Textile Dyeing, Printing and

Finishing Industry
(Wastewater Management)

Dr. Akepati S. Reddy

Head, Dept. Analytical Services, TCIRD
Thapar University
Patiala
 Textile Dying and Finishing Industry

• Wastewater Management Strategies

• Core Activities and Environmental Concerns
• Supporting Activities and Environmental Concerns
• Statutory Environmental Requirements
• Wastewater Management Systems
Textile Dying and Finishing Industry:
Wastewater Management Strategies
 Wastewater Management
What do you mean by wastewater management?
Is it wastewater collection, treatment and disposal?
Got ill?
– Then stop working.
– Go to doctor and take medicine.
– Take rest, get well and get back to work
incur losses and only losses!
Wastewater generated?
– Then collect it
– Treat to comply with standards and to make wastewater
compatible for disposal into the environment
– Dispose
Spend resources and bear the burden or face the music
from the regulator and pollute the environment!
 Wastewater Management
Should be more than collection, treatment and disposal
Have to include
Source Reduction
Wastewater Recycling and Reuse
(in addition to wastewater Collection, Treatment & Disposal)
Hierarchical order is important
Importance should be given to
Wastewater generation
Segregation of wastewaters
Pretreatment and recycling and reuse to minimize
wastewater generation
Treat and dispose unavoidable wastewaters and not
recyclable and reusable wastewaters
 energy, water
and chemicals
Industrial
raw material process product

recycling
& reuse wastes for
recycling & reuse

secondary wastes
energy, water Waste pre-
and chemicals treatment byproducts &
resources recovered

wastes from
other processes
treated wastes for
recycling & reuse
Pre-treated wastes
From other units

secondary wastes
energy, water Waste
and chemicals treatment
byproducts &
resources recovered
treated wastes for
recycling & reuse

treated wastes
for disposal
 Source Reduction
Source reduction
– Eliminate wastewater generation
– Reduce volume or strength or both of the wastewater
– Increase of strength in the process of volume reduction
usually proves beneficial
Wastewater is generated at many points because of many
reasons
– Identify all the points of generation and understand the
mechanism of generation
– Both core activities and support activities are equally
important
– Take into account even unintended wastewater
generations from leaks & spills and housekeeping
– Better prepare an inventory of the wastewaters generated
 Source Reduction
Work for source reduction
– Do not forget that the wastewater generation rates are closely
related to the water consumption rates
– Process modifications can be beneficial
– Maintain the source reductions achieved
Examples
– Use of eco-friendly and non-hazardous inputs
– One step fabric preparation (minimize number of dumps and
washings)
– Minimize liquid to fabric ratio
– Batch washing and/or counter-current washing in place
continuous single step washing
– Minimize liquid retention during bath dump
– Minimizing reprocessing of fabric
 Recycling and Reuse
Wastewater collection (segregation and mixing scheme)
Decide which one is wastewater and which one is not
– Are cooling water and steam condensate wastewaters?
– Allow only the wastewater into the drain leading to ETP
Segregate waste streams
– With potential for recycled and reused (after pretreatment!)
– That demand pretreatment for compatibility to mix with other
wastewater for further treatment and disposal
– That need separate treatment and disposal – dye effluents
– From which resources and byproducts can be recovered
Bath dumps represent concentrated waste and warrant
segregation
Dye effluents may need segregation for treatment and
disposal
 Recycling and Reuse
• Wastewater from a process can be a useful resource for
some other process
• Wastewater generated by a process may have
– altered quality (from the water used in the process)
– residual and unused input materials of the process
– residual product & byproducts that could not be recovered
– wastes generated from the process.
• Segregated wastewaters of a process can be recycled
and reused either directly or indirectly after pre-treatment
– May be reused in the same process or recycled and
reused in some other process
• Recycling and reuse may require storage and
transportation of the wastewater
 Recycling and Reuse
Wastewater pre-treatment
– Through removing undesirable contaminants and altering
the quality it can enhance recycle and reuse potential of
the wastewater
– It can facilitates recovery of residual input materials and
unrecovered products and byproducts
– It can transform some of the contaminants of the
wastewater into useful resources
– It can transform the wastewater into compatible for mixing
with other wastewaters and enhance treatability of the
effluent
Pre-treatment requires resource input and can be costly
It can generate secondary wastes that need proper handling
and disposal
 Textile Dying and Finishing
Industry: Core Activities and
Environmental Concerns
 Textile fiber and textile industry
Textile fibers are two types: natural and man-made
• Natual fibers:
– Protein fibers of animal origin (wool and silk)
– Cellulosic fibers of plant origin (cotton, flax and jute)
• Man made fibers:
– Synthetic polymers (polyester, nylon and acrylic)
– Regenerated cellulose (viscose and lyocell)
– Cellulose acetate (diacetate and triacetate)
Textile industry is concerned with
– Preparation of fiber and transformation into
yarn/thread/web
– Conversion of yarn into fabric or related products
– Garment manufacturing
 Textile dying and finishing industry
A wet, water and energy intensive process industry
Dyeing and finishing can be carried on
– Fibers
– Yarn
– Fabric
– Garments
Dyeing and finishing industry can be considered to include
– Pretreatment
– Dyeing
– Printing
– Finishing operations
 Man-made Man-made Raw wool
Filament fiber Staple fiber Cotton

