WASTE MANAGEMENT IN DYEING

UNITS

NAME -RITIKA GUPTA

CLASS - 9 SECTION - A
ROLL NUMBER – 33
SCHOOL - CARMEL CONVENT HIGH
SCHOOL
YEAR - 2018-2019

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I would like to thanks my dear parents, friends and
all those who co-operated with me to conduct the
said survey. Special thanks to our beloved teacher
Mrs. Soma Choudhury. Under her supervision,
careful supports and valuable guidance in every step
provided to me has truly helped me in my
progression with the said survey. Without their help
and support I would not have been able to complete
my survey.

SIGNATURE:-

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This is to certify that Miss Ritika Gupta of class IX,
section- A of Carmel Convent High School roll
number – 33 of year 2018- 2019 has successfully
carried out the present project work entitled in “waste
management in dyeing units” under my guidance in
fulfilment of the of the school leaving certificate
form from sister Reshma A.C.

SIGNATURE

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The author of the project “Waste management in
dyeing units” ,Miss Ritika Gupta , roll no – 33 , a
student of standard IX of Carmel Convent High
School, M.A.M.C, Durgapur has completed the
project work through care and effort along with
honest observation and meaningful analysis .

Signature of the candidate

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 TABLE OF CONTENTS
TOPIC PAGE NO

1. TITLE PAGE
a. ACKNOWLEDGEMENT
b. APPROVAL OF THE GUIDE
c. DECLERATION OF THE CANDIDATE
d. LIST OF TABLES
e. LIST OF PICTURES
2. INTRODUCTION
a. STATEMENT OF THE PROBLEM
b. SIGNIFICANCE OF THE PROBLEM
c. PURPOSE OF THE STUDY
d. ASSUMPTIONS AND DELIMITATIONS
3. REVIEW OF RELATED LITERATUE
4. DESIGN OF THE SURVEY
5. PRESENTATION AND ANALYSIS OF
DATA
6. SUMMARY AND CONCLUSION
7. BIBLIOGRAPHY AND INTERNET
8. APPENDIX AND INDEX

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 CHART 1 -% of wet and air dye CHART- rate
of dyes used in
used in dyeing units dyeing
units by different countries

CHART 3-rate of dyeing of different CHART 4-

graph showing the

Dyes percentage
of colours used in dyeing

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 FIG 1- AMARKOT INDUSTRY FIG 2- MENOKA INDUSTRY

FIG 3- SAVITA INDUSTRY FIG 4- BATIQUE INDUSTRY

FIG 5- AMARKOT INDUSTRY FIG 6- THAKURBARI

INDUSTRY

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Dyeing is the process of adding colour to textile products
like fibres, yarns, and fabrics. Dyeing is normally done in a
special solution containing dyes and particular chemical material.
After dyeing, dye molecules have uncut chemical bond with fibre
molecules. The temperature and time controlling are two key factors
in dyeing. There are mainly two classes of dye, natural and man-
made.
The primary source of dye, historically, has generally been nature,
with the dyes being extracted from animals or plants. Since the mid-
19th century, however, humans have produced artificial dyes to
achieve a broader range of colours and to render the dyes more stable
to resist washing and general use. Different classes of dyes are used
for different types of fibre and at different stages of the textile
production process, from loose fibres through yarn and cloth to
complete garments.
Acrylic fibres are dyed with basic dyes, while nylon and protein
fibres such as wool and silk are dyed with acid dyes,
and polyester yarn is dyed with disperse dyes. Cotton is dyed with a
range of dye types, including vat dyes, and modern synthetic reactive
and direct dyes.

a. STATEMENT OF THE PROBLEM- dyeing wastewater

includes a large variety of dyes and chemical additions that make the
environmental challenge for dyeing industry not only as liquid waste

