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    Welcome To MY Presentation: Advanced Dyeing & Printing

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    Shumi Nahar
    This presentation discusses sustainability challenges and innovation opportunities in the textile and dyeing industries. Traditional dyeing processes use large amounts of water, dyes, and energy, causing environmental pollution. Innovative technologies are needed to reduce or eliminate water, energy, and chemicals used in dyeing. Examples discussed include supercritical carbon dioxide dyeing of polyester, which uses no water and nearly 100% of the dye, and dye transfer inhibiting polymers that significantly reduce water and energy usage when washing out reactive dyes from cotton. Fiber coloration directly during synthesis and nanocellulose dyeing processes are also summarized as more sustainable alternatives.

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    Welcome To MY Presentation: Advanced Dyeing & Printing

    Uploaded by

    Shumi Nahar
    199 views26 pages
    This presentation discusses sustainability challenges and innovation opportunities in the textile and dyeing industries. Traditional dyeing processes use large amounts of water, dyes, and energy, causing environmental pollution. Innovative technologies are needed to reduce or eliminate water, energy, and chemicals used in dyeing. Examples discussed include supercritical carbon dioxide dyeing of polyester, which uses no water and nearly 100% of the dye, and dye transfer inhibiting polymers that significantly reduce water and energy usage when washing out reactive dyes from cotton. Fiber coloration directly during synthesis and nanocellulose dyeing processes are also summarized as more sustainable alternatives.

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    This presentation discusses sustainability challenges and innovation opportunities in the textile and dyeing industries. Traditional dyeing processes use large amounts of water, dyes, and energy, causing environmental pollution. Innovative technologies are needed to reduce or eliminate water, energy, and chemicals used in dyeing. Examples discussed include supercritical carbon dioxide dyeing of polyester, which uses no water and nearly 100% of the dye, and dye transfer inhibiting polymers that significantly reduce water and energy usage when washing out reactive dyes from cotton. Fiber coloration directly during synthesis and nanocellulose dyeing processes are also summarized as more sustainable alternatives.

    Copyright:

    © All Rights Reserved
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    Download as pptx, pdf, or txt
    199 views26 pages

    Welcome To MY Presentation: Advanced Dyeing & Printing

    Uploaded by

    Shumi Nahar
    This presentation discusses sustainability challenges and innovation opportunities in the textile and dyeing industries. Traditional dyeing processes use large amounts of water, dyes, and energy, causing environmental pollution. Innovative technologies are needed to reduce or eliminate water, energy, and chemicals used in dyeing. Examples discussed include supercritical carbon dioxide dyeing of polyester, which uses no water and nearly 100% of the dye, and dye transfer inhibiting polymers that significantly reduce water and energy usage when washing out reactive dyes from cotton. Fiber coloration directly during synthesis and nanocellulose dyeing processes are also summarized as more sustainable alternatives.

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    You are on page 1of 26

    WELCOME TO

    MY
    PRESENTATION

    COURSE:
    ADVANCED DYEING & PRINTING
    WPE_541

    TITLE:
    SUSTAINABILITY CHALLENGES & INNOVATION
    OPPORTUNITIES IN THE TEXTILE & DYEING
    INDUSTRIES.

    Presented by :
    Jannatul Ferdush
    Id:2016-02-03-010
    BUTex

    Submitted To :
    Prof. Dr. Engr. Md. Zulhash Uddin
    Dean, Faculty Of Textile Chemical
    Engineering
    BUTex

    INTRODUCTION
    Dyeing process is the huge consumption of water, dyes auxiliaries and
    energy/power that occurs environmental pollution. This led our aspect
    towards the sustainable process through innovative concept.
    Due to the Innovative technologies needed to reduce, or eliminate, water,
    energy and auxiliary chemicals in dyeing, because of various health
    hazards leaving negative footprint in the environment.
    This given an impetus to the rising demand for producing textiles
    through innovation opportunities and sustainable process.

    WHAT IS
    SUSTAINABILITY?
    The
    most popular definition of sustainability is
    "Development that meets the needs of the present
    without compromising the ability of future generations
    to meet their own needs."
    Bruntland Report for the World Commission on Environment and Development (1992)

    Pillars of Sustainability

    renewable resource harvest, pollution


    creation, and non-renewable resource.
    defined level of economic production indefinitely.
    social system, such as a country,

    NECESSITY OF SUSTAINABILITY

    2016 - world population 7.5 billion

    2050 - expected to rise to over 9.5


    billion

    Increases demand

    food, energy, water, resources, chemicals

    Increases environmental burden

    pollution
    depletion of finite non renewable
    resources (e.g. fossil fuels)

    IDEAL SUSTAINABLE PRODUCT


    Provide an equivalent function to the product it replaces
    Performs as well as or better than the existing product
    Be available at a competitive or lower price
    Have a minimum environmental footprint for all the processes
    involved
    Be manufactured from renewable resources
    Use only ingredients that are safe to both humans and the
    environment
    No negative impact on food supply or water

    SUSTAINABILITY CONSIDERATIONS IN TEXTILE


    INDUSTRY
    WATER
    Reduce waste water,
    Reduce waste
    pollution .

