Cleaner Technology Transfer to the Polish Textile ... - Miljøstyrelsen

The new recipes were tested in a laboratory scale at the Textile Research Institute,
and the results were tested with respect to colour, shade and fastness. The
results were satisfactory.
Besides the dyeings themselves, tests were made for neutralisation with other
agents than the most commonly used acetic acid.
Selected recipes were then tested in full-scale in the dye-house of Teofilów,
and the results were to a high extent in accordance with the laboratory results.
Phase 2 As preparation to the pilot-scale testing of Phase 4, the existing dyeing equipment
was examined and an extra outlet was mounted in order to tap rinsing
water for treatment in a pilot plant with membrane filter.
The dye-house is divided into an old and a new section. At project start it was
expected that the old machines in the old dye-house would be replaced by
modern machines due to an expected increase in production. This has, however,
not happened yet, and a disproportionate level of water is used in the old
ineffective machines. The old machines ought to be replaced by new ones,
however, it is being evaluated if it would be more profitable to build a larger
membrane filter plant for the rinsing water in order to reduce the water consumption
until the financial situation allows a replacement of machines.
The machines within the new sector are top modern, however, they are not all
being used optimally. We are trying to solve this problem.
Phase 3a-3c After going through the recipes, a number of typical rinsing water types were
selected. A laboratory membrane filter was used in tests of these water types
of filration on different membranes, with both nano-filters and reverse osmosis-filters.
The choice of membrane was based on Danish experiences from a
similar project.
The results were satisfactory. No surprises were discovered in respect of
destroyed membranes due to the chemicals used and flux rates as a function of
pressure, temperature and degree of concentration were satisfactory,
A pilot-scale membrane filter using standard membrane filter cartridges was
installed at the company. A series of tests with rinsing water from different
cotton dyeings, with the use of different types of membranes at different pressures
and temperatures was made. The results are satisfactory and will be used
for dimensioning a full-scale membrane filter for the dye-house.
At the beginning of the project it was expected that dyeing of polyester and
mix of cotton-polyester would be strongly reduced during the coming years so
that these products would amount to less than 20% of the total production.
This has turned out not to be the case at least till now. Todays production is
divided in 50% cotton, 30% cotton-polyester and 20% polyester. It has, therefore,
been urgent to investigate the possibility of re-using rinsing water from
the polyester dyeings, even though this is not included in the original project
definition, which covered only cotton dyeings. After finishing the planned
pilot tests with rinsing water from cotton, the employees from Teofilów have
continued making pilot tests with guidance from the Textile Research Institute.
The preliminary results are promising, and we soon expect to be able to
decide if the full-scale membrane filter should also be dimensioned to handle
this water type.
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