Presented by: Filiz MOROVA
İzmir Development Agency
Assessment of Counter Current Washing and Change in Rope Route for Water Use Minimization in a Wet
Processing Textile Mill
Textile Manufacturing is one of the Largest Industrial Consumers of Water
• “Environmental Technology Best Practice Program, guide Code EG98, Water Use in TextileDyeing and Finishing” states that;
the water consumption is:
150-200 kg/kg of product
Reducing the Water Consumption inTextile Mills
Reducing the water consumption REDUCE WASTEWATER GENERATED&INCREASE THE COST EFFECTIVENESS.
In the Guide called as “A Step Towards Cleaner Production”,Susan Barclay and Chris Buckley states that;
Within any process, there are five main aspects that should be taken
into account when considering the implementation of waste
minimisation.
• raw materials used and other input materials such as water• the type of technology,
• the manner is which the process is executed,
• the products that are formed, and• the wastes and emissions that are generated.
The Textile Mill Studied
The Textile Mill studied;
• is one of the major mills in Turkey
• has a capacity of 20 000 ton denim fabric per year
• includes Cotton Fiber Production, Dyeing, Sizing and Finishing
8
The Textile Mill Studied
�The production is 24 hours a day & 3 shifts/day
�The water consumption of 2000 m3/day
�Chemical consumption of 1000 ton/month
�Over 100 chemicals used
�It has own WWTP and Co-generation Units
9
Production Flow
COTTON FIBER
PRODUCTION DYING PROCESSES
WEAVING
FINISHING PROCESSES
150-200 kg of water/kg of product
SIZING PROCESSES
Dyeing Processes
• Dyeing Machine includes the equipment which is used for preparation and softening processes.
The flow chart for Dyeing Processes in the Mill;
Preparation Pre-Washing Dyeing Back-Washing
Water consumed in these processes is;
about 40 % of the total water used through this whole production line of the Mill
Softening
How to minimize the waste- How to reduce water consumption -
NEW TECHNIQUES
WATER CONSUMPTIONREDUCTION STUDY
PROCESS REVIEWING
DETERMINING THE WATER USAGE IN DYING PROCESS
ASSESSMENT OF THE WATER CONSUMPTION REDUCTION OPTIONS
ASSESSMENT OF TECHNICAL FEASIBILITY OF CHOSEN OPTIONS
Through out the study;
• Brain storms with the managers of the selected Textile Mill / Site Visits
• Literatural Reviews
European Integrated Pollution Prevention and Control (IPPC)
Reference Document on Best Available Techniques (BAT) for the
Textiles Industry was accepted as main reference document.
WATER CONSUMPTIONREDUCTION STUDY
WATER CONSUMPTION REDUCTIONSTUDY
• Rerouting the Rope-Guide
• Counter-Current Washing in Back-
washing
Rerouting the Rope-Guide
What is Rope-Guide?
• Different Dyeing recipes exist for Different Denim Products.
• Each recipe has its own application method in the Textile Mill.
• There are four Dyeing Machines in the Mill, which includes;
Preparation, Pre-washing, Dyeing and Back-washing Units in different numbers of their application tanks.
•Therefore, there are some differences of applications of different Dyeing recipe.
• To adjusting the following Dyeing recipe application to the Dyeing machine, Rope-Guide is used in the Mill.
Prepara
tion
Tank
Pre-
w ash
ing 1
Pre-
w ash
ing 2
Pre-
w ash
ing N
Dyeing 1
Dyeing 2
Dyeing N
Back-
washi
ng 1
Back-
washi
ng 2
Back-
washi
ng N
Route of Rope-Guide (Dyeing Recipe A)
Water Flow
New Route of Rope-Guide (Dyeing Recipe B)
Rerouting the Rope-Guide
• Rope guide is fixed to the rope which will be going through the
Dyeing processes, and it determines the route of the rope which will
be dyed.
• ReroutingRerouting is to change the route of the rope-guide in an
environmental friendly way, which provides reduction of water
consumption.
• 5 dyeing recipes (X, Y, Z, W, U) in different dyeing machines
– Application Frequency within the period of the study:
30% of the number of the total dyeing recipe
– Rerouting is applicable
• Rerouting alternatives were determined and application conditions were examined and application was achieved.
• Water saving was determined.
• The effect of varying dyeing time was observed.
