Green/White Biotechnology

2004 , 10.13. 10.14.

Outline
Textile Biotechnology - Enzymes in Textile Wet Processing - Examples of Industrial Use Bioscouring - Mechanism of Bioscouring - Bioscouring vs. Conventional Alkaline Scouring Evaluation as White/Green Technology - Quality - Environmental : water pollution loads of effluent and each chemical - Economic : chemicals, water usage, wastewater treatment, energy consumption

Future

Enzyme Technology in Textile Industry

Desizing
Amylase Pectinase Scouring : - - -
- Fading-out

Laccase Bleaching
Catalase

Dyeing
Peroxidase

Finishing

Cellulase Laccase Protease Esterase Amidase Nitrase

1954 1973 1981 1984 1986 1987 1991 1996 1997 1997 1999 1999 2003

Amylase for low-temperature desizing Amylase for high temperature desizing Protease for the degumming of silk Protease for wool softening Acid cellulase for Bio-Polishing Multi-component cellulase for denim abrasion Catalase for Bleach Clean-up Laccase for bleaching denim or enhanced abrasion Combined lipase and amylase for desizing Mono-component cellulases for denim abrasion BioPrep (pectinase) for scouring of raw cotton Peroxidase for post-wash of reactive-dyed textiles Scourzyme TM L(pectinase) for scouring of raw cotton

Bioscouring
, , ( )

Bioscouring (Scourzyme)

(NaOH)

Total cotton fiber Cellulose 95.4 % Pectin 0.9 % Waxes 1.4% Protein 0.8 % Ash 0.3 % Other 1.2 %

/1 ( 10% )

Cellulose 54 % Pectin 9 % Waxes 14 % Protein 8 % Ash 3 % Other 12 %

Pectin : Ca++
Cuticle Primary Wall

Secondary Wall

Intermolecular Structures of Wax and Pectin Combined by Calcium Ion

O Wax

CH3-(CH2)x-C-O-Ca-O-C-(CH2)x-CH3 O O PECTIN

CH3-(CH2)x- C-O-Ca-O-C

O P E C T I N

O P E C T I N

C-O-Ca-O-C

C-O-Ca-O-C

O O C HO

O R

OH O HO

O OH O O O C

Pectate Lyase
O O HO OH R O

HO OH

O O C HO

O O C

O R

+
O OH OH HO

O O HO OH R

HO OH O

OH O

Preparation Process
Desizing (woven)
removal of starch

Deoiling (knitted)
removal of knitting
lubricant

Scouring
removal of waxes

Bleaching (optional)
not necessary for dark shades

Dyeing

Works done in the KNCPC-funded Project

Search for Worldwide Industrialized Sites Laboratory Examination of Critical Factors : pH, surfactant, after-treatment at high-temp. Pilot and Industrial Scale - Batchwise Bioscouring for Knitted Cotton - Cold-Pad-Batch Biopretreatment for Woven Cotton Evaluation : - Quality - Environmental : water pollution loads of effluent and each chemical - Economic : chemicals, water usage, wastewater treatment, energy consumption

Visit to Implemented Bioscouring Site

Dr. L.T. Holst, Dexter Chemical Corp., Charlotte, N.C., U.S.A, March, 2003. Saadet Erkul, Taner Triko in Corlu, Turkey, June, 2003.

Jet dyeing machine (capacity : 450 kg) 100% cotton knitted fabric with Ne = 30 400 kg, Bath Ratio 1:6

Process Profiles for Enzymatic vs. Alkaline Scouring of Cotton Knits

Conventional

Alkaline Scouring high alkalinity

Neutralization Washing Dyeing

Fabric Input

Alternative

Enzymatic Scouring

No neutralization

low alkalinity (pH 8.5)

Comparison of pH values Processing Bath

12

pH

0 scouring bath washing bath scouring 1st washing 2nd washing bath bath bath

Bioscouring

Alkaline Scouring

Comparison of pH values Fabric

12

pH

0 without washing after 1st washing without washing after 1st washing after 2nd washing

Bioscouring

Alkaline Scouring

Wastewater Discharged

Alkaline Scouring

Bioscouring

Washing after Bioscouring

Water pollution load of effluents

Organic Pollution
10000
TOC COD Mn COD Cr BOD

pH
12

7500

8
ppm

pH

5000

4
2500

0 Bioscouring Alkaline Scouring

0 Bioscouring Alkaline Scouring

TDS
9000

Color
2000

1500
6000
ppm

1000
3000

500

0 Bioscouring Alkaline Scouring

0 Bioscouring Alkaline Scouring

BOD / CODcr Ratio

Su

0.0
ct an tA tB an tC ct an

0.2

0.4

0.6

0.8

1.0

rfa rfa fa ct xi da O

Su Su r es iz in g

Chemicals Enzymes

BOD to CODcr ratios of chemicals and enzymes

nt Em ul si fie Pi r St nab ho iliz le Pr er ev en tiv e Su pe rs iz er -N Te rm am yl Bi oP re p Li po la se

Process Profiles for Enzymatic versus Alkaline Scouring of Cotton Knits

95 oC, 30 min. 80 oC, 10 min. 50 oC, 15 min.

