Pollution control in Textile dyeing

Industry

Pollution control in textile industries

A dye can generally be described as a colored substance that has an
affinity to the substrate to which it is being applied. The dye is generally applied
in an aqueous solution, and may require a mordant to improve the fastness of the
dye on the fiber.
Both dyes and pigments appear to be colored because they absorb some
wavelengths of light preferentially. In contrast with a dye, a pigment generally is
insoluble, and has no affinity for the substrate.

Historical Background of Textile Production in Bangladesh:

Textiles play an important role in the economic life of Bangladesh. The sector, in
addition to meeting the demand of fabrics and apparel domestically, contributes
significantly to the textiles and clothing (T&C) export trade. At present, more than
78 per cent of the countrys export earnings come from T&C. The sector provides
employment to a workforce of 4.5 million and contributes 40 per cent value
addition to the manufacturing sector. Textiles as a whole play the most significant
role in the alleviation of poverty, provision of employment to rural women and
economic empowerment of women. The sector provides 200,000 jobs in the waste
recycling industry related to ready-made garments (RMG), contributes 10.5 per
cent to GDP, provides indirect employment for an 800,000-workforce in
accessories industries related to T&C and generates a huge cliental base for
banking, insurance, shipping, transport, hotel, cosmetics, toiletries and related
economic activities.

Bangladesh entered the international T&C trade in the early part of the
1980s, when the Government opted for a market-oriented economy. Investments in
the primary textile sector (PTS), i.e., spinning, weaving and dyeing-printingfinishing (textile product processors), started at the same time as the expansion and
entry of ready-made garments (apparels and clothing) into international markets.
When Bangladesh entered the global T&C markets, export earnings were
insignificant. For example, during fiscal year 1981/82 (July-June), the share of
T&C in total export earnings was 1.1 per cent (comprising only woven garments).
Over the years, that share increased to 78 per cent of the total earnings, to reach
US$ 8.1 billion during fiscal 2005/06.

Immediately after liberation in 1972, the Government opted for a

socialistic economic policy by nationalizing all big industries. At that time, all
large textile mills were nationalized. However, when the Government opted for a
market-oriented economic policy, the textile mills were gradually handed over to
the private sector in phases.

Ministry of Textiles records show that as of 2006 there were 23 textile mills under
Government ownership with 400,000 installed spindles and a total capacity of
40 million kg of yarn production. However, most of the mills are non-functional
and the machinery is obsolete. Although the performance of public sector mills has
slowly declined, private sector mills have flourished under the supportive policy of
successive governments.

Growth pattern of primary textile mills in Bangladesh:

Source: Bangladesh Textile Manufacturers Association.

Classification of Dyes:

Acid Dye

Basic Dye

Direct Dye

Sulphur Dye

Azo Dye

Vat Dye

Acid Dyes:

These are generally applied to textile fibers from dye baths containing acid. Most
have one or two sodium sulfonate (SO3Na) groups which are water soluble and
capable of bonding with fibers having cationic sites. They give a wide range of
bright colors on textiles, especially when monoazo and anthraquinone
structures are used.

Basic dyes
Basic dyes were developed to dye negatively charged acrylic fibers, forming ionic
bonds. They owe their name to the presence of aromatic amino (basic) groups, and
in this case a cationic amino group is present. Generally, they have excellent
brightness and color strength, their light fastness is often Low.

Direct dyes
Direct Dyes or substantive dyeing is normally carried out in a neutral or
slightly alkaline dyebath, at or near boiling point, with the addition of
either sodium chloride (NaCl) or sodium sulfate (Na2SO4).
Direct dyes are used on cotton, paper, leather, wool, silk and nylon. They
are also used as pH indicators and as biological stains.
Direct dyes are anionic colorants that have affinity for cellulosic fibers.
They were the first dyes with the ability to dye cotton in the absence of a
mordanting agent, giving rise to the term direct-cotton dyes.

