Textile Dyehouse Research Articles

An approach for the valorization of bio-waste pistachio shells (Pistacia vera L.): Dyeing of cellulose-based fabrics

The waste management subject is a very important issue today and in the future. Therefore, lots of scholars are endeavoring to investigate the valorization of wastes from different sources, such as paper, metal, glass, and vegetables. In this study, the pistachio soft and hard shells, as an industrial waste material, were used as natural dye sources. For this purpose, waste were collected from Gaziantep province in the south of Türkiye. Then, the soft and hard pistachio shells that had been dried in the shadow were investigated in terms of FTIR analysis and then used as a dyestuff source in the dyeing of cotton fabrics with the help of bio-mordants and metal mordants. Additionally, the antioxidant capacity of the soft and hard shell of pistachio was assessed through the DPPH and FRAP assay methods, and the antibacterial activities were tested against Staphylococcus aureus and Escherichia coli for selected dyed samples. A spectrophotometer was used to determine the CIE L*a*b* color values and (K/S) of cotton fabrics that had been dyed. The results exhibited that the tested wastes could be useful for the coloration of the cotton fabrics, and depending on the used natural dye source, mordanting agent, and mordanting method, the colors were found to have changed, but in general, light brown-ecru-brown colors were observed in the dyed samples. Meanwhile, the fastness of the samples was examined, and the sources were found to exhibit limited light fastness values but good or perfect washing, rubbing, and perspiration fastness. In conclusion, the evaluated conditions were found to be useful for the coloration of cotton, and even more importantly, the pistachio soft and hard shells were observed to reveal great potential for use in textile dye houses as a natural dye source.

Separation of cationic methylene blue dye from its aqueous solution by S-sulfonated wool keratin-based sustainable electrospun nanofibrous membrane biosorbent

The use of electrospun nanofibrous membranes for the treatment of dyehouse effluent is drawing attention because of their high surface area, and dye adsorption capability. In this work, nanofibrous membranes of S-sulfonated wool keratin protein/poly(vinyl alcohol) or PVA were prepared by electrospinning, and their effectiveness as an adsorbent for the removal of cationic methylene blue (MB) dye was studied. The electrospun nanofibers fabricated from keratin/PVA had a considerably finer average diameter (79.0 nm) compared to the average diameter (255.4 nm) exhibited by nanofibers produced from PVA alone. The optimal adsorption capacity was attained at a pH value close to neutral at ambient temperature (238.7 mg g−1), and the pseudo-second-order model was determined to be a reliable fit for the experimental data. Based on the fitted Langmuir model and MB adsorption data, the adsorption mechanism followed a monolayer pattern on the surface of the membrane. The MB dye adsorption capacity was slightly influenced by the presence of sodium chloride. The study demonstrated that the PVA/keratin nanofibrous membrane exhibited good reusability as only a small loss in absorption capacity was observed after three recycling and reuses. The developed biosorbent could be suitable for the high removal of dyes from textile dyehouse effluent.

COLOR REMOVAL OF DISPERSE DYEING WASTE WATER BY OZONE IN AN EXAMPLE DYEHAUSE

As a result of rapid population growth and industrialization, wastewater generated in various sectors poses a threat to the environment and living things.Textile industry wastewater comes first among these wastewater sources.These wastewaters contain dyestuffs and different chemicals. These waters, which contain many impurities, must be treated well, otherwise they may cause serious problems in the environments where they are discharged. Various physical, chemical and biological methods are used for color removal in wastewater. However, due to the cost and low efficiency of these methods, researches are carried out on innovative and more economical methods. Among the new technologies, advanced oxidation processes (AOPs) are highly efficient new methods being studied for the purification of certain impurities that cannot be removed by general techniques. AOP methods include photocatalytic reaction with UV, ultrasound, Fenton/Peroxide, ultrasound sound waves and similar reactions. One of these methods is ozonation method. In this study, ozone decolorization of wastewater after disperse dyeing taken from textile dyehouse was investigated. In the determined procedure, the removal of color by ozonation method, which is one of the advanced oxidation methods for wastewater recipes after dyeing, was investigated and the color absorbance and COD values of the samples were examined and the results were evaluated.

