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Dr. M. RAMESH KUMAR,

Dept. of Garment and Fashion Technology,Sona College of Technology,

Salem 636 005.

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TEXTILE INDUSTRY WASTEWATER

TREATMENT - AN OVER VIEW

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SOURCES OF WATER

The worldswater is found in oceans and seas,lakes and reservoirs, rivers and streams, glaciers

and snowcaps in the polar regions in addition to

ground water.

Distribution of water Percentage ofwater

Oceans and Seas 96 - 97%

Glaciers and Polar

icecaps

2 - 3%

Fresh water < 1%2

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ReservoirVolume

(cubic km x

10,000,000)

% of Total

Oceans 1370 97.25

Ice Caps/Glaciers 29 2.05

Deep

Groundwater

5.3 0.38

Shallow

Groundwater

4.2 0.30

Lakes 0.125 0.01

Soil Moisture 0.065 0.005

Atmosphere 0.013 0.001

Rivers 0.0017 0.0001

Biosphere 0.0006 0.00004

Inventory of Water at the Earth's Surface

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Water Allocation Priority

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Indias Water Demand

Present water demand in India - 703 km3

/year. For domestic use43 km3/year

For industrial use37 km3/year

For agricultural use550 km3/year

India receives annual precipitation of

about 4000 km3

Only 35% of surface water is

utilizable.

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Water Pollution

Discharge of partially or untreatedindustrial effluent.

Discharge of untreated domestic

sewage.

Mismanagement practice of solid

wastes. Unscientific use of synthetic fertilizers.

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Effluent Water is referred as wastewater (effluent) when it is

impaired by anthropogenic contaminants

Domestic Effluent

Biologically Active

Effluents

Landfill Leachates

Water Disinfection

Malodourous

Effluents

Industrial Effluent

Ammoniacal Wastes

Coloured Effluents

Hazardous Effluents

Malodourous Effluents

Recalcitrant Effluents

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Polluting Industries

Pulp and Paper

Industries

Dairy Industries

Slaughter Houses

Ceramics Industry

Fruits and Vegetables

Processing

Fish Processing and

Canning

Metal Plating Industries

Paint Industries

Pharmaceutical Industries

Refineries

Petrochemical Complexes

Textile Industries

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Discharge of Textile Industry Effluent

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Textile Industries

Complicated Industry among other

manufacturing Industries. Second largest Employment Generator.

Textile account for

- 17 % of Export Earnings

- 14% of Indias industrial production

- 4% to GDP

Third largest polluter in the world.

Erode, Tirupur and Karur are hub of textile

sector.

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Textile Industries.

More than 1 lakh commercial dyes areavailable.

Dye annual production approximately10,00,000 tons.

Azo dyes account for 60 to 80% of the dyesconsumed in textile processing

About 5200 organized bleaching and dyeing

industries are in India & more unorganizedindustries are also available.

50% industries at Tirupur, Karur and ErodeDistricts

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Government Action against Polluting

Industries

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Wastewater Issues

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Wastewater Issues

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Need for treatment....,

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Fresh Water Scarcity

Huge demand for fresh water due to rapid

increase in population, coupled withcivilization and expanding economy of thecountry-led to the depletion of ground and

surface water.Poor Rainfall- lesser recharge of aquifer

Availability of fresh water in the globe isfixed & limited

Hence the fresh water requirement hasbecome a matter for serious concern. Thereis a huge demand for fresh water.

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Major Classification of Textile

Dyeing Industries

- Woven fabric dyeing industry

- Knitted fabric dyeing industry

- Yarn dyeing industry

- Printing industry

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Woven fabric dyeing industry

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Knitted fabric dyeing industry

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Yarn dyeing industry

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Printing industry

Rotary Printing

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Environmental Problems due to

Textile Industries

Even though Textile Industry plays an important role inIndian economy in multiple ways it also causes majorenvironmental impact.

Erode, Tirupur and Karur districts are hub of textile

industries in which more than ten thousand small andmedium scale industries are functioning.

This super power continuously threatens the livelihoodby discharging the effluent into river (Cauvery, Bhavani

and Noyal) & near by canals (Kalingarayan canal )

Hence, proper treatment is essential for a healthyatmosphere.

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l ifi i f h d

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Classification of Wastewater Treatment Methods

Bioaugmentation

Activated sludge

Extended aeration

Anaerobic processes

Rotating biological

contactors

SBR and trickling filters

Adsorption, Filtration

Stripping/

Sedimentation

Membranetechnologies

Chemical Oxidation/

Precipitation/Coagulation

air flotation/Flocculation

Hydrolysis/Neutralization

Solvent Extraction

Ion Exchange

CHEMICAL PHYSICAL BIOLOGICAL

INDUSTRIAL WASTEWATER TREATMENT METHODS

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Cl ifi i f W T M h d

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Classification of Wastewater Treatment Methods

Bioaugmentation

Activated sludge

Extended aeration

Anaerobic processes

Rotating biological

contactors

SBR and trickling filters

Adsorption, Filtration

Stripping/

Sedimentation

SkimmingMembrane

technologies

Chemical Oxidation/

Precipitation/Coagulation

air flotation/Flocculation

Hydrolysis/Neutralization

Solvent ExtractionIon Exchange

CHEMICAL PHYSICAL BIOLOGICAL


Physical/Chemicalprocesses if chemical

agents as coagulating

agents are added.

