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Application of chemical, biological and membrane separation processes in textile industry with recourse to zero effluent discharge--a case study.

Environmental concerns associated with textile processing had placed the textile sector in a Southern State of India under serious threat of survival. The textile industries were closed under the orders of the Statutory Board for reason of inadequate compliance to environmental discharge norms of the State for the protection of the drinking water source of the State capital. In compliance with the direction of the Board for zero effluent discharge, advanced treatment process have been implemented for recovery of boiler feed quality water with recourse to effluent recycling/reuse. The paper describes to a case study on the adequacy assessment of the full scale effluent treatment plant comprising chemical, biological and filtration processes in a small scale textile industry. In addition, implementation of measures for discernable improvement in the performance of the existing units through effective operation & maintenance, and application of membrane separation processes leading to zero effluent discharge is also highlighted.

Conservation of Natural Resources↗

Physico-chemical treatment of wastewater from clusters of small scale cotton textile units.

Small scale industries can not own individual wastewater treatment facility due to non-availability of land and skilled manpower for operation and maintenance of wastewater treatment plants. A centralized wastewater treatment facility for clusters of small scale industries is appropriate. This concept is gaining popularity in recent years. In India, various textile process operations are undertaken by individual small scale units. The wastewater generated at these units is conveyed to a common effluent treatment facility comprising of equalization, flocculation-clarification, activated sludge process, secondary clarification and finally discharge into inland surface water bodies. The wastewater from small scale cotton textile processing units was highly coloured and alkaline with average BOD and COD concentration of 205 and 790 mg l(-1), respectively. Due to the presence of several dyes, particularly reactive dyes, the biological treatment is often found less effective. Therefore, applicability of various physico-chemical treatment methods needs to be investigated in pursuit of an alternative to biological treatment of textile wastewater. A physico-chemical treatment scheme, involving chemical coagulation-sedimentation, dual media filtration, activated carbon adsorption followed by chemical oxidation was investigated in this paper. The quality of final treated wastewater in terms of BOD and COD was 18-24 and 230-240 mg l(-1), respectively through this scheme. A scheme of treatment comprising coagulation-sedimentation, dual media filtration, activated carbon, chemical oxidation may be considered as an alternative to biological treatment of textile wastewater.

Coloring Agents↗

The effect of nutrient deficiency on removal of organic solvents from textile manufacturing wastewater during activated sludge treatment.

Textile manufacturing wastewater is often deficient in nitrogen and phosphorus and contains hazardous solvents, including methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), toluene (TOL), and xylenes (XYL). The objectives of this study were to evaluate the effectiveness of a short-term batch assay for predicting when a nutrient deficient condition exists in textile wastewater activated sludge, and to determine if nutrient deficiency affects biodegradation of MEK, MIBK, TOL,and p-XYL to a greater or lesser extent than bulk soluble chemical oxygen demand (sCOD). Addition of N + P significantly improved sCOD removal during treatment of textile wastewater in laboratory-scale sequencing batch reactors (SBRs). Batch tests using mixed liquor suspended solids (MLSS) from the SBRs correctly predicted the nutrient deficiency in the reactors that received unamended wastewater. During batch tests in sealed containers (to prevent volatilization) when N + P were added, the solvents biodegraded faster and to a greater extent than the bulk wastewater sCOD. MEK and MIBK were also completely consumed in MLSS from the SBR that received unamended wastewater, indicating that a shortage of nutrients did not significantly impact biodegradation of these ketones. However, nutrient deficient conditions significantly decreased the rate of TOL and p-XYL biodegradation. The difference in biodegradability of the ketones and monoaromatics under nutrient deficient conditions may be related to loss of plasmids required for aerobic catabolism of TOL and p-XYL. These results demonstrate that N + P addition to nutrient-deficient textile wastewater improves bulk sCOD removal and also significantly improves the biodegradability of TOL and p-XYL, thereby reducing the amount released to the atmosphere by volatilization.

Biodegradation, Environmental↗

Genotoxicity testing of four textile dyes in two crosses of Drosophila using wing somatic mutation and recombination test.