Merging treatability results and sustainability assessment: a segregated textile dyehouse effluent

Merging treatability results and sustainability assessment: a segregated textile dyehouse effluent

Developing Sustainable Methods for Softener and Fixing Agent Application in HT Dyeing Machines

Global warming, which is one of the problems brought by the increasing population day by day, and the rapid depletion of water resources have increased the restrictions on water use. Thus, more environmentally friendly and sustainable production processes are developed by producers and consumers. The number of studies carried out to minimize the use of raw materials in textile dyehouses is increasing day by day. The high chemical load, waste water usage rate and energy cost resulting from pretreatment, dyeing and other processes vary according to the processes used in textile factories.
 Our company aims to support environmentally friendly studies that contribute to the economy in production processes. While producing in the paint shop, energy, water, chemicals, etc. It also aims to use raw material resources sparingly. In this study, the efficiency studies carried out in HT dyeing and finishing processes in the dyehouse of our company were examined. By optimizing the post-processing performed in HT machines after dyeing, softener and fixator chemicals applied in HT machines were carried out by using double pads before drying in stenter machines after trials. Obtained results were compared with old methods. A sustainable new method has been developed without any color, fastness or touch difference between the old system and the new system.
 With this new process study, our company's water, energy and chemical savings and the company's impact on the environment have been reduced, while time savings have been achieved by shortening the process time. In the test results, there was no problem in washing, color and rubbing fastness efficiency. No change was observed in the touch of the products after the application of the softener step with the impregnation method instead of shrinking. As a result of the study, while the water consumption was reduced by 20%, the process time was also reduced by 19%.

Efficient Removal and Conditions Optimization of Textile Dyes Using UV/TiO<sub>2</sub> Based Advanced Oxidation Process

Textile and other dye house effluents from different industries have many worst effects on aquatic as well as non-aquatic life. The present work was carried out for the conditions optimization of degradation of Allura Red AC dye. This was done by UV treatment and examining the effects of different parameters on degradation i.e. pH, concentration of the dye, temperature, radiation exposure time and concentration of TiO2. The efficiency of the treatment was monitored by checking the highest degradation value, parameters of water quality such as chemical oxygen demand (COD), biological oxygen demand (BOD) and toxicity. The end products of degradation of dye were checked out by UV/visible spectrophotometer, Fourier transform- infra red (FT-IR) and gas chromatographymass spectrometry (GC-MS) techniques. From the results, it was concluded that the degradation efficiency was in the order UV/H2O2/TiO2> UV/H2O2> UV alone. Furthermore, it was also concluded that UV/H2O2/TiO2 could be implemented on industrial scale for the removal of the toxic pollutants from industrial effluents.

Alkanna tinctoria-based sustainable alkanin natural colorant for eco-dyeing of wool.

The awareness of sustainability and widespread utilization of green technologies in textile dye houses are revolutionizing not only textile industries but related fields. The current study is concerned with ultrasonic (US)-assisted utilization of extracts of Alkanna tinctoria (a source of natural alkanin dye) for wool dyeing. The extracts are obtained in various media, and both extracts andwool fabrics have been US treated for 15-60min. Dyeing is performed by applying variable parameters and utilizing herbal-based extracts as a source of bio-mordant, hence improving the fastness rating and enhancing color strength. Good color strength and fastness ratings are obtained using irradiated extract at 4 pH when the US-treated wool fabric is dyed at 65°C for 60min before and after chemical and bio-mordanting. For comparative studies, chemical mordants are also employed. In contrast to chemical mordants, the bio-mordants have made the dyeing process more sustainable with good toexcellent fastnessrating.