Sulfur Dyes
Sulfur dyes are water-insoluble dyes that are applied to cotton. These
are mainly give dull shades. While yellow, red, brown, olive, and blue
colors can be produced, sulfur dyes are most important for their ability
to deliver washfast black shades on cotton

Examples of (a) sulfur yellow and (b) red dye structures

Azo Dyes:
It is a technique in which an insoluble azoic dye is produced directly onto or
within the fibre. This is achieved by treating a fibre with both diazoic and
coupling components. With suitable adjustment of dyebath conditions the two
components react to produce the required insoluble azo dyes.
This technique of dyeing is unique, in that the final color is controlled by the
choice of the diazoic and coupling components

Representative Anthraquinone vat dye structures (a) Vat Red 13, (b) Vat Black
27, (c) Vat Orange 2, (d) Vat Blue 4, and (e) Vat Green 1.

Vat Dyes:
Water insoluble and fast dyes applied along with strong reducing
agents (sodium hydro sulfite) and alkali to make the dye soluble.
The cloth is then exposed to air for oxidation.
The excess alkali remaining on the cloth is neutralized by scouring.
Vat dyes have mainly anthraquinone (82%) or indigoid/thioindigoid (9%)
structures, with the former having better fastness properties
Vat dyes are easier to reoxidize than sulfur dyes and the oxygen in air is
often the agent used. As would be anticipated, most vat dyes display high
wash fastness .

Manufacturing processes of dyeing Industries:

Grey Textile Materials( Fiber, Yarn or Faric)

Singing

Desizing

Scouring

Bleaching

Mercerizing

Dyeing/Printing

Finishing

Marketing

Figure: Flow chart of Manufacturing processes of dyeing Industries

Singeing is the first steps of pre-treatment. By this process by which loose, hairy
and projecting fibers are removed is called Singing.
Desizing is the second steps of pre-treatment. By this process gummy materials are
removed. Also size materials removed by this process.
Scouring : This process is performed for removing impurities of the textile
materials.
Bleaching:This is used to reduce natural colo of the raw materials. Dyeing
performance depends on it much more.
Mercerizing: is the special types of treatment. It performs if buyer wants. It is an
additional treatment. It increases the strength and luster of the materials.
Dyeing: is the main process where a white material becomes decorated by
different colos.
Printing: is called as localized dyeing. Different types of printing are done for
giving special appearance on colored or white fabric.
Finishing: is the last treatment of wet processing. Different types of properties can
be added to the materials by different finishing effects.
Marketing: is our main goal. If we dne everything but there have no buyer then
everything is waste. So we should have a strong marketing department.

Sources of effluent

Dyeing and printing

industries

Textile industries

Paper and ink manufacturing industries

Cosmetics

Pharmaceuticals

Food

Properties of effluent

Impart color to water bodies even if present in small quantity

Reduces light penetration and photosynthesis

Carcinogenic or mutagenic

Azo dyes are more toxic as they affect microbes thereby affecting biological
degradation treatment.

Dyes increases BOD of effluent thereby affecting aquatic life

Toxic to fish & microbial organisms

The discharge of heavy metals into aquatic ecosystems Increase in alkalinity of

water

The turbidity and color along with oil and scum create an unsightly appearance.

The mineral materials, mostly sodium salts increase salinity of the water.

Volume of effluent

The volume of effluent generated in dyeing is comparatively more.

It contains dyes, mordants, acids (acetic acid), alkalis, nitrites,

chromium salts, sodium chloride and soaps.

These effluents are usually hot, highly coloured with a high pH and sulfide
content

Care must be taken while neutralising these liquors as acid

may liberate hydrogen sulfide gas.