– The duration of dyeing can be changed between 165 min and 1000 min.
Rerouting the Rope-Guide Materials and Methods
Dying Tank used as
washing tank
Washing
TankWashing
Tank
Fresh water feeding tank
Q
Q/3 Q/3Q/3
Dying Tank used as
washing tank
Washing
TankWashing
Tank
Fresh water feeding tank
Q
Q/2 Q/2
Fresh
water
Dying Machines
3 and 4
Dying Machines
1 and 2
Q
Q/2 Q/2
q
Rerouting the Rope-GuideX Type Dyeing recipe/Machine 1
V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L
V=1000 L V=1000 L V=1000 L
Dying 1
Dying 2
Dying 3
Dying 4
Dying 5
Dying 6
Dying 7
Dying 8
Dying 9
Dying 10
Backwashi
ng 3
Backwashi
ng 2
Backwashi
ng 1
New route of guide-rope
Water (new dying method)
Old route of guide-rope
Water (Old dying method)
33.3 L/min
33.3 L/min
33.3 L/min
33.3 L/min 33.3 L/min 33.3 L/min
33.3 L/min
33.3 L/min
33.3 L/min
33.3 L/min
33.3 L/min
33.3 L/min
• 7 dyeing tanks
• There isn’t any extra freshwater feeding tank for dying tanks BUT..
66.6 L/min
66.6 L/min
66.6 L/min
66.6 L/min
66.6 L/min
66.6 L/min
Rerouting the Rope-Guide X Type Dyeing recipe
• Water consumptions and water saving data for X type dying in machine 1
Amount of water consumed for back-washing in old dying method (L) 63800
Amount of water consumed for back-washing in new dying method (L) 56000
Water saving (%) 12
• 265 minutes (6625 m of rope to be dyed, machine velocity=25 m/min)
• maximum water saving is 19 % where the minimum water saving is 4 %
0
2
4
6
8
10
12
14
16
18
20
0 200 400 600 800 1000 1200
Duration of dying (min)
Wate
r savi
ng p
er d
yin
g (%
)
Amount of water consumed for back-washing in old dying method: (265 min * 200 L/min) + (1000 L/tank * 3 tank) + (2600 L/tank * 3 tank) = 63800 L
Amount of water consumed for back-washing in new dying method:
(265 min * 200 L/min) + (1000 L/tank * 3 tank) = 56000 L
Rerouting the Rope-Guide Y Type Dyeing recipe/Machine 2
Preper
atio
n
Prewas
hing
1
Prewas
hing
2
Prewas
hing
4
Dying 9
Dying
8
Dying 7
Dying
10
25 L/min
25 L/min
25 L/min
25 L/min
25 L/min
25 L/min
25 L/min
Dying
1
Dying
2
Dying
3
Dying
4
Dying
5
Dying
6
New route of guide-rope
Water
Old route of guide-rope
V=600 L
V=1000 L V=1000 L V=1000 L V=1000 L
V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L V=2600 L
V=2600 L
Prewas
hing
3
25 L/min
• 4 dyeing tanks are required for this type.
• In old method: 6 dyeing tanks are used as pre-washing tanks.
Flow is splitted into 10 freshwater pathways.
Rerouting the Rope-Guide Y Type Dyeing recipe
•Water consumptions and water saving data for Y type dying in machine 2
Amount of water consumed for pre-washing in old dying method (L) 40600
Amount of water consumed for pre-washing in new dying method (L) 25000
Water saving (%) 38
• Duration of Dyeing is; 210 minutes
• Maximum water saving is 45 %
• Minimum water saving is 14 %.0
10
20
30
40
50
0 200 400 600 800 1000 1200
Duration of dying (min)
Wa
ter
sa
vin
g p
er
dy
ing
(%
)
Amount of water consumed for pre-washing in old dying method: (210 min * 100 L/min) + (1000 L/tank * 4 tank) + (2600 L/tank * 6 tank) = 40600 L
Amount of water consumed for pre-washing in new dying method:
(210 min * 100 L/min) + (1000 L/tank * 4 tank) = 25000 L
Rerouting the Rope-Guide Z Type Dyeing recipe/machine 3
Dying 2
Dying 3
Dying 4
Dying 5
Dying 6
Dying 7
Prewashi
ng 4
Prewashi
ng 3
25 L/min
25
L/min
25
L/min
Preperati
on
Prewashi
ng 1
Prewashi
ng 2
25 L/min
25 L/min
25
L/min
Dying 8
Dying 9
Dying 10
Dying 1
25
L/min
25 L/min
20 L/min
20 L/min
V=600 L V=1000 L
V=1000 L
V=1000 L
V=1000 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
V=2600 L
New route of guide-ropeWater (new dying method)
Old route of guide-rope
Water (old dying method)
9 dyeing tanks are required.