Effectiveness of Carbon Electrode Electrolysis Effluent Treatment System in Textile Dyeing

The electrolysis process is an easy alternative for the treatment of textile dyehouse wastewater. To study the effectiveness of the carbon electrode electrolysis method in dyehouse effluent treatment is the main objective of this research. In most cases, the metal electrode used in the electrolysis system becomes decayed and needs to be replaced after a certain time. In this study, an inert carbon electrode has been chosen to treat the cotton dyehouse wastewater that can function longer than a metal electrode. Hence, the process is named as Carbon Electrode Electrolysis (CEE) method. In this method, a combined effect of electro-coagulation and electro-reduction has occurred. Electro-coagulation happens by direct charge supplied from a carbon electrode and then neutralizing negative effluent charges using positive charge. The color chromophore becomes broken down by a reduction in the cathode. Through electrolysis of sodium chloride in the effluent, sodium hypochlorite is produced, which later oxidizes organic compounds and reduces BOD. The effects of different treatment parameters of the CEE method like salt concentration and operating time have been studied and found that higher salt concentration and around 65 minutes operating time is effective. The results are analyzed based on four criteria: Color change, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD) and Total Dissolved Solids (TDS). Results show that the CEE method minimizes effluents’ color and reduces BOD and COD within the acceptable limits of the Department of Environment (DoE), Bangladesh. Moreover, the CEE Effluent Treatment Plant (ETP) needs less space than the other existing biological and chemical ETP. However, this method is failed to remove TDS from wastewater.

Removal of Acid Violet 90 Dyestuffs in Aqueous Solutions by Ozonation Method

Due to the colored wastewater from many industries, especially textile dyehouses, the dyestuffs that increase in variety with the developing technology, the risk of toxicity, as well as the aesthetic concerns, create a danger for human and environmental health and their treatment is becoming increasingly important. Color in wastewater can only be partially removed by conventional treatment methods. However, by treating with ozone, which is a strong oxidant, not only the color of the waste water is removed, but also the amount of organic pollution is reduced. In this study, color removal was investigated by ozonation method in synthetic water containing Acid Violet dye with an initial concentration of 50 mg/L. As a result of the study, the maximum efficiency was reached with pH 7, ozone dose 0.375 g/L.h, time 7.5 minutes, and 48.578 mg/L substance removal was achieved.

Effluent-free deep dyeing of cotton fabric with cacao husk extracts using the Taguchi optimization method

Textile dyehouses are under scrutiny because they discharge colored and hazardous effluents to waterways. There is a need to develop an alternative dyeing system that does not produce any hazardous effluent. The waterless dyeing method could be a viable eco-friendly alternative to the traditional aqueous dyeing method. In this work, cacao husk extracts were used as a natural dye in the decamethylcyclopentasiloxane (D5) medium for the dyeing of cotton fabric, and subsequently, the dyed cotton was treated by a fixation treatment with a cationic dye-fixing agent in the D5 medium. The cotton fabric dyed with cacao husk extracts exhaustion in the waterless D5 medium exhibited better exhaustion, fixation rate, color strength (K/S), and colorfastness to washing and rubbing compared to the fabric dyed with the same extracts using the conventional aqueous dyeing and dye-fixing methods. The dye exhaustion percentage and the dye fixation rate were 95.6% and 94.8% in the D5 medium respectively, which is significantly higher in comparison to a 48.2% dye exhaustion percentage and a 35.3% dye fixation rate in the conventional water medium. An orthogonal array design (L9) was adopted to optimize the dyeing conditions with respect to exhaustion percentage. The results indicated that the dyebath temperature was the most important factor for achieving the optimal dye exhaustion, and dyeing time also showed considerable effects. Linear regression was used to predict the exhaustion percentage, and the resulting p value of 0.000 demonstrated that a strong coefficient was proven among all selected factors. This study has demonstrated that dyeing of cotton fabric with cacao husk extracts in the D5 dyeing system can be a viable method for the textile industry with minimal environmental pollution.

