Professional Documents
Culture Documents
Received 30 January 2006; received in revised form 22 June 2006; accepted 22 June 2006
Available online 26 July 2006
Abstract
Textile dyeing industries in Tirupur and Karur of Tamil Nadu (India) usually discharge effluents
ranging between 80 and 200 m3 /t of production. Dyeing is performed either by conventional winch
process or by advanced soft flow reactor process. Hypochlorite, the commonly used bleaching chem-
ical is being gradually phased out by alkaline hydrogen peroxide solution that generates less effluent
and fewer solids in the effluents. Coloring of yarn/cloth takes place in the presence of high concentra-
tion of sodium chloride or sodium sulphate (25–75 kg/m3 ) in dye solutions. Dye bath wastewaters and
wash waters are the process effluents of dyeing industry which are collected separately or together
and follow the advanced treatment for maximum recycling of recovered waters.
Dye bath water after treating by sand and nanofiltrations (NF), the permeate is used in process for
dye bath preparation and the reject of about 20–30% is sent to multi effect evaporator (MEE)/solar
evaporation pond (SEP). Wash waters treated using a sequence of physicochemical and biological unit
processes are passed into two stages reverse osmosis (RO) membrane systems and then the permeate is
reused in the processes. The rejects about 15–20% of the inlet volume is subject either to nanofiltration
for salt recovery or sent to evaporators. The final rejects from nanofilter systems is directed to multi
effect evaporator system where condensed waters are recovered. The removal of total dissolved solids
(TDS), chemical oxygen demand (COD), chloride and sodium are in the range of 80–97%, 91–97%,
Abbreviations: INR, Indian rupees (one USD equal to INR 44); CPCB, Central Pollution Control Board;
APHA, American Public Health Association; RO, reverse osmosis; NF, nanofiltration; MEE, multiple effect
evaporators; TDS, total dissolved solids; BOD, biochemical oxygen demand; COD, chemical oxygen demand;
SAR, sodium absorption ratio; TH, total hardness
∗ Corresponding author. Tel.: +91 80 23495981; fax: +91 80 23498207.
0921-3449/$ – see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.resconrec.2006.06.004
76–97% and 96%, respectively. Multiple effect evaporators out flows of about 2–3% of the effluent
volume are allowed for solar evaporation and the solids are disposed off. The cost of operation of
MEE is about INR 400/m3 of the rejects. The cost of water recovery is about INR 60–80/m3 including
commissioning and maintenance whereas price of raw-water in Tirupur is about INR 100/m3 .
© 2006 Elsevier B.V. All rights reserved.
Keywords: Dyeing industry; Wastewater recycling; Reverse osmosis; Membrane process; Nanofiltration
1. Introduction
Next to food the second basic needs of man ‘cloth’ is supplied by processing of natural
and synthetic fibers in the industries called textiles. Increased population and modernized
civilization trend gave rise to blooming of textile sectors in India. An estimate shows that
textiles account for 14% of India’s industrial production and around 27% of its export
earnings. India is the second largest producer of cotton yarn and silk and third largest
producer of cotton and cellulose fiber (Report of Business India, 2004). The total production
of yarn during the year 2003–2004 was 3051 kt (Annual Report of Ministry of Textiles,
2004). There are about 10,000 garment manufacturers and 2100 bleaching and dyeing
industries in India. Majority are concentrated at Tirupur and Karur in Tamil Nadu, Ludiyana
in Punjab and Surat in Gujarat. The processes followed in textile industries are spinning of
fiber to yarn, sizing to improve stiffness, scouring, kiering and desizing to remove excess
sizing materials, bleaching to remove pectin and wax from the yarn and fabric and coloring
and printing to provide desired color and design to the cloth. Dyeing is a combined process of
bleaching and coloring, which generates voluminous quantities of wastewaters and in turn
causes environmental degradation. The effluents consist of high TDS, sodium, chloride,
sulphate, hardness and carcinogenic dye ingredients. High BOD effluents are generated
from the sizing and desizing processes and treated by conventional anaerobic and aerobic
biological methods (Tchobanoglous and Burton, 1995).