    ENERGY
    Low energy use

    EMISSIONS
    Reduce co2 emission,
    Reduce air pollution.

    RAW MATERIALS
    Organic Cotton, Silk,
    Hemp, Bamboo, Wool

    TEXTILE DYEING PROCESSES

    Traditional dyeing processes use 5.8 trillion litres water p.a.


    ~3.7 billion Olympic swimming pools

    10-20% dye remains after dyeing (plus other chemicals),


    leaving potential for wastewater pollution
    One fifth of the world's industrial water pollution
    (World Bank)

    391 billion kWh energy for dyeing processes

    Innovative technologies needed to reduce, or eliminate, water,


    energy and auxiliary chemicals in dyeing

    TREATMENT OF TEXTILE DYEING EFFLUENT

    Wastewater discharged from dyeing processes one of biggest


    contributors to textile effluent
    Mainly residual dyes and auxiliary chemicals
    >50,000 tpa dye discharged into effluent
    Dye Class

    Fibre

    Loss to effluent (% applied)

    acid

    polyamide

    5-20

    basic

    acrylic

    0-5

    direct

    cotton

    5-30

    disperse

    polyester

    0-10

    metal-complex

    wool/polyamide

    2-10

    reactive

    cotton

    10-50

    sulfur

    cotton

    10-40

    vat

    cotton

    5-20

    TREATMENT OF TEXTILE DYEING EFFLUENT

    Dyeing effluent in a watercourse aesthetically


    undesirable, but has a more serious environmental impact

    High BOD combined with spectral absorption of dye


    Can affect photosynthetic processes
    Reduction in O2 levels in the water suffocation
    of aquatic flora and fauna

    Dyestuffs may be also have aquatic toxicity


    (metals, AOX)

    Several methods developed to remove colour from dye


    house effluent

    Varying in effectiveness, economic cost, and


    environmental impact (of the treatment process itself)

    Blackburn RS, Environ. Sci. Technol. 2004, 38,


    4905.

    POLYESTER DYEING PROCESS

    Hydrophobic fibre dyed with


    hydrophobic disperse dye
    Traditional aqueous process requires
    dispersing agents/surfactants and high
    temperatures (typically 130 C) under
    pressure
    Other dyeing auxiliaries often required
    Large amount of waste dye left over in
    effluent
    Surface dye removed with surfactants
    and/or reducing agents
    Innovation in scCO2 dyeing to completely
    change polyester dyeing process

    SCCO2 DYEING
    START

    FINISH

    Fabric loaded

    Dyed fabric

    STEP 6

    STEP 1
    Liquid CO2
    released into
    dyeing vessel

    Pressure lowered
    and CO2 leaves
    vessel as gas.
    95% recovered

    STEP 2

    STEP 5

    Heat + pressure
    liquid CO2 scCO2

    STEP 3

    STEP 4

    scCO2 and dye


    forced
    through fibre

    Fresh CO2
    pumped through
    and used CO2 to
    separator

    Separator
    evaporates CO2 to
    remove excess
    dye and residue

    SCCO2 DYEING
    System comparison with traditional polyester dyeing
    WATER

    ENERGY

    Zero water used

    Reduces energy
    consumption by 63%

    WASTEWATER
    Nearly 100% dye used
    in process.
    Zero waste

    PROCESS
    CHEMICALS
    No auxiliary chemicals
    required

    EFFICIENCY
    40% faster than
    traditional dyeing
    processes

    FOOTPRINT
    of physical footprint
    to dye same amount of
    fabric

    SCCO2 DYEING - TIMELINE


    Dyeing of modified
    cotton in scCO2 at Univ
    of Leeds

    Process further developed


    by Knittel et al.