Texturizing Fiber
preparation

Warping Spinning

Slashing

Knitting Knitting

Weaving

Preparation

Dyeing

Printing

Finishing
 Textile dying and finishing industry
Core processes/activities
• Fabric preparation
– Scouring, desizing, mercerizing, bleaching, etc.
– Singeing, heat setting, etc.
• Dyeing
• Printing
– Print paste preparation
– Printing
– Print fixing and drying
– Print washing
• Finishing
– Mechanical finishing
– Chemical finishing
 Key equipment and machinery used in
the core activities
• Jet washer
• Winche machine
• Jigger
• Preparation of woolen fabric
• Printing range
• Ager
• Print wash
• Wet or chemical finishing (Stenter)
• Mechanical finishing
 Jet washers
Used for
• Washing of the fabric specially at high temperature
– for the removal of stains and sizing chemicals
– for conditioning the fabric for dying
• Dying of the farbic specially at high temperature (>90°C
at 125-135°C)
– Winch machine or jigger can be used in place of jet washer
specially for dying at lower temperature (<90°C)
Two types of jet washers are in use: Long tube type and U-
tube types jet washers
Jet washers of stainless steel body are used and the
washers are not insulated (?)
 Jet washers
Includes
• Body of the jet washer for retaining the circulating fabric
and liquid and bringing fabric in contact with liquid
• Provisions for draining out the liquid, for the loading and
unloading of the fabric and for circulating the fabric
• External heat exchanger for heating/cooling jet washer
contents through indirect heating/cooling of the
circulating liquid of the jet washer with steam/cooling
water
• Pump and necessary piping for circulating the liquid
through the heat exchanger
• Provisions for adding water, and solution of dyes and
other chemical ingradients
 Jet washers
Requires
• Cooling water for use in the heat exchanger for indirect
cooling
• Water use in the jet washer
– for the preparation dye bath or chemical wash bath
– for maintaining liquid-fabric ratio
– for the fabric washing
• Saturated steam in the heat exchanger for indirect
heating
• Dyes and other dye bath ingradients
• Soaps, detergents, scouring agents, desizing chemicals
 Jet washers
Concerns associated with the jet washers
• Dumped dye baths, desize baths, scour baths, etc.
• Washwater from the jet washing of the fabric
• Steam condensate generated at the external heat
exchanger (can be contaiminated by leaks in the heat
exchanger)
• Cooling water generated at the external heat exchanger
(can be contaiminated by leaks in the heat exchanger)
• Packing material with residual chemical left behind after
chemical use
• Hot surfaces of the jet washer and heat loss
 Winch machine
• Used for washing and also for low temperature dying
– used for cotton dyeing and also for dyeing silk with nylon
or polyester
• Includes a tub and a winch for passing the fabric through
the wash liquid or dye solution
• The tub has provisions for
– Direct injection of steam and maintaining tub temperature
at the desired level
– Addition of water for cooling the tub contents and washing
the fabric
– Draining off the tub contents
• Material of the tub and relative surface area exposed
matter in the heat loss
 Winch machine
Requires
– Washing and dying chemicals: aqueous solutions are made and
added to the tub
– Saturated steam for heating and maintaining the tub contents
temperature
– Water for maintaining the fabric-liquid ratio, for cooling the tub
contents and for washing the fabric
Concerns associated with the winche machine
– Dumped dye baths, desize baths, etc.
– Wastewater generation from the cooling and washing of the
fabric
– Vapours and heat loss from the liquid and fabric surface
– Liquid/water spills and leaks
– Generation of chemicals packing waste
 Jigger
Used for
• Chemical application and padding of the fabric
• Washing, conditioning and dying (cotton!) of the fabric
• In one of units it is used for washing, mercerizing, bleaching,
and neutralization
Includes
• Vat with liquid (hot washing/dying chemical solution and
hot/cold water for rinsing the fabric)
• Winding and unwinding rolls and rolls submerged in the vat
contents for facilitating passing of the unwinded fabric through
the vat contents
• Vat with provisions for the addition of water and chemical
solutions, direct injection of steam and for the draining out the
vat contents
 Jigger

Requires
– Chemicals for washing, mercerizing, pre-treatment
(conditioning) and dying: aqueous solutions are made and
added to the vat
– Steam for heating and maintaining temperature of the vat
contents
– Water for preparing different chemical solutions, for
maintaining the liquid-fabric ratio and for the fabric washing
Concerns associated with the jigger include
– Generation of wastewater in the form of vat dumps, fabric
washwaters and vat overflows, spills and leaks
– Generation of chemicals packing waste
 Preparation of woolen fabric
Preparation of woolen fabric in one of the unit visited
involved
– Carbonizing
– Drying and width setting on stenter
– Dry bitting
– Neutralization/washing
– Miffing
Carbonizing
– Meant to remove leaf particles, bits of grass and other
cellulosic impurities from woolen fabric
– Woolen fabric is passed through sulfuric acid bath and
padded with the acid
– Fabric padded with acid is allowed to rest for carbonizing
– Mange squeezing of the fabric after carbonizing
 Preparation of woolen fabric
Drying and width setting on Stenter
– Done at 120-130°C while using steam as heating medium
Dry bitting
– Fabric is rotated over a winch like milling machine for the
removal of vegetable matter
Neutralization/washing:
– Batch neutralization with soda in water (in the presence of
non-ionic wetting agent) at 40-60°C to 6-7 pH
– Washing in plain water and then hydrosqueezing
Miffing
– Involves application of slurry of Lap (petroleum product) in
H2SO4 at ambient temperature
– Optionally water based wetting agent is used
 Printing of the fabric

