HOUSE

TYPE OF SUBSTRATE PROCESSED

WATER CONSERVATION MEASURES ADOPTED BY THE MILL

NO. OF UNIT OPERATIONS CARRIED OUT DURING
PROCESSING

EFFLUENT GENERATION FOR THE WET CHEMICAL
PROCESSING OF VARIOUS TEXTILE SUBSTRATES
EFFLUENT GENERATION DEPENDS ON THE FOLLOWING
FACTORS :
S.NO. TYPE OF TEXTILE SUBSTRATE EFFLUENT
GENERATION
LITRE/KG.OF
PRODUCT
1 COTTON YARN DYEING
110-150

2 DENIM (COTTON) YARN DYEING
10
3 HANDLOOM (COTTON) YARN DYEING
55-60
4 POLYESTER COTTON BLENDED YARN
DYEING
90-110
5 ACRYLIC FIBRE DYEING
25-30
6 POLYESTER FIBRE DYEING
35-40
7 COTTON KNITTED FABRIC
PROCESSING
120-150
8 COTTON WOVEN FABRIC
PROCESSING
130-150
9 POLYESTER-VISCOSE (BLENDED)
FABRIC PROCESSING
80-100
10 POLYESTER COTTON BLENDED
FABRIC PROCESSING
100
11 WOOL YARN (HANK) DYEING
110-150


SPECIFIC EFFLUENT GENERATION FOR PROCESSING OF
VARIOUS TEXTILE SUBSTRATES

DESIZING
KIERING/SCOURING
BLEACHING
MERCERISING
DYEING
PRINTING
FINISHING
VARIOUS UNIT OPERATION OF WET CHEMICAL
PROCESSING OF TEXTILES
EACH OF THESE UNIT OPERATIONS OF PROCESSING FOLLOWS
SEVERAL WASHING STEPS TO REMOVE EXCESS CHEMICALS
FROM THE SUBSTRATE.

WATER CONSUMPTION IN WET TEXTILE PROCESSING
Finishing
3%
Soaping
3%
Scouring
2%
Bleaching
5%
Mercerising
4%
Dyeing
13%
Washing
70%
EFFLUENT CHARACETERISTICS OF VARIOUS WET TEXTILE
PROCESSING OPERATIONS
S.NO. SOURCE OF
EFFLUENT
GENERATION

PARAMETERS
A PROCESS
EFFLUENTS
pH COD mg/l BOD mg/l
1 Desizing 5.83-6.50 10,000-
15000
1700-5200
2 Scouring 10.0-13.0 1200-3300 260-400
3 Bleaching 8.5-9.6 150-500 50-100
4 Mercerising 8.0-10.0 100-200 20-50
5 Dyeing 7.0 10.0 1000-3000 500-1500
B WASH EFFLUENTS
1. After bleaching 8.0-9.0 50-100 10-20
2. After acid rinsing 6.5-7.60 120-250 25-50
3. After dyeing
(hot wash)
7.5-8.5 300-500 100-500
4. After dyeing
(acid & soap wash)
7.5 8.64 50/100 25-50
5. After dyeing
(final wash)
7.0-7.8 25-50 -
6. Print washing 8.0-9.0 250-450 125-200
7. Blanket washing of
Rotary Printer
7.0 8.0 100-150 25-50


NECESSITY OF WATER RECOVERY AND REUSE FROM
WASTE WATER

DWINDLING NATURAL WATER RESOURCES AND
CONTAMINATION OF BOTH SURFACE AND GROUND WATER

INCREASING DEMAND OF WATER DUE TO CONTINUED
INDUSTRIAL AND POPULA-TION GROWTH

UNEVEN DISTRIBUTION OF WATER RESOURCES

PERIODIC DRAUGHTS

WATER RECOVERY AND REUSE OPPORTUNITIES FROM
TEXTILE PROCES-SING WASTE WATER
INTER OR INTERA-PROCESS WATER RECOVERY AND REUSE
OPPORTUNITIES

