Textile Printing



Textile printing is used to signify the production, by various means of colored patterns on designs upon all sorts of textile fiber.
Textile printing is the most important and versatile of the techniques used to add design, color, and specialty to textile fabrics. In other words, dyes and pigments are applied locally or discontinuously to produce the various designs. In fact, printing is described as ‘localized dyeing.’ The forces which operate between the dye and the fiber (on mechanical retention, hydrogen bonding, chemical reaction, electrostatic attraction etc.) are the same in dyeing and printing.
The term 'colorant' is used here because it covers both dyes and Pigments.

STEPS OF PRINTING

01.Preparation of the fabric
02.Preparation of the print paste.
03.Printing the fabric.
04.Drying the printed fabric.
05.Fixation of the printed dye or pigment.
06.Afterwashing.


STYLES OF PRINTING
Percentage of rejection is lower than the discharge method01.Direct style
02.Discharge: white and colored
03.Resist style
04.Raised style
05.Flock style
06.crimp/ crepon style
07.Burn out style

METHODS OF PRINTING
A.Block printing
B.Stencil printing
C.Roller printing
D.Screen Printing
01.Hand screen
02.Semi automatic flat screen
03.Rotary screen
E.Transfer printing
01.Flat bed
02.Continuous transfer
03.Vaccum transfer
F.Digital Inkjet Printing

Textile Finishing

 
STAIN RESISTANCEThe development of stain repellent general wearing apparel has taken place in response to the consumers’  desire for easy-care garments.

Stain Repellent (or Resistant) Finish: 
Prevents water and/or oils from penetrating the fabric causing potential aqueous and oily stains to bead up and roll off.

Stain/Soil Release Finish:
 Enhances the ability of a fabric to release stains during laundering. For a release finish, liquids may not bead up, but usually soak into the fabric.

Combination Repellent/Release Finish: 
Provides limited stain repellency plus soil release with the objective of overall stain management.
Stain repellants are used on a variety of cotton fabrics from apparel to home furnishings. The main advantage is that the fabrics resist soiling during use. When a spill occurs, it can usually be spot cleaned easily, since the stain is confined to the surface rather than penetrating deep into the fabric.

SOIL RELEASE:
Soil release is the term used to describe the cleanability of fabrics by the laundering process. Even though stain resistance finishes made fabrics more resistant to soiling; however, in practice it has been found that soils have a way of penetrating even the best of repellent finishes, the textile item must be cleaned anyway.

Type of Soils:

Soils can be defined as unwanted substances at the wrong place. Most common soils fall into one of four categories:
01.Water borne stains : Water borne stains are not much of a problem; the stains are soluble in the wash water. Food stains and dried blood, although not water soluble, are responsive to proteolytic enzymes found in most commercial detergents.
 02.Oil borne stains, Oily soils, e.g. salad oil, motor oil, food grease are particularly difficult to remove from synthetic fabrics such as polyester. The sorption forces between the oils and the synthetic fiber surfaces are so strong that it is virtually impossible to completely remove them by conventional laundering.
04.Dry particulate soils: Dry particulate soils such as flour, clay and carbon black are mechanically entrapped in the yarn interstices and reside on the surface of the fiber.
05.Composite soils involving oil and grease adsorbed on particulate matter.



How Fabrics are soiled:

Soil can be airborne particles that settle by01. Gravitational forces or are
02. Electrostatically attracted to the fabric.
03. Airborne: Soot is a troublesome airborne particulate that is difficult to remove from fabrics. Drapes, carpets and upholstery are items prone to being soiled by airborne soils.
04. Contact with a dirty surface and they can be ground in by pressure or rubbing.
05. By wicking; liquid soils in contact with fabrics will wick into the structure by capillary action.
06. Redeposition: Soils removed in the laundering process may redeposit back onto the fabric, emulsified oily soils may break out of solution unless the emulsion is well stabilized.

Soil Removal:The adhesion between particulate soil and the fiber depends on the location within the fabric structure, the forces of attraction between the soil and fiber, and the area of contact. The greater the area of contact, the more difficult it is to break the adhesive bond. Fine particles have a greater area of contact. The tighter the fabric, the smaller are the interfiber voids which make also make the outward transport more difficult.

Roll-up Mechanism:
Oily-soil removal will depend on the three phase boundary interaction that occurs in the detergent solution. The roll-up mechanism first postulated by Adams argues that for removal to take place, the surface forces generated at the three phase boundary of fiber/detergent solution/oily soil results in progressive retraction of the oil along the fiber surface until it assumes a contact angle of 180 degrees. The various phases of the roll-up mechanism is shown in figure

Soil Release Chemicals:

01. Acrylic Soil Release Finishes:
The chemical composition of acrylic SR finishes may be generalized as follows:
02. Polymethacrylic Acid PMAA:Poly(methacrylic) acid is completely water soluble and functions as a soil release finish. However the proper amount of cross-linking is necessary before the finish to functions properly.

03. Methacrylic Acid - Ethyl Acrylate Co-PolymersCo-polymers of methacrylic or acrylic acid and ethyl acrylate have been found to be particularly useful as soil release agents. A particularly good combination for soil release is 70% methacrylic acid and 30% ethyl acrylate.

Practical Considerations and Fabric Properties:

01. About 6 to 10% acrylic soil release agent is needed to give good results. The polymeric films are stiff and brittle, giving the fabric a stiff and harsh hand. Being brittle and stiff, the finish tends to cause dusting, excessive needle and sewing thread breakage.

02. Most of the finish is lost after the first wash; however, the small amount remaining is effective for many launderings. The fabric is considerably softer after washing.

03. Excellent soil release results can be obtained when the optimum conditions are met. It is the most effective finish against dirty motor oil.

04. The finish is temperamental. It takes precise condition at the finishing plant to give reproducible results.

05. The finish is cost-effective for work clothing when dirty motor oil release is a significant quality.

Fluorochemical Soil Release:
A unique block co-polymer, developed by the 3M company (Scotchgard Brand Dual-Action Fabric Protector) combines oil repellency with soil release. The hybrid polymer backbone is comprised of segments based on polyoxyethylene united with segments containing long-chain perfluoroaliphatic groups. Figure shows the structure of the H portion (the hydrophilic portion), the F portion ( the perfluoroaliphatic portion) and the block co-polymer. The individual segments alone do not confer effective soil release; however, when combined into a single molecule, the new composition is effective both as a soil release agent and an oil repellent finish.