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Membrane Technology

Micro filtration

Ultrafiltration

Nanofiltration

Reverse Osmosis Membrane

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Reverse Osmosis

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RO Membrane Technology

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KOCH MEMBRANE

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ROSA MEMBRANE ( FILMTEC)

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MEMBRANE SPECIFICATIONS

PARTICULARS

KOCH

MEMBRANE

ROSA

MEMBRANE

Membrane Thin Film

Composite

Filmtech

Materials of

Construction

Polyamide Polyamide

Software ROPRO ROSA

Pore size 0.1 Micron 0.1 Micron

Range of operating

pressure

30 - 40 bar 30 - 40 bar

Temperature 30 400C 30 400C

pH 2 11 2 11 32

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Advantages of RO Membrane

Highly efficient High recovery%

Lower rejection%

Lower maintenance cost Lower power consumption

Lower pressure

Cost effectiveness Easy to operate & Maintain

Wastewater can be reused in Large

proportion 33


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Conventional

Treatment

High-qualityTreatment

Wastewatertreatment

process

Its a combination of

physical, chemical, and

biological processes

PRELIMINARY

TREATMENT

PRIMARY

TREATMENT

SECONDARY

TREATMENT

ADVANCED

TREATMENT

Feed wastewater

stream

To discharge or

reuse/recycling


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Removal of grit, debris and excessive

amounts of oils or greases.

Wastewater pretreatment plant.

Wastewatertreatment

process


physical, chemical, and


PRELIMINARY

TREATMENT

PRIMARY

TREATMENT

SECONDARY

TREATMENT

ADVANCED

TREATMENT

Feed wastewater

stream

To discharge or

reuse/recycling

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Wastewater

treatmentprocess

Its a combinationof physical,

chemical, and


PRELIMINARY

TREATMENT

PRIMARY

TREATMENT

SECONDARY

TREATMENT

ADVANCED

TREATMENT

Feed

wastewater

stream

To discharge or

reuse/recycling

The reached removal is up to

85-95% of BOD and SS &

65% of COD.

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Wastewater

treatment

process


physical, chemical,

and biological

processes

PRELIMINARYTREATMENT

PRIMARY

TREATMENT

SECONDARY

TREATMENT

ADVANCED

TREATMENT

Feed wastewater

stream

To discharge or

reuse/recycling

Removal of :

Additional organic and suspended

solids.

Nitrogenous Oxygen Demand (NOD)

Nutrients

Toxic materials

Also called Tertiary

Treatment

Membrane separation

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WASH WATER PLANT TREATMENT SCHEME

PRIMARY TREATMENT (PHYSICO-CHEMICAL)

SECONDARY TREATMENT (BIOLOGICAL)

TERTIARY TREATMENT (PHYSICO-CHEMICAL) UF/RO RECYCLING PLANT

DYE BATH PLANT

FIVE EFFECT FALLING FILM EVAPORATOR

EVAPORATOR AND SALT RECOVERY PLANT

TREATMENT METHOD

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SCHEMATIC DIAGRAM OF WASHWATER PRIMARY TREATMENT

RAW EFFLUENT FROM

MEMBER UNITS ( TDS< 2100mg / lit)

PRIMARY OUTLET

TO BIOLOGICAL

TREATMENT

RECEIVING SUMP EQUALISATION TANK

FLASH MIXING TANK

LIME, FeCl2, POLY

CLRIFLOCCULATOR

CLARIFIED EFFLUENT SUMP

THICKENERFILTER PRESS

CENTRIFUGE

SLUDGE SUMP

SLUDGE TO SLUDGE STORAGE YARD 39

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PRIMARY TREATMENT

RECEIVING SUMP Wash water effluent received and screened.

EQUALISATION TANK

The effluent is homogenized with high speedfloating aerators.

FLASH MIXING TANK

Coagulant and flocculent addition, Such asLime , FeCl2 and Poly electrolyte.

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SCHEMATIC DIAGRAM OF SECONDARY TREATMENT

(BIOLOGICAL TREATMENT)

FROM PRIMARY OUTLET

NUTRIENTS

RETURN ACTIVATED SLUDGE

AERATION TANK

SECONDARY CLARIFIER

TO TERTIARY

TREATMENT

EXCESS TO THICKENER

AIR SUPPLY

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SECONDARY TREATMENT (BIOLOGICAL)

SECONDARY CLARIFIER

The mixed liquor from the biologicalrector is sent to secondary clarifier forsettling the bio mass and a portion is

pumped to biological rector for re-activation.

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TERTIARY TREATMENT

To improve the quality of secondary treatedeffluent

By reducing the suspended solids. By reducing the colloidal particles.

By destroying the micro organism.

By reducing the alkalinity.

