OBEM SpA – Biella - Italy produces Fully Robotized Dyeing ... Conference Presentations... · OBEM...

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May 9, 2012 AQUAFIT End Congress 1


OBEM SpA – Biella - Italyproduces

Fully Robotized Dyeing Plantsfor Fiber – Yarn - Fabric

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OBEM Previous AOP Experience

DYEING MACHINE

BIOFLOTATOR

WATER RECOVERY TANK

pH, TEMPERATURE, OXIGEN PEROXIDE

CONTROL

pH, TEMPERATURE,

CONTROL

DYEING

LIQUOR

WASHING

WATER

DECOLORED

WATER

DEPURATED

WATER DRAIN

REUSE OF DEPURATED

WATER

AOP REACTOR

ADVANCED OXIDATION

PROCESS AND

BIOTREATMENTS FOR WATER

RECYCLING IN TEXTILE

INDUSTRY


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


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AquaFit - New OBEM Approach

for Better Results & Cost Reduction

� Power reduction

� Increasing Efficiency

� Liquor Flow Optimisation

� New Combination of Processes from Advanced Partners

Reduction of

Total Process Cost


AquaFit New Approach


Fresh water

Softening

Coolingwater

Te

xti

le f

inis

hin

g

pro

ce

ss

es

Concentrated

WW from

pre-treatment,

dyeing, printing,

finishing

Non-

concentrated

WW from

washing, rinsing Membrane NF/RO

Evapoconcentration/ controled crystallization

*AOP

Water for reuse Concen-trate

Heat recuperation

heat

*AOP = H2O2 / UV; H2O2 /O3; H2O2 / US; …

Incinerationor use in other

domains

possible path

Prefiltration

Processwater


Processes schema

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AquaFit New Approach


Filtration technology


End Users

Concentration technology

AOP reactor

Partners Involvement

New AOP Block Diagram

Storage tank 1000 liters

SandFilter

PreTreatment

TankAOP

TreatedWater

RecoveryTank

H2O2 H2SO4 NaOH

Reuse of depuratedwater or to following

process

pH

ORP


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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


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


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New OBEM AOP 3D View


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Usually Textile wastewaters have different properties

- Strongly Acidic - Strongly Alkaline

Proper Pretreatment

Process Combination(nanofiltration, ultrafiltration, bioflotation,

evapoconcentration, ecc.)


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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


ECOTINT

May 9, 2012 AQUAFIT End Congress

Processes of textile dyeing with supercritical CO2

Partners involved:- OBEM spa- Filatura di Chiavazza- Filatura di Grignasco- Filtex - Como- Tintoria Vago- ENEA- Politecnico di Torino

MIUR

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ECOTINT


Processes of textile dyeing with Supercritical CO2

Started in 1998 – Ended in 2001More than 50 tests on polyester, silk, wool and cotton yarnRated disperse and acid dyes

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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)

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ADOPBIO


Advanced Oxidation Processes and Biotreatments for Water Recycling in the Textile Industry

Started in 2004 – Ended in 2007Manufactured a dyeing machine intefaced with the AOP reactor and the Bioflotation reactorTested different combination of AOP + Bioflotation treatmentsTested different wastewater of End Usersstandard production

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INTEXUSA


Optimisation of dyeing processes with UltraSonic Technology and its integration with automatic on-line control

Partners Involved:ENEAPolitecnico di TorinoFLAINOXOBEMFinissaggio di TriveroITTTintoria Ferraris

POR-FESR 2007-2013

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INTEXUSA


Optimisation of dyeing processes with UltraSonic Technology and its integration with automatic on-line control

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

POR-FESR 2007-2013

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STARTES


Developement of an advanced dyeing system of weaving yarn in bobbins whith online monitoring system and its integration into the production chain

Partners involved

Lanificio F.lli CerrutiOBEMFARBOTEX

POR-FESR 2007-2013POLI DI INNOVAZIONE

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STARTES


Developement of an Advanced DyeingSystem on Packages of Yarn for Weaving with online monitoringsystem and its integration into the production chain

Started in 2011 …. Work in progress.

Test on dyestuff and chemicalsOptimization of dyeing parametersOptimization of liquor flow and material holders

POR-FESR 2007-2013POLI DI INNOVAZIONE

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Universities and Research Institutes

Politecnico di Torino- Ecotint - Intexusa

ENEA- Ecotint - Intexusa

University of Maribor- Adopbio – Aquafit

Stazione Seta- Adopbio

OBEM Collaboration Experience with

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A ….green ….Thank You

for Your Kind Attention!


Spare Slides

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Previous OBEM AOP Experience

� ADOPBIO SYSTEM REACTORS

Dyeing waste drains too dense:the UV light is completely absorbedin few mm of thickness of waste water.

No UV rays can penetrate in externalreactor chambers

Low reactor efficiency

Real flow capacity approx 15-20 l/h

May 9, 2012 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


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Type of UV Lamps of New OBEM AOP

� Lamp type: GPHA1554T6L (Amalgam)

� Lamp power : 240 W

� Lamp quantity: 6

� Total power: 1440 W

� Ballast: electronic

� Power control: 70 to 100 %


Comparison of UV Lamps Between 2 AOPs

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)

Low pressure Amalgam (New AOP)


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AOP Diagram


AOP Working Diagram

WORKING MODE 1BATCH 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

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AOP Working Diagram

WORKING MODE 2CONTINOUS 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

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AOP Working Diagram

WORKING MODE 3CONTINOUS RECICLING INSIDE AOP

THE WASTE LIQUOR IS PUMPED BY THE PUMP P2 INSIDE THE AOP REACTORS. WHEN THEREACTORS ARE COMPLETELY FILLED UP THE UV LAMPS ARE ACTIVATED. THE VALVE V6CLOSE, THE VALVE V12 OPENS AND THE VALVE V7 OPENS THE WAY FROM V12 TO THEPUMP P2THE PUMP P2 IS ACTIVATED AND THE LIQUOR IS CONTINOUSLY RECICLED INSIDE AOP FORTHE PRESET TIMEAT THE END OR THE TREATMENT TIME THE TREATED LIQUOR IS REPLACED AND SENT INTHE TANK 2

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AOP Working Diagram

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 1THE PUMP P2 IS ACTIVATED AND THE LIQUOR IS CONTINOUSLY RECICLED FROM THE TANK 1 TO THE AOP FOR THE PRESET TIMEAT THE END OR THE TREATMENT TIME THE TREATED LIQUOR IS SENT TO THE TANK 2

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OBEM SpA – Biella - Italy produces Fully Robotized Dyeing ... Conference Presentations... · OBEM...

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