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but also in its chemical composition. Main pollution in dyeing
wastewater comes from dyeing and finishing processes. These
processes require the input of a wide range of chemicals and
dyestuffs, which generally are organic compounds of complex
structure.
Because all of them are not contained in the final product, became
waste and caused disposal problems. Water is used as the principal
medium to apply dyes and various chemicals for finishes. Major
pollutants in dyeing wastewaters are high suspended solids, chemical
oxygen demand, heat, colour, acidity, and other soluble substances.
Substances which need to be removed from dyeing wastewater are
mainly COD, BOD, nitrogen, heavy metals and dyestuffs. An
integrated cotton textile mill produces its own yarn from the raw
cotton. This process includes opening & cleaning, picking, carding,
drawing, spinning, winding, and warping. All these are Dry operation
and as such as do not contribute to the liquid waste from the mill.
Different type of waste generated are Appearance, Ph, Colour ,
Heavy Metal, Suspended Solid , Total Dissolved Solid, Chemical
Oxygen Demand (COD), Bio Chemical Oxygen Demand (BOD), Oil
& Grease, Surfactant.
The entire liquid waste from the textile mills comes from the
following operation of Sizing (caboxymethyl cellulose (CMC),
polyvinyl alcohol (PVA) Desizing (mineral acid) Scouring(Caustic
soda, soda ash, detergent ) Bleaching(sodium hypochlorite (NaOCl)
or hydrogen peroxide (H202)) Mercerizing (caustic soda solution)
Dyeing (vat dyes, developing dyes , naphthol dyes, sulphur dyes,
basic dye, direct dyes etc.) Finishing (starches, dextrines , natural
and synthetic waxes, synthetic resins)

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b. SIGNIFICANCE OF THE PROBLEM – the main significance
of the problem is that it causes a large scale land, air and water
pollution which is a major threat to the common human beings who
live near the dyeing industries. And moreover, waste from a dyeing
and finishing process are contributed by the spent liquors and by
subsequent washing of wool after bleaching, dyeing, and finishing.

c. PURPOSE OF THE STUDY- The purpose of the study is to

bring about some changes and to bring it in view , the large scale
pollution generated by the dyes, chemicals and the fabric clothes used
in the dyeing units. The use of organic raw material can help in
fighting the emission of pollutants by the textile units. Organic cotton
is especially beneficial as the production of cotton asks for the
maximum amount of pesticides and fertilizers. Besides, the waste
generated from textile manufacturing plants should be processed in a
manner that it is free from toxic chemicals before it is disposed.
Earlier, people lacked in fashion sense, making new varities of
different coloured clothes and thus there were less dyeing units and as
a result waste production was also less in quantity . But in the present
scenario, due to industrialization , number of dyeing units increased
and as a result, more waste production.

d. ASSUMPTIONS AND DELIMITATIONS- The crude waste if

discharged into streams causes rapid depletion of the dissolved
oxygen of the streams. The alkalinity and the toxic substance like
sulphides and chromium affect the aquatic life and also interfere with
the biological treatments. The colour often renders the water unfit for
use for some industrial purposes. The presence of sulphides makes
the waste corrosive particularly to concrete structures.

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It involves removal of large solids such as rags, sticks, grit and grease
that may result in damage to equipment or operational problems
(Physical treatment). It involves removal of floating and settable
materials, i.e. suspended solids and organic matter (Physical and
Chemical). It involves removal of biodegradable organic matter and
suspended solids (Biological and Chemically). It involves removal of
residual suspended solids / dissolved solids (Physical, Chemical and
Biological). It has become utterly necessary to reduce the pollutants
emitted by the textile industry. Contamination of the air, water, and
land by textile industries and its raw material manufacturing units has
become a serious threat to the environment. It has endangered the life
of human beings and various other species on Earth. Global warming
is a direct result of the pollutants released by such industries. It also
causes harmful diseases and health issues in people getting exposed
to the pollutants in the long run.