In this study, four textile dyes, namely Astrazon Yellow, Red, Blue, and Black, were tested for their genotoxic effects in the wing cells of Drosophila melanogaster. Two crosses were used, the standard cross (ST) and the improved high-bioactivation cross (HB), the latter being characterized by increased sensitivity to the genotoxic effects of promutagens and procarcinogens. Three-day-old larvae were exposed to different concentrations of dyes. Commonly known mutagens were applied as positive controls. All concentrations of textile dyes, ethyl methanesulfonate (EMS), and urethane caused a decrease in survival proportional to concentration used. EMS and urethane caused an increase in the number of all types of spots in both standard and high-bioactivation crosses. Compared to ST crosses, the number of induced spots in the HB cross treated with urethane was considerably high. Treatment of the standard and the high-bioactivation crosses with textile dyes gave positive results, apparent from increase in the frequency of the small single spots. Yellow and red dyes also increased the number of large single spots in both crosses, whereas the twin spots were positive only at the highest dose of yellow dye. All these results indicate that D. melanogaster wing spot test can be recommended as a suitable in vivo test for the determination of genotoxicity of textile dyes.

Animals↗

Advanced treatment of biotreated textile industry wastewater with ozone, virgin/ozonated granular activated carbon and their combination.

Biotreated textile wastewater (CODo = 248 mg L(-1); TOCo = 58 mg L(-1); A620 = 0.007 cm(-1); A525 = 0.181 cm(-1); A436 = 0.198 cm(-1)) was subjected to advanced treatment with ozonation, granular activated carbon (GAC) adsorption in serial and simultaneous applications. Experiments were conducted to investigate the effects of applied ozone dose, ozone absorption rate, specific ozone absorption efficiency, GAC dose, and reaction pH on the treatment performance of the selected tertiary treatment scheme. In separate experiments, the impact of virgin GAC ozonation on its adsorptive capacity for biotreated and biotreated + ozonated textile effluent was also investigated. Ozonation appeared to be more effective for decolorization (kd = 0.15 min(-1) at pH = 3), whereas GAC adsorption yielded higher COD removal rates (54% at pH = 3). It was also found that GAC addition (4 g/L) at pH = 7 and 9 enhanced the COD abatement rate of the ozonation process significantly and that the sequential application of ozonation (at pH = 3-11, 675 mg L(-1) O3) followed by GAC adsorption (at pH = 3-7, 10 g L(-1) GAC) resulted in the highest treatment performances both in terms of color and COD reduction. Simultaneous application of GAC and ozone at acidic and alkaline pH seriously inhibited COD abatement rates as a consequence of competitive adsorption and partial oxidation of textile components and GAC. It could also be established that ozone absorption efficiency decreased after color removal was complete. Ozonation of biotreated textile wastewater with 113 mg L(-1) ozone resulted in an appreciable enhancement of GAC adsorptive capacity in terms of residual color removal. Ozonation of GAC at relatively low doses (= 10.8 mg/g GAC) did not improve its overall adsorption capacity.

Adsorption↗

Organic field effect transistors for textile applications.

In this paper, several issues concerning the development of textiles endowed with electronic functions will be discussed. In particular, issues concerning materials, structures, electronic models, and the mechanical constraints due to textile technologies will be detailed. The idea starts from an already developed organic field-effect transistor that is realized on a flexible film that can be applied, after the assembly, on whatever kind of substrate, in particular, on textiles. This could pave the way to a variety of applications aimed to conjugate the favorable mechanical properties of textiles with the electronic functions of transistors. Furthermore, a possible perspective for the developments of organic sensors based on this structure are described.

Clothing↗

Contact allergy to textile dyes in southern Sweden.

Contact allergy to disperse dyes in textiles is documented in prevalence studies from southern Europe. To evaluate the prevalence of allergic patch test reactions to different textile dyes in southern Sweden, and to look at the sites of dermatitis in individuals hypersensitive to textile dyes, we retrospectively investigated 3325 consecutively patch-tested patients. They had all been patch tested with the standard test series supplemented with a textile dye mix (TDM) consisting of 8 disperse dyes, i.e. Disperse (D) Blue 35, 106 and 124, D Yellow 3, D Orange 1 and 3 and D Red 1 and 17. All but 3 of the TDM-positive patients were additionally tested with the separate dyes included in the mix. The frequency of contact allergy to TDM was 1.5%, which is comparable with studies from southern Europe. The most common dye allergen was D Orange 1. The high prevalence of allergic reactions to D Orange 1 was unexpected, whereas test reactions to D Blue 106 and 124 were lower than expected from other studies. Compared to all tested patients, the TDM-positive patients more often had dermatitis on their arms, face, neck and axillary folds, and women also had a higher frequency of hand dermatitis.

Adolescent↗

Efficacy and functionality of silver-coated textiles in patients with atopic eczema.