Surface Modification of TiO2 @Pvc Composite Membrane for Textiledye House (Brome Phenol Blue) Filtration

The continued increase in the costs of chemicals, energy and water makes their recovery more important today than it was years ago when separation techniques by membrane filtration were first introduced to the textile industry. The aim of introducing membrane filtration is not only to reduce water consumption and wastewater streams. The paper describes the results of research works and implementation project concerning cleaner technology and water reuse in textile dye house by TiO2 @PVC composite membrane. Fabricated membranes were characterized with various analytical and experimental techniques. Results showed that the TiO2 blend TiO2 @PVC composite membrane were nano porous in nature with improved porosity and permeability. Addition of TiO2 improved the mechanical stability and water permeability of the composite membranes.TiO2 doped membrane showed better dye rejection behavior with a permeate flux. Size and charge based exclusions along with adsorption were identified as the separating principles. Fouling analysis clearly showed that TiO2 incorporated membranes possessed better antifouling effect than membrane without TiO2 .Thus the TiO2 blended TiO2 @PVC composite membrane are promising for the treatment of dye polluted wastewater.

Evaluation of a tannin-based coagulant on the decolorization of synthetic effluents

Natural-based coagulants have demonstrated significant advantages over conventional ones. In this work, the treatment of dyehouse effluents by coagulation-flocculation-sedimentation was studied using a commercial tannin-derived coagulant and compared with the common use of iron salt. Two aqueous solutions simulating textile dyehouse effluents were prepared using an azo dye (Direct Blue 85): E1, containing only dye and salts, and E2, with also three auxiliary dyeing chemicals. The treatment of E1 and E2 was optimized in batch mode (Jar tests) in terms of coagulant dosages and pH, in order to maximize color removal and find an acceptable settling velocity of flocs. Although the pH of the effluents is around 8, acidic conditions (pH 4–5) were experimentally found to be optimal for their total decolorization, at minimum coagulant dosages. In these conditions, iron sulfate provided decolorization using much lower dosages than those required for the tannin-coagulant. At pH 4, for instance, tannin-coagulant dosage required to find 100% color removal and easily settleable flocs was 3-times higher than that of iron(III) sulfate. However, at neutral and alkaline conditions, which are of major relevance in practical terms, the tannin-coagulant was much more efficient than the iron coagulant. At pH 8 (natural pH of E2), total decolorization was achieved using 180 mg L−1 of tannin-coagulant, while dosages up to 240 mg L−1 of iron sulfate were unable to provide more than 20% of decolorisation and settleable flocs. Continuous mode experiments, conducted in optimum conditions, confirmed the performance levels observed in jar tests.

Pollutant footprint analysis for wastewater management in textile dye houses processing different fabrics

AbstractBACKGROUNDThis study investigated the water and pollution footprints of a dye house, which processed cotton knits, polyester (PES) knits and PES‐viscose woven fabrics. Experimental evaluation was carried out for each processing sequence. Variations in wastewater flow and quality were established as a function of the production program in the plant. A model evaluation of wastewater dynamics was performed and defined specifications of an appropriate treatment scheme.RESULTSThe plant was operated with a capacity of 4300 t year−1 of fabric, which generated a wastewater flow of 403 500 m3 year−1 and a COD load of 675 t year−1. The overall wastewater footprint of the plant was computed as 91 m3 t−1 and the COD footprint as 160 kg t−1 of fabric. Depending on the fabric type, results indicated expected changes in wastewater flow between 600 and 1750 m3 day−1; in COD load between 1470 and 2260 kg day−1 and in COD concentration between 1290 and 3400 mg L−1.CONCLUSIONA model simulation structured upon COD fractionation and related process kinetics revealed partial removal of slowly biodegradable COD, coupled with high residual COD, which would by‐pass treatment. Resulting biodegradation characteristics necessitated an extended aeration system, which could also enable partial breakdown of residual COD. Effluent COD could be reduced to 220–320 mg L−1 with this wastewater management strategy. © 2018 Society of Chemical Industry

