1 OBEM SpA Biella - Italy produces Fully Robotized Dyeing Plants for Fiber Yarn - Fabric 2 1
OBEM Previous AOP Experience DYEING LIQUOR AOP REACTOR ph, TEMPERATURE, OXIGEN PEROXIDE CONTROL DYEING MACHINE DECOLORED WATER ADVANCED OXIDATION PROCESS AND BIOTREATMENTS FOR WATER RECYCLING IN TEXTILE INDUSTRY ph, TEMPERATURE, CONTROL WATER RECOVERY TANK WASHING WATER DEPURATED WATER DRAIN REUSE OF DEPURATED WATER BIOFLOTATOR 3 Notes on OBEM Previous AOP Experience ADOPBIO Project (Sixth Framework Programme) TRIPLE CELLS AOP reactors combined with BIOFLOTATION Single AOP Cell Features 800 W conventional Medium Pressure lamp Horizontal mounting Triple internal flow Forced air lamp cooling Total installed UV power: 2400 W 4 2
AquaFit- New OBEM Approach for Better Results& Cost Reduction Power reduction Increasing Efficiency Liquor Flow Optimisation New Combination of Processesfrom Advanced Partners Reduction of Total Process Cost 5 AquaFit New Approach for Better Results& Cost Reduction Processes schema Fresh water Softening Process water Cooling water T e x tile fin is h in g p ro c e s s e s Concentrated WW from pre-treatment, dyeing, printing, finishing Nonconcentrated WW from washing, rinsing Evapoconcentration/ controled crystallization Prefiltration Heat recuperation heat Water for reuse *AOP Incineration or use in other domains Concentrate Membrane NF/RO *AOP = H 2 O 2 / UV; H 2 O 2 /O 3 ; H 2 O 2 / US; possible path 6 3
AquaFit New Approach for Better Results& Cost Reduction Partners Involvement Concentration technology Filtration technology End Users AOP reactor 7 New AOP Block Diagram Storagetank 1000 liters H2O2 H2SO4 NaOH Sand Filter Pre Treatment Tank AOP Treated Water Recovery Tank ph ORP Reuse of depurated water or to following process 8 4
New AOP Main Features Capacity : approx 100 to 150 liters/hour Power comsumption: approx 9 to 18 kwh per cu.m UV lamps: 1.44 kw LP Amalgam type Mixing device, ph and Redox control Circulating pump with flow control Batch or continuous working 1000 liters storage tank 9 New AOP Design Main features Minimum gap between lamps (19 mm) and between lamps and inner reactor surface (10 mm) Reduced section (92 x 182 mm ) Chamber height closed to lamp height (1570 mm) Reduced volume (approx 20 liters) Cooling jacket Vertical mounting The small gap between lamps assure a good UV activity also with dense dyeing waste 10 5
New OBEM AOP 3D View 11 12 6
13 Usually Textile wastewaters have different properties - Strongly Acidic - Strongly Alkaline Proper Pretreatment Process Combination (nanofiltration, ultrafiltration, bioflotation, evapoconcentration, ecc.) 14 7
It will be Necessary to Work on: Cost of Process to be Economically Sustainable Variability of Cost of the Water versus Cost of Process Adaptability of Process to the Requirements of National Regulation in force in various Countries 15 ECOTINT Processes of textile dyeing with supercritical CO 2 Partners involved: - OBEM spa - Filatura di Chiavazza - Filatura di Grignasco - Filtex - Como - Tintoria Vago - ENEA - Politecnico di Torino MIUR 16 8
ECOTINT Processes of textile dyeing with Supercritical CO 2 Started in 1998 Ended in 2001 More than 50 tests on polyester, silk, wool and cotton yarn Rated disperse and acid dyes 17 ADOPBIO Advanced Oxidation Processes and Biotreatments for Water Recycling in the Textile Industry Partners Involved: Stazione Sperimentale Seta (It) Univers. Of Maribor (Sl) Ecologia Applicata (It) Helios Italquartz (It) Robert Blondel (Fr) Dama Engineering (Sl) OBEM (It) TSP (Sl) 18 9
ADOPBIO Advanced Oxidation Processes and Biotreatments for Water Recycling in the Textile Industry Started in 2004 Ended in 2007 Manufactured a dyeing machine intefaced with the AOP reactor and the Bioflotation reactor Tested different combination of AOP + Bioflotation treatments Tested different wastewater of End Users standard production 19 INTEXUSA Optimisation of dyeing processes with UltraSonic Technology and its integration with automatic on-line control POR-FESR 2007-2013 Partners Involved: ENEA Politecnico di Torino FLAINOX OBEM Finissaggio di Trivero ITT Tintoria Ferraris 20 10