By reducing the color and metal ions.

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SCHEMATIC DIAGRAM OF TERTIARY

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SCHEMATIC DIAGRAM OF TERTIARY

TREATMENTFLASH MIXING TANK

LIME, FeCl2, POLY

TERTIARY CLARIFIER THICKENER

SLUDGE SUMP

COLLECTION TANK

DUAL MEDIA FILTER

TO RO PLANT

FILTER PRESS

SLUDGE TO

SLUDGE YARD

FROM

BIOLOGICAL

TREATMENT

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MEMBRANE BASED RECYCLING

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MEMBRANE BASED RECYCLING

PLANT

ULTRAFILTRATION

It will remove the colloidal particles,silica, suspended solids, biologicalmatters (bacteria, Algae, Fungi) and

also to reduce the total organiccompounds.

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UF FEED TANK CIP

ULTRAFILTRATION SYSTEM

PG

PG PT

FT

UF PERMEATE TANK

FT

PG

PG

PG

PT

PT

PT

AV

AV

AV

AV

AV

AV

UF RECIRCULATION

PUMP

BAG FILTER 100

BACK FLUSH PUMP57

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REVERSE OSMOSIS - I

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PG

PRESSURE VESSEL 2

PRESSURE VESSEL 4

PRESSURE VESSEL 5

PRESSURE VESSEL 3

PRESSURE VESSEL 6

PRESSURE VESSEL 7

PRESSURE VESSEL 8

PRESSURE VESSEL 9

PRESSURE VESSEL 13

PRESSURE VESSEL 12

PRESSURE VESSEL 11

PRESSURE VESSEL 10

PG

PG

PG

PG

FROM RO CIP

RO CIP

FT

RO CIP

PG

UF PERMEATE TANK

TO RO II FEED

ANTI SCALANT

HCl SMBS

PRESSURE VESSEL 1

FT

MICRON FILTER 5

MICRON FILTER

10

CIP PUMP

HIGH PRESSURE PUMP

FEED PUMPPERMEATE TO STORAGE TANK

AV

AV

PT

SDI

PT

PT

PT

ORP

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H

CI

S

M

BS

A

ntis

ca

le

nt

HPP

Feed

30m3/h

RO Feed

Tank

MCF

HPP HPP HPP

RO Permeate

27 m3/h

(90%)

RO Reject

3m3/h (10%)

MCF

Feed

Pump RO I, 1stArray RO I, 2ndArray RO II, 1stArray RO II, 2ndArray

RO Feed and Permeate

RO flow m/hr

RO Feed Flow - 30.00 m/hr

RO Permeate Flow - 27.00 m/hr

RO Reject Flow - 3.00 m/hr

RO Recovery % - 90.00 %

RO Array Classification

RO Stage I 5 X 6: 3 X 6

RO Stage II 2 X 5: 1 X 5

RO 1, 5 vessels and 3 vessels (48 elements)Stage I, Feed 5 membranes

Stage II, Feed 3 membranes

RO II, 2 vessels and 1 vessel (15 membranes)

Stage I, Feed 2 membranes

Stage II, Reject 1 membrane

No. of RO Elements used

RO Stage I 48 Elements

RO Stage II 15 Elements

Total 63 Elements

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Comparison of Raw effluent RO Feed and Permeate

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Parameters Raw Effluent

(ppm)RO Feed (ppm)

RO Permeatevalue

KOCH ROSA

TDS 6080.00 6357.00 110.13 244.28

COD 700.00 50.00 6.61 8.31

BOD 200.00 6.00 4.82 5.52

Cl 3250.00 3380.00 61.64 133.56

Ca2+ 45.00 50.00 0.16 0.54

Mg2+ 25.00 25.00 0.08 0.28

Na+ 2250.00 2363.00 42.75 91.49

K+ 8.00 5.00 0.12 0.69

NH4+ 8.00 0.60 0.03 0.33

HCO3 700.00 300.00 7.27 9.61

SO42- 338.00 350.00 1.08 5.27

NO3 7.80 5.00 0.42 2.02

SiO2 20.50 15.00 0.26 0.42

Comparison of Raw effluent, RO Feed and Permeate

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Comparison of RO Feed and RO Permeate

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0

1000

2000

3000

4000

5000

6000

7000

RO

PermeateVa

luesinppm

TDS COD BOD Cl Ca2+ Mg2+ Na+ K+ NH4+ HCO3 SO42- NO3 SiO2

Parameters

RO Feed

RO Permeate - ROSA

RO Permeate - KOCH

Comparison of RO Feed and RO Permeate

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CONCLUSION

The overall performance of ReverseOsmosis Membranes is better in

Textile industry.

The Reverse Osmosis Membrane

treatment is very effective in Textile

industry. RO membrane was found to be

more efficient and economical.71

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CONCLUSION

90% - 93% of RO Permeate watercan be used for recycling.

Remaining 7% - 10% RO Rejectwater can be sent to Solar

evaporation/Multipleevaporation for salt recovery.

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LET US MAKE OUR NATION

iei 26-01-2013

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