We selected 210 m3 capacity existing concrete activated sludge tank for bio cultivation process. Maintained mlss as 3000 mg/litre 7000 mg/litre , do value maximum 4 mg/litre and minimum 1.0 mg/litre., ph 6.5 to 7.9 , sv-30 as 300 to 500 ml/litre, temperature is < 37 degree celsius and constant feed flow rate. Control of the activated sludge tank process is important to maintain a high treatment performance level under a wide range of operating conditions
Activated sludge treatment
After equalization process using acid to reduce ph from 9.0 to 6.5. After neutralization process the effluent are giving constant feed flow rate 20 m3/hr into bio tank. Here 20 m3 to 24 m3/hr is re circulated from secondary clarifier and fed in to bio tank process .the heavy organic solids, gradually fed into biological tank ( capacity 210 m3 ) process containing millions of microorganisms that can only survive and multiply in an environment containing free oxygen that is dissolved in the water and a food source. This method for treating wastewater is referred to as the activated sludge process. Oxygen is provided by pumping and diffusing air (similar to how air is pumped and diffused in a fish aquarium) into large tanks containing the microorganisms and raw effluent. The mixture of microorganisms, raw effluent and dissolved oxygen is referred to as mixed liquor suspended solids (mlss). After the aeration period, the mlss is transferred to secondary clarifier, where it is allowed to settle by gravity leaving a clear liquid referred to as electro coagulation feed effluent . While the settled mlss is returned to the aeration tanks to maintain the appropriate population and cultures of microorganisms. Return of the mlss from secondary m clarifier tanks to the front of the aeration tanks is referred to as return activated sludge (ras). As the microorganisms multiply, the amount of food available in the raw effluent will become insufficient and the quality of treatment can degrade. . This wasting is referred to as waste activated sludge (was) ,this excess sludge tank fed in to sludge bed and reused ( like natural fertilizer) . After biological process input raw effluent cod reduces minimum50%.
Biological process reaction :
Important maintaince of process:
The principal factors in procedure control are the subsequent:
Maintenance of dissolved oxygen levels within the aeration tanks.
Water is the most important element of the nature for every living creature. Without industrial waste water treatment plant we cannot live a single day. Three-forth of this earth is filled up with water. But, now a day this most essential element is contaminating in every moment. It’s very alarming news for us. The contaminated water also polluting the soil & air. In this way, it unstable the whole ecological system. If it cannot be prevented in time, then it will destroy human, animal, plants even the small bacteria. And the earth will destroy in very quick time. So we should be very careful right now.
What is waste water?
Waste water is any water that has been adversely affected in quality by anthropogenic influence. It comprises liquid waste discharged by domestic residence, commercial properties, industry and agriculture a wide range of potential containments and concentration.
Where it came from?
We, only the people are responsible for the water pollution. Every moment we are polluting the water cautiously or un-cautiously. From our home to our factory, every where we are using plenty of water. After usage, the water is going into the river, land and inside the soil. All the water is not polluted. Waste water or sewage can come from:
Human waste, known as black water.
Septic tank discharge.
Sewage treatment plant.
Washing water, known as grey water.
Industrial site drainage.
Industrial cooling water.
Industrial process water.
Organic or biodegradable waste water from ceramics and ice cream factory.
Organic or non biodegradable waste from pharmaceuticals or pesticide factory.
Extreme pH from acid, alkali manufacturing.
Solid and emulsion from paper, oil manufacturing.
Waste water constitute
The composition of waste water varies widely. This is the partial list of what it may contain:
Water (95%) which is often used to carry waste through drain.
Pathogens, such as bacteria, virus and parasitic worms.
Organic particles such as feces, hair, food, paper, fiber etc.
Soluble organic materials such as Urea, proteins, drugs, pharmaceuticals etc.
Soluble in organic materials such as ammonia, G.salt, sea-salt, cyanides, thiosulfates etc.
In organic materials like sand, grit, metal etc.
Hydrogen (H2), sulphide (SO2), methane (CH4) and carbon-di-oxide (CO2).
Emulsion like paints, adhesives, colors, emulsifier etc.
Toxin such as pesticides, poisons, herbicides etc.
All these materials are very much deleterious for environment and human life.
How waste affect the water
We know water containing only Hydrogen (H2) and Oxygen (O2). Oxygen(O2)is very essential for any living creature. For existence of aquatic life in water, the dissolve oxygen (DO) should not be less then 5 ppm. But in our country, most of the river water losing it very quickly. Any oxidizable mater present in the natural water or in an industrial water will be oxidized by biochemical or chemical processes. The result is that the Oxygen (O2) content of the water will be decreased. Since all natural water contains bacteria and nutrients, almost any waste compounds introduced into such waterways will initiate the biochemical reaction. Biological oxygen demands (BOD) and Chemical oxygen demand (COD) are most important criteria of the water. But as a result of these reactions both BOD and COD are decreasing in an alarming rate. The color permissible limit in water for domestic use is only 20 ppm. But in most of our river and canal already have 150 ppm. So this water is for no use. Waste water also increasing the temperature of the water. This is responsible for global warming. The solid materials are very poisonous to our lands. It decreases lands food productivity. This water also increases the pH of normal water. The gases from the waste water like carbon-di-oxide (CO2), hydrogen sulphide ( H2S), methane (CH3) are very harmful for environment.CO2 is responsible for green house affect. Excessive nutrients such as phosphorus and nitrogen can be harmful to aquatic life. Chlorine and inorganic chloramines can be toxic to algae and fish. Metals like mercury, lead, cadmium, chromium, arsenic can have acute and chronic toxic effect on species..