Removal of Sulfides by treatment with chlorine or hypochlorites

Spent vat dyes are strongly alkaline and have fairly high permanganate value

Characteristics of pollutants from different section in textile

industry:Industrialization of the textile industry and use of a large variety of chemical
treatments and dyes has resulted in a public health threat created by pollution. 17 20% of industrial freshwater pollution is caused by textile dyeing and treatment.
Estimations state that 10-15% of total dyestuffs (equivalent to 280,000 tonnes of
dyestuffs) used during the manufacturing of textile products is released into the
environment worldwide annually.
There are a wide range of mostly organic compounds of complex structure used in
the textile dyeing and finishing process. In regards to waste-water, dyestuffs may
be classified into two groups; those that dont undergo chemical reactions (acid,
basic, direct, disperse, pigment, and solvent), and those that do (reactive, vat,
sulphur, azoic). Of these the processes involving reactive chemistry use chemicals
that independently are non-toxic, but react with the other chemicals used in
manufacturing to create a third substance which is toxic. This reaction can occur
during various stages in the product lifecycle, and can vary greatly dependent not
only on the dye compound created, but also on factors such as the fiber choice,
fabric structure, or machinery used. Composite textile waste-water is
characterized mainly by measurements of biochemical Oxygen Demand (BOD),
Chemical Oxygen Demand (COD) suspended solids (SS), and dissolved solids

(DS). Typical characteristics of textile industry waste-water are presented in the

table below.
Table: Composite Textile Industry Waste-water Characteristics
Parameters

Values

pH

7.0-9.0

Biochemical Oxygen Demand (mg/L) 80-6,000

Chemical Oxygen Demand (mg/L)

150-12,000

Total Suspended Solids (mg/L)

15-8,000

Total Dissolved Solids (mg/L)

2,900-3,100

Chloride (mg/L)

1,000-1,600

Total Kjeldahl Nitrogen (mg/L)

70-80

Harmful effects of dyeing wastewater from textile

industries:1. Textile wastewater contains many pollutants including acids, dispersants,
alkalis, dyes, heavy metals, organic-chlorines, PBDE, PFOA, phthalates, pigments,
salts, and many more. The release of these hazardous materials into public drains

2. Several azo dyes cause damage of DNA that can lead to the genesis of
malignant tumors. Electron-donating substituents in ortho and para position can
increase the carcinogenic potential. The toxicity diminished essentially with the
protonation of aminic groups.

3. The colour in watercourses is accepted as an aesthetic problem rather than an

eco-toxic hazard. Therefore, the public seems to accept blue, green or brown
colour of rivers but the non-natural colour as red and purple usually cause most
concern.

4. Some of the best known azo dyes (e.g. Direct Black 38 azo dye, precursor for
benzidine; azodisalicylate, precursor for 4-phenylenediamine) and their breakdown
derivatives inducing cancer in humans and animals are benzidine and its
derivatives, and also a large number of anilines (e.g. 2-nitroaniline, 4chloroaniline, 4,4-dimethylendianiline, 4- phenylenediamine, etc.), nitrosamines,
dimethylamines, etc

Pollution control in textile dyeing industries:

Primary Treatment:A.SCREENING:
1.Screening is the filtration process for the separation of coarse particles from
influent.
2.Stainless steel net is used for screening.
3.Hard plastic brushes are used to clean the net, which are driven mechanically.

Figure: screening

SCHEMTIC DIAGRAM OF DRUM SCREENER:

Figure: SCHEMTIC DIAGRAM OF DRUM SCREENER

B.Equalization:
Effluent equalization is the process to make the waste water
-Homogenous &
-Cool
Equalization tank also called homogenous tank.

C.Sedimentation:
This process is particularly useful for treatment of wastes containing high
percentage of settable solids or when the waste is subjected to combined treatment
with sewage. The sedimentation tanks are designed to enable smaller and lighter
particles to settle under gravity. The most common equipment used includes
horizontal flow sedimentation tanks and centre-feed circular clarifiers. The settled
sludge is removed from the sedimentation tanks by mechanical scrapping into
hoppers and pumping it out subsequently.

Secondary Treatment:Secondary treatment removes the soluble organic matter that escapes primary
treatment. It also removes more of the suspended solids. Removal is usually
accomplished by biological processes in which microbes consume the organic
impurities as food, converting them into carbon dioxide, water, and energy for their
own growth and reproduction. The sewage treatment plant provides a suitable
environment, albeit of steel and concrete, for this natural biological process.

