ENVIRONMENT FRIENDLY DYEING PROCESSES FOR COTTON

R.B.CHAVAN DEPARTMENT OF TEXTILE TECHNOLOGY INDIAN INSTITUTE OF TECHNOLOGY HAUZ-KHAS, NEW DELHI 110016

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PLANATE EARTH
KALPANA CHAWLA

IT IS THE ONLY PLANATE WHERE LIFE

EXISTS FROM THE SPACE EARTH LOOKS BEAUTIFUL OUR ENDEVOUR SHOULD BE TO ENHANCE THE BEAUTY OF THIS PLANATE ALL EFFORTS SHOULD BE MADE TO PROTECT IT FROM DESTRUCTION

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DESTRUCTIVE FORCES
ONE TIME DESTRUCTION
NUCLEAR THREAT RED BUTTON SHOULD BE IN THE HANDS OF BALANCED
PERSONS

SLOW DEATH

ENVIRONMENT POLLUTION OZONE DEPLETION ULTRA VIOLET PROTECTION VEHICULAR AIR POLLUTION NUCLEAR AND BIOLOGICAL WASTE ASIAN BROWN CLOUD (INCOMPLETE COMBUSTION OF WOOD, COW DUNG CAKES ETC. INDUSTRIAL ACTIVITIES
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INDIAN EXPERIENCE

AIR POLLUTION : VEHICLE

BAN ON 15 YEAR OLD PUBLIC TRANSPOT

VEHICLES USE OF CNG CLEAN AIR IN DELHI GANGA RIVER PROJECT: CLEAN WATER FOREST PROTECTION

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CUMULATIVE EFFECT

INDUSTRIAL ACTIVITIES

LARGE SCALE SMALL SCALE COTTAGE SCALE TRADITIONAL CUMULATIVE EFFECT ON ENVIRONMENT POLLUTION ATTEMPTS TO MINIMIZE POLLUTION USE OF NEWER TECHNOLOGIES
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WORD FIBRE CONSUMPTION

CONSUMPTION (1000 TONNE)
YEAR COTTON REGENERATED WOOL SYNTHETIC TOTAL

1990 1995 2000

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18700 2700 (49%) 20700 2500 (49%) 23400 2400 (49%)

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2000 2000 2200

14900 (39%) 17300 (41%) 20500 (42%)

39300 42600 48500

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DYE CONSUMPTION (TONNE)

DYE CLASS

1988a

1992

2004b

SULPHUR
DIRECT VAT

INDIGO AZOIC REACTIVE

TOTAL
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90 000 74 000 36 000 12 000 28 000 60 000

300 000

70 000 60 000 21 000 12 000 18 000 109 000

290 000
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70 000 68 000 22 000 12 000 13 000 178 000

354 000
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REASONS FOR LACK OF GROWTH EXCEPT REACTIVE DYES

VAT DYES

HIGH PRICE AND LIMITED SUPPLY

ENVIRONMENT VAT: HYDROSULPHITE, ORGANIC HALOGEN,RESIDUAL METAL CATALYST SULPHUR : SODIUM SULPHIDE, AZOIC : CARCINOGENIC AMINE

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CURRENT RESEARCH
MAJOR AREAS

1. ENVIRONMENTAL CONSIDERATIONS LOW COLOUR IN EFFLUENT LESS CHEMICAL USAGE

2. INCREASED PRODUCTIVITY VIA
SHORTER AND RELIABLE PROCESSING

3. HIGHER FASTNESS REQUIREMENTS

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Chemicals in effluent streams

Vat
Chemicals in effluent streams Residual dyestuff (5 - 20 %) Reducing agents Oxidising agents Detergents Salt Residual dyestuff (20 - 50 %)

Reactive

Salt Alkali Detergent

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Chemicals in effluent streams

Direct
Residual dyestuff (5 - 20 %)

Salt Dye fixing agents

Sulphur

Residual dyestuff (30 - 40 %) Sodium sulphide Alkali Salt

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Chemicals in effluent streams

Acid

Metal complex

Residual dyestuff (1 - 20 %) Organic acid Residual dyestuff (2 - 5 %) Organic acid Leveling agent Organic acid Heavy metal

Chrome

Disperse

Residual dyestuff (10 - 20 %) Acid Dispersing agents Leveling agents Reducing agents Alkali
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COLOUR IN EFFLUENT
END OF PIPE TECHNOLOGY REMOVAL OF COLOUR FROM EFFLUENT EXPENSIVE APPROACH

CONVENTIONAL REACTIVE DYES 6070% EXHAUSTION

SUBSTANTIAL COLOUR IN EFFLUENT ADSOPTION OF HYDROLYZED DYE ON

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BIOMASS IS NOT EFFICIENT I.I.T.DELHI