Figure Fluorochemical Soil Release Agent



Recipe
A suggested formulation for a woven fabric is shown below (percent on weight of bath):6% - 8% Fluorochemical repellent
5% Extender (optional)
0.2% Non-rewetting, wetting agent
5% Glyoxal (DMDHEU) resin
1.5% MgCl2 catalyst


Extender: An extender is less expensive aliphatic or wax water repellent that is used to boost performance and help reduce the amount of fluorochemical needed.

Non-rewetting, wetting agent: A non-rewetting, wetting agent will then evaporate or “flash off” during curing. If a regular wetting agent is used, it may remain on the fabric after curing and interfere with water repellency.

Hydrophilic Soil-Release Finishes for 100% Polyester:

Effective soil release finishes have been developed for 100% polyester fabrics which are best applied during the dye cycle and are often called Exhaustible SR finishes.

These finishes work best on loosely structured, textured polyester fabrics. Fabrics made from continuous filament or spun 100% polyester yarns are not responsive to these finishes.

Water quickly penetrates treated fabrics and is transported away from the source. This quality has been promoted as improved summer comfort, the ability to adsorb and wick away body perspiration. The finish is not effective at all on polyester/cotton blends. The finish imparts good soil anti-redeposition protection to treated fabrics and a modest measure of antistatic protection.

Water


Water:

Water is a common chemical substance that is essential for the survival of all known forms of life. In typical usage, water refers only to its liquid form or state, but the substance also has a solid state, ice, and a gaseous state, water vapor or steam. About 1.460 petatonnes (Pt) (1021kilograms) of water covers 71% of the Earth's surface, mostly in oceans and other large water bodies, with 1.6% of water below ground in aquifers and 0.001% in the air as vapor, clouds (formed of solid and liquid water particles suspended in air), and precipitation.[1] Saltwater oceans hold 97% of surface water, glaciers and polar ice caps 2.4%, and other land surface water such as rivers, lakes and ponds 0.6%. Some of the Earth's water is contained within water towers, biological bodies, manufactured products, and food stores. Other water is trapped in ice caps, glaciers, aquifers, or in lakes, sometimes providing fresh water for life on land.

Water moves continually through a cycle of evaporation or transpiration (evapotranspiration), precipitation, and runoff, usually reaching the sea. Winds carry water vapor over land at the same rate as runoff into the sea, about 36 Tt (1012kilograms) per year. Over land, evaporation and transpiration contribute another 71 Tt per year to the precipitation of 107 Tt per year over land. Clean, fresh drinking water is essential to human and other life. However, in many parts of the world—especially developing countries—there is a water crisis, and it is estimated that by 2025 more than half of the world population will be facing water-based vulnerability.[2] Water plays an important role in the world economy, as it functions as a solvent for a wide variety of chemical substances and facilitates industrial cooling and transportation. Approximately 70% of freshwater is consumed by agriculture.

A plentiful supply of water is essential for dyeing and bleaching plant.Before modern methods of water purification were available, the textile industries tended to congregate in areas where the natural water supply was plentiful and sufficiently pure. Water with a high degree of purity is rarely obtainable from natural source.
Water is also used in many industrial processes and machines, such as the steam turbine and heat exchanger, in addition to its use as a chemical solvent. Discharge of untreated water from industrial uses is pollution. Pollution includes discharged solutes (chemical pollution) and discharged coolant water (thermal pollution). Industry requires pure water for many applications and utilizes a variety of purification techniques both in water supply and discharge.

Types of water:

Liquid water in motion can appear in three states. Water takes many different forms on Earth: water vapor and clouds in the sky; seawater and rarely icebergs in the ocean; glaciers and rivers in the mountains; and aquifers in the ground.

Water can dissolve many different substances, giving it different tastes and odors. In fact, humans and other animals have developed senses to be able to evaluate the potability of water, avoiding water that is too salty or putrid. Humans also tend to prefer cold water rather than lukewarm, as cold water is likely to contain fewer microbes. The taste advertised in spring water or mineral water derives from the minerals dissolved in it, as pure H2O is tasteless. As such, purity in spring and mineral water refers to purity from toxins, pollutants, and microbes.

Different names are given to water's various forms:


A. according to state1. solid - ice
2. liquid - water
3. gaseous - water vapor 

B. according to meteorology:1. hydrometeor
2. precipitation

C. levitating particles
1. clouds
2. fog
3. BR (according to METAR)

D. ascending particles (drifted by wind)1. spindrift
2. stirred snow

* according to occurrence:

o groundwater
o meltwater
o meteoric water
o connate water
o fresh water
o surface water
o mineral water – contains much minerals
o brackish water
o dead water – strange phenomenon which can occur when a layer of fresh or brackish water rests on top of more dense salt water, without the two layers mixing. It is dangerous for ship traveling.
o seawater
o brine

* according to uses:

o tap water
o bottled water
o drinking water or potable water – useful for everyday drinking, without fouling, it contains balanced minerals that are not harmful to health (see below)
o purified water, laboratory-grade, analytical-grade or reagent-grade water – water which has been highly purified for specific uses in science or engineering. Often broadly classified a.

*Type I, Type II, or Type III, this category of water includes, but is not limited to the following:

§ distilled water
§ double distilled water
§ deionized water

*according to other features:

1.soft water – contains less minerals
2.hard water – from underground, contains more minerals
3.distilled water, double distilled water, deionized water - contains no minerals
4.Water of crystallization — water incorporated into crystalline structures
5.Hydrates — water bound into other chemical substances
6.heavy water – made from heavy atoms of hydrogen - deuterium. It is in nature in normal water in very low concentration. It was used in construction of first nuclear reactors.
7.tritiated water
8.according to microbiology
9.drinking water
10.wastewater
11.stormwater or surface water

*according to religion:
1.holy water
 
The water which is suitable for dyeing process: In dyeing process the most suitable water is rain water.Rain collected immediately after precitation, is the purest of all natural waters.It is suitable for boiling , washing and dyeing processes.Deep well water is also suitable for dyeing processing.This type of water is obtained 500m below the surface.It is free from organic matters.
 
