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Submitted by : M ayur Shukl a 0915ex091030 8th sem. 4th year IITM (EEE)
14,000 dyes and chemicals are used and a significant quantity of these goes in the solid, liquid and air wastes, thereby impart pollution of air, land and surface water. Towards the end of 20th century, world has become more ecology consciousness and thus green textile concept is emerged to facilitate eco-management in textile arena. Different unit operations, which contribute to eco degradation, are described and analysed in this chapter.
In order to minimize the risk of industrial diseases among the workers, Occupational Safety and Health Authority (OSHA) of U.S.A has specified concentration limits of dust in the air streams of production rooms for compliance by the concerned industries is given in Table II. Air circulation per hour is optimized to keep the air streams clean and hygienic to prevent any risk to the health of the workers and depicted in Table III.
withstand the stresses and strains of weaving. Certain preservatives like pentachlorophenol are added to the starch paste in order to protect it from the attack of microorganisms. They have toxic effect on human skin and the effluent generated from this process is due to spills and floor washing. Use of synthetic starches reduce the use of such preservatives and thereby reduce the health hazards. 2.4.2 Grey Inspection During weaving operation, oil stains are produced if proper precautions are not taken. Stain removers like carbon tetrachloride are used prior to chemical processing. In fact, carbon tetrachloride has 10% more ozone depletion capacity than Freon gas. 2.4.3 Chemical Processing Analysis of water consumption and pollution in effluent of textile chemical processing of cotton goods has been adapted from literature [6] and is presented in Table IV. 2.4.3.1 Desizing This process removes size ingredients such as starch, softeners, preservatives etc used in sizing. Enzymes are used to break the starch into water-soluble dextrin. Bacteria can easily attack the watersoluble dextrin and these are very degradable and have high BOD.
2.4.3.2 Scouring The scouring process is meant to remove impurities in fibre such as oils, fats, waxes, seed particles, spinning oils applied and the residual size ingredients still remaining after desizing. All these increase the BOD of effluent. 2.4.3.3 Bleaching The process destroys the natural colour of the fibre and makes it white. Sodium hypochlorite is a common bleaching agent. But due to its highly toxic nature, many countries have banned their use. Hydrogen Peroxide bleaching is preferred over other bleaching agents due to negligible toxic effect. Stabilizer is commonly used in peroxide bleaching. Silicate and phosphate based stabilizers have been found to be non-biodegradable and hence their use has been banned by number of countries. 2.4.3.4 Mercerization
In this process, cotton fabric is treated with a strong caustic soda solution at room temperature and washing it off with water. It improves the strength, elasticity, luster, dye uptake and dimensional stability of the fabric. Large volume of dilute caustic soda solution generated in the process, if allowed to discharge down the drain, will cause water pollution. However, this wash liquor can be re-used in scouring, dyeing with vat dyes and mercerization. 2.4.3.5 Dyeing Dyes, which form carcinogenic amines on reduction, contribute substantially for increased BOD/COD need to be avoided for use in dyeing. Dyes, which contain heavy metal such as chromium, cobalt, and copper, are detrimental for the environment. Major pollutants in dyeing include unfixed dye, fixing agents, reducing agents, alkali, organic acids, oxidizing agents, salts, metals, carriers etc. However, there is increasing awareness in recent years towards the use of number of natural dyes, which are eco-friendly and have no impact on the environmental pollution. 2.4.3.6 Printing Colours selected should be non-toxic and not based on forbidden amines. Dyes with high fixation properties and modified printing process needing less wash out are recommended to be used in printing. Printing gums with low BOD and free from pentachlorophenol are preferred. Use of urea is to be minimized, citric acid in disperse prints should be replaced; phenol used in nylon fabric printing is to be substituted by diethylene glycol. Use of kerosene in pigment printing should be completely eliminated. Formaldehyde based fixers for improving rubbing fastness of pigment prints should be restricted. Major pollutants in textile printing are: suspended solids, urea, solvents, colour, metals, vapours during drying and curing, screen cleaning solvents. 2.4.3.7 Finishing Formaldehyde based cross-linking agents applied to cellulosic textiles for crease resistance and dimensional stability are the highly toxic chemicals. Reactive softeners, certain flame-retardants, water repellent and rot proofing finishes, are the other pollutants. In the replacement of formaldehyde based finishing agent, polycarboxylic acid like butane tetra carboxylic acid, citric acid and copolymer of maleic acid met many requirement for satisfactory performance in terms of the level, reactivity, durable press performance, durability to laundering, fabric strength retention, low reagent volatility and absence of odour. 2.4.3.8 Enzyme Treatment Application of various enzymes in desizing, scouring, degumming of silk, finishing has brought a new horizon in textile wet processing technology. Enzyme is eco-friendly, completely biodegradable and they will not leave any chemical residues on the processed materials, and the colour change on the dyed goods is minimal.
A large number of various chemicals, besides pulp or monomer, as the case may be, are required during the manufacture of each fibre. Ingredients include acetic acid, titanium dioxide, spin finish, catalyst, methyl acrylate or vinyl acetate, sulphuric acid, sodium hydroxide, carbon disulphide, Zinc, sodium sulphate, di-sodium sulphide, acetic anhydride, thermal stabilizer, light stabilizer, antioxidants etc.