Coimbatore district of Tamil Nadu is well known for cotton production and also called as
Manchester of Southern India. Tirupur, one of the towns in Coimbatore District is located at
the bank of river Noyyal, a tributary to river Cauvery. The quality of Noyyal river water and
climatic condition of Tirupur has been ideal for dyeing operation of yarn and fabric since
long time. Presently there are 712 dyeing and bleaching industries in Tirupur that generate
87,000 m3 /d of wastewater. Out of this a total of 281 industries are attached with common
effluent treatment plants (CETP) and others are having their individual effluent treatment
plants. Presently adopted technology is able to remove the color and other organic impurities
to the stipulated standards but failed to arrest the inorganic contaminants. Continuance
of effluent discharges has caused gross damages to the nearby aquatic systems receiving
body like Orathupalayam dam located at the down stream of river Noyyal and as such
the water quality has become unfit for irrigation. The reservoir water’s TDS, chloride and
sodium were reported as high as 5054, 2869 and 1620 mg/L, respectively (Central Pollution
Control Board, 2005). Also the concentration of dissolved solids in the ground and river
water is reported in the range of 5000–7000 mg/L i.e. almost ten times higher than the
desirable drinking water standard (Indian Standard, 1991). A study carried out by Rajaguru
et al. (2002) indicates that the ground water in the Tirupur area is also contaminated with
substances capable of inducing DNA damage in human cells. One more town Karur located
at the bank of river Amaravathy, another tributary to river Cauvery is also concentrated with
600 bleaching and dyeing industries. Advanced treatment technologies are imperative to
protect the water resources in these areas.
Membrane technology for treatment of dye house effluents was studied by Bucklay
(1992) and reported 95% color removal. Vandevivere et al. (1998) and Ciardelli et al.
(2000) have reviewed and studied successful application of membrane technology in textile
wet processing industries. In view of the above impacts of the dyeing effluents on the
environment, the industries in Tirupur and Karur are also forced to adopt technology leading
towards zero discharge systems. There are 20 dyeing industries that have already installed
effluent treatment technologies with advanced techniques and attained zero discharge. Four
industries adopted such technologies are extensively studied and the results are discussed
in this paper.
Four dyeing units namely M/s. Sivasakthi Textile Processors, Tirupur, M/s. Rennaisance
Creations Processing Division, Tirupur, M/s. Leeds Spinning Mills (P) Ltd., Tirupur and
M/s. Karur Amaravathy Textiles Industry, Karur were visited and information on manu-
facturing process, production status and wastewater quantity were collected. Waste water
samples from the dye bath collection tank and wash water collection tanks, intermediate
points and at the outlets of effluent treatment plants were collected and analyzed at mobile
as well as stationary laboratory using standard methods. Eight hourly composite and grab
samples were collected for the first two units and other two units, respectively. The samples
were preserved and analyzed as per the standard methods (APHA, 1995; CPCB, 2001).
Percent sodium and sodium absorption ratio (SAR) values were calculated using the
following formulas:
concentration of Na × 100
percent sodium =
concentrations of Na + K + Ca + Mg
concentration of Na
sodium absorption ratio (SAR) = √
(concentration of Ca + concentration of Mg)/2
where the concentrations of the ions are expressed in mequiv./L. All the chemicals used
were of analytical and laboratory grades.
M/s. Sivasakthi Textile Processors engaged in dyeing of yarn (cotton and polyester)
is located at Mangalam, Tirupur. Six numbers of soft flow reactors (batch process) with
different capacities are used for dyeing including wetting, bleaching, neutralizing, washing,
coloring, washing, etc. In the reactors, 1 t of cotton yarn requires 10 m3 of water whereas 1 t
of polyester yarn consumes only 4 m3 in each steps. Dye bath solution requires dyes, alkali
and sodium salt in the process. Quantity of salt (sodium chloride) used usually depends
on the requirement of color shade. The total quantity of yarn/fabric processed in the unit
is 1500–2000 kg/d and the volume of effluent generated is of the order of 100–200 m3 /d.