20 ~ 30 oC

Alkaline Scouring
95 oC, 5 min.

60 oC, 15 20 min.

60 oC, 10 min.

20 ~ 30 oC
80 oC, 15 min.

Bioscouring A

60 oC, 15 - 20 min.

60 oC, 10 min.

Bioscouring B
20 ~ 30
oC

Input Data for Simulation Program

The program has an unique formula built up for the energy consumption according to the type of machine using some constants such as : - specific heat of water - specific heat of fabric - average specific heat of steel - latent heat of water evaporation - energy per 1 kg of steam - energy per 1 kWh of electricity etc. Facility : one tube rapid dyeing machine Input parameters : - for facility : 1000 kg weight, 11.2 m2 surface and electric power 6.8 kWh. - 100 kg fabric weight with a bath ratio of 1:8 - temperature rate of 2C /min.

Energy Calculation using a Simulation Program

250000

200000

Energy (kcal)

150000

100000

50000

Bioscouring A

Bioscouring B

Alkaline Scouring --

Bioscouring A
1.Scouring (60 C,15min) o 2.After-treatment (95 C,5min) o 3.Washing (60 C,10min)
o

Bioscouring B
4.Scouring (60 C,15min) o 5.After-treatment (80 C,15min) o 6.Washing (60 C,10min)
o

Alkaline Scouring
7.Scouring (95 C,30min) o 8.1st washing (80 C,10min) o 9.2nd Washing (50 C,15min)
o

Energy Calculation using a simulation program

2.5 2.0
E le c tr ic ity S te a m T o ta l

Cost (US $)

1.5 1.0 0.5 0.0 1 2 3 4 5 6 7 8 9

Bioscouring A
1. scouring (60, 15 min) 2. after-treatment (95, 5 min) 3. washing (60, 10 min)

Bioscouring B
4. scouring (60, 15 min) 5. after-treatment (80, 15 min) 6. washing (60, 10 min)

Alkaline Scouring
7. scouring (95, 30 min) 8. 1st washing (80, 10 min) 9. 2nd washing (50, 15 min)

Estimation of CODcr generated due to input of each chemical for one ton production of cotton knits
based on one ton production of cotton knits.

Bioscouring
Raw Materials BioPrep Soda Ash Wetting/Scouring agent Anti-creasing agent Sequestrant Acetic acid Total Amount used (kg) 1 2.5 8 8 8 CODcr (g/Kg)* 267 424 295 184 CODcr (g) 267 3392 2360 1472 7,491

Alkaline Scouring
Amount used (kg) 40 8 8 8 4 CODcr (g/Kg)* 424 295 184 966 CODcr (g) 3392 2360 1472 3864 11,088

Description of overall financial picture

based on one ton production of cotton knits

Enzymatic Scouring
Costs : 11.9 USD UP
- Investment Not needed (the same facility is used) Chemicals including Enzyme : 58.6 USD

Alkaline Scouring

- Raw Materials

Chemicals including Alkali : 46.7 USD

Savings: 16.5 USD Down

- Water - Wastewater treatment - Operation: reduction of energy use such as steam and electricity 16 tons = 5.3 USD 16 tons = 10.7 USD 32.7 USD 24 tons = 8.0 USD 24 tons = 16.0 USD 41.2 USD

Overall

Increase due to enzyme cost(11.9 USD) is offset by savings(16.5 USD) from water, wastewater treatment and steam & electricity.

Economic Evaluation
80
Alkaline scouring Enzymatic scouring

60 Cost ( US $ / ton)
Enzyme Acid Soda Ash Electiricity Soda Ash Electiricity

40

20

24 tons 2400 L 16 tons 1600 L 24 tons 2400 L

Steam Steam

16 tons 1600 L

0
Wastewater Chemicals
Water Energy

Overall Cost Reduction for Bioscouring

US $ 4.6 / ton for Knitted 100% Cotton Fabric

4th

International Conference on Textile Biotechnology

June 11-14, 2006 Seoul, Korea

www.intb.org