The presence of calcium, magnesium salt i.e bi carbonates, sulphates, chloride in water is called causes of hardness of water.The water which contains these salt is called hard water. Hard water does not easily form lather with soap to form insoluable organic salts.
 
Quality of water used in dyeing process:
1. Appeaence: Clear, without residue.
2. Residual hardness:<0.05°dh.>

Standard components (gm/L) in water for dye house:
1. PH should be in the range of 7-8.
2. Water should be odorless and colourless.
3. Water hardness-Total hardness max 5°dH.
4. Solid content<50>

Chemical and physical properties: 

Water is the chemical substance with chemical formula H2O: one molecule of water has two hydrogen atoms covalently bonded to a single oxygen atom. [4] Water is a tasteless, odorless liquid at ambient temperature and pressure, and appears colorless in small quantities, although it has its own intrinsic very light blue hue. Ice also appears colorless, and water vapor is essentially invisible as a gas.[5] Water is primarily a liquid under standard conditions, which is not predicted from its relationship to other analogous hydrides of the oxygen family in the periodic table, which are gases such as hydrogen sulfide. Also the elements surrounding oxygen in the periodic table, nitrogen, fluorine, phosphorus, sulfur and chlorine, all combine with hydrogen to produce gases under standard conditions. The reason that water forms a liquid is that it is more electronegative than all of these elements (other than fluorine). Oxygen attracts electrons much more strongly than hydrogen, resulting in a net positive charge on the hydrogen atoms, and a net negative charge on the oxygen atom. The presence of a charge on each of these atoms gives each water molecule a net dipole moment. Electrical attraction between water molecules due to this dipole pulls individual molecules closer together, making it more difficult to separate the molecules and therefore raising the boiling point. This attraction is known as hydrogen bonding. The molecules of water are constantly moving in relation to each other, and the hydrogen bonds are continually breaking and reforming at the timescales faster than 200 femtoseconds.[6] However, this bond is strong enough to create many of the peculiar properties of water described in this article, such as the ones that make it integral to life. Water can be described as a polar liquid that dissociates disproportionately into the hydronium ion (H3O+(aq)) and an associated hydroxide ion (OH−(aq)). Water is in dynamic equilibrium between the liquid, gas and solid states at standard temperature and pressure (0 °C, 100.000 kPa) , and is the only pure substance found naturally on Earth to be so.

The major chemical and physical properties of water are:

1. Water is a tasteless, odorless liquid at ambient temperature and pressure. The color of water and ice is, intrinsically, a very light blue hue, although water appears colorless in small quantities. Ice also appears colorless, and water vapor is essentially invisible as a gas.

2. Water is transparent, and thus aquatic plants can live within the water because sunlight can reach them. Only strong UV light is slightly absorbed.

3. Since oxygen has a higher electronegativity than hydrogen, water is a polar molecule. The oxygen has a slight negative charge while the hydrogens have a slight positive charge giving the article a strong effective dipole moment. The interactions between the different dipoles of each molecule cause a net attraction force associated with water's high amount of surface tension.

4. Another very important force that causes the water molecules to stick to one another is the hydrogen bond.

5. The boiling point of water (and all other liquids) is directly related to the barometric pressure. For example, on the top of Mt. Everest water boils at about 68 °C (154 °F), compared to 100 °C (212 °F) at sea level. Conversely, water deep in the ocean near geothermal vents can reach temperatures of hundreds of degrees and remain liquid.

6. Water sticks to itself. Water has a high surface tension caused by the strong cohesion between water molecules because it is polar. The apparent elasticity caused by surface tension drives the capillary waves.

7. Water also has high adhesion properties because of its polar nature.

8. Capillary action refers to the tendency of water to move up a narrow tube against the force of gravity. This property is relied upon by all vascular plants, such as trees.

9. Water is a very strong solvent, referred to as the universal solvent, dissolving many types of substances. Substances that will mix well and dissolve in water, e.g. salts, sugars, acids, alkalis, and some gases: especially oxygen, carbon dioxide (carbonation), are known as "hydrophilic" (water-loving) substances, while those that do not mix well with water (e.g. fats and oils), are known as "hydrophobic" (water-fearing) substances.

10. All the major components in cells (proteins, DNA and polysaccharides) are also dissolved in water.

11. Pure water has a low electrical conductivity, but this increases significantly upon solvation of a small amount of ionic material such as sodium chloride.

12.Water has the second highest specific heat capacity of any known chemical compound, after ammonia, as well as a high heat of vaporization (40.65 kJ mol−1), both of which are a result of the extensive hydrogen bonding between its molecules. These two unusual properties allow water to moderate Earth's climate by buffering large fluctuations in temperature.

13.The maximum density of water is at 3.98 °C (39.16 °F).[5] Water becomes even less dense upon freezing, expanding 9%. This causes an unusual phenomenon: ice floats upon water, and so water organisms can live inside a partly frozen pond because the water on the bottom has a temperature of around 4 °C (39 °F).

Water, ice and vapor
Heat capacity and heats of vaporization and fusion
 
Main article: Enthalpy of vaporization
Water has the second highest specific heat capacity of any known chemical compound, after ammonia, as well as a high heat of vaporization (40.65 kJ mol−1), both of which are a result of the extensive hydrogen bonding between its molecules. These two unusual properties allow water to moderate Earth's climate by buffering large fluctuations in temperature.
 
The specific enthalpy of fusion of water is 333.55 kJ kg−1 at 0 °C. Of common substances, only that of ammonia is higher. This property confers resistance to melting upon the ice of glaciers and drift ice. Before the advent of mechanical refrigeration, ice was in common use to retard food spoilage.