In old method: 1 dyeing tank is used as a pre-washing tank.when a dying tanks is used as a washing tank, there shouldbe an extra total flow coming from the tank which feedsdying tank with freshwater. This total flow is 10-20 L/min.
Rerouting the Rope-Guide Z Type Dyeing recipe
Water consumptions and water saving data for Z type dying in machine 3
Amount of water consumed for pre-washing in old dying method (L) 51000
Amount of water consumed for pre-washing in new dying method (L) 41000
Water saving (%) 20
• In this case dying lasts 370 minutes
• Maximum water saving is 23 %.
• Minimum water saving is 18 %. 0
5
10
15
20
25
0 200 400 600 800 1000 1200
Duration of dying (min)
Wa
ter
sa
vin
g p
er
dy
ing
(%
)
Amount of water consumed for pre-washing in old dying method: (370 min * 100 L/min) + (370 min * 20 L/min) + (1000 L/tank * 4 tank) + (2600 L/tank) = 51000 L
Amount of water consumed for pre-washing in new dying method:
(370 min * 100 L/min) + (1000 L/tank * 4 tank) = 41000 L
• According to data obtained from the facility; for the three months, in which the rerouting
has taken place, the percentage of those types of dyeing recipes are determined as 30 % of
the total production.
• Preparation, dying, washing and softening processes are defines “rope dyeing processes” by
the facility.
Rerouting the Rope-Guide Reduction in Water Consumption
Amount ofconsumed
water in rope
dyeing process(L)
Washing water
consumption
(new method) (L)
Washing water
consumption
(old method)
(L)
Difference
(L)
Reduction in total
(X,Y,Z,W,U) water
consumption (%)
X 110872 56000 63800 7800 7,0
Y 93479 25000 40600 15600 16,7
Z 265683 41000 51000 10000 3,8
W 156767 85500 93300 7800 5,0
U 163750 92000 99800 7800 4,8
Total 790551 299500 348500 49000 6,2
March-April-Mai total water use for rope dying processes
Amount of consumed water (L)
March 42475000
April 28191000
Mai 31736000
Total 102402000
Rerouting the Rope-Guide Reduction in Water Consumption
Water consumed in three months for X,Y,Z,W,U type dyings (30% of total consumption) can be calculated as follow;
102402000 L * 0.3 = 30720600 L
Water reduction amount in three months is equal to
30720600 L * 0.062
= 1,904,677 L
• Within the selected five specific type of dying the effect of the
method was investigated. By investigating this effects, it was
obviously seen that water saving can be achieved.
• The effect of duration of dying on water saving was also
investigated:
when there is an additional freshwater feeding tank to the washing
tank there is not significant effect of duration of dying on the water
saving percentage.
Rerouting the Rope-Guide Conclusion
Counter-Current Washing in Textile Industry
• The more important consideration is to achieve the required washing efficiency by using less amount of rinsing water.
• The counter-current washing principle is the most common and efficient one among those techniques.
Counter-current washing is often practiced by introducing raw water into the last wash of the washing series.
The wastewater is then circulated from the last step to the next preceeding step and so on up the line.
The cleanest product is washed with the cleanest water and and the most contaminated product is washed with dirtiest water. The system leads to huge savings in water use.
Counter-Current Washing in Textile Industry
Material Flow
Water Flow
Counter-Current Washing in Textile Industry
Typical water savings obtained by counter-current washing
Number of washing tank Water saving
(%)
2
3
4
5
50
67
75
80
Source:(US EPA, 1995)
Since preparation and dying processes are typically continuous, counter-current washing can be used to great advantage for water conservation in washing processes. The principle of counter-current washing in textile industry is simple and usually not expensive or difficult to implement.
Counter-Current Washing in TextileIndustry
•Sillanpää states that the one of the developed techniques is the split flow counter current washing which is the variation of counter-current washing.