INTEXUSA Optimisation of dyeing processes with UltraSonic Technology and its integration with automatic online control POR-FESR 2007-2013 Started in 2009 Ended in 2011 Manufactured one lab US dyeing machine and three industrial scale device for US dyeing of yarn, pantyhose, garnment, fabric. Carried out more than 50 tests on wool, cotton, polyester, acrilic, viscose 21 STARTES Developement of an advanced dyeing system of weaving yarn in bobbins whith online monitoring system and its integration into the production chain POR-FESR 2007-2013 POLI DI INNOVAZIONE Partners involved Lanificio F.lli Cerruti OBEM FARBOTEX 22 11
STARTES Developement of an Advanced Dyeing System on Packages of Yarn for Weaving with online monitoring system and its integration into the production chain POR-FESR 2007-2013 POLI DI INNOVAZIONE Started in 2011. Work in progress. Test on dyestuff and chemicals Optimization of dyeing parameters Optimization of liquor flow and material holders 23 OBEM Collaboration Experience with Universities and Research Institutes Politecnico di Torino - Ecotint - Intexusa ENEA - Ecotint - Intexusa University of Maribor - Adopbio Aquafit Stazione Seta - Adopbio 24 12
A.green.Thank You for Your Kind Attention! AQUAFIT End Congress 25 Spare Slides AQUAFIT End Congress 26 13
Previous OBEM AOP Experience ADOPBIO SYSTEM REACTORS Dyeing waste drains too dense: the UV light is completely absorbed in few mm of thickness of waste water. No UV rays can penetrate in external reactor chambers Low reactor efficiency Real flow capacity approx 15-20 l/h End Congress 27 Previous OBEM AOP Experience ADOPBIO Project (Sixth Framework Programme) TRIPLE CELLS AOP reactors combined with BIOFLOTATION Single AOP Cell Features 800 W conventional Medium Pressure lamp Horizontal mounting Triple internal flow Forced air lamp cooling Total installed UV power: 2400 W End Congress 28 14
Typeof UV Lampsof New OBEM AOP Lamp type: GPHA1554T6L (Amalgam) Lamppower: 240 W Lampquantity: 6 Total power: 1440 W Ballast: electronic Powercontrol: 70 to100 % End Congress 29 Comparison of UV Lamps Between 2 AOPs Low pressure Amalgam (New AOP) Output wavelenght: 254 nm UV emission: approx 400-500 % than conventional UV lamp Operating life extended to over 12000 hours Operating temperature lower than 100 C (No cooling required) End Congress 30 15
AOP Diagram End Congress 31 AOP Working Diagram 1 2 WORKING MODE 1 BATCH FROM TANK 1 TO TANK 2 THE WASTE LIQUOR IS PUMPED BY THE PUMP P2 INSIDE THE AOP REACTORS. WHEN THE REACTORS ARE COMPLETELY FILLED UP THE UV LAMPS ARE ACTIVATED FOR A PREDETERMINED TIME, THEN THE TREATED LIQUOR IS REPLACED END SENT IN THE TANK 2 End Congress 32 16
AOP Working Diagram 1 2 WORKING MODE 2 CONTINOUS FROM TANK 1 TO TANK 2 THE WASTE LIQUOR IS PUMPED BY THE PUMP P2 INSIDE THE AOP REACTORS. WHEN THE REACTORS ARE COMPLETELY FILLED UP THE UV LAMPS ARE ACTIVATED. THEN THE PUMP IS AUTOMATICALLY ACTIVATED BY THE SYSTEM CONTROL WHICH MAINTAIN A LIQUOR FLOW FROM 4 TO 60 LITERS PER HOURS. THE TREATED LIQUOR IS SENT TO THE TANK 2 End Congress 33 AOP Working Diagram 1 1 WORKING MODE 3 CONTINOUS RECICLING INSIDE AOP THE WASTE LIQUOR IS PUMPED BY THE PUMP P2 INSIDE THE AOP REACTORS. WHEN THE REACTORS ARE COMPLETELY FILLED UP THE UV LAMPS ARE ACTIVATED. THE VALVE V6 CLOSE, THE VALVE V12 OPENS AND THE VALVE V7 OPENS THE WAY FROM V12 TO THE PUMP P2 THE PUMP P2 IS ACTIVATED AND THE LIQUOR IS CONTINOUSLY RECICLED INSIDE AOP FOR THE PRESET TIME AT THE END OR THE TREATMENT TIME THE TREATED LIQUOR IS REPLACED AND SENT IN THE TANK 2 End Congress 34 17
AOP Working Diagram 1 WORKING MODE 4 CONTINOUS RECICLING FROM TANK 1 TO AOP THE WASTE LIQUOR IS PUMPED BY THE PUMP P2 INSIDE THE AOP REACTORS. WHEN THE REACTORS ARE COMPLETELY FILLED UP THE UV LAMPS ARE ACTIVATED. THE VALVE V12 OPENS AND THE VALVE V7 OPENS THE WAY FROM V12 TO THE TANK 1 THE PUMP P2 IS ACTIVATED AND THE LIQUOR IS CONTINOUSLY RECICLED FROM THE TANK 1 TO THE AOP FOR THE PRESET TIME AT THE END OR THE TREATMENT TIME THE TREATED LIQUOR IS SENT TO THE TANK 2 End Congress 35 18