Removal of soluble organic matter at the treatment plant helps to protect the
dissolved oxygen balance of a receiving stream, river, or lake.
There are three basic biological treatment methods: the trickling filter, the
activated sludgeprocess, and the oxidation pond. A fourth, less common method is
the rotating biological contacter.

Trickling filter:
A Trickling filter is simply a tank filled with a deep bed of stones. Settled sewage
is sprayed continuously over the top of the stones and trickles to the bottom, where
it is collected for further treatment. As the wastewater trickles down, bacteria
gather and multiply on the stones. The steady flow of sewage over these growths
allows the microbes to absorb the dissolved organics, thus lowering the BOD of
the sewage. Air circulating upward through the spaces among the stones provides
sufficient oxygen for the metabolic processes.
Settling tanks, called secondary clarifiers, follow the trickling filters. These
clarifiers remove microbes that are washed off the rocks by the flow of wastewater.
Two or more trickling filters may be connected in series, and sewage can be
recirculated in order to increase treatment efficiencies.

Activated sludge:
The Activated sludge treatment system consists of an aeration tank followed by a
secondary clarifier. Settled sewage, mixed with fresh sludge that is recirculated
from the secondary clarifier, is introduced into the aeration tank. Compressed air is
then injected into the mixture through porous diffusers located at the bottom of the

tank. As it bubbles to the surface, the diffused air provides oxygen and a rapid
mixing action. Air can also be added by the churning action of mechanical
propeller-like mixers located at the tank surface.
Under such oxygenated conditions, microorganisms thrive, forming an active,
healthy suspension of biological solidsmostly bacteriacalled activated sludge.
About six hours of detention is provided in the aeration tank. This gives the
microbes enough time to absorb dissolved organics from the sewage, reducing
the BOD. The mixture then flows from the aeration tank into the secondary
clarifier, where activated sludge settles out by gravity. Clear water is skimmed
from the surface of the clarifier, disinfected, and discharged as secondary effluent.
The sludge is pumped out from a hopper at the bottom of the tank. About 30
percent of the sludge is recirculated back into the aeration tank, where it is mixed
with the primary effluent. This recirculation is a key feature of the activated sludge
process. The recycled microbes are well acclimated to the sewage environment and
readily metabolize the organic materials in the primary effluent. The remaining 70
percent of the secondary sludge must be treated and disposed of in an acceptable
manner (see Sludge treatment and disposal).
Variations of the activated sludge process include extended aeration, contact
stabilization, and high-purity oxygen aeration. Extended aeration and contact
stabilization systems omit the primary settling step. They are efficient for treating
small sewage flows from motels, schools, and other relatively isolated wastewater
sources. Both of these treatments are usually provided in prefabricated steel tanks
called package plants. Oxygen aeration systems mix pure oxygen with activated
sludge. A richer concentration of oxygen allows the aeration time to be shortened
from six to two hours, reducing the required tank volume.

Oxidation pond :
Oxidation ponds, also called lagoons or stabilization ponds, are large, shallow
ponds designed to treat wastewater through the interaction of sunlight, bacteria,
and algae.Algae grow using energy from the sun and carbon dioxideand inorganic
compounds released by bacteria in water. During the process of photosynthesis, the
algae release oxygen needed by aerobic bacteria. Mechanical aerators are
sometimes installed to supply yet more oxygen, thereby reducing the required size
of the pond. Sludge deposits in the pond must eventually be removed by dredging.
Algae remaining in the pond effluent can be removed by filtration or by a
combination of chemical treatment and settling.

ROTATING BIOLOGICAL CONTACTER:

In this treatment system a series of large plastic disks mounted on a horizontal

shaft are partially submerged in primary effluent. As the shaft rotates, the disks are
exposed alternately to air and wastewater, allowing a layer of bacteria to grow on
the disks and to metabolize the organics in the wastewater.

Tertiary treatment:
When the intended receiving water is very vulnerable to the effects of pollution,
secondary effluent may be treated further by several tertiary process.

Ultraviolet radiation
A disinfection process for water and wastewater treatment that involves passing
Ultraviolet (UV) light through water. UV light destroys microorganisms and can
reduce dissolved organic material.