Involves application of dyes/pigments in the form of thick

paste (print paste) and fixation of applied colour through
a suitable after-treatment
Can be considered to include
– Printing of the fabric
– Drying and fixation of the dyestuff
– Washing off
Paint kitchen (place of paint preparation) and cleaning of
screen plates/drums are integral parts of printing
 Preparation of Print Paste
Usually prepared in paint kitchen
Ingradients of print paste include
– Dyes/pigments
– Thickeners, binders and cross linking agents
– Sequestrants, dispersing agents (like surfactants), and
water retaining agents (humectants)
– Adhesion promoters, defoamers, catalysts, etc.
Print paste formulations depend on the fiber, colorant
system and type of the printing machine
– Paste for discharge printing of cotton uses soda ash base
dye and sodium sulfoxilate formaldehyde
– Paste for discharge printing of polyester uses stannous
chloride and urea
– Discharge printing of silk uses zinc dust
 Printing of the fabric
In one of the units (print kitchen) preparation of disperse
and discharge colour bases (print pastes) involved
– Cooking of gum in water with steam
– Mixing of other ingradients to the cook and keeping in hold
– Mixing dye in the preparation prior to use
For preparing the pigment colour base the unit mixed
pigment, binder, fixer and other ingradients in kerosene
 Printing
• Either dyed or undyed fabric is printed
• Either flat screen printing or rotary screen printing is
followed
• Fabric is loaded on the blanket (conveyor belt), printed
and transferred into oven for after treatment
– Blanket is applied with a film of water proof chemical coat
may be once in a week or so
– Over this film fabric, adhesive is applied thrice or four
times a day (holds the fabric in position on blanket)
• Blanket is cleaned while returning back by brushing and
application of water
– The washing apparently does not affect either the
adhesive coat or the water proofing coat
 Printing
Printing involves
– In case of flat screen printing, raising and falling of the
screen and drawing of a rubber edged squeegee across
the screen forces the paste onto the fabric
– In case of rotary screen printing, continuous rotation of the
cylindrical screen with paste pumped inside and with a
stationary flexible squeegee causes the printing
Screens need cleaning – manual or mechanical cleaning -
done at a site specified for the purpose
Environmental concerns
– Water consumption and wastewater generation from on-
site blanket cleaning and off-site flat bed or rotary screens
cleaning
– Drippings and spills of paint paste, water proof chemicals
and binders on the floor in the premises
– Residual paste in the screens and in paste containers
 Fixation of the Print
Printed dyes are fixed at high temperatures in the presence
of steam in an Ager
– Ager has two compartments!: in the 1st compartment dye
fixation occurs and in the 2nd drying of the fabric occurs
– Circulating thermic fluid is used for indirect heating and
maintaining temperature in the ager at desired level
– Through steam injection humidity level is maintained
– Controlled ventilation helps both in humidity maintenance
and drying of the fabric
– In one of the units visited, 160-175°C temperature and 30 lb
pressure is maintained in the ager
Fixing of pigment prints is through baking the printed fabric
– Temp. and pH conditions of baking should be suitable
Evaporative solvents used in the pigment paste preparation
are lost in the vents
 Print Washing
Meant for for the removal of the unfixed dye, thickeners
and auxiliary chemicals after the fixation
Print washing uses
– Wash tubs with provisions for the supply of water (and
steam!) and for the draining out of washwaters
– Winche machines, mangles, etc.
– Hydro-squeezers for dewatering the print washed fabric
Involves use of chemicals (including detergents) for the
removal of residual paint, gums, etc., and for the fabric
neutralization
 Print Washing of cotton fabric
Steps involved in print washing of cotton fabric
– Cold wash
– Hot soap wash (in non-ionic soap at 60-80C)
– Simple cold rinse
– Neutralization (with acetic acid or HCl)
– Softner application
– Dewatering on hydrosqueezer
Washings and neutralization are usually carried out in 2 or
more than two stages
Print washing of polyester and nylon
– Sequence of washing is similar to that of cotton
– In place of hot soap wash caustic and hydrosulfite treatment
is practiced
– Acetic acid (not HCl) is used for neutralization
 Print washing
Acrylic print wash
– Sequence of washing is similar to that of cotton
– In place of hot soap wash bleaching and brightening with hypo
and peroxide are practiced
– HCl is used for neutralization
Silk and woolen print washing
– Similar to the washing of cotton print
– No chemical other than soap and softner are used
Silk, wool and viscose are soluble in sodium hydroxide
Pigment prints do not require washing - Pigments do not directly
associate with the fibers – they are fixed to the textile with a
binding agent incorporated into the paste
 Print washing
Print washing in one of the units is started with dipping in
HCl solution, and in another unit with dipping in soda
In one more unit in the last wash tub 0.5% luke worm liquid
ammonia is used to neutralize the sulfuric acid print and
avoid impression on the fabric
Key concerns associated with print washing are
– Consumption of chemicals like caustic, soda, sodium
hydrosulfite, HCl, acetate, softners, soaps, detergents, etc.
– Consumption of water (and steam to maintain
temperature!) at almost almost all the stages
– Wastewater generation in the form of overflows and dumps
of different wash tubs
– Squeeze water generation at the hydro-squeezer
– Overflows, spills, splatters and leaks
 Hydro-squeezer
• Used for dewatering the fabric prior to drying
• Fabric is loaded into the central well with screen walls
and securely closed from top
• With the help of an electrical motor the loaded well is
spinned for separating liquid from the fabric by
centrifugal force
• The process reduces the liquid to fabric ratio to about 1:2
Environmental concerns
– Centrifugally separated water comes out as wastewater
– Electrical energy is needed for powering the drive
 Stenter
Used for
– Heat setting prior to any processing for removing oil from
the fabric
– Chemical or wet finishing of fabric
Can be considered to include
– Chemical applicator
– Mangle squeezer
– Drier (includes pinning, oven and depinning sections – a
cooling section may also be a part)
Oven portion - an enclosed chamber and inlcudes
– Radiator heaters, blowers, ducting and nozzles for
applying hot dry air on fabric and maintaining temperature
– Ventilation system comprising exhaust fans, ducting and
vent for the removal of humid vapours from the oven
 Fabric

