Rerouting rope-guides, which determine the route fabrics take through dyeing machines, reduced water use by 6.2% on average for 5 dye recipes. Counter-current washing, where wastewater is recycled from the last wash step to the next, reduced consumption by 50-80% compared to normal flow washing and showed decreasing pollution concentrations from the first to last wash tanks. Both techniques provide simple, effective ways to minimize water and wastewater in textile dyeing and finishing.

1. TEXTILE MANUFACTURING PROCESS
Presented by:
Vishal Kumar
Kushwaha
(141050004)

2. 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

3. 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.

4. 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

5. 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

6. COTTON FIBER
PRODUCTION DYING PROCESSES
WEAVING
FINISHING PROCESSES
150-200 kg of water/kg of product
SIZING PROCESSES

7.  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

8. NEW TECHNIQUES

9. WATER CONSUMPTION
REDUCTION 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;

10.  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 CONSUMPTION
REDUCTION STUDY

11.  Rerouting the Rope-Guide
 Counter-Current Washing in
Back-washing

12. 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.

13. Prepara
tion
Tank
Pre-
wash
ing 1
Pre-
wash
ing 2
Pre-
wash
ing N
Dyein
g 1
Dyein
g 2
Dyein
g 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)
• 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.

14.  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

15. Dying Tank
used as
washing tank
Washing
Tank
Washing
Tank
Fresh water feeding tank
Q
Q/3 Q/3Q/3
Dying Tank
used as
washing tank
Washing
Tank
Washing
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

16.  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.
Amount of consumed
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
Rerouting the Rope-Guide
Reduction in Water Consumption

17. 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

18.  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

19. • 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.

20. 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.
Material Flow
Water Flow

21. 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.

22. Filtrate System Saving in
water
(%)
Direct counter-current 50-80
Split flow counter-current 40-65
Source: Sillanpää, 2005
•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
Washin
g 2
Washin
g 1
Washin
g 3
Washin
g 4
Wastewater Wastewater

23. 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.
Product
Flow
Fresh water
Wastewater
Washin
g 2
Washi
ng 1
Washin
g 3
Washin
g 4
Wastewater Wastewater
Filter

24. 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
2
1 3 4
WW WW WW
Product Flow
Fresh water
ww
21 3 4
ww ww
Filter
Q F
F/3 F/3 F/3
Q/4 Q/4
Q/4 Q/4

25. Counter-Current Washing
A Type recipe
Product Flow
Fresh water
ww
Washin
g 2
Washin
g 1
Washin
g 3
ww ww
300 L/min
100 L/min 100 L/min 100 L/min
2 3
Product Flow
Fresh water
Washin
g 1
Washin
g 2
Washin
g 3
ww ww
Filter
185 L/min
92,5 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

26. 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
Was
hing
2
Waste
water
Was
hing
4
Was
hing
3
Waste
water
Waste
water
275
L/min
55
L/min
55
L/min
55
L/min
1
1
2 3
Waste
water
Was
hing
1
Waste
water
Was
hing
5
4 5
55
L/min
55
L/min
Product
Flow
Fresh water
Washin
g 2
ww
Washin
g 3
ww
Washin
g 5
Filter
165 L/min
41,25
L/min
Washin
g 1
ww
Washin
g 4
ww
41,25
L/min
41,25
L/min
41,25
L/min
a
b
cdef

27. Counter-Current Washing
C 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
Was
hing
2
Wastew
ater
Was
hing
4
Was
hing
3
Wastew
ater
Wastew
ater
260 L/min
52 L/min 52 L/min 52 L/min
1 2 3
Wastew
ater
Was
hing
1
Wastew
ater
Was
hing
5
4 5
52 L/min 52
L/min
Product
Flow
Fresh water
Washin
g 2
ww
Washin
g 3
ww
Washin
g 5
Filter
135 L/min
33,75
L/min
Washin
g 1
ww
Washin
g 4
ww
33,75
L/min
33,75
L/min
33,75
L/min
a
b
cdef

28. 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 A
New 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
(s/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.

29. Counter-Current Washing
B 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

30. Counter-Current Washing
C 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

31. 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

32.  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

33.  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
conservation applications on the water consumption
of the facility.
Conclusion for the Presentation

34. Thank You for your
Attention and Interest on
Cleaner Production !!! VISHONAL