Activated carbon absorption

A physical process that is typically applied as tertiary treatment to remove low
concentrations of contaminants from water that are difficult to remove by other
means. Activated carbon has been processed to make it extremely porous, thereby
creating a very large surface area available for adsorption of contaminants.
Activated carbon may have a surface area as great as 1500 m2/g (7.3 million
ft2/lb).

Ion exchange
Ion exchange is a reversible chemical reaction used to remove ions from water and
wastewater. An ion in solution, such as ammonium, copper, calcium, magnesium,
and many others, is exchanged for a similarly charged ion attached to an immobile
solid ion exchange particle. These solid ion exchange particles are either naturally
occurring inorganic zeolites or synthetically produced organic resins.

Chlorination
A water treatment method that destroys harmful bacteria, parasites, and other
organisms. Chlorination also removes soluble iron, manganese, and hydrogen
sulfide from the water.

Thermal evaporation:
The use of sodium per sulphate has better oxidizing potential than NaOCl in the
thermal evaporator. The process is ecofriendly since there is no sludge formation
and no emission of the toxic chlorine fumes during evaporation. Oxidative
decolourisation of reactive dye by persulphate due to the formation of free radicals
has been reported in the literature.
In every textile dyeing industry , there should be effluent treatment plant . in
echotex limited there is a ETP which is mainly of physical and bio chemicals
treatment plant. Bio-chemical treatment plant can treat wastewater and bacteria.
Daily treatment capacity of this treatment is 3000 m3.

Equalization tank:
Equalization tank is mainly used cool down the temperature of the
wastewater and increase the homogenesity of the wastewater .the daily workin
hour of the equalization tank is 8 hr and its capacity is 2750 m3.

Ozone contact tank:ozone tank is used to mainly reduce the color of the wastewater

and

increase the DO level of the wastewater and kii the anaerobic bacteria. Mainly
coagulants are used to perform these processes.

Figure: Ozone contact tank

FLOCCULATION TANK:
Flocculation tank is use for:
1.Coagulant-flocculants (lime, ferrous & polymer)
2.Break down Color Bond

Figure: Flocculation tank

SEQUENCING BATCH REACTOR:

Sequencing batch reactors are industrial processing tanks for the treatment of
wastewater . SBR reactors treat waste water from industrial area, and sewage or
output from anaerobic digesters or mechanical biochemical and biological
treatment facilities in batches, Oxygen is bubble through the waste water to reduce
Biochemical oxygen demand (BOD) , chemical oxygen demand (COD) to make
suitable for use in land and aquatic life. Here used bacteria should be aerobic.

Figure: Sequencing batch reactor

AEROBIC DIGESTER TANK:

Aerobic digestion is an open system that utilizes oxygen and biologically treats
waste with naturally occurring organ.

In Bangladesh due to textile dyeing industries, the main negative

impact afflicting the local environment severely is the hazards caused by dye
effluents, which contain both chemical and organic pollutants. These can be highly
toxic. The results of the study reveal that, the textile dyeing industries in Gazipur
area discharge large quantities of effluent composed of various physicochemical
pollutants at significant higher level than standard value of DOE except some
industries which have authentic waste water treatment plant. From the above
findings it can be easily said that, the water of Turag and Shitalakkhya River is
getting highly polluted by the effluent discharged by the dyeing industries of the
study area. The pollutants is increasing in an alarming rate with the increasing
number of textile dyeing industries.

REFERENCES:
1. www.wikipedia.org
2. Y. R. Sharma, Elements of organic spectroscopy, S. Chand & Company
LTD, New Delhi, India.
3. Kirk Othmer, Encyclopedia of chemical technology, 5th

Edition, 9th Volume, Wiley Interscience, John Wiley & Sons, Inc.,
Publication

4. S.Eshwaramoorthi, K. Dhanapal and D.S.Chauhan, Environment With

People's Involvement & Co-ordination in India, Coimbatore, India,
www.ecpconsulting.in
5. http://www.scribd.com/doc/12949482/Dyestuff-Industry-Treatment, 2003