Process water
Residual Padding Cleaning chemicals
Chemical soln. Mangle

Wash water Finishing

chemicals

Pinning
Air
Thermic fluid

Drying Exhaust Emission into

Blowers range blowers atmosphere

Thermic fluid

Air Air cooling Blowers Air

chamber

Depinning

Fabric
 Stinter
Requires
• Circulating thermic fluid for maintaining oven
temperature at desired level
– Steam is often (in woolen mills where temp. required is
lower) used in place of thermic fluid
• Finishing chemicals and water (and solvents!) for
chemical solutions preparation (to fill applicator vat)
• Electrical energy for running the fabric through
• Water for cleaning the vat and the mangles (20-30 L per
wash!) – occasionally acid is used for the cleaning
 Stenter
Concerns associated with the stenter
• Hot surfaces of the oven and loss of energy
• Hot humid air (contaminated with fumes/vapours of oil,
finishing chemicals & their degradation products)
• Discarded finishing chemical preparation (spoiled and/or
residual preparation) – 2-5% of finishing chemical used
– Finishing chemical batch can get spoiled from stopping of
operations for sometime (20-30 minutes) - a case with urea
formaldehyde!
• Washwater generated from the mangle and vat cleaning
• Generation of steam condensate when steam is used as
a heating medium
 Singeing and cropping
Singeing
• Involves brushing passing through flame and again
brushing
– Water may be used for cooling the rollers close to the
flame in singeing
• Has ventilation systems for handling
– Exhaust gases from singeing
– SPM laden vent gases from pre-singeing and post-
singeing brushing processes
• Vent gases of pre-singeing brushing may need passing
through fabric bag filters for fiber removal
• Vent gases of post singeing brushing may require treatment
(scrubbing with water) for SPM removal
Cropping
• Cutting surface hair from fabric to give smooth appearance
• Practiced on woolen fabric where singeing is not possible
 Soft feel (sueding) machine
Dry process involving abrasion of the fabric surface
– Rollers with emory paper (or abrasion brush) are used
Carried out in enclosed space with a ventilation system
– Ventilation system can have fabric bag filters for removing
the dust
– In one of the units visited the vent gases are disposed off
over the shed
– Wet cleaning of the enclosed space is also possible
• Water used for wet cleaning can be collected filtered and
recycled and reused
Grazing
– Similar to sueding but used for woolen fabric
– Involves shearing on a rotary machine
 Sanforizing
Dry mechanical process involving moistening, shrinking,
ironing & lustering and cooling of the fabric
• Moistening
– Required if the fabric has less than required moisture
– Done with steam maintained in a perforated drum which is
covered by viscose belt
– Provisions made for removing humid vapours (ventilation
system) and pumping out steam condensate from drum
• Compressive shrinkage
– Done by overfeeding the fabric between a hot stainless
steel drum and rubber blanket
– Steam injected into SS drum maintains temp.
– There is provision for draining out steam condensate
– Rubber blanket is maintained wet and cool through
application of water shower
 Sanforizing
Ironing and luster is done
• By simple and/or glazing calendering
– Simple calendering: passing the fabric around and
between heated stainless steel cylinders
– Glazing calendering: here a friction calender, rotating at
much higher speed than the fabric, is used to produce
highly glazed and polished effect
• Or on a palmer drum
– Fabric is passed between a hot rotating drum and 100%
polyester needle punched felt
– Steam heated cylinders are also used along with the drum
Fabric cooling: done by passing the fabric over (internally)
water cooled cylinders
Textile Dying and Finishing Industry:
Supporting Activities and
Environmental Concerns
 Textile dying and finishing industry
Supporting activities and processes
• Water pumping, storage and supply system
• Soft water plant or RO water plant or DM water plant
• Boiler and steam distribution system
• Thermopac boiler and thermic fluid circulation system
• Amenities (drinking water closets, wash basins and
toilets)
• Electrical power system
• DG sets
• Compressed air and instrumental air system
• Procurement, storage and handling of fuels
 Water supply system
Pumping of water from groundwater source, storage,
and supply as both process water and as drinking
water
– Storage and supply is associated with losses through
seepages and overflows
– Wasteful, inefficient and unintended use
– Leakages from the supply lines
• Metering and keeping record of water being pumped
is needed
• Groundwater quality checks may be needed
 Soft water system
Produced from process water by
– Ion-exchange process
– Reverse osmosis process
Ion-exchange process based soft water plant
– Pressure filter
– Activated carbon column
– Salt for regenerating ion-exchange resin beds
– Soft water storage and supply mostly as boiler feed
water
In one unit HCl regeneration based ion-exchange resin
bed and degassifier is also used parallely
 process water

backwash water Pressure common salt

to drain sand filter

Salt tank process

regeneration chemical
wastewater to drain water

Water Salt dose

slow and rapid softner
rinse water (resin bed) tank

backwash water
to drain

soft water
 Environmental concerns
Water consumption for
– Backwashing of pressure filter, activated carbon
column and ion-exchange resin beds
– Preparing the salt solution
– Regenerating ion-exchange resin beds (chemical draw,
slow rinse and rapid rinse)
Wastewater generation from
– Backwashing of pressure filter, activated carbon
column and ion-exchange resin beds
– Regeneration of the resin beds during chemical draw,
slow rinsing and rapid rinsing
Salt (HCl!) consumption for resin beds regeneration
Generation of discarded spent activated carbon and
spoilt ion-exchange resin
 Soft water system
Reverse osmosis based soft water plant includes
– Chlorination
– Iron removal column
– Dechlorination
– RO unit
– Soft water storage and supply (as boiler feed water)
 Process water

Chlorinating chemical Chlorination

Water for backwashing Iron removal Backwash water

dechlorinating agents Dechlorination

cleaning chemicals RO process Wastewater from cleaning

Reject water

RO water
 Environmental concerns
• Reject stream of water
• Backwash water from iron removal column
• Wastewater from the cleaning of RO unit
• Water for cleaning of the RO unit and for
backwashing the iron removal column
• Chlorinating chemicals and dechlorinating agents
• Chemicals for RO unit cleaning
 Circulating Cooling Water System
Circulating cooling water system usually includes
– Cooling tower (includes sump and fans)
– Pumps and piping for circulation between cooling
towers and heat exchangers
– Heat exchangers
Conserves water through avoiding once flow through
Cooling tower blow down needed to avoids salt built-up
Requires makeup water to compensate evaporation,
drift and blow down losses; leaks and spills and
consumptive uses
 Circulating cooling water
Process Evaporation
Cooling losses
system
Consumptive use of Drift losses
cooling water
distributor
Process
Cooling
system Conditioning
Cooling
chemicals tower
Process sump
Cooling Pump(s)
system