BACKGROUND: Microbial skin colonization with Staphylococcus aureus is known to play an important role in atopic eczema (AE). Recently, an antibacterial effect of silver-coated textiles on S. aureus colonization has been demonstrated. OBJECTIVES: To investigate clinical efficacy and functionality of silver-coated textiles in AE, a multicentre, double-blind, placebo-controlled trial was conducted. PATIENTS/METHODS: From November 2001 to August 2002, 68 consecutive outpatients clinically diagnosed with generalized AE were included in the study. Inclusion criteria were the clinical diagnosis of AE with a moderate severity as measured by the scoring of atopic dermatitis (SCORAD) index with at least 20. Patients were instructed to wear either silver-coated (verum, 35 patients + 2 dropouts) or cotton garments (placebo, 22 patients + 9 dropouts) directly on the skin for 2 weeks. Only basic skin care and ongoing therapy with topical steroids or oral antihistamines was permitted. Clinical severity was assessed using the 'SCORAD' before, during and at the end of study. Quality of life (QOL), wearing comfort (WC) and functionality (FU) of study clothes were measured in parallel. Patients documented their subjective and objective symptoms daily. RESULTS: In the verum group, eczema improved significantly after 1 week with further enhancement until the end of study (P = 0.03 and P < 0.001). Silver-coated textiles were comparable to cotton in WC and FU. Pruritus and self-assigned skin condition improved significantly more than with placebo (P < 0.001 and P = 0.003). CONCLUSIONS: In conclusion, silver-coated textiles are able to improve objective and subjective symptoms of AE significantly within 2 weeks, showing a good wearing comfort and functionality comparable to cotton.

Adolescent↗

Sensitization to reactive textile dyes in patients with contact dermatitis.

Reactive dyes are used especially for colouring natural fibres (cotton, silk and wool) that are widely used in Western countries, particularly Italy, in the production of clothes. The aim of our study was to investigate sensitization to the most commonly used reactive textile dyes in patients undergoing patch tests, and to assess the clinical relevance of contact sensitization to these dyes. 1813 consecutive patients underwent patch tests with the GIRDCA standard series and an additional textile series of 12 reactive dyes. 18 of these patients were sensitized to reactive dyes (0.99%) (4 only to reactive dyes). The dyes most frequently responsible for positive patch tests were Red Cibacron CR and Violet Remazol 5R (respectively, 8 and 5 positivities). In 5 cases only was a history of intolerance to particular garments given; of 4 patch tests performed with pieces of garment, 2 were positive. In 1 occupationally-exposed patient, airborne contact dermatitis was suspected. Owing to the lack of up-to-date patch test series, some cases of allergic contact dermatitis from textile dyes are probably misdiagnosed: new colouring agents are continuously introduced to the market, so that a close relationship with textile industry is necessary to improve our diagnostic tools.

Adolescent↗

Occupational risk factors for nasopharyngeal cancer among female textile workers in Shanghai, China.

AIMS: To investigate whether occupational exposure to dusts and chemicals in the Chinese textile industry are associated with risk of nasopharyngeal cancer. METHODS: Sixty seven nasopharyngeal carcinoma (NPC) cases identified during 1989-98 and a random sample (n = 3188) of women were included in a case cohort study nested in a cohort of 267,400 women textile workers in Shanghai, China. A complete occupational history of work in the textile industry was obtained for each woman. A job exposure matrix developed by experienced industrial hygienists was used to assess exposures to specific dusts and chemicals. RESULTS: Risk of NPC is associated with cumulative exposure to cotton dust. The hazard ratio for women cumulatively exposed to >143.4 mg/m3 x years of cotton dust was 3.6 (95% CI 1.8 to 7.2) compared with unexposed women. Trends of increasing risk were also found with increasing duration of exposure to acids and caustics (p = 0.05), and with years worked in dyeing processes (p = 0.06). Women who worked at least 10 years in dyeing processes had a 3.6-fold excess risk of NPC (95% CI 1.0 to 12.1). CONCLUSIONS: Occupational exposure to cotton dust, acids, and caustics, and work in dyeing and printing jobs in the textile industry may have increased risk of NPC in this cohort.

Adult↗

Longitudinal changes in pulmonary function and respiratory symptoms in cotton textile workers. A 15-yr follow-up study.