Effluents are segregated into dye bath wastewater and wash water and treatment is effected
accordingly.
Wash water is collected in holding tanks and pumped to primary treatment unit (lime and
ferrous sulfate slurries are flash-mixed with effluent and allowed for settling). Following
primary treatment the effluent is carried to pressure sand filter, iron removal filter, ion
exchange filter and reverse osmosis (RO) system. Double stage RO system (each with six
membranes) with spiral wound membrane is in operation. Pump pressure is maintained in
the range of 21.2–28.2 kg/cm2 . Rejects of first RO is sent to second RO and the final reject
(20%) is sent to MEE. Condensate water is recycled in the cleaning operations. Outlet with
100 g/L solid content is allowed for solar evaporation and the combined permeate is used in
the process. Dye bath water is collected in a separate tank and are subject to nanofiltration
after following pre-filtration. Total reject of about 30% is sent for multi effect evaporation
and solar evaporation systems. The permeate is used for preparation of dye bath solution.
The characteristics of the raw effluents, intermediate effluents and permeate are presented
in the Table 1. The low hardness of permeate is an added advantage in the process. Permeate
of NF filtration contains 4.8% of salts that is mixed with more salts and used in the process.
Salt recovery from the dye bath alone has 50% returns.
The industry which process 4000 kg of yarn and fabric per day generates 3000 m3 /d of
wash water and 30 m3 /d of dye bath water. The wash effluents and bath effluent are collected
separately and treatment is effected. The dye bath effluents are subject to nanofiltration after
gravitational settling. NF modules are extremely sensitive to fouling by colloidal materials
and polymers. It can be used to separate fiber reactive dyes and cationic dyes from the
salt. The permeate collected contains merely NaCl that is used in the dyeing process. The
rejects are diverted to solar evaporation ponds. The wash waters after treating with lime
and ferric chloride is passed to sand filtration followed by iron removing cartridges. It is
then subjected to double stage reverse osmosis system and 80% of permeate is used in
the industrial process and the reject are sent for nanofiltration and solar evaporation. Solar
evaporation pond is designed keeping water evaporation rate of 4 mm/d. To minimize the
area requirement for solar evaporation, the industry has proposed to install one more RO
system in conjunction with treatment plant. The results of treated and untreated waters are
presented in the Table 3. The permeate has shown the lowest TDS concentration of 212 mg/L
out of the studied industries.
Due to scarcity of fresh water in the area, the unit had purchased 400 m3 /d of water
through tankers. After installation of the advanced water recovery system, the unit is pur-
chasing only 3–4 m3 /d.
The unit located at the bank of river Amaravathy processes yarn and fabric dyeing with
production capacity of 4000 kg/d and generates effluent of about 400 m3 /d. Both wash waters
and dye bath waters are collected together in a tank and subject to advanced treatment. There
is no system for BOD, color and other impurities removal. The effluent is sent directly to the
disc type RO membrane after settling. There are four modules in the RO system wherein the
rejects of first module is sent to second module and so on. Permeates from the each module
are collected together and recycled back in the industrial processes. The rejects of the last
module are subject to nanofiltration and permeate is used for making dye solution and the
reject is sent for solar evaporation. The characteristics of effluent, inlet to RO, individual
permeate, combined permeate and rejects are shown in the Table 4. The BOD of permeate
is high due to no prerequisite of primary and secondary treatment of wastewaters.