Process Cooling tower

Makeup water Blowdown
Cooling
system
Leaks from circulating water

Cooling tower and circulating cooling water system

 Environmental concerns
Cooling tower blow down water
– Has high TDS, may also have some TSS and
conditioning chemicals added
– May not need any treatment – can be mixed with
treated effluents for regulating TDS and disposed off
Water consumption to make up cooling tower blow
down, evaporation, drift and other losses
Chemicals for conditioning circulating cooling water
– Antifouling agents, like, pesticides, copper sulfate -
algal growth, toxic compounds (chromium based!), etc.
– Alkali for controlling pH (low pH cause for corrosion)
Electrical energy for
– Pumps that circulate cooling water
– Fans that create upward air draft (hastening cooling)
 Steam system
Includes
• Steam generating boilers
– Fuel is burnt for steam generation
– Flue gases are generated -discharged into atmosphere
– Boiler blow-down water is generated
• Steam distribution system
– Steam condensate is generated at steam traps
• Supplied steam is used for
– Direct injection heating
– Indirect heating (generates steam condensate)
• Condensate collection and return system to the boiler
house for reuse as boiler feed water
• DM water/ Softwater/ RO water supply for makeup
Direct use
for heating Flue gases
to stack
steam

Indirect use
For heating Combustion
Steam boiler air
Condensate Fuel
condensate

at steam traps
?? Condensate
drained out Boiler blowdown
Flue gases
or not collected
to stack
Pre-heater of
Condenstae Boiler feed
Boiler feed
tank Water tank
Water tank

Soft water/ Flue Gases

RO water/DM water from
thermopac boiler
 Steam boilers
• Fuel is loaded along with combustion air and burnt in the boiler
furnace
– May be mixed with lime to take care of SO2 emissions
– Loading may be pneumatic or mechanical or manual
– FD fan is used to supply combustion air (in small fire tube
boilers natural draught is depended on)
– For pneumatic loading combustion air is divided into primary
and secondary air and primary air is further powered and
used for fuel loading
• Hot combustion gases after use for steam generation and
treatment in APCDs are discharged into atmosphere through a
stack
– ID fan sucks flue gases and pushes through stack
– Cyclones/multiclones or fabric filter bag houses are used
– Height and diameter of stack are important
– Stack should have a sampling port and sampling platform
• Conventional/Fluidized bed technology is used
• Discarded bed material, bottom ash and fly ash are generated
 Steam boilers
• Deaerated boiler feedwater is pressurized and loaded
to the boiler usually after pre-heated in an
economiser
– Some of the units are preheating the feedwater in the
thermopac boiler preheater
• Feed water is chemically conditioned prior to use
(chemicals are also directly added to the boiler)
– avoid oxidative & acidic corrosion, and scaling by
removing DO, regulating pH, maintaining precipitates
in suspension
• Fire tube boiler is preferred over water tube boiler for
the water boiling and steam generation
– Low pressure saturated steam is generated
• For regulating TDS and TSS, boiler blow-down is
practiced
 rice husk larger size treated flue gases
received in Vibratory feeder foreign materials into atmosphere
tractors & trucks And dust through stack

Husk bunker ID fan

Saturated steam

feeding air boiler bed

material vent

Air External boiler flue gases Cyclone/

box furnace Fire tube boiler multiclone
sec. air
blowdown
flyash discarded flyash tank
bed material
Flyash Boiler feed Rotary valve
FD fan quenching water pumps (electrical motor
Operated)
blowdown water
to drain
process water vent
for quenching
air flyash
Bottom
Feed water tank Conditioning
chemiclas

Return soft water

condensate
 Steam boilers
One units visited has a 3 ton fluidized bed boiler
– Pet coke added with lime is burnt as fuel
– Soft water is used as boiler feed water
– Produces 120 psi pressure steam
Another unit has 5 ton coal fired boiler
– Produces 8 kg/cm2 pressure steam
– Softwater is used as boiler feed water (planning for RO
plant)
3rd unit has 5 ton petcoke fluidized bed watertube boiler
– Produces steam at 10-12 kg/cm2 pressure
– Soft water and decationized & degassified water is used
as boiler feed water
4th unit has rice husk fired 5 ton capacity water tube and
smoke tube boiler
– Produces steam at 10.5 kg/cm2 pressure
– DM water is used as boiler feed water
 Steam boiler
Requirements
– Fuel (and lime in case of petcoke as fuel)
• Moisture content is important (efficiency drops from
evaporative consumption of energy)
– Boiler feedwater (steam condensate + softwater or RO
water or DM water)
– Boiler feed water conditioning chemicals
– Steam for the deaeration of boiler feed water
– Bed material (in case fluidized bed technology)
– Electrical energy for powering FD fan (primary air fan)
and ID fan
 Thermic fluid system
Thermic fluid circulation system
– Hot circulating thermic fluid (of temp. as high as 250 is
used as heating medium in stenter, ager, etc., units
– Used fluid is returned to a balancing tank and from their
pumped, reheated in a thermopac boiler and supplied
back for reuse as heating medium
Thermopac boiler
– Very similar to water tube hot water boiler
– Petcoke, coal, saw dust, wood, etc., are fired as fuels
– Fuel firing and thermic fluid heating occur either in the
same chamber or in two different chambers
– Instead of boiler feedwater, thermic fluid is forced to flow
through the tubes (water tubes!) for heating
– A pre-heater for heat recovery from hot flue gases may
also be a part of the thermopac boiler
 Incoming used
thermic fluid

Header for
incoming

Expansion Makeup Makeup fluid

tank tank ??

Circulation Boiler
pump feed water

Hot flue Pre to

Fuel Boiler ID Fan Stack atmosphere
gases heater

FD fan Carbon dust

Header for Boiler
outgoing feed water
Combustion
air Outgoing hot
thermic fluid
 Thermic fluid system
Requirements
– All the requirements of a steam boiler except the boiler
feedwater and conditioning chemicals
– Fresh thermic fluid for makeup
– Electrical energy for powering the thermic fluid
circulation pump
Environmental concerns
– All the concerns identified with the steam boiler but not
the boiler blowdown
– Risk of fire and explosion associated with the hot
thermic fluid
 Electrical power system
Electrical power system
– Sources of power are grid power and captive power
from DG sets
– Important constituents of a power system are power
meters, LT and/or HT panels, capacitor banks,
transformers (and rectifiers), power cables and
distribution lines, etc.
– Electrical power is supplied to various points of use,
like drives, heating units, lighting systems, etc.
Key environmental concerns power system
– Electrical power consumption
– Transformer oils
– Batteries
 DG sets
• Run on high speed diesel (HSD) as fuel
• Includes two parts: diesel engine (prime mover) and
alternator/generator
• Usually multi-cylinder two stroke engines
• Has a common crank case filled with engine oil
• Engine oil is cooled by circulating coolant oil –
circulating coolant oil is either air cooled or water
cooled
• Turbo-charger, run on exhaust gases, is used for
compressing and heating the combustion air
• Diesel is injected into the hot compressed air
cylinders after filtering for spontaneous ignition
• Shaft of the diesel engine is coupled with the
alternator for generation of electric power
 Air for Exhaust
combustion gases