    1992

    1998

    1988

    1995

    Schollmeyer et al.
    patent scCO2 dyeing of
    polyester

    Pilot scale dyeing of


    polyester up to 30 L
    (Bach et al.)
    Abel Kirui wins silver
    in London 2012
    Marathon singlet in
    dyed using DyeCoo
    process

    2012
    2010
    DyeCoo deliver first
    industrial-scale scCO2
    dyeing machine to
    factory in Thailand

    2013
    Nike opens
    dedicated waterless
    dyeing factory in
    Taiwan

    SCCO2 DYEING - LIMITATIONS

    Machines are more expensive than traditional water-dyeing


    machines
    costs will come down through scale and lower water
    and energy expenses

    Only works on polyester fabrics and can't be used to dye


    cotton
    Cotton made up about 32% global fibre market in
    2012
    Some relatively unsuccessful work on modifying
    cotton

    Significant opportunity to develop low or zero


    water dyeing systems for coloration of cellulosic

    COLORATION OF COTTON

    Dyeing of cotton primarily conducted using reactive dyes


    Despite development of dyes with high fixation, dyeing still uses high
    quantities of salt, water (and energy), and creates colour pollution

    Soil too alkaline to support


    crops
    Kills aquatic life
    Fresh watercourses turned saline
    downstream from dyehouses
    Difficult to remove from effluent

    10-40% dyestuff
    hydrolysed
    Goes down drain
    Aesthetically
    unpleasant
    Blocks sunlight
    Kills aquatic life
    Clean effluent
    High cost

    High level in dyeing


    Incredible volume in wash-off
    Up to 10 separate rinsings
    High energy consumption
    50% total cost dyeing
    procedure

    WASH-OFF OF REACTIVE DYEINGS ON COTTON


    Dye transfer inhibiting (DTI) polymers (used in laundry
    detergents) were employed to remove unfixed dyes
    Much more efficient, economical and sustainable process
    developed
    Significantly reduces operation time, water consumption and
    energy consumption

    poly(vinylpyridine-N-oxide) polymers were the most effective


    poly(vinylpyridine betaine) polymers also highly efficient

    Procedure

    Time
    (min)

    Water
    (L/kg fabric)

    Energy
    (MJ/kg fabric)

    recommended
    wash-off

    250

    60

    9.21

    DTI wash-off

    50

    30

    0.84

    Amin MN, Blackburn RS, ACS Sus. Chem. Eng. 2015, 3, 725.

    BIGGER PROBLEMS WITH COTTON

    NATURAL doesnt necessarily mean


    sustainable
    Cotton production >25 million tpa

    High levels of pesticides (25% world total)


    High levels of insecticides (11% world total)
    Very high irrigation levels

    1 kg of cotton fibre requires 20,00040,000 L


    Water average person consumes in a
    lifetime

    Only grows in certain climates


    Deforestation to grow cotton

    High area of land for mass of useable fibre

    FIBRE COLORATION- DOPE

    DYED

    Dope dyeing is also known as solution


    dyeing or spun dyeing, this is the process of
    adding pigments or insoluble dyes to the
    spinning solution before the solution is
    extruded through the spinneret.

    Only manufactured fibers can be solution


    dyed.

    This is very good application which require


    excellent color-fastness properties. Because
    the color pigments become a part of the
    fiber, solution dyed materials have excellent
    colorfastness to light, washing, crocking
    (rubbing), perspiration and bleach.

    FIBRE COLORATION- DOPE

    DYED

    Solution Dye Comparison Chart


    Dope dyed is an ideal solution to replace dyeing process in
    manufacturing process.
    This will affect directly on the cost of production.
    capacity will automatically get increased.

    FIBRE COLORATION- DYECAT PROCESS

    Catalytic process that allows


    colour to be integrated directly
    into polyesters
    Eliminates need for conventional
    dyeing
    Colour in fibre is generated at the
    same time the polymer is made
    Colours locked into fibre
    providing a technically superior
    product
    No need for wasteful dyeing
    processes
    DyeCat PLA fibre
    Renewable
    Technically superior
    Saves chemicals and
    energy

    FIBRE COLORATIO- DYECAT PROCESS

    Coloration of polymer during synthesis


    Demonstrated on PLA using coloured catalysts

    MacRae RO, Pask CM, Burdsall LK, Blackburn RS,


    Rayner CM, McGowan PC, Angew. Chem. Int. Ed. 2010,
    50, 291.

    TEXTILENOVEL, SUSTAINABLE AND COST-EFFECTIVE


    TEXTILE DYEING USING NANOCELLULOSIC FIBRES DYEING
    PROCESSES

    Dr. Yunsang Kim et al.,


    University of Georgia
    Innovative dyeing processes using coloured Nano
    cellulose
    Winner of Green and Sustainable Chemistry Challenge
    nano-sized cellulose fibrils (wood pulp) + dye
    dyed nanocellulose dispersion
    Apply dyed nanocellulose dispersion onto the textile material
    using low water process
    Coloured nanocellulose permanently binds to textile surface
    Greatly reduces energy and water needed

    CONCLUSION

    Greater use of sustainable raw materials


    Lower energy & water consumption and pollution generation in
    production
    Lower impact in use
    Water, energy, chemicals in cleaning/laundering

    Design for easy disassembly/disposal/ recycling

    DESIGN FOR REDUCED CONSUMPTION AND LONGER


    LIFE
    Disposable products unsustainable

    THANKS YOU

    QUESTION?

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