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ARTICLE- Waste management in Nallur dyeing units
PUBLISHION- First published in “The Hindu” by F.D Snell on
11 April 2013
The Tamil Nadu Pollution Control Board has issued consent to
establish two facilities for disposal of sludge generated from textile
dyeing effluents
TNPCB- Dyeing waste disposal units
The Federation of Common Effluent Treatment Plants (CETPs),
Tiruppur and Federation of CETPS and Effluent Treatment Plants,
Karur have identified sites at Nallur and Mathagiri to establish a
secure land fill facility for disposal of sludge generated from
treatment of textile dyeing effluents.
Various cement manufacturing units are using hazardous waste either
on trial basis or permanently as raw material or fuel, said a state
Environment Ministry policy note, adding that action was being taken
for establishing a common hazardous waste treatment storage and
disposal facility at Perundurai in Erode district.
“To adopt recycling and reuse principles, cement industries are
encouraged to utilise hazardous sludge from various industries like
textile, engineering, chemical and petroleum,” it said. TNPCB has
been making efforts for disposal of hazardous waste in an
environmentally safe manner and has identified 2771 units generating
hazardous waste.
This article covers all the important points on waste management in
the nallur region.
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RANDOM SAMPLING-
The data was collected
randomly by visiting
the local dyeing units.
Due to shortage of
time, we could survey
only ten dyeing units.

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SURVEY NAME OF LOCATION TYPES OF % OF
UNIT WASTE WASTE

Survey 1 Batique Bolpur Non- 56%

printers Biodegradable
Survey 2 Leather Bolpur Non- 87%
workshop Biodegradable
Survey 3 Savita Bolpur Non- 78%
handicraft Biodegradable
Survey 4 Triratna Bolpur Non- 90%
stores Biodegradable
Survey 5 Shoonya Bolpur Non- 67%
unit Biodegradable
Survey 6 Thakurbari Bolpur Non- 45%
unit Biodegradable
Survey 7 Amita unit Bolpur Non- 64%
Biodegradable
Survey 8 Madhu Srirampur Non- 82%
dyeing Biodegradable
Survey 9 Narayana Srirampur Non- 70%
printers Biodegradable
Survey 10 Puja Srirampur Non- 54%
enterprise Biodegradable

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The pollutants from the dyeing units are generally non-
biodegradable. They mainly include the chemical dyes containing
sulphur, chlorine and other corrosive chemicals which is very
dangerous to all forms of living beings. They also include cloth
pieces and different fabrics- nylon, cotton, silk, rayon etc which
causes land ,air and water pollution if preventive measures and
safe dumping and disposal is not taken by the dyeing unit in
charge. The dyes used in the dyeing units mainly consists of the
following chemicals:-

 Arsenic- causes skin manifestations, visceral cancer

 Cadmium- causes kidney damage, renal disorder, human
carcinogen
 Chromium- causes headache, Diarrhoea, nausea, vomiting,
carcinogenic
 Copper- causes liver damage, Wilson disease, insomnia
 Nickel- causes dermatitis, nausea, chronic asthma, coughing,
human carcinogen
 Zinc- causes depression, Lethargy, neurological signs, and
increased thirst
 Lead- Damages the fetal brain, diseases of the kidneys,
circulatory system and nervous system
 Mercury- causes rheumatoid arthritis

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The dyeing process includes various stages of dyeing the fabric.
that process , at each stage some wastes are being generated which
contains the major pollutants, corrosive metals, various chemicals
which has high toxicity , corrosivity , persistence , alkalinity and
BOD (Biological Oxygen Demand).The various stages of dyeing
are:-
Designing- Starch, glucose, CMC, PVA, resins, fats and waxes. It
has high BOD (35%-50%).
Scouring- NaOH, waxes, greases, sodium carbonate and
fragments of clothes. It has strong alkalinity and high BOD
( 30%).
Bleaching- Na(OCl), chlorine, sodium hydroxide, water, acid etc.
It has alkalinity (5%).
Mercerisation- NAOH. It is strongly alkaline and has low
BOD(less than 1%).
Dyeing- various dyes, salts, alkali, acid, soaps and detergents. It
has strongly coloured fair BOD(6%)
Printing- colours, starch, china clay, gum, oil, mordents, acids,
alkali, and various metallic salts. It is highly coloured oily
appearance with BOD( 6%-10%).
Finishing- traces of starch, tallow and different finishing agents.
It has low BOD( 2%-4%).
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DYES:-
Dyes are colourless soluble in a carrier, mostly water or an organic
solvent. Classification of dyes according to method of application is
shown below, together with types of textile fibre that can be
commercially dyed by each method:

 Basic--Cationic dyes (wool blends, silks, acrylic)

 Acid--anionic dyes (wool, silk and nylon)
 Direct--anionic dyes (cotton, linen, viscose)
 Chrome--anionic dyes that must be applied with sodium
dichromate (wool)
 Azoic--Insoluble pigments formed within (cotton, linen) the
fibre initially by soluble coupling compound and then a
diazotized base
 Vat and sulphur--Insoluble in water and converted into
soluble colourless compound by use of sodium
hydrosulphite. Ex: cotton, viscose, linen, silk.
 Disperse--non ionic dyes such as polyester, triacetate,
secondary acetate
 Metal complex--anionic dye containing chromium ex: wool,
nylon

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Role of machines in dyeing
Modern dyeing machines are made from stainless steels. Steels
containing up to 4 percent molybdenum are favoured to withstand the
acid conditions that are common. A dyeing machine consists
essentially of a vessel to contain the dye liquor, provided with
equipment for heating, cooling, and circulating the liquor into and
around the goods to be dyed or moving the goods through the dye
liquor. The kind of machine employed depends on the nature of the
goods to be dyed. Labour and energy costs are high in relation to total
dyeing costs; the dyer’s aim is to shorten dyeing times to save steam
and electrical power and to avoid spoilage of goods.
A widely used machine is the conical-pan loose-stock machine; fibres
are held in an inner truncated-conical vessel while the hot dye liquor
is mechanically pumped through. The fibre mass tends to become
compressed in the upper narrow half of the cone, assisting efficient
circulation. Levelling problems are less important because uniformity
may be achieved by blending the dyed fibres prior to spinning.
The Hussong machine is the traditional apparatus; it has a long,
square-ended tank as dye bath into which a framework of poles
carrying hanks can be lowered. The dye liquor is circulated by an
impeller and moves through a perforated false bottom that also
houses the open steam pipe for heating. In modern machines,
circulation is improved especially at the point of contact between
hank and pole. This leads to better levelling and elimination of
irregularities caused by uneven cooling.
In package-dyeing machines dye liquor may be pumped in either of
two directions: (1) through the perforated central spindle and outward
through the package, or (2) by the reverse path into the outer layers of
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the package and out of the spindle. In either case levelness is
important. In the case of soluble dyes the dye liquor must be free of
suspended matter. In the case of disperse dyes, in which particles of
dye are dispersed in, rather than dissolved in, the solution, no
gross aggregates can be allowed; otherwise the packages would retain
undesirable solids on the outer and inner surfaces. Some package-
dyeing machines are capable of working under pressure at
temperatures up to 130 °C.
The winch is the oldest piece-dyeing machine and takes its name
from the slatted roller that moves an endless rope of cloth or endless
belt of cloth at full width through the dye liquor. Pressurized-winch
machines have been developed in the United States. In an entirely
new concept, the Gaston County jet machine circulates fabric in rope
form through a pipe by means of a high-pressure jet of dye liquor.
The jet machine is increasingly important in high-temperature dyeing
of synthetic fibres, especially polyester fabrics.
Another machine, the jig, has a V-shaped trough holding the dye
liquor and guide rollers to carry the cloth at full width between two
external, powered rollers. The cloth is wound onto each roller
alternately; that is, the cloth is first moved forward, then backward,
through the dye liquor until dyeing is complete. Modern machines,
automatically controlled and programmed, can be built to work under
pressure.
Solutions or suspensions of colorants or their precursors may be
padded onto piece goods by passing the cloth through a trough
containing the liquor and then between rollers under pressure.