Turbo charger
HSD Air for Exhaust
combustion gases

HSD day Oil Internal Generator/

tank pump Combustion alternator
chambers
Lube oil
Lube oil Lube oil
Engine oil
reservoir

Coolant oil Coolant oil

Coolant
Oil cooler

Cooling water Cooling water

Cooling
Makeup water tower Evap. & drift
water loss
Cooling tower
blowdown
 DG sets
Requirements
• High speed diesel for burning as fuel
• Lubricating oil, grease and coolant oil
– Replacement of lubrication oil after specified hours
(250 hours) of running
– Replacement of circulating coolant oil after specified
hours (750 hours) of running
• Batteries for running the DG set (turbo-charger)
during startup
• Circulating cooling water if used to cool circulating
coolant oil
 DG sets
Environmental concerns
• Exhaust gases discharged into atmosphere through
stack (represent waste heat and air pollution)
• Discarded engine oil, coolant oil, oil filters, etc.
(hazardous wastes needing handling)
• Noise pollution problems
• Discarded batteries (statutory requirements
applicable for disposal)
• Leaks of oil and grease (housekeeping problem)
 Compressed air
and instrumental air system
• Ambient air is filtered, compressed, cooled to
separate moisture, stored for use as compressed air
– Air compression is single stage or two stage process
– Compressed air is cooled with circulating cooling water
in coolers (and inter-coolers!)
• Compressed air is passed through an air drier, stored
for use as instrumental air
• Air drier beds require regeneration
– hot compressed air, after further (electrically) heating,
is passed through drier beds for regeneration
– Air used for regeneration can be cooled for
demoisturizing and passed through already
regenerated drier for dry air
 cooling water cooling water
cooling
cooling Intercooler water
fresh air
water
Stage-2 compressor Stage-1 Filter
compressn compressn
cooling cooling
water water
lube oil
cooling water waste oil

Precooler Moisture
separator

cooling water
cooling water

Electric Drier Aftercooler Moisture Direr

heater Tower-1 separator Tower-2

cooling water condensate

cooling Afterfilter
cooling
water water

Aftercooler compressn Filter Receiver

tank
lube oil compressor
fresh air compressed dry air
waste oil
 Compressed air
and instrumental air system
Requirements
– Electrical energy for powering the compressors
– Lubricating oil in the compressors for replacing the oil
after running the compressor for specified hours
– Circulating cooling water both in the compressors and
driers for compressed air cooling
Environmental concerns
– Discarded lubricating oil
– Oil spills and leaks (posing house keeping problems)
– Noise pollution problems
 Textile Dying and Finishing Industry:
Statutory Environmental Requirements
 Statutory Requirements
Under Water (prevention and control of pollution) act, 1974
and Air (prevention and control of pollution) act, 1981
• Systems for the collection, treatment and disposal of
wastewater (including STPs and ETPs)
• Devices (APCDs) and systems (including stacks) for
collection, treatment and discharge of emissions from
– from core processes
– from DG sets, boilers and thermopac boilers
• Compliance with the standards as specified in the
consent as consent conditions (EPA standards in EP
Rules, 1986)
– Effluent standards applicable to trade effluents & sewage
– Emission standards including stacks and noise applicable
 Statutory Requirements
Under the Water (Prevention and Control of Pollution) Cess
Act, 1977
• Water consumption monitoring, water consumption
records and water consumption returns
Under the Environmental (Protection) Act, 1986
• Under the hazardous wastes (management and
handling) rules, 1989
– Authorization and system and facilities for the
management and handling of hazardous wastes
– ETP sludge, paint sludge, cans and packing materials, etc.
• Batteries, waste oil and used oil, noise and stacks
• Prohibited and regulated dyes
 Applicable Standards
Effluent standards
Stack heights for
– Boilers
– DG sets
Emission standards for
– Boilers
– DG sets
Noise standards for DG sets
 6. Cotton Textile Industries
(composite and processing)
pH 5.5 to 9
Suspended solids (mg/L) 100
BOD3 at 27°C (mg/L) 150
Oil and grease (mg/L) 10
Total chromium (as Cr in mg/L) 2
Sulfide (as S in mg/L) 2
Phenolic compounds (as C4H2OH in mg/L) 5
Bio-assay test 90% fish survival
after 96 hours
Depending upon the dye used SPCB can stipulate special parameters
Limits on total chromium, sulfide and phenolic compounds shall be imposed
where chrome dyes, sulfur dyes and/or phenolic compounds are used
If quality requirement of the recipient system warrants limit of BOD should be
lowered to 30 mg/L
Limit on sodium absorption ratio of 26 should be imposed in case of disposal on
land
 7. Composite Woolen Mills)
pH 5.5 to 9
Suspended solids (mg/L) 100
BOD3 at 27°C (mg/L) 100
Oil and grease (mg/L) 10
Total chromium (as Cr in mg/L) 2
Sulfide (as S in mg/L) 2
Phenolic compounds (as C4H2OH in mg/L) 5
Bio-assay test 90% fish survival
after 96 hours
Depending upon the dye used SPCB can stipulate special parameters
Limits on total chromium, sulfide and phenolic compounds shall be imposed
where chrome dyes, sulfur dyes and/or phenolic compounds are used
If quality requirement of the recipient system warrants limit of BOD should be
lowered to 30 mg/L
Limit on sodium absorption ratio of 26 should be imposed in case of disposal on
land
All effluent discharge into surface waters shall conform to the
BOD limit of 30 mg/L
For discharge into public sewers, on land for irrigation and into
marine coastal waters BOD shall be 350, 100 and 100 mg/L
respectively
If observed COD in treated effluent is persistently greater than
250 mg/L, then the industry is required to identify the
chemicals causing the same
If the identified chemicals are found to be toxic as defined in
schedule-1 of Hazardous Chemicals rules, 1989 then SPCB
shall direct to install tertiary treatment within a stipulated time
Standards for discharge into public sewer shall be applicable
only if the sewer leads to a secondary treatment – otherwise
the discharge into a public sewer should be treated as
discharge into inland surface waters
All efforts should be made to remove colour and unpleasant
odour as far as practicable
 59. Bagasse fired boilers and
97. Boilers using agricultural waste as fuel