Fuzzy Modelling for Prediction of Bursting Strength of Knitted Cotton Fabric using Bleaching Process Variables

A fuzzy prediction model has been built based on hydrogen peroxide concentration, bleaching temperature, and time of bleaching as the input variables and knitted cotton fabric bursting strength as the output variable. Fuzzy expert systems can map efficiently in nonlinear domains with minimal experimental data. The model developed in the present study has been validated by new experimental data. The root mean square, mean absolute error percentage, and coefficient of determination ( R 2 ) between the predicted and experimental values were found to be 4.89, 0.707, and 0.965 respectively. The results confirm that the model can be applied successfully for the prediction of fabric bursting strength in textile dye houses.

Examination of serum oxidant-antioxidant levels of workers at dyehouses of textile sector in Denizli's industrial estate

The textile sector is one of the production sectors that contribute greatly to the national economy in domestic and foreign trade. Despitethe production of textile products in Turkey, it is still a developing technology- driven human labor. This requires the textile industry to be a business line that must be taken very seriously in terms of occupational health and safety. In this study, it was aimed to determine oxidant- antioxidant parameters and compare with control group in workers in a large textile factory dye house. The control group consisted of 40 people working in the factory or different areas of the factory that had not been exposed to paint and the experimental group consisted of 40 people working in the dye- exposed dye house. From each volunteer 5 ml fasting venous blood sample were taken into yellow cover vacuum plastic gel tube and centrifuged at 4000 rpm for 5- 10 minutes and their serums were separated. Vitamins A, E, C, malondialdehyde (MDA), total antioxidant status (TAS) and total oxidant status (TOS) levels were determined by using appropriate kits in high performance liquid chromatography (HPLC) and auto analyser devices in the laboratory and compared with the control group. As a result, it was found that vitamins A, E, C and TAS levels decreased significantly in the dye house compared to the control group (p< 0.001) and TOS and MDA levels increased significantly compared to the control group (p< 0.001). In the results, the relationship between the control group and the experimental group was examined and evaluated with the help of SPSS program. The finding sand results were discussed and suggestions we represented.

Comparing the Influence of the Drop Fill and Overflow Rinsing On the Reactive Dyeing Process in a Textile Dye House

Drop/fill rinsing method was used for reducing the high water consumption of overflow rinsing process in textile dye house. However, it is not known whether this drop/fill method has adverse effects on the final fabric properties or not. In this study, the effects of using drop/fill method instead of overflow rinsing process on colorimetric and fastness properties of 100% cotton towel fabrics are investigated. It is found that, skipping to the drop fill rinsing method from the over flow rinsing process and obtained fresh water saving has no negative effect on colorimetric and color fastness values of the processed fabric samples and can be used conveniently in the industrial sized production.

Extraction of polyphenolic substances from bark as natural colorants for wool dyeing

In Europe, considerable amounts of bark are available from wood‐processing industries such as forestry and timber production. Polyphenolic components can be collected by hot water extraction. The extracted compounds can then be applied as colorants in textile dyeing operations. In this study, a comparative assessment of four different tree species with regard to their colouristic potential for wool dyeing was performed. Aqueous extracts from alder, ash tree, spruce and oak bark were prepared and analysed for their total phenolic content and ultraviolet (UV) absorption at 360–370 nm. The extracts were used for meta‐mordant dyeing by adding iron sulphate mordant (FeSO4 × 7H2O). For comparison, iron salt‐based dye lakes were prepared and used in dyeing experiments. For each tree species, a specific correlation between the total phenolic content of the dyebath and the colour depth in terms of K/S and CIELab coordinates was observed, both for the aqueous extracts and the dye lakes. Based on this relationship, standardisation and quality control of raw materials and dye lakes can be installed as important stages in the industrialisation of natural colorants from bark. The preparation of concentrated dye lakes permits formation of a concentrated colorant as dye product, which then can be standardised and delivered to textile dyehouses, similar to synthetic dyes. The preparation of dye lakes offers a relevant route towards achieving the commercialisation of bark extracts as natural colorants.