ACN is toxic and as a consequence stringent measure in acrylic manufacturing plant is necessary to ensure that it does not contaminate liquid discharge. One of the major pollutants in viscose plant liquid effluent causing concern is the presence of zinc. The average consumption of zinc is in the range of 15 Kg/MT fibres. The zinc concentration in the effluent is on an average 15-40 mg/l. The average consumption and parameters for liquid effluent discharged by nylon and polyester industries are given in Table VI. In India, for nylon and polyester, the wastewater generated is on an average of 170 3 3 m /MT and for viscose 1200 m /MT, respectively. 2.5.1 Pollution Control Standard The Central Pollution Control Board formulated a minimum National standard (MINAS) for all polluting industries including fibre industry. MINAS as depicted in Table VII must be adhered to before the liquid can be discharged outside the factory premises.
Effluent treatment of man-made fibre industry, especially synthetic fibre may not be very complicated. However, there is pollution control problem in viscose and acrylic fibre production.
4 Eco-Management
Textile industry encompasses a range of unit operation covering a variety of natural and synthetic fibres to produce fabrics. Various parameters such as turbidity, acidity, alkalinity, total dissolved solids, BOD, metal content, toxic substances etc. are bench marked so as to ensure that the effluent water before being released into city sewage, stream, river or sea is not harmful to human, animal or plant life. With the concept to bring the parameters of effluent water to acceptable standards, the effluent is treated. The appropriateness of their choice and sequence is critical for the success of treatment plant 4.1 Treatment of Textile waste Three types of process are normally used for treatment and recycle of effluent from the textile industry. These are physico-chemical, biological and membrane process.
Physico-chemical processes remove suspended and colloidal impurities, to coagulate and flocculate reactive, disperse and vat dyes and to facilitate their removal by sedimentation. The removal is a function of entrapment within a voluminous precipitate consisting primarily of the coagulant itself. Result of addition of chemicals is net increase in the dissolved constituents in the wastewater. Coagulants usually added include alum, lime etc. [9]. These processes offer a good pre-treatment to the downstream biological and membrane processes. Biological processes used to remove dissolved organics from effluent and thus to reduce chemical and bio-chemical oxygen demands of the effluent. This is achieved biologically wherein bacteria is used to convert the colloidal and dissolved carbonaceous organic matter into various gases and into cell tissue. Because the cell tissue has a specific gravity slightly greater than that of water, removal from the treated effluent is facilitated under gravity. Biologically treated effluent contains dissolved salts and residual impurities that have passed through the previous processes. These are removed in the membrane process such as reverse osmosis, which is suitable for removing high salt concentrations so that the treated effluent can be re-used again in the processing. A typical flow chart of a water recycle plant for textile industry is shown in Figure 1
4.2 Re-Use of Wastewater In textile industry, the wastewater in certain processes like continuous scouring, mercerizing is re-used, thereby not only economises the wastewater costs but also reduces the volume of effluent to be disposed. In a mill, if wastewater is clean enough after secondary and tertiary treatment, it can be reused in processes like washing, soaping etc.
5 Conclusions
Green minded consumers prefer "eco-friendly" textiles. In the present global scenario, if the textile industry wishes to bring prosperity through diversification and modernization, they have to manufacture eco-friendly products and the overall textile processing will have to be modified in such a way so as to avoid any toxicity as efficiently as possible. Our motto is to save living species and its surrounding environment. Thus we must start using sophisticated and better-designed machines with less noise and follow improved method of air purification and circulation system. And we should stop using chemicals
and dyes, which produce harmful effect to the biotic and abiotic factors in our eco-systems. Reduction of waste at the source is the preferred strategy instead of the traditional method of "end of pipe waste treatment". Apart from problematic chemicals and dyes, the main pollutant is, of course, water. So, the new technologies, which aim to reduce or eliminate water, are to be conceived.
References:
Lal, R. A. "Problems of Environmental Control in Chemical Processing Units, NCUTE Extension Programme on Environmental Problems in Chemical Processing of Textiles", KCT, Coimbatore, 21-22 June 2001. Shastree, N. K., "Environmental Resource Management, Noise Pollution: Standards and Control", pp. 175-215, Anmol Publication Pvt. Ltd., New Delhi, 1997. Prabhaka, V.K., "Environmental Noise Pollution, Nature of Noise", pp. 60-61, Anmul Publications Pvt. Ltd., New Delhi, 2001. Ertem, M., Ilcin, E., Meric, F., "Noise induced Hearing Loas Among Cotton Textile and Carpet Mill Workers", Tr. J. of Medical Sciences, 28, pp. 561-565 (1998). Subramanian, S., and Phalgumani, G.R., "Processing of Eco-friendly Textiles: International Norms", A Bilateral Symposium on Eco-Friendly Textile processing, IIT Delhi, Nov 6-7, 1995. Wagle, N.P., "Eco-Management for Textile Industry", NCUTE Programme on Eco-Friendly Textile Wet Processing, S.S.M. College of Engineering, Komarapalayam, Tamil Nadu, 26-27 July 2001. Mukherjee, A. K., "Pollution Control in Man-made Fibre Industry", A bilateral symposium on Eco-friendly Textile Processing (India and Japan), IIT Delhi, 6-7 November 1995. Das, S., and Ghosh, A., "Studies on Eco degradation During Processing of Textiles", National Conference on Environmentally Conscious Design and Manufacturing - Issues and Challenges, KCT, Coimbatore, 2324 July 2004. Metcaff and Eddy, "Waste Water Engineering, Treatment, Disposal and Reuse", 3rd Edition, Mc-Graw-Hill International Edition, Singapore, 1997