Density of water and ice:

Water changes its density in respect to its temperature, but not on a linear scale, and not even continuously in one direction. The table to the right, "The density of water in Kilograms per cubic meter" shows how water's density varies with its temperature. The solid form of most substances is more dense than the liquid phase; thus, a block of pure solid substance will sink in a tub of pure liquid substance. But, by contrast, a block of common ice will sometimes float in a tub of water because solid water can be less dense than liquid water at some temperatures. This is an extremely important property of water. At room temperature, liquid water becomes denser with lowering temperature, just like other substances. But at 4 °C (3.98 to be precise), just above freezing, water reaches its maximum density, and as water cools further toward its freezing point, the liquid water, under standard conditions, expands to become less dense. The physical reason for this is related to the crystal structure of ordinary ice, known as hexagonal ice Ih. Water, lead, uranium, neon and silicon are some of the few materials which expand when they freeze; most other materials contract. Not all forms of ice are less dense than liquid water however, HDA and VHDA for example are both denser than liquid phase pure water. Thus, the reason that the common form of ice is less dense than water is somewhat non-intuitive and relies heavily on the unusual properties inherent to the hydrogen bond.
 
Generally, water expands when it freezes because of its molecular structure, in tandem with the unusual elasticity of the hydrogen bond and the particular lowest energy hexagonal crystal conformation that it adopts under standard conditions. That is, when water cools, it tends to stack in a crystalline lattice configuration that stretches the rotational and vibrational components of the bond. Although the H-bond length is actually shorter in solid ice than between molecules of liquid water, the rigidity of the ice crystalline structure ensures that each given H2O molecule has fewer neighbors, and thus the solid is less dense. This effectively reduces the density ρ of water when ice is formed under standard conditions.
 
Water shares the higher-density liquid state with only a few materials like gallium, germanium, bismuth and antimony.
 
The importance of this property cannot be overemphasized for its role on the ecosystem of Earth. For example, if water were denser when frozen than it is at 0-4 °C (just before it is frozen) then lakes and oceans in a polar environment would eventually freeze solid. This would happen because frozen ice would settle on the lake and riverbeds, and the necessary warming phenomenon (see below) could not occur in summer, as the warm surface layer would be less dense than the solid frozen layer below. It is a significant feature of nature that this does not occur naturally in the environment.
 
Nevertheless, the unusual expansion of freezing water (in ordinary natural settings in relevant biological systems), due to the hydrogen bond, from 4 °C above freezing to the freezing point offers an important advantage for freshwater life in winter. Water chilled at the surface increases in density and sinks, forming convection currents that cool the whole water body, but when the temperature of the lake water reaches 4 °C, water on the surface decreases in density as it chills further and remains as a surface layer which eventually freezes and forms ice. Since downward convection of colder water is blocked by the density change, any large body of fresh water frozen in winter will have the coldest water near the surface, away from the riverbed or lake bed.
 
Water will freeze at 0 °C (32 °F, 273 K), however, it can be supercooled in a fluid state down to its crystal homogeneous nucleation at almost 231 K (−42 °C) [2].
 
Water expands significantly as the temperature increases. The density is 4% less than maximum as the temperature approaches boiling

Density of saltwater and ice:

The density of water is dependent on the dissolved salt content as well as the temperature of the water. Ice still floats in the oceans, otherwise they would freeze from the bottom up. However, the salt content of oceans lowers the freezing point by about 2 °C and lowers the temperature of the density maximum of water to the freezing point. That is why, in ocean water, the downward convection of colder water is not blocked by an expansion of water as it becomes colder near the freezing point. The oceans' cold water near the freezing point continues to sink. For this reason, any creature attempting to survive at the bottom of such cold water as the Arctic Ocean generally lives in water that is 4 °C colder than the temperature at the bottom of frozen-over fresh water lakes and rivers in the winter.
 
As the surface of salt water begins to freeze (at −1.9 °C for normal salinity seawater, 3.5%) the ice that forms is essentially salt free with a density approximately equal to that of freshwater ice. This ice floats on the surface and the salt that is "frozen out" adds to the salinity and density of the seawater just below it, in a process known as brine rejection. This denser saltwater sinks by convection and the replacing seawater is subject to the same process. This provides essentially freshwater ice at −1.9 °C on the surface. The increased density of the seawater beneath the forming ice causes it to sink towards the bottom. On a large scale, the process of brine rejection and sinking cold salty water results in ocean currents forming to transport such water away from the pole. One potential consequence of global warming is that the loss of Arctic ice could result in the loss of these currents as well, which could have unforeseeable consequences on near and distant climates.


Water treatment plant

 

Water treatment plant (WTP)

WTP is the abbreviation of ‘Water treatment plant’ . Water treatment systems provide for renovation, recovery, and reuse of water heretofore discarded into streams. So,water recycling is defined as putting water back into processes in which it was first used after desirable materials have been removed.
 
Types of WTP:
Four different recycling methods are available and provide for the removal of solid materials. These methods are:
1) Evaporation
2) Microfiltration
3) Ultra filtration
4) Reverse Osmosis

Evaporation:
Evaporation is a process in which waste water is brought to its boiling point and pure water is vaporized and then collected for power production or condensed for recycling as hot water. The result is that solids are concentrated, process materials are recovered and hot water is produced. However, material recovery is not always possible but waste materials handling is made easier by reducing the volume.

Principle of Operation:
Wastewater treatment evaporators are generally heated by steam condensing on metallic, cylindrical tubes. As stream condenses on the outside of the tube, the heat of condensation causes water flowing on the inside of the cylinder to be evaporated. The efficiency of an evaporator is directly related to its heat transfer rate through the metal tubes to the heating surface.
This rate of heat transfer is the product of three factors, which are the heat transfer co-efficient the heating surface area, and the overall change in temperature between the waste and the condensing system.

Application of evaporation:
Very pure water for recycling can be obtained using the recovery method because it is a distillation process. However, for textile waste water treatment, the major factor to be considered when selecting evaporation is its energy cost.



Figure:- Evaporation System

The value of hot water in energy cost currently is estimated to be $3/1000 gal, the energy cost of pure water is $25/1000 gal. Therefore, the evaporation process is economical only when the concentrate is reusable and its value outweighs the energy cost of evaporation. 

Microfiltration:
Microfiltration (MF) is a physical separation process in which suspended solids, ranging in size from 0.02 to 10 and larger, are removed from waste systems. These suspended particles may be either organic or inorganic material. For a perspective of the size of particles with which microfiltration is concerned.
The performance of filtering material in microfiltration is based on three factors. These are the size of the particles it is able to retain, the permeability or filtration rate, and the time lapse before the filter is replaced or cleaned. 