Optimization of photocatalytic degradation of real textile dye house wastewater by response surface methodology.

This study evaluates the advanced oxidation process for decolorization of real textile dyeing wastewater containing azo and disperse dye by TiO2 and UV radiation. Among effective parameters on the photocatalytic process, effects of three operational parameters (TiO2 concentration, initial pH and aeration flow rate) were examined with response surface methodology. The F-value (136.75) and p-value <0.0001 imply that the model is significant. The 'Pred R-Squared' of 0.95 is in reasonable agreement with the 'Adj R-Squared' of 0.98, which confirms the adaptability of this model. From the quadratic models developed for degradation and subsequent analysis of variance (ANOVA) test using Design Expert software, the concentration of catalyst was found to be the most influential factor, while all the other factors were also significant. To achieve maximum dye removal, optimum conditions were found at TiO2 concentration of 3 g L-1, initial pH of 7 and aeration flow rate of 1.50 L min-1. Under the conditions stated, the percentages of dye and chemical oxygen demand removal were 98.50% and 91.50%, respectively. Furthermore, the mineralization test showed that total organic compounds removal was 91.50% during optimum conditions.

Bentonitic clay as adsorbent for the decolourisation of dyehouse effluents

Textile dyehouses generate high volumes of coloured wastewaters, which require convenient treatment in order to avoid water bodies' contamination, adverse effects to aquatic life and risks to human health. The complete decolourisation of such contaminated waters in a cost-effective manner is still a challenge nowadays. This work focuses on the use of a clayey material as a low-cost adsorbent for a basic textile dye (Red 46), commonly used in acrylic fibres dyeing. The bentonitic clay (49% of montmorillonite) presents a considerable (50 cmolc/kg) cationic exchange capacity and a porosity of 10%. Dye adsorption kinetics was successfully described by a pseudo-second order model, resulting an average kinetic constant of 0.23gdyegclay−1min−1. Adsorption equilibrium was reached in 12–24 h and data were successfully fitted to Freundlich and Langmuir equations. The maximum adsorption capacity predicted by the Langmuir model depends on the pH, varying between 217 mg/g at pH 8 and 584 mg/g at pH 9 (25 °C). Increasing the temperature from 25 to 35 °C also led to an increase in adsorbed amounts. In addition to the excellent adsorption performance, the clay showed a great affinity to the dye, indicating high propensity to complete decoulorization of textile dyeing wastewaters. The results obtained in the present work show that a natural, readily-available and cheap material i.e. a bentonitic clay can be used as an effective and environmentally-friendly adsorbent for basic dyes.

Electrochemical Degradation of Indigo Carmine Textile Dye Powered by Solar Photovoltaic Energy

The proposed photovoltaic electro oxidation process combines the autonomous and environmentally friendly photovoltaic solar energy with the capability of electro oxidation at boron doped diamond electrodes to effectively decolorize and degrade indigo carmine textile dye from wastewater. The photovoltaic array can be connected directly to the electrochemical reactor without batteries increasing, in this way, the system sustainability and eliminating the environmental threat of improper battery disposal. The system is made versatile according to the instantaneous solar irradiation by adjusting the wastewater flow rate to the current intensity supplied by the photovoltaic panel. All operating parameters affecting the efficiency of the proposed process, such as wastewater conductivity, pH, flow rate, current density, electro processing time and solar irradiance were studied and optimal conditions were investigated. The experimental results showed that by applying current densities of 1, 2.5 and 5 mA cm2 the initial dye concentration of 100 mg L-1 in the treated wastewater was quantitatively eliminated in 45, 20 and 10 minutes of electro processing respectively. The process is appropriate for treatment of colored industrial textile dye house effluents and especially for applications in remote and isolated locations without connection to public electric grid.