To evaluate the chronic effects of exposure to cotton dust, a 15-yr follow-up study in cotton textile workers was performed in Shanghai, China from 1981 to 1996. Testing occurred four times during the 15-yr period. The achieved follow-up rates were 76-88% of the original 447 cotton textile workers, and 70-85% of the original 472 silk textile workers (as a control group). Identical questionnaires, equipment, and methods were used throughout the study. The prevalence of byssinosis increased over time in cotton workers, with 15.3% at the last survey versus 7.6% at the baseline, whereas no byssinosis was found in silk workers. More workers in the cotton group consistently reported symptoms than in the silk group, although symptom reporting varied considerably from survey to survey. Cotton workers had small, but significantly greater, adjusted annual declines in FEV(1) and FVC than did the silk workers. Years worked in cotton mills, high level of exposure to endotoxin, and across-shift drops in FEV(1) were found to be significant determinants for longitudinal change in FEV(1), after controlling for appropriate confounders. Furthermore, there were statistically significant associations between excessive loss of FEV(1) and byssinosis, chest tightness at work, and chronic bronchitis in cotton workers. Workers who consistently (three or four of the surveys) reported byssinosis or chest tightness at work had a significantly greater 15-yr loss of FEV(1). We conclude that long-term exposure to cotton dust is associated with chronic or permanent obstructive impairments. Consistent reporting of respiratory symptoms, including byssinosis and chest tightness at work, is of value to predict the magnitude and severity of chronic impairments in textile workers.

Adult↗

Brain tumors and occupational exposures in a cohort of female textile workers in Shanghai, China.

OBJECTIVES: This study assessed the associations between brain tumors and specific processes and exposures among female textile workers in Shanghai, China. METHODS: A case-cohort study was conducted that was nested in a cohort of textile workers originally included in a randomized trial of breast self-examination. Incident brain tumor cases (N=114) were identified from 1989 to 1998 from a tumor and death registry operated by the Shanghai Textile Industry Bureau. A subcohort (N=3188), representing an age-stratified random sample of the entire cohort, was selected as a comparison group. Job-exposure matrices were created to assess historical exposures to specific agents, including quantitative assessments for cotton dust and endotoxin exposure. Cox proportional hazards modeling, modified according to a case-cohort design, was used to analyze associations between jobs and exposures and the risk of brain tumors. RESULTS: Employment in maintenance workshops was associated with an increased brain tumor incidence (ever-never exposed hazard ratio 2.36, 95% confidence interval 1.12-4.97), with increasing hazard ratios by duration of employment in maintenance jobs. Handling or processing wool fibers was associated with an increased risk of brain tumors, as was specific exposure to wool fibers; however, estimates did not increase with duration of employment. CONCLUSIONS: These results provide some preliminary suggestion that employment in textile industry maintenance jobs and exposure to wool products may be associated with an increased risk of brain tumors.

Aged↗

Integration of chemical and biological treatments for textile industry wastewater: a possible zero-discharge system.

Theoretical and experimental studies have established that integrated treatment systems (mostly chemical and biological) for various industrial wastewaters can achieve better quality of treatment and can be cost-effective. In the present study, the objective is to minimize the use of process water in the textile industry by an economical recycle and reuse scheme. The textile wastewater was first characterized in terms of COD, BOD5, salinity and color. In order to recycle such wastewater, the contaminants should be mineralized and/or removed according to the reusable textile water quality standards. Typical results show that this is achievable. An economic analysis has been conducted on the proposed integrated system. The economic analysis shows that the integrated system is economically more attractive than any of the single treatment technologies for achieving the same target of treatment. The information presented in this paper provides a feasible option for the reduction of effluent discharges in the textile industry.

Conservation of Natural Resources↗

Membrane bio-reactor for advanced textile wastewater treatment and reuse.

Textile wastewater contains slowly- or non-biodegradable organic substances whose removal or transformation calls for advanced tertiary treatments downstream Activated Sludge Treatment Plants (ASTP). This work is focused on the treatment of textile industry wastewater using Membrane Bio-reactor (MBR) technology. An experimental activity was carried out at the Baciacavallo Wastewater Treatment Plant (WWTP) (Prato, Italy) to verify the efficiency of a pilot-scale MBR for the treatment of municipal wastewater, in which textile industry wastewater predominates. In the Baciacavallo WWTP the biological section is followed by a coagulation-flocculation treatment and ozonation. During the 5 months experimental period, the pilot-scale MBR proved to be very effective for wastewater reclamation. On average, removal efficiency of the pilot plant (93% for COD, 96% for ammonium and 99% for total suspended solids) was higher than the WWTP ones. Color was removed as in the WWTP. Anionic surf actants removal of pilot plant and WWTP were very similar (92.5 and 93.3% respectively), while the non-ionic surfactants removal was higher in the pilot plant (99.2 vs. 97.1). In conclusion the MBR technology demonstrated to be effective for textile wastewater reclamation, leading both to an improvement of pollutants removal and to a draw-plate simplification.