Principle of Operation:
The total resistance to flow consists of two parts . The first is the resistance to flow contributed by the filter medium . The second resistance to flow is the cake of accumulated particles on the upstream surface of the filter medium or within the pores.
Application of Microfiltration:
A type of microfiltration recently introduced is cross flow microfiltration. This involves
flowing the waste feed stream parallel to the suface of the filter to prevent concentration build up. Higher capital and operating costs are incurred using this method due to the need for pumps for circulating the waste stream over the surface of the microfilter medium, but usually higher fluxes and minimum filter replacements can be obtained.

Ultra filtration:
Ultrafiltration is a pressure driven separation process involving the filtering of waste streams by microporous membranes capable of removing macromolecules in solution as well as collides and suspended solids. In this process the feed solution is pumped past the membrane at high velocity at cross flow fashion.
The objective of UF is to separate the feed stream into two strams, one containing the purified nwater or permeatr, and the other containg a high concentrationof separated impurities called concentrate. Water, containing impurities smaller than the membrane pore size, is forced through the membrane and becomes the permeate.

Application of Ultra filtration:
The main application for Ultra filtration so far has been area where valuable components of waste streams can be recovered. In textile wet processing, UF has been used to concentrate and recover poly vinyl alcohol sizing from the desize waste stream .

Reverse Osmosis:
Reverse Osmosis is a pressure driven separation process involving the filtering of waste of stream by membranes capable of separation substantial fraction of dissolved inorganic and organic impurities as well as the larger colloidal and suspended material. In reverse Osmosis a feed stream under under pressure is passed across the surface of membrane. Osmosis is the spontaneous passage of water from a dilute solution to a more concentrated solution across an ideal semipermiable membrane that allows the passage
Of water but not dissolved colloidal or suspended materials. The transfer of water is continued until the pressure in the concentrated is sufficiently large preventing further transfer of water, when osmotic equilibrium is reached. When pressure is applied to the concentrated solution greater than the osmotic pressure differential, water flows through the membrane from the concentrated solution to the dilute solution. Because this flow is reversed of that encountered in that normal osmotic process, it is named reverse osmosis.

Principle Of Operation: 
Pretreated water is pumped into the membrane housings along the membrane surface. Pure water is permitted to pass through the membrane while ionic, organic, colloidal and bacterial contaminants are swept away in a concentrated solution. Consequently, a reverse osmosis system always creates two continuous exit streams: pure water and brine. Normally 50 to 75 percent of the feed water can be recovered as pure water.As an example caustic (NaOH) is recovered from the mercerizing process .As fabric passes through the washing solutions, hot wash water flows in the opposite direction. As the water flows , the concentration of caustic in solution increases. At the exit end of the water flow , water contains two valuable products , high temperature water and caustic. The water is then diverted to a heat exchanger and transfer heat to cold water which in turn can be introduced into other processes.
 
Application of Reverse Osmosis:
 As an example caustic (NaOH) is recovered from the mercerizing process .As fabric passes through the washing solutions, hot wash water flows in the opposite direction. As the water flows , the concentration of caustic in solution increases. At the exit end of the water flow , water contains two valuable products , high temperature water and caustic. The water is then diverted to a heat exchanger and transfer heat to cold water which in turn can be introduced into other processes.

 

VAT DYE



History:

the vat dye is found amongst the oldest natural coloring matters used for textiles. Indigo has been known in India since the earliest periods of which historical records exist. According to the writings of Julius Caesar the ancient Britons used Woad to stain their Bodies and faces and Tyrian purple was exported from Tyre to the Mediterranean countries nearly 4000 years ago. Tyrian purple is extracted from a shell fish and is therefore of animal origin but woad and indigo exist in plants, combined with glucose in the form of glucosides the vat dyes are all insoluble in water and cannot be used for dyeing without modification when treated with reducing agents they are converted into leuco compounds all of which are soluble in water in the presence of alkalis. These leuco compounds are substantive towards cellulose and reoxidize to the insoluble coloured pigment within the fibre when exposed to air. The leuco compounds are often colourless or of quite a different colour from the product of oxidation.
Vat dyes so named: the word vat means vessel. The dye takes their generic name from vatting , the vat dyes are naturally obtained colouring matter from the ancient time and kept into wooden vat and make solubilise in vat by the process of fermentation – so it is called vat dye.

Properties of vat dyes:

1. Vat dye is water insoluble and can’t be applied directly on textile material.
2. Mainly use fir cellulose fibre dyeing but in protein fibre dyeing PH should be controlled.
3. Rubbing fastness is not good.
4. Various shades is found.
5. Dyeing process is difficult.
6. Costly.
7. Washing fastness of vat dye is very good with rating 4-5.

Classification of vat dyes:

For quinone vat dyes, there is no single classification according to dyeing properties as is the case for the direct dyes. The German interessen Gemeinschaft fur farbenindustrie (IG) developed one popular classification for their indanthrene rangr of vat dyes based on leuco compound substantivity and the required dyeing conditions.

Three main types:

1. The 1N (indanthrene normal) group of dyeing temperatures (60C) and dyeing temperatures (60C). no salt is added to the dyebath because of the high substantivity of the leuco dyes for cotton;

2. The IW (indanthrene Warm) group of dyes requires the use of concentrated NaOH and lower vatting (50C) and dyeing temperatures (50C). the leuco forms of these dyes have moderate substantivity for cotton and some addition of salt is needed during dyeing to aid exhaustion;

3.The IK group of dyes only need a low concentration of NaOH with low vatting (40C) and dyeing temperatures (20C). these dyes have low substantivity for cotton and need considerable salt for good dyebath exhaustion. Some have amide groups that would be hydrolyswd under the vatting and dyeing consitions used for IN and IW dyes.

There are special processes for some black vat dyes that require an oxidative aftertreatment to develop the full black colour. Table 17.1 compares the characteristics of these three tupes of vat dye . the required concentrations of hydros, caustic soda and salt increase with increasing amounts of dye in the bath and with increasing liquor ratio.