3.5. Comparison of the ROs performance in the studied textile dyeing units
The characteristics such as TDS, chloride, percent sodium and SAR show that the
untreated and primarily treated wastewaters are unfit for irrigation and their discharge into
river may further aggravate the problem. Therefore, the advanced treatments such as reverse
Table 2
Characteristics of effluents of M/s. Renaissance Creations, Tirupur
Parameter Wash water Dye bath wastewater
osmosis and/or nanofiltration separation technologies are essentially used to remove the
inorganic (mainly) and organic constituents from aqueous solution and non-aqueous solu-
tion by membrane (polyamide). The principle followed in all the units are same where as
different module such as disc type module and spiral wound module membrane are housed
in the RO system. Before charging into RO membrane it is important to remove impurities
such as suspended and colloidal impurities of organic and inorganic compounds and dis-
solved polyvalent ions to extend the life of the membrane. Almost all the systems attained
complete removal of suspended solids. Fig. 1 shows the percent removal of major pollutants
such as BOD, COD, TDS, total hardness, sulphate and chloride. The industry referred at
3.4 has disc type membrane module showed better performance in terms of TDS and other
ions removal. The life of the membrane would be reduced due to the absence of preliminary
treatment. The water regenerated using the advanced technology is found good quality and
could be directly used in the dyeing process. A typical schematic diagram of the effluent
treatment plant provided with primary, secondary and advanced treatment technologies for
recycling of wastewater is exhibited in the Fig. 2.
To extend life of RO membranes, flushing the membrane periodically with clean water
and occasional chemical cleaning is required. The pH around 5–6 is desirable to prevent
both hydrolysis of membrane and precipitation of calcium carbonate (CaCO3 ). A model
flow chart of zero discharge scheme for the textile dyeing units is shown in the Fig. 3.
Solar evaporation is followed in the units referred above namely M/s. Sivasakthi Textile
Processors and M/s. Leeds Spinning Mills (P) Ltd. Solar evaporation pond is lined with a
concrete layer and arrangements are made to avoid ground water infiltration. An area of
about 1000 m2 is required per 4 m3 of wastes for solar evaporation. The final dried salts are
packed in polythene bags for final disposal.
Wastewater treatment plant installation and commissioning cost is in the range of INR
40–100 lacs, INR 100–200 lacs and INR 200–300 lacs for small (below 300 m3 /d), medium
Fig. 2. Typical schematic diagram of advanced wastewater treatment technology for recycling of textile dyeing
wastewaters.
(300–600 m3 /d) and large (above 600 m3 /d) scale textile dying industries. The maintenance
and operation cost is as below:
Total expenses incurred for the water treatment and recovery is about INR 80/m3 of the
effluent. Due to non-availability of good quality water for dyeing processes in Tirupur, it
is purchased from villages 15 km away from the towns and hence the cost of the water is
approximately INR 100/m3 including transportation. Hence, the technology is also eco-
nomically viable in the studied area.
Fig. 3. Flow diagram of conceptual zero discharge in textile dyeing unit using advanced wastewater treatment.
The bottlenecks in adopting the technology are high cost of operation for MEE and
maintenance of RO membrane module. Multi effect evaporation is a costly system for
concentration of the effluents before crystallization. It requires more maintenance in terms
of consuming more fuel and an average of INR 400 is required per m3 of rejects. The
recovered salt has poor purity and market value of salt is also very less i.e. INR 4 per
kg. When the availability of land has become constraint, the MEE would be preferable.
A common MEE set-up as joint ventures may be an economical recommendation. Proper
preliminary treatments should be followed to reduce the maintenance cost of RO membrane.
4. Conclusion
The study shows the recycling of treated wastewater and zero wastewater discharge
concept are found technically feasible and economically viable in the textile dying industries
located in the area of Tirupur and Karur, Tamil Nadu. The average percent removals of BOD,
COD, TDS, Sodium and Chloride in the advanced treatment technology are in the range
of 88–98%, 91–97%, 80–97%, 96% and 76–97%, respectively. The most attracting part
of water recovered from these membranes is its extremely low hardness, which is always
demanded in textile sector for an improved finish and better quality dyeing. The treatment
and maintenance cost INR 80/m3 is cheaper than the water cost INR 100/m3 in Tirupur and
Karur areas. Common facility for Multistage Evaporator would be economical.
Acknowledgements
The authors are thankful to Dr. V. Rajagopalan, Chairman, Central Pollution Control
Board, Delhi for his keen encouragement, Mr. Sunnel Dave, Environmental Engineer for
valuable suggestions and Laboratory members of CPCB, Bangalore for their kind co-
operation in sample analysis.
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