Bioreactors↗

Development of textile-based high-tech products: the new challenge.

The new generation of smart textiles is represented by fibers, yarns, fabrics and other resulting products that have special properties, regarding mechanical, chemical, electrical and thermal performances. These high-tech products, being able to respond to external stimuli through the integration of electronic components, phase change materials, shape memory materials or nano materials, enabled the development of different active and functional products. These products when combining the functions of medium, carrier and interface for micro-systems applications represent the ideal connecting channel between humans and the environment. This is a field of innovation that broadened the scope of the traditional textile and apparel products to high-tech textiles, designed to meet specific needs, involving different technologies and produced according to required properties, like personal protection, safety, leisure or health wear. The development of smart wear is a new challenge for the textile and clothing industry: it has to develop products based not only on design, fashion and comfort concepts but also in terms of functions. Moreover these products must be easy to care and durable.

Biosensing Techniques↗

Waste sizing solution as co-substrate for anaerobic decolourisation of textile dyeing wastewaters.

Dyeing wastewaters and residual size are textile factory waste streams that can be treated anaerobically. For successful anaerobic treatment of dyeing effluents, a co-substrate has to be added because of their low concentration of easily biodegradable compounds. Starch-based size contains easily biodegradable material, but is too concentrated to be treated without difficulties. Although residual size makes up only a small volume, when mixed with the other textile wastewater streams it has a considerable impact on the overall organic load. Many textile dyes can pass through a conventional aerobic treatment plant without being degraded. Anaerobic pre-treatment of the dyeing wastewaters before discharge to the aerobic plant can solve this problem, as many dyestuffs are partly degradable under anaerobic conditions, rendering aerobically degradable products. In this study, the possibility of using waste size as a co-substrate for the anaerobic pre-treatment of dyeing wastewaters was investigated. It was found that waste size was applicable as co-substrate for the decolourisation of the two textile dyeing wastewaters studied. Adding a redox mediator could enhance decolourisation rates for both wastewaters.

Acetates↗

Integrated microelectronics for smart textiles.

The combination of textile fabrics with microelectronics will lead to completely new applications, thus achieving elements of ambient intelligence. The integration of sensor or actuator networks, using fabrics with conductive fibres as a textile motherboard enable the fabrication of large active areas. In this paper we describe an integration technology for the fabrication of a "smart textile" based on a wired peer-to-peer network of microcontrollers with integrated sensors or actuators. A self-organizing and fault-tolerant architecture is accomplished which detects the physical shape of the network. Routing paths are formed for data transmission, automatically circumventing defective or missing areas. The network architecture allows the smart textiles to be produced by reel-to-reel processes, cut into arbitrary shapes subsequently and implemented in systems at low installation costs. The possible applications are manifold, ranging from alarm systems to intelligent guidance systems, passenger recognition in car seats, air conditioning control in interior lining and smart wallpaper with software-defined light switches.

Algorithms↗

Airborne endotoxin concentrations in various work areas within two cotton textile mills in the People's Republic of China.

As part of a multidisciplinary longitudinal approach to assess the roles of airborne cotton dust and endotoxins in affecting the respiratory health of cotton textile workers, this study was designed to quantify the endotoxin contamination of airborne vertically elutriated and total dusts. Yarn preparation areas (opening through fine spinning) were studied at two cotton textile mills which had been studied 5 years previously in Shanghai. People's Republic of China, Filter, with vertically elutriated (VE) or total dusts were mailed to the United States and endotoxin analyses were performed for each filter in duplicate with the quantitative chromogenic modification of the Limulus amebocyte lysate assay. Dusts from all areas of the textile mills contained endotoxins. Endotoxin burdens in VE dusts from the carding area were similar in both milk while the endotoxin contamination of total dust from carding in Mill 1 was over threefold greater than that of total dust from carding in Mill 2. All other areas differed between milk in both VE and total dust endotoxin burdens. Mean endotoxin levels in VE dusts from all areas of both mills were well above the reported threshold of 90 EU/m3 for acute pulmonary function effects in humans. Comparison of selected areas of both mills from the present study with the same work areas from the previous study showed that, in general, the airborne endotoxin burden was higher than levels found 5 years ago in these two mills. The data suggest that even with reduced or unchanged gravimetric dust levels in these two cotton textile mills, airborne endotoxin levels were higher and provided an increased potential for adverse respiratory response in exposed workers.

Air Pollutants, Occupational↗