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ALTERNATIVE METHODS FOR LOW COLOUR IN EFFLUENT

DYEING AT LOW LIQUOR RATIO CAREFUL FOLLOW UP OF DYESTUFF MANUFACTURERS RECOMMENDATION FOR DYEING CONDITIONS FOR OPTIMUM DYE FIXATION RIGHT FIRST TIME APPROACH TO AVOID

SHADING ADDITIONS STRIPPING AND REDYEING OF OFF SHADES USE OF HIGH FIXATION BIFUNCTIONAL REACTIVE DYES
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BIFUNCTIONAL REACTIVE DYES

HOMO BIFUNCTIONAL REACTIVE DYES
ORIGINALLY PROMOTED BY ICI (NOW ZENECA) AS PROCION
SUPRA DYES FOR PRINTING AND THEN PROCION H-E DYES FOR DYEING (HOMO BIFUNCTIONAL MONO CHLORO TRIAZYNYL)

HETRO BICUNTIONAL REACTIVE DYES

CHARACTERIZED BY THE PRESENCE OF TWO REACTIVE
GROUPS OF DIFFERENT REACTIVITIES CAN BE APPLIED OVER A TEMPERATURE RANGE OF 60-800 c BETTER SHADE REPRODUCIBILITY EVEN WITH TEMPERATURE VARIATION AVAILABLE FROM MAJOR DYESTUFF MANUFACTURERES
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BIFUNCTIONAL REACTIVE DYES

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LOW SALT REACTIVE DYES

SALT REQUIREMENT
CONVENTIONAL REACTIVE DYES 60-80 g/l LOW SALT REACTIVE DYES 20 g/l
FEATURES (CIBACRON LS) BIFUNCTIONAL REACTIVE DYES TWO CHROMOPHORES CONTRIBUTE HIGH
AFFINITY AND HIGH COLOUR STRENGTH HIGH FIXATION STABLE DYE-FIBRE BOND
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EFFECT OF SALT ON ENVIRONMENT

EFFLUENT TREATMENT REMOVES ONLY SMALL
QUANTITY OF SALT MAJOR QUANTITY OF SALT REMAINS IN WATER RIVERS AND LAKES GET POLLUTED WITH EFFLUENT CONTAINING HIGH SALT CONCENTRATION FRESH WATER ORGANISMS CAN SUFFER TOXIC EFFECTS IN REGIONS WITH SCARCE FRESH WATER RESOURCES SUCH WASTE WATER HAS TO BE USED FOR LAND IRRIGATION REDUCTION IN LAND FERTILITY AND ULTIMATELY HAVE TO BE ABONDONED R.B.CHAVAN I.I.T.DELHI 18

APPROACHES TO SOLVE PROBLEMS OF SALT LOAD

DYEING AT LOWEST POSSIBLE LIQUOR

RATIO USING DYE CLASSES OTHER THAN REACTIVE SUCH AS VAT REQUIRING LOW SALT CONCENTRATION FOR DYEING USING REACTIVE DYES GIVING HIGH EXHAUSTION AND FIXATION AT LOW SALT CONCENTRATION
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GENERAL STRUCTURE OF LOW SALT REACTIVE DYES

CHROMOPH -ORE

BRIDGE

CHROMOPH ORE

REACTIVE GROUP

REACTIVE GROUP

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ADVANTAGES OF HIGH DYE FIXATION

Conventional dyes 60 % fixation Cibacron LS (bireactive) 80 % fixation

600 gm on the fibre

+ 33% %
1 kg dye

800 gm on the fibre

1 kg dye

400 gm into the waste water

- 50% %

200 gm into the waste water

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ECOLOGICAL BENEFITS OF LOW SALT REACTIVE DYES

Property Benefit

High fixation rate

Low dye concentration in effluent

Low electrolyte concentration Low salt effluent

and cost/time saving

Good wash off Halogen-free chromophores Free from carcinogenic amines High repeatability of dyeing
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Less water and energy Low BOD values No AOX in effluent No health risk to dyes No risk of ban Less shading and stripping
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ECO FRIENDLY REDUCING AGENTS FOR VAT DYES

SODIUM HYDROSULPHITE IS UNIVERSALLY USED
DURING DYEING CONVERSION TO SULPHITE AND
SULPHATE

SULPHITE IS TOXIC TO FISH AND BACTERIA SULPHATE IS NON-TOXIC TO FISH AND BACTERIA
IT MAY CAUSE CORROSION OF CONCRETE PIPES
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ALTERNATE REDUCING SYSTEMS HYDROXY ACETONE