RECOVERY AND RECYCLING OF WATER FROM FINAL
EFFLUENT i.e. END OF PIPE OPPORTUNITIES
CLASSIFICATION OF WATER RECOVERY OPPORTUNITIES
WASH EFFLUENT FROM JET DYEING OF POLYESTER FABRIC
SELECT DYEING PROGRAM IN THE ORDER LIGHTSHADE
MEDIUM SHADE DARK SHADE FOR A SINGLE JET DYEING
MACHINE OR ALLOCATION OF MACHINES EXCLUSIVELY FOR
LIGHT, MEDIUM AND DARK SHADE WHERE SEVERAL JET
DYEING MACHINES ARE IN USE.
COLLECT WASH EFFLUENT FROM LIGHT SHADE DYEING IN
ONE HOLDING TANK AND THAT OF MEDIUM ONE IN SECOND
HOLDING TANK
USE EFFLUENT FROM FIRST HOLDING TANK INTO DYEING
OF MEDIUM SHADE AND FROM SECOND HOLDING TANK
INTO DYEING OF DARK SHADE.
INTER OR INTRA PROCESS WATER RECOVERY AND
REUSE OPPORTUNITIES

PROVIDE FILTRATION AND SUITABLE ADSORBENT FOR
FINAL POLISHING IF NECESSARY.

EVALUATE EFFECT OF THE COLOUR PRESENT IN THE
EFFLUENT ON DYEING BY CARRYING LABORATORY
SCALE DYEING.

RINSE WATER FROM MERCERISING OR BLEACHING OPERATIONS
CAN BE USED IN SCOURING OR DESIZING. THE WATER FROM
BLEACHING OPERATION SHOULD BE TESTED FOR SUITABILITY IN
ENZYMATIC DESIZING.

CAN BE USED IN DESIZING OPERATION WHERE SIZE RECOVERY
IS NOT PRACTICED.

CAUSTIC OR BLEACHING COMPOUNDS IN THIS STREAM
GENERALLY DEGRADE MANY SIZE COMPOUNDS.
REUSE OF MERCERISING OR BLEACH WASH EFFLUENT
FOR SCOURING OR DESIZING
RINSE WATER FROM SCOURING OPERATION CAN BE
USED IN DESIZING OPERATION WHICH DO NOT REQUIRE
HIGH WATER QUALITY.

THIS IS PARTICULARLY TRUE FOR THE SCOURING WASTE
WATER FROM SYNTHETIC OR COTTON SYNTHETIC
BLEND FABRICS.

SCOURING RINSE WATER CAN ALSO BE USED IN
WASHING OF FLOOR AND EQUIPMENTS.
REUSE OF SCOURING RINSES FOR DESIZING
COLOURED WASTE WATER FROM THE SOAPING
OPERATION CAN BE USED AT THE BACK GREY WASHER
WHICH DOES NOT REQUIRE HIGH QUALITY WATER.
ALTERNATIVELY, IT CAN BE USED FOR CLEANING OF
FLOORS AND EQUIPMENTS IN THE PRINT AND COLOUR
SHOP.
REUSE OF SOAPER WASTE WATER
RECYCLE/REUSE OF WATER FROM JET WEAVING
WASTE WATER
JET WEAVING EFFLUENT CAN BE REUSED WITHIN THE
JET LOOMS

CAN ALSO BE USED IN THE DESIZING OR SCOURING
PROCESS PROVIDED FABRIC IMPURITIES AND OILS
ARE REMOVED BY ON LINE FILTERS

60-70% WATER CONSUMPTION IS ENCOUNTERED IN THE
WASHING STAGES
HARDLY 30-40% WATER IS REQUIRED TO EXECUTE THE
MAJOR CHEMICAL OR DYEING OPERATIONS.
THE WASH EFFLUENT IS LIGHT COLOURED WITH LOW TO
MODERATE LOAD OF POLLUTANTS LIKE BOD, COD, SS
ETC.
EFFLUENT FROM MAJOR CHEMICAL OR DYEING
OPERATIONS (30-40%) IS INTENSIVELY COLOURED WITH
HIGH POLLUTION LOAD.
RECOVERY AND RECYCLING OF WATER FROM
FINAL EFFLUENT

IN WET CHEMICAL PROCESSING OF TEXTILES -

collection of combined effluent from all the effluent generation
sources, providing suitable treatment including teritiary treatment for
water recovery.

segregation of effluent according to the pollution load from various
effluent generation sources in the mill, providing suitable primary
treatment to individual streams, combining all the streams for
suitable secondary and teritiary treatment for water recovery.
suitable for composite mill or big process house.
APPROACH TO RECOVERY OF WATER FROM TEXTILE
WASTE WATER (END OF PIPE) TREATMENT SCHEME
segregation of effluent from process house into two separate streams
namely wash effluent stream (washing from all processing
operations) with light colour and low to moderate pollution load and
concentrate effluent stream (from dye bath and other main operations)
containing high pollution load and dark colour.