•Because the various reasons for each industry, the counter-current washing was modificated and called as split flow counter current washing
Product
Flow
Fresh
water
Wastewater
Washing 2
Washing 1
Washing 3
Washing 4
Wastewater Wastewater
Filtrate System Saving in
water
(%)
Direct counter-current 50-80
Split flow counter-current 40-65
Source: Sillanpää, 2005
Reasons for using split flow counter current washing
• The company uses cotton as raw material.
• According to Textile Sector Environmental Report; in opposition of dying of synthetic raw materials, counter-current washing applications are not common in cotton dying. The cotton fiber pollution is the main reason for that.
• For the last washing tank, from which water is sent to the previous, the cotton fiber pollution is minimum. Therefore using filter is a solution and does not create a clogging problem.
• But for the washing tanks before the last tank, the fiber pollution is a problem, because the cotton lets its fiber in a suspended situation in these tanks at most. For this reason, it is thought that the filter clogging would be a big problem if direct counter-current washing were applied.
Counter-Current Washing in Textile Industry
Product
Flow
Fresh
water
Wastewater
Washing 2
Washing 1
Washing 3
Washing 4
Wastewater WastewaterFilter
• 3 dyeing recipes (A, B, C) were selected.
• Two methods of washing was applied.
– Normal Flow Washing (old system)
– Split flow counter current washing (new system)
F<Q where the product quality is said to be the same.
• Water saving was determined.
• Analysis of wastewater characteristics for water from each washing tank was done to compare with literatural truth.
• Samples from each washing tanks were taken after the retention time was exceed.
Counter-Current Washing in Textile Industry Materials and Methods
Product Flow
Fresh water
WW
21
3 4
WW WW WW
Product Flow
Fresh water
ww
21 3 4
ww wwFilter
Q FF/3 F/3 F/3
Q/4 Q/4Q/4 Q/4
Counter-Current WashingA Type recipe
Product Flow
Fresh
water
ww
Washing 2
Washing 1
Washing 3
ww ww
300 L/min
100 L/min 100 L/min 100 L/min
2 3
Product Flow
Fresh water
Washing 1
Washing 2
Washing 3
ww ww
Filter
185 L/min92,5 L/min 92,5 L/min
a
b
c
Flow diagram for new system washing of dying type A
Flow diagram for old system washing of dying type A
• Each washing tank is 1000 L
• 500 min washing period
•Retention time is 10 minute for each tank
• Flowrate of freshwater is 300 L/min
•Each washing tank is 1000 L
•115 min washing period
• Retention time is 10.8 for first two and 5.4 min.
•Flowrate of freshwater is 185 L/min
1
Counter-Current Washing B Type recipe
Flow diagram for new system washing of dying type B
Flow diagram for old system washing of dying type B
• First washing tank is 1600 L, where others are 1000 L.
• 330 min washing period
•Retention time is 30 min for first tank where it is 18 min for others.
• Flowrate of freshwater is 275 L/min
•First washing tank is 1600 L, where others are 1000 L.
•330 min washing period
• Retention time is 39 min for first tank and 24.3 min for 2,3,4 and 6 min for WT 5.
•Flowrate of freshwater is 165 L/min
Product
Flow
Washing
2
Waste
water
Washing
4
Washing
3
Waste
water
Waste
water
275 L/min
55 L/min
55 L/min
55 L/min
11
2 3
Waste
water
Washing
1
Waste
water
Washing
5
4 5
55 L/min
55 L/min
Product
Flow
Fresh
water
Washing 2
ww
Washing 3
ww
Washing 5
Filter
165 L/min41,25 L/min
Washing 1
ww
Washing 4
ww
41,25 L/min
41,25 L/min
41,25 L/min
a
b
cdef
Counter-Current WashingC Type recipe
Flow diagram for new system washing of dying type C
Flow diagram for old system washing of dying type C
• First washing tank is 1600 L, RT =30.7 minutes
• the other WT 1600 L with RT=19.2 minutes
• 330 min washing period
• Flowrate of freshwater is 260 L/min
•First washing tank is 1600 L, where others are 1000 L.
•115 min washing period
• Retention time is 47 min for first tank and 29.6 min for 2,3,4 and 7.5 min for WT 5.