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Serial Name of Physical Chemical Biological
no. branch pollutants pollutants pollutants
Cloth piece, Vat-dyes, Algae,toxic
fabrics, silk, sulphur, spirit acids,bacteria,
cotton, thread colour protozoa
1. Batique
printers
2. Leather
workshop
3. Savita
handicraft
4. Triratna
stores
5. Shoonya
unit
6. Thakurbari
unit
7. Amita unit
8. Madhu
dyeing
9. Narayana
printers
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10. Puja
enterprise
CONCLUSION:-
Despite the various new technologies that are emerging for solid
waste disposal, land filling still remains the most common solution in
the north-eastern Illinois region. The establishment and closure of
landfills could pose a potential hazard to ground water, due to leach
ate seepage, and air quality due to gases released. Unless proper
maintenance and management is sustained for a fairly long time (30
years), public health may be compromised as a result. Such
management is costly and potentially dangerous if faulty. Thus, a
safer and more sustainable approach may be minimizing the number
of landfills constructed and insuring their longevity so as not to
continue taking viable land for waste disposal. It is therefore critical
to divert waste from landfills through reduction and recycling.

The Kolkata metro area produces the most waste per capita in the
state in spite of advanced and available resource reduction and
recycling options. If we continue on this trend, we will face grave
consequences by 2040 or before. Clear and decisive actions must be
taken today to avert costly and environmentally compromising means
for disposing off our waste in the near future

There seems to be significant awareness of the importance of

recycling in the region, however not all communities have curb side
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collection at single and multi-family homes, specifically in the
unincorporated areas. Generally, businesses in the region do not have
a mandate or incentive to recycle other than consumer appeal which
does not necessarily prompt them to partake in these activities.
Open/illegal dumping and burning of unacceptable wastes has been
listed by several solid waste professionals in the area whom we
surveyed. Although these experts are in consensus that land filling
waste is the most economical disposal method, they also agree that
more recycling and resource reduction should be attained to reduce
the continuous need for landfills. That said, not all counties have
recycling ordinances, the main reasons being political opposition and
lack of funding for personnel to propose, monitor and enforce
regulations. The various counties and municipalities will have to
collaborate to reach a comprehensive solution that addresses solid
waste disposal regionally. CMAP can play an important role towards
that end in proposing policies and techniques that will handle this
issue in an innovative and sustainable manner.

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 Frank certificate biology (cl. 9)- Dr. Rajendra Sharma
Anita Prasad biology (cl.9)- Dr. Anita Prasad
Concise biology (cl.9)- R.P Goyal, S.P. Tripathi
www.google.co.in
www. Wikipedia.com
www. Icsebio .com
www. Waste generation.com
www. Textile units.com
www. Dyes.org.in
www. Byju’s / waste management.com
www. Treatment of wastes.com
www. Paperback. Dyeingunits.com
S Chand’s biology (cl.9)- Dr. P.S. Verma
Pradeep’s biology (cl.9)- H.N. Shrivastava
Core Science biology (cl.9)- S.K.Aggarwal
Foundation Science biology (cl.9)- L.C. Saha , L.K.Malhotra
www. Foundation wastes management.com

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APPENDIX:-
A

Acid – compounds that form hydrogen ion when dissolved in water.

Acrylic - water soluble kind of paint.

Alkali – water soluble bases.

Carding – mechanical process of cleaning fibres.

Corrosivity - corrosion is rusting, when iron combines with oxygen and water.

Disposal – removing or destroying unwanted substances.

Dyes – coloured substance applied in fibre.

ph - a measure of acidity or alkalinity of a fluid.

Sludge – semi- solid leftover municipal wastes.

Tallow – solid, fatty made from animal fat

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Warping – to bend or twist out shape from something that is usually flat or
straight

INDEX:-

Sludge-(22;10)
Dyes-(22;17;16;15)
ph-(22;10;8)
alkali-(22;17;16;15;10;11)
acid-(22;15;’10;17)
tallow-(22;16)
carding-(22;16)
corosivity-(22;15;11;9)
toxicity-(22;10;11)
persistence-(10;11)
disposal-(22;19;12;10)
hazardous-(12;19)

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pollutant- (8;9;11)

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