Boiler type Parameter Prescribed limit

(normalized to 12% CO2)
Step grate Particulate matter 250
Horse shoe/ Particulate matter 500 (12% CO2 normalized)
pulsating grate
Spreader stroker Particulate matter 800 (12% CO2 normalized)
 70. Small boilers
Boiler capacity Parameter Prescribed limit (mg/Nm3)
(normalized to 12% CO2)
< 2 ton/hr. Particulate matter 1200*
2 to <10 ton/hr. Particulate matter 800*
10 to <15 ton/hr. Particulate matter 600*
>15 ton/hr. Particulate matter 150**

* cyclone/multiclone is recommended for meeting the standards

** bag filter/ESP is recommended for meeting the standards
For coal or liquid fuel firing boilers stack height shall be calculated by
H = 14 Q0.3 (H is stack height in meters; Q is SO2 emission rate in kg/hr.)
In no case stack height shall be less than 11 meters
If calculated stack height not provided SO2 limit of 400 mg/Nm3 is applicable
 Sch.-6 part-D-II: Equipment based standards
(min. stack height for dispersal of SO2)
Steam generation Stack height (m)
capacity
< 2 tonne/hr 9
2 to 5 tonne/hr 12
5 to 10 tonne/hr 15
10 to 15 tonne/hr 18
15 to 20 tonne/hr 21
20 to 25 tonne/hr 24
25 to 30 tonne/hr 27
> 30 tonne/hr 30 or height from
H=14Q0.3

For boilers of capacity <2 tonne/hr and 2-5 tonne/hr capacity

PM emissions shall be within 1000 and 1200 mg/Nm3
Standards prescribed for small boilers
(Entry-1, emission standards, Guidelines of PPCB)
Parameter capacity
< 2ton/hr. 2-5 ton/hr. 5-10 ton/hr. 10-15 ton/hr.
SPM 1200 1000 1000 500
(mg/Nm3)
Stack height 9m 12 m 15 m 18 m
94. Noise limits for generator sets run with diesel
For DG sets upto 1000 KVA capacity manufactured after 1-1-05
• 75 dB(A) at 1 meter from the enclosure surface
• DG set should be provided with integral acoustic enclosure at the
manufacturing stage itself
• Manufacturer or importer of DG sets must have valid certificates of
type approval and also valid certificates of conformity of production
for the year
• No person shall sell, import or use of the DG sets not having a valid
Type Approval Certificate and Conformity of Production Certificate
• The Dg set must be affixed with a conformance label (which shall be
durable and legible) on a part necessary for normal operation and
not requiring replacement during the DG set life
• Conformance label must contain
– Name and address of the supplier
– Statement “This product conforms to the Environment (Protection)
Rules, 1986”
– Noise limit at 1 m in dB(A)
– Type approval certificate number
– Date of manufacturing of the product
94. Noise limits for generator sets run with diesel
Noise limits for DG sets not covered under “upto 1000 KVA
capacity and manufactured on or after 1-1-2005”
• Noise shall be controlled by providing an acoustic enclosure or by
treating the room acoustically at the user end
• Acoustic enclosure or acoustic treatment shall be designed for
minimum 25 dB(A) insertion loss or for meeting the ambient noise
standards (whichever is on the higher side)
• Insertion loss may be measured at different points at 0.5 m from the
acoustic enclosure/room and then averaged
• Proper exhaust muffler of 25 dB(A) minimum insertion loss shall be
provided
• Manufacturer shall offer a standard acoustic enclosure and suitable
exhaust muffler each of 25 dB(A) insertion loss
• Efforts should be made to bring down noise levels by DG sets
outside the premises within ambient noise requirements
• Installation of DG sets must be strictly in compliance with the
recommendations of the manufacturer
• A proper routine and preventive maintenance procedure should be
set and followed in consultation with the manufacturer to prevent
deterioration of noise level with use of the DG set
 Ambient air quality standards in respect of Noise
(Exerpts from Schedule-3 of EP Rules, 1986)
Noise limit in dB(A)
Category of area
Day time (6am-9pm) Night time (9pm-6am)

Industrial area 75 70
Commercial area 65 55
Residential area 55 45
Silence zone** 50 40
**: Silence Zone is upto 100m distance from hospitals,
educational institutions and courts

Mixed areas are to be declared as one of the above categories

Competent Authority
 Emission limits for new DG sets
(Entry-95, Schedule-1, EP Rules, 1986)
DG set Date of Emission limits Smoke Test cycles
Capacity imple- (in gram/kWh) limit*
mentation
NOx HC CO PM Torque Weightin
% g factors

> 176 – 1-7-2004 9.2 1.3 3.5 0.3 0.7 10 0.10

800 kW

*: smoke limit absorption coefficient (WI) (at full load)

• No person should use a DG set, which is not having valid Type

Approval Certificate and Conformity of Production Certificate
• Specifications for the fuel should be the same as those for
commercial HSD for diesel vehicles of the area (Entry-78,
Schedule-I, EP Rules, 1986 provides specifications diesel fuel)
 Prescribed Stack height for DG sets
(Entry-1, emission standards, Guidelines of PPCB)
Stack height
H = h + 0.2 KVA0.5
‘h’ is the height of the building housing the DG set in meters
This stack height is relaxed to the following if there are
provisions for the removal of SPM or gaseous emissions are
installed
H = 14 Qg0.3
Here Qg is gaseous emission in kg/hr.
H = 74 Qp0.24
Here Qp is particulate emission in ton/hr
Minimum stack height should be 9 meters
 National Ambient Air Quality Standards
(Exerpts from Schedule-7 of EP Rules, 1986)
Pollutant Time
weighted Concentration of ambient air
average
Industrial Resid./
area Rural area Method of measurement
Sulfur Annual 80 60 Improved West and Gacke
dioxide average method
24 hours 120 80 Ultraviolet fluorescence
Oxides of N Annual 80 60 Jacab Hochheister modified
as NO2 average (Na Arsentire) method
24 hours 120 80 Gas phase chemilimine
scence
SPM Annual 360 140 High volume sampling
average (average flow rate not less
24 hours 500 200 than 1.1 m3/min.)