•Flowrate of freshwater is 135 L/min
Product
Flow
Washing
2
Wastew
ater
Washing
4
Washing
3
Wastew
ater
Wastew
ater
260 L/min
52 L/min 52 L/min 52 L/min
1 2 3
Wastew
ater
Washing
1
Wastew
ater
Washing
5
4 5
52 L/min 52 L/min
Product
Flow
Fresh
water
Washing 2
ww
Washing 3
ww
Washing 5
Filter
135 L/min33,75 L/min
Washing 1
ww
Washing 4
ww
33,75 L/min
33,75 L/min
33,75 L/min
a
b
cdef
Counter-Current Washing A Type recipe
Results for each tank in dying type A, old system
Dying Type A
Old System
Washing
Tank 2
(2)
Washing
Tank 3
(3)
TSS (mg/L) 196 44
TDS (mg/L) 2348 1760
Color (Pt-Co) 6920 3320
Turbidity(NTU) 690 389
Alkalinity (mg/L
CaCO3) 870 680
COD (mg/L) 1002 400
Conductivity
(s/cm) 3470 2760
pH 11,1 10,62
Results for each tank in dying type A, new system
Dying Type ANew System
Washing Tank 2
(c)
Filter Inlet(Washing
tank 3)
(a)
TSS (mg/L) 322 34
TDS (mg/L) 5198 882
Color (Pt-Co) 9060 2515
Turbidity(NTU) 726 354
Alkalinity (mg/L CaCO3) 1874 310
COD (mg/L) 1372 264,5
Conductivity (Ks/cm) 8660 1221
pH 11,8 9,5
Pollution concentration is less in last washing tanks for new system where it is more in 2nd washing tank.
Counter-Current WashingB Type recipe
Results for each tank in dying type B, old system Results for each tank in dying type B, new system
Dying Type B
Old System(1) (5)
TSS (mg/L) 206 26
TDS (mg/L) 13456 688
Color (Pt-Co) 8600 4750
Turbidity(NTU) 360 543
Alkalinity (mg/L
CaCO3) 3300 220
COD (mg/L) 3740 238
Conductivity ()s/cm) 17850 969
pH 12,03 9,75
Dying Type B
New System
1
(f)
5
(a)
TSS (mg/L) 546 22
TDS (mg/L) 24134 558
Color (Pt-Co) 22300 935
Turbidity(NTU) 1709 209
Alkalinity (mg/L CaCO3) 6960 178
COD (mg/L) 4823 102
Conductivity ()s/cm) 30400 893
pH 12,17 9,08
Counter-Current WashingC Type recipe
Results for each tank in dying type C, old system Results for each tank in dying type C, new system
Dying Type C
Old System (1) (5)
TSS (mg/L) 54 35
TDS (mg/L) 2688 908
Color (Pt-Co) 2280 1330
Turbidity(NTU) 138 282
Alkalinity (mg/L CaCO3) 1150 440
COD (mg/L) 511 125
Conductivity ()s/cm) 4200 1366
pH 11,12 10,18
Dying Type C
New System
1
(f)
5
(a)
TSS (mg/L) 108 14
TDS (mg/L) 3592 632
Color (Pt-Co) 2860 715
Turbidity(NTU) 251 94
Alkalinity (mg/L CaCO3) 1548 240
COD (mg/L) 650 87
Conductivity ()s/cm) 6470 954
pH 11,81 9,48
Counter-Current Washing Reduction in Water Consumption
Old System
water consumption
(L/min)
New System
water consumption
(L/min)
Reduction in water
consumption
(%)
Type A 300 185 38
Type B 275 165 40
Type C 260 135 48
• All the processes in the Textile Mill were investigated to identify
the water conservation opportunities.
• As well as the Literatural Review, after some site visits to the facility
the processes were detected and the possible changes especially
related to the water consuming processes were determined.
• Possible water use reduction techniques were detected.
• The techniques were applied in the facility.
Conclusion for the Presentation
• The water conservations obtained through the techniques of “Rerouting the Rope-Guide” and “Split Flow Counter Current” were determined in the application base.
• For counter-current washing, the washing water were analysed to compare the character of it, with the literatural knowledge.
Future Work:
Determination of the total effect of this water conservationapplications on the water consumption of the facility.
Conclusion for the Presentation
This study was funded by The Scientific and Technological Research Council of Turkey
Studies on Adopting the EU IPPC Directive in Textile Sector: BAT Applications
Project No: 105Y088
Thank You for your Attention and Interest on Cleaner Production !!!