There are various other classifications of vat dyeing methods . the SDC recommend tests to determine the best dyeing methods. In this , the colour strengths of dyeing produced under different dyeing conditions are compared with those of standarad dyeing using a grey scale . this test applies only toanthrawuinone dyes . thereare also SDC tests for determine the strike, migration and leveling characteristics of vat dyes . different companies have different classification systems for thir vat dyer. Because vatting and dyeing conditions vary from one another, the suppliers’ recommendations should be consulted.


17.5.3 problems with anthraquinone dyes
A number if chemical problems aruse with some quinone vat dyes . these include:
1. Multiple reduction steps for poluquinones such as iudanthrone;
2. Isomerusm of leuco compounds to oxanthrones;
3. Hydrolysis of amide groups;
4. Over-oxidation after dyeing;
5. Dehalogenation of some dyes,

To minimize these types of problems , the supplier’s recommendations for vatting and dyeing must be followed.
Indanthrone (Cl var blue 4) and some of its derivatives show a number of these problems indanthrone has two anthraquinoe residues in its molecule. The normal blue leuco compound used in dyeing is that corresponding to the reduction of one of the anthraquinone groups (5, in figure 17.5). If both anthraquinone groups are reduced. The final product (6) gives a brownish yellow solution. Has poor substantivity for cotton and is more difficult to oxidize. Such over-reduction produces duller blue dyeing of lower colour yield.

ACID DYE


Definition:

The name “acid dye” derives from the use of an acidic dye bath. Most pre-metallised and mordant dyes are acid dyes. In case of mordant dyes, the dyeings are aftertreated with a suitable metal ion mordant, usually chromium. In fact, mordant dyes are often referred to as chrome dyes. The metal in pre-metallised dyes is incorporated into the dye molecule during the manufacturing process.

Acid dyes are usually sodium salts of sulphonic acids, or less frequently of carboxylic acids, and are therefore anionic in aqueous solution. They will dye fibres with cationic sites. These are usually substituted ammonium ion groups in fibres such as wool, silk and nylon. These fibres absorb acids. The acid protonates the fibres amino groups, so they become cationic. Dyeing involves exchange of the anion associated with an ammonium ion in the fibre with a dye anion in the bath. The strength (fastness) of this bond is related to the desire/ chemistry of the dye to remain dissolved in water over fixation to the fiber.

Structures:

Dyes are normally very large aromatic molecules consisting of many linked rings. Acid dyes usually have a sulphonyl or amino group on the molecule making them soluble in water. Water is the medium in which dyeing takes place. Most acid dyes are related in basic structure to the following:

Anthraquinone type: Many acid dyes are synthesised from chemical intermediates which form anthraquinone-like structures as their final state. Many blue dyes have this structure as their basic shape. The structure predominates in the levelling class of acid dye.

Azo dyes:The structure of azo dyes is based on azobenzene, Ph-N=N-Ph (see right showing cis/ trans isomers) Although Azo dyes are a separate class of dyesuff mainly used in the dyeing of cotton (cellulose) fibers many acid dyes have a similar structure, most are red in color.

Triphenylmethane related:Acid dyes having structures related to triphenylmethane predominate in the milling class of dye. There are many yellow and green dyes commercially applied to fibers that are related to triphenylmethane.

Chemistry:

Acid dyes are thought to attach to fibers by ionic bonds, hydrogen bonds, and Van der Waals forces. They are normally sold as the sodium salt, therefore they are in the form of anions in solution. Animal protein fibers and synthetic nylon fibers contain many cationic sites, therefore there is an attraction of the anionic dye molecule to a cationic site on the fiber. The strength (fastness) of this bond is related to the tendency of the dye to remain dissolved in water vis-a-vis its tendency to be fixed to the fiber.

The chemistry of acid dyes is quite complex. Dyes are normally very large aromatic molecules consisting of many linked rings. Acid dyes usually have a sulfonyl or amino group on the molecule making them soluble in water. Water is the medium in which dyeing takes place.


Properties of Acid Dyes:

Levelling Acid Dyes

 Dyeing wool with leveling acid dye requires sulphuric or formic acid in the dyebath, along with glauber’s salt. Considerable amounts of a strong acid are needed to achieve good exhaustion, typically 2-4% owf of sulphuric acid.

Because of the case of migration of levelling acid dyes during dyeing, the fastness to washing of their dyeing is only from poor to moderate. Their light fastness, however, ranges from fair to good. If the dye molecules do aggregate in solution at the maximum dyeing temperature, the aggregate are quite small, or there are enough individual molecules present in the solution for good penetration into the pores of the wool.
Wool contains about 820 mmol kg-1 of amino groups, some of which converts into ammonium ions in the presence of sulphuric acid, with a bound bisulphate anion. During dyeing, a dye anion displaces the bisulphate ion associated with an ammonium ion site. The wool is far from being saturated with dye anions.
The added glauber’s salt act as a retarding and leveling agent. It promotes leveling and reduces the dyebath exhaustion. As dyeing proceeds, more acid is then gradually added to decrease the bath pH.
Levelling dyes give decreasing exhaustion on increasing the dyebath pH to values above 4, and with increasing temperature. These effects are consistent with a simple ion exchange process that is exothermic.

Fast Acid Dyes
These are usually monosulphonated acid dyes of somewhat higher molecular weight than typical leveling dyes. They dye wool by essentially the same dyeing method using acetic acid (1-3% owf) and glauber’s salt (5-10% owf). These dyes are used wehere level dyeing is necessary but when the washing and perspiration fastness of leveling acid dyes are inadequate.

Milling acid dyes
These anionic dyes have higher molecular weights and greater substantivity for wool than leveling or fast acid dye. They are medium to high wet fastness. Some milling dyes have poor light fastness in pale shades. Generally not combinable. Used as self shades only.

Metal complex acid dyes
More recent chemistry combined transition metals with dye precursors to produce metal complex acid dyes with the highest light fastness and wet fastness. These dyes are also very economical. They, however, produce duller shades.