RPM (size Annual 120 60

< 10 µ m) average Respirable particulate
24 hours 150 100 matter sampler

Lead (Pb) Annual 1.0 0.75 AAS method after sampling

average using EPM 2000 or
24 hours 1.5 1.0 equivalent filter paper

Carbon 8 hours 5.0 2.0 Non dispersive infrared

monoxide spectroscopy
National Ambient Air Quality Standards
(contd..)
(Exerpts from Schedule-7 of EP Rules, 1986)

• Annual average to be taken from 104 measurements

over a year (twice a week 24 hour interval)
• Limits prescribed for 24 and 8 hrs. average should be
met 98% of time
• Limits prescribed for 24 and 8 hrs. average not to
exceed on two consecutive days - If exceeding,
regular/continuous monitoring and further
investigations can be instituted
Textile Dying and Finishing Industry:
Wastewater Management Systems
 Wastewaters from core activities
Fabric preparation
– Chemical bath dumps
– Wash effluents
Dyeing
– Dye bath dumps
– Wash effluents
Printing
– Screen wash water
– Blanket cleaning water
– Print wash effluents
Finishing
– Applicator and mangle cleaning water
 Wastewaters from support activities
Soft water unit
– Backwash water
– Regeneration wastewater
– Slow rinse water
– Rapid rinse water
RO water unit
– Reject water stream
– Other wastewater stream
Cooling tower
– Cooling tower blowdown water
Boiler
– Boiler blowdown water
Domestic wastewater
 Wastewater Treatment
Cost-effective and consistent treatment of the unavoidable
wastewater to comply with the applicable effluent
standards
Prescribed standards to be complied with include
– Oil and grease, BOD, TSS, Total chrome, sulfides,
phenolic compounds and toxicity
– Colour, COD and TDS are other parameters of concern
Most units dispose effluents into the public sewers that are
not connected to STP with secondary treatment
Treatment thus is needed to comply with the standards
prescribed for discharge into surface water bodies
 Wastewater Treatment
Use of appropriate substitutes can to a great extent take
care of chrome, sulfides, and phenolics and even toxicity
– Avoid use of dyes containing heavy metals and
toxic/hazardous materials
– Substitute dichromate with peroxide in case of vat and
sulfur dyeing
Segregation of wastewaters into three streams for further
treatment disposal
– Dye and chemical bath dumps
– Wash waters and other effluents from core processes
– Wastewater generated by support activities
Treatment scheme for zero-effluent
discharge
Segregation at source

Dye effluent Wash effluent

Primary, secondary &

Pre-treatment
tertiary treatment

Multiple effect Reject stream

Reverse osmosis
evaporator
Condensate
for reuse
Accepts stream
Salt crystallizer for reuse

Recovered salt for reuse

Existing Effluent Treatment Plants (ETPs)
All wastewaters generated are collected together in an
equalization tank and treated
Treatment involved
– Coagulation-flocculation-settling and filtration
– Adsorption in activated carbon column
Coagulating agents are dosed into wastewater while pumping
from equalization tank to flocculation tank
In one unit these are dosed into equalization tank
Flocculating agent is dosed into flocculator and flocculation is
brought about by hydraulic (and mechanical) mixing
Flocs formed are separated in the tube settler (or plate settler)
through gravity settling
Clarified effluent is polished in a pressure filter and further
treated in activated carbon column prior to disposal
Sludge drained out from the tuber settler is dried in sludge
drying beds and stored as hazardous waste
 Existing Effluent Treatment Plant (ETPs)
Lime/caustic

Equalization Polyelectrolyte
pump Flocculator
tank

Ferrous sulfate
Backwash
Raw Tube settler Settled sludge
water
Wastewater

Clarified Pressure
pump
effluent sump sand filter

Water for
Activated
backwashing
carbon column

Treated effluent Treated

effluent sump
 Existing ETP
• In one unit equalization tank has a provision for aeration
mixing
• lime slurry (or caustic) and ferrous sulfate (or alum)
solution are used as coagulating agents
• Coagulating agents dosing is neither optimized nor
sufficiently regulated
• In some units flocculating agents are not dosed
• In one unit adsorption in activated carbon column is not
practiced, instead two pressure filters in series are used
• In one unit ion-exchange resin bed is provided between
the pressure filter and the activated carbon column
– Purpose served by this is not sufficiently clear - high TDS
effluent may increase the regeneration frequency
 Existing ETP
• Activated carbon in the column is neither replaced nor
reactivated
– Serves no purpose specially after the pressure filter
• Sludge drying beds appear to be not adequate in size for
handling the sludge generated
– Sludge sump and a filter press may be appropriate in view of
non-availability of space
• Fresh water is used for backwashing the pressure filter
and for preparing coagulation-flocculation chemical
solutions
– Treated effluent can be used in place of fresh water
 Suggestions
A two chambered equalization tank to facilitate batch coagulation
in the equalization tank
– Coagulating agents are dosed into the equalization tank
– Equalization tank requires provision for mixing
– Facilitates optimal and controlled dosing of chemicals and better
decolourization
Treatment may not ensure removal of BOD and COD to the
desired level
• A sequencing batch reactor may be provided downstream to
tube settler or to the pressure sand filter
– May require diffused aeration system in the reactor
• Secondary sludge may also be created because of this
Wastewater from supporting activities may be bypassed, clarified
and mixed with treated effluent prior to disposal