CAN TOTALLY REPLACE HYDROSULPHITE

BIO-COMPATIBLE

GIVE 20% HIGHER COLOUR YIELD WITH

INDIGO

EXPENSIVE NOT READILY AVAILABLE YET TO USE ON COMMERCIAL SCALE

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ELECTROCHEMICAL REDUCTION

DIRECT REDUCTION OF DYE BY CONTACT

BETWEEN DYE DISPERSION AND ELECTRODE

ADDITION OF SMALL QUANTITY OF

HYDROSULPHITE IS ESSENTIAL TO MAINTAIN DYE IN REDUCED STATE

METHOD PRODUCES LIGHTER SHAED

COMPARED TPO HYDRO SULPHITE
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IRON COMPLEXES
USE OF Fe(OH)2 AS REDUCING AGENT

COPPERAS METHOD KNOWN FOR LONG FOR DYEING OF

INDIGO

USE OF FeSO4 AND Ca(OH)2

Fe(OH)2 HAS VERY LOW WATER SOLUBILITY

PRECIPITATES IN DYEBATHNON REPRODUCIBLE RESULTS NOT SUITABLE FOR VAT DYES OTHER THAN INDIGO USE OF GLUCONIC ACID IS SUGGESTED IN GERMAN
LITERATURE FOR ENHANCING SOLUBILITY OF Fe(OH)2

GLUCONIC ACID IS EXPENSIVE

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STUDY AT IIT DELHI R.B.chavan, J.N.chakraborty

USE OF CITRIC ACID, TARTARIC ACID AND
TRIETHANOL AMINE TO ENHANCE SOLUBILITY OF Fe(OH)2 REDUCTION POTENTIAL HIGHER THAN HYDRO SYLPHITE POSSIBLE TO REDUCE VAT DYES AT ROOM TEMPERATURE DYEING AT ROOM TEMPERATURE COLOUR YIELD AND FASTNESS PROPERTIES COMPARABLE TO HYDROSULPHITE TOTAL REPLACEMENT OF HYDROSULPHITE ENVIRONMENT FRIENDLY AND ENERGY SAVING SYSTEM R.B.CHAVAN I.I.T.DELHI 27

SULPHUR DYES
Na2S IS COMMONLY USED REDUCING AGENT NO ODOUR NUISANCE ABOVE pH 9 LIBERATION OF H2S UNDER ACID CONDITIONS FOUL SMELL OF ROTTEN EGGS TOXIC WHEN INHALED ODOUR THRESHOLD LIMIT 10 ppm TOXIC TO FISH
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OXIDATION
USE OF HALOGENATED COMPOUNDS LIKE
BROMATE, IODATE PRODUCE ORGANIC HALOGEN COMPOUNDS RESPONSIBLE FOR ADSORBABLE ORGANIC HALOGEN (AOX) AOX IS TOXIC TO AQUATIC LIFE DICHROMATE IS MORE RISKY, HEALTH HAZARDS SAFE OXIDIZING AGENT IS H2O2
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Na2S REPLACEMENT
MERCAPTOETHANOL MARKETED BY
BASF AS MOLESCAL SF

LOWER COLOUR YIELD COMPARED TO

Na2S

INCOMPLETE DISSOLUTION OF SOME

SULPHUR DYES

SUITABLE FOR LIMITED RANGE OF

SULPHUR DYES

COSTLY
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 GLUCOSE
CAN BE USED AS REDUCING AGENT FOR
SULPHUR DYES GIVES REDUCTION POTENTIAL SUITABLE FOR REDUCTION OF SULPHUR DYES UNDER ALKALINE CONDITIONS AT ABOVE 600 c CENTURY MILL (MUMBAI) HAS SUCCESSFULLY REPLACED Na2S WITH GLUCOSE ON INDUSTRIAL SCALE HYDROL, VISCOUS LIQUID AVAILABLE COMMERCIALLY AT LOW COST
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HYDROL/GLUCOSE
HYDROL IS COST EFFECTIVE
ENVIRONMENT FRIENDLY SUBSTITURE OF Na2S ELIMINATION OF FOUL SMELL OF NA2S 3500 kg OF COTTON IS BEING DYED WITH SULPHUR BLACK EVERY DAY USING HYDROL AT CENTURY MILL NO CAPITAL EXPENDITURE INVOLVED IN THIS SUBSTITUTION
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CONCLUSION
USE OF BIFUNCTIONAL REACTIVE DYES
FOR LOW COLOUR IN EFFLUENT USE OF LOW SALT REACTIVE DYES FOR REDUCTION OF SALT IN EFFLUENT REPLACEMENT OF Na2S WITH GLUCOSE IN SULPHUR DYEING REPLACEMENT OF HYDROSULPHITE IN VAT DYEING BY IRON COMPLEXES ELECTROCHEMCAL REDUCTION METHOD
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