Process:
The invention provides a process for dyeing a textile substrate comprising wool fibres, which process comprises bringing the substrate into contact with an aqueous dyebath containing an acid dyestuff or a mixture of acid dyestuffs having(a) a build-up power on wool of from 90 to 98% at pH 4.5; together with(b) a migrating ability on wool of from 25 to 40%, at pH 4.5;(a) and (b) being determined under specific conditions, in the presence of a levelling agent which is the alkoxylation product of an aminesubstituted by a fatty saturated or unsaturated residue, the aqueous dyebath containing a mixture of acid dyestuffs when the substrate is a wool/synthetic polyamide fibre blend. These dyestuffs give level, fast and reproducible dyeings of a highquality.


Problems of acid dyes:
Temperature and pH control

i) Unequal access of the fibres to the dye solution, resulting from densely packed fibres or yarns and from poor agitation of the dyebath.

ii) Variation of the temperature throughout the dyebath and the goods.

iii) Uneven pH in the bath and the material.

Dyeing damaged wool fibres:
i) Dyeings with colored patches of different depths caused largely by uneven treatment with chemical during processes such as scouring, bleaching or chlorination, or incomplete and non-uniform removal of residual chemicals,

ii) Skitteriness: The uneven dyeing of individual wool fibres whose tips have degraded more from the greater exposure to the elements during the growth of the wool fleece.



Dehumidification





Dehumidification

A dehumidifier is a household appliance that reduces the level of humidity in the air, usually for health reasons, as humid air can cause mold and mildew to grow inside homes, which has various health risks. Relative humidity is preferably 30 to 50%.[1] Very high humidity levels are also unpleasant for human beings, can cause condensation and can make it hard to dry laundry or sleep.

Processes:

Mechanical/refrigerative


Mechanical/refrigerative dehumidifiers, the most common type, usually work by drawing moist air over a refrigerated coil with a small fan. Since the saturation vapor pressure of water decreases with decreasing temperature, the water in the air condenses, and drips into a collecting bucket. The air is then reheated by the warmer side of the refrigeration coil. This process works most effectively with higher ambient temperatures with a high dew point temperature. In cold climates, the process is less effective.[2] They are most effective at over 45% relative humidity, higher if the air is cold. [3]

Desiccative 

A desiccant dehumidifier is a device that employs a desiccant material to produce a dehumidification effect. As they are more effective for low-temperature and low (relative) humidity levels, they are generally used for these conditions instead of mechanical/refrigerative dehumidifiers - or are used in tandem with them.[3]
Desiccant materials have a high affinity for water vapor. An example of dessicant material is silica gel. Typically their moisture content is a function of the relative humidity of the surrounding air. Exposed to low relative humidities desiccant materials come to equilibrium at low moisture contents and exposure to high relative humidities results in equilibrium at high moisture contents. The process involves exposing the desiccant material to a high relative humidity air stream, allowing it to attract and retain some of the water vapor and then exposing the same desiccants to a lower relative humidity air stream which has the effect of drawing the retained moisture from the desiccant. The first air stream is the air that is being dehumidified while the second air stream is used only to regenerate the desiccant material so that it is ready to begin another cycle. Note that the first air stream's water vapor content is reduced while the second air stream's water vapor content is increased. Typically the low relative humidity air stream is air taken from any available source and heated to reduce its relative humidity. Hence
desiccant dehumidifiers consume heat energy to produce a dehumidifying effect.








In general a desiccant dehumidifier comprises four major components:
the component that holds the desiccant, of which there are several types;
1. a fan to move the air to be dehumidified (process air) through the desiccant holder;

2. a heater to heat the air that will be used to dry the desiccant (regeneration air);

3. a fan to move the low humidity air for drying the desiccant through the desiccant holder.



There are many different companies who have create dehumidifier like as Aprilaire.

Why Do I Need a Whole-House Dehumidifier?

Have you ever experienced any of the following uncomfortable and/or unhealthy conditions:

· Do you have trouble sleeping at night due to clammy skin or stuffiness in the air?

· Have you ever reduced the temperature setting because you're uncomfortable with the stuffy feeling?

· Have your floors or other surfaces ever felt sticky or “sweaty”?

· Are you concerned with mold and mildew growth in your home?

· Do you have musty odors or smells in any area of your home?

· Do you have condensation on your water pipes?

· Have you seen wet stains on walls or ceilings?

· Do you or a family member have allergies (over-moist air can encourage the growth of mold, bacteria, and dust mites—three commonly known household allergens).

Core Benefits

Every Aprilaire product provides important key benefits for your family and home.

Health

Excess indoor humidity provides the perfect breeding ground for mold, mildew, dust mites, bacteria and more. An Aprilaire Whole-House Dehumidifier combats these nasty home invaders, which are linked to asthma, allergies and other serious respiratory problems.

Comfort

Few things impact your home’s comfort more than excess indoor humidity. When you turn up your air conditioner to try and get rid of indoor stickiness, you’re really just making your home uncomfortably cool. An Aprilaire Dehumidifier allows you to wipe out that clammy feeling and say goodbye to musty odors. Plus optional built-in ventilation allows you to bring in conditioned, fresh outside air - ensuring your home remains properly ventilated.

Protection

Excess indoor humidity allows mold and mildew to thrive—ruining carpets, draperies, furniture and even clothing. It also can cause condensation build-up on windows, destroying their finishes and structural integrity. An Aprilaire Whole-House Dehumidifier helps protect your home and its contents by removing unnecessary moisture from your home’s air whenever it rises to an inappropriate and harmful level.

Energy Savings

Many homeowners turn up their air conditioning to get rid of the stickiness or clammy-feeling caused by high indoor humidity. An Aprilaire Whole-House Dehumidifier eliminates the need to over-cool, allowing for a higher thermostat setting for the same comfort level. And because it is more energy efficient than portable dehumidifiers, it uses less energy for the same amount of moisture removed.

Aprilaire Whole-House Dehumidifier Models There are two different models of Aprilaire Whole-Home Dehumidifiers that can solve your home’s excess humidity problems.

· Aprilaire Models 1710 Free Standing Dehumidifier

· Aprilaire Models 1750/1770 Whole-House Dehumidifiers The only truly effective solutions for total home excess moisture control.

Humidification



Humidification

A humidifier is a household appliance that increases humidity (moisture) in a single room or in the entire home. There are point-of-use humidifiers, which are commonly used to humidify a single room, and whole-house or furnace humidifiers, which connect to a home's HVAC system to provide humidity to the entire house.


Evaporative humidifiers:The most common humidifier, an "evaporative" or "wick humidifier", consists of just a few basic parts: a reservoir, wick and fan.
WickThe wick is a filter that absorbs water from the reservoir. Evaporation of water from the wick is dependent on relative humidity. A room with low humidity will have a higher evaporation rate compared to a room with high humidity. Therefore, this type of humidifier is self-regulating: As the humidity of the room increases, the water vapor output naturally decreases. These wicks regularly need cleaning and replacement — if this does not happen, the humidifier stops humidifying the area it is in and the water in the tank remains at the same level.
Fan
The fan is adjacent to the wick and blows air onto the wick, thus aiding in the evaporation of the water within


Other types of humidifiers:Other types of humidifiers include:
Vaporizer (Steam Humidifier) (Warm Mist Humidifier) — Boils water, releasing steam and moisture into the air. A medicated inhalant can also be added to the steam vapor to help reduce coughs. Vaporizers are more healthful[1] than cool mist types of humidifiers because steam is sterile and free from minerals. Vaporizers use more electricity to boil the water.
Impeller Humidifier (Cool Mist Humidifier) — A rotating disc flings water at a diffuser, which breaks the water into fine droplets that float into the air.
Ultrasonic Humidifier — A metal diaphragm vibrating at an ultrasonic frequency creates water droplets that silently exit the humidifier in the form of a cool fog. Ultrasonic Humidifiers should be cleaned regularly to avoid bacterial contamination which may be projected into the air.

Disadvantages and risks:
The use of a humidifier can allow the reproduction of dust mites or the growth of harmful mold, which can be especially harmful for children and the elderly. The relative humidity should be kept between 30% and 50%. [2]. Can also cause Hypersensitivity pneumonitis (humidifier lung) [3]
Some humidifiers now use Microban technology to reduce mold and bacteria growth within the humidifier.
The EPA provides detailed information of the risks as well as recommended maintenance procedures[1]. One of the main concerns cited by EPA regarding ultrasonic or impeller humidifiers is a "white dust" that has been reported by some consumers, which usually spreads over furniture, is attracted to static electricity generating devices such as CRT monitors and possibly affects the lungs. Although EPA does not explain the "white dust" generation mechanism, which is undesired and potentially harmful, some manufacturers claim that not only is it beneficial but also that it is intentionally produced. It is claimed[who?] that the process is associated to the release of negatively charged ions which attach themselves to allergens and dust particles neutralizing and purifying the air, protecting against molds, mildews, fungi, bacteria, viruses and dust mites.


Whole-Home Humidification vs. Portable


Too much humidity can be as much of a problem as too little humidity. Unlike portable units the Aprilaire Whole-Home Humidifier continually monitors relative humidity levels in your home, then works to deliver the right amount of moisture (click here to view an Optimum Relative Humidity Chart) —never too much or too little— to your entire house. Aprilaire Humidifiers don't require the daily cleaning and disinfecting that many portable units require and you never need to worry about the risk of microbial organism growth due to standing water.

“Humidifiers are commonly used in homes to relieve the physical discomforts of dry nose, throat, lips, and skin. The moisture they add to dry air also helps alleviate common nuisances brought on by winter heating, such as static electricity, splitting woodwork, and cracks in paint and furniture.”
Humidistat:A controller that measures and controls relative humidity. A humidistat may be used to control either humidifying or dehumidifying equipment by the regulation of electric or pneumatic switches, valves, or dampers.
An electronic humidistat includes a sensing element and a relay amplifier. The sensing element consists of alternate metal conductors on a small flat plate. An increase or decrease of the relative humidity causes a decrease or increase in the electrical resistance between the two sets of conductors and the change in resistance is measured by the relay amplifier.



There are many different companies who have create humidifier like as Aprilaire.

How It Works:
An Aprilaire Whole-House Humidifier is installed directly to your central new or existing heating and cooling system. Humidity is introduced into your home’s air in the form of water vapor, which prevents minerals from entering the air in your home and potentially into your lungs. Water is supplied to the distribution tray, allowing it to flow evenly across the Aprilaire Water Panel®. The resulting humidified air is then distributed via your heating and cooling system ductwork throughout your home.

Core Benefits:
Every Aprilaire product provides these important key benefits for your family and home.
Health An Aprilaire Whole-House Humidifier can reduce the chance of upper respiratory problems. “Humidity reduces the incidence of respiratory infections and speeds recovery from the common cold.”—William J. Hitschler, MD, Archives of Otolaryngology.Comfort When the air in your home becomes too dry, your body is robbed of precious moisture, leaving you and your family with dry, itchy skin, and dry nose and throat symptoms. An Aprilaire Whole-House Humidifier can help alleviate all of these uncomfortable symptoms and more.Protection Dry air pulls moisture from walls and hardwood floors which leads to damaging, unsightly cracks. Valuable furniture, artwork and electronics are also subject to the adverse effects of dry air. An Aprilaire Whole-House Humidifier can help protect your home and its contents by supplying the correct amount of moisture to your home’s air.Energy Savings Most homeowners turn up the thermostat because they feel cold. An Aprilaire Whole-House Humidifier allows you to feel warmer at lower thermostat settings, saving up to 4% on your heating bill for every degree you lower your thermostat, according to the EPA.

Aprilaire Whole-House Humidifier Models:There are several models of Aprilaire Whole-House Humidifiers, designed to satisfy your family’s specific needs.
· Aprilaire Model 700A Whole-House Humidifier This humidifier features a powered fan to increase air flow for the highest capacity available. Perfect for larger homes.
· Aprilaire Model 600A Whole-House Humidifier Features a built-in bypass damper, which means fewer parts to install.
· Aprilaire Model 500A Whole-House Humidifier This humidifier is designed for use in smaller homes.
· Aprilaire Model 400A Whole-House Humidifier This humidifier utilizes new evaporative technology to minimize the amount of water used.
· Aprilaire Models 350/360 Whole-House Humidifiers These humidifiers are specifically designed for installation in homes with radiators or baseboard heat.