Effect of industrial waste water treatment plant
Sewage may drain directly into major watersheds (like river, canal, ponds etc) with minimal or no treatment. When untreated, sewage can have serious impact on the quality of the environments and on the health of the people. In many part of the world, including United States health problems and disease have often been caused by the discharging untreated water. Such water is responsible for spreading of disease, fish kills and destruction of other forms aquatic life. The industrial waste water treatment plant has a serious impact on all living creature and can negatively affect the use of water for drinking, household needs, recreation, fishing, transportation and commerce. This water is using in our lands. It causes the decrease in food productivity of the land. Pathogens can cause a verity of illness. Some chemical pose risks even at very low concentration and can remain a threat for long period of time because of bioaccumulation in animal or human tissue. Waste water from fertilizer plant contains nitrogen oxides (NOx), carbon-di-oxide(CO2).This is responsible for liver and kidney damage. At last we can say waste water can be a life destroying cause for living creature and also for our environment.
Waste Water Characteristics and target parametres
Effluent characteristics Target
pH : 8.0 to 9.0 7.0 to 7.5
DO mg/L : 0 4.5 to 8.0
BOD mg/L : 300 to 500 < 30
COD mg/L : 900 to 1700 < 200
TDS mg/L : 200 to 1000 < 2100
TSS mg/L : Not Specified < 30
Temperature : Not Specified < 37 °C
Discharge Norms
DoE norms, BSR Guidelines
pH : 6.0 to 9.0 6.0 to 9.0
DO mg/L : 4.5 to 8.0 not specified
BOD mg/L : ≤ 50 ≤ 30
COD mg/L : ≤ 200 ≤ 200
TDS mg/L : ≤ 2100 not specified
TSS mg/L : Not Specified ≤ 30
Temperature : Not Specified ≤ 37 °C
Industrial Waste Water Treatment Plant
The most effective solution of this problem is to use effluent treatment plant (ETP) in each individual factory. Water treatment describes those processes used to make water more acceptable for desired end use. These can include as drinking water, industrial process, medical and many more uses. 70% of Israel’s irrigated agriculture is based on waste water treatment. The goal of water treatment plant is to existing contaminants in the water or reduces the concentration of those contaminants. So the water becomes fit for use. One such use water is returning that has been used back into the natural environment without adverse ecological impact. ETP is essential to save our lives and also the environment. For the future generation to be safe and secure, we should keep the water safe. Use of ETP will save a huge amount of water and as well as money too.
From the above discussion we can say, to save our world form undesired destruction we should keep the water safe and secure. And for that we must use the ETP in every individual factory. Or otherwise, one day there will be plenty of water around us, but not a single drop to use without an industrial waste water treatment plant
Md. Saiful Islam.Confident Engineering India Private Limited,
678 /1, kurichi village, Madukarai Road, Sidco industrial Estate Post ,Coimbatore – 641021 Tamilnadu, INDIA.
The yarn produced by mixing Polyester fibre and Cotton fibre with each other during yarn preparation process is known as polyester-cotton blended yarn. Generally, two types of polyester-cotton blended yarn are produced. These are :
65% Polyester + 35% Cotton = PC or TC
40% Polyester + 60% Cotton = CVC (Cheap Value Cotton)
1.2 Pre-treatment Process for Blended Fabric
Pre-treatment process for Polyester-Cotton blended fabric is similar to the 100% Cotton pre-treatment process. Refer to Specification No. 51-301 for detailed pre-treatment process.
1.3 Dyeing Process for Blended Fabric
Two types of dyeing methods are used to dye blended fabric. These are :
One-bath Dyeing Method
Two-bath Dyeing Method
1.3.1 One-bath Dyeing Method
One-bath dyeing method is a dyeing process whereby, polyester part and cotton part are dyed together in one bath.
1.3.2 Two-bath Dyeing Method
Two-bath dyeing method is a dyeing process whereby, polyester part and cotton part are dyed separately in separate bath.
2.0 Process Requirements
2.1 Equipment used
Three types of Thies machines are used for dyeing process. These are :
Mini-soft
Eco-soft
Luft-roto
2.2 Key Accessories
Key accessories used in dyeing process are :
Mixing tank
Machine Tank
Bohme meter
pH meter
Eye protecting glass
Hand gloves
Sewing machine
Hand lifter for carrying the batch, and
Gum boot.
2.3 Materials / Chemicals used
Following materials/chemicals are used in the dyeing with reactive dyes process :
Water
Steam
Compressed Air
Wetting agent
Detergent
Sequestering agent
Acid
Anti-creasing agent
Dispersing Agent
Gluber salt, and
Soda ash, etc.
3.0 Safety
In order to ensure floor and personnel safety, floor personnel are instructed to follow the safety guidelines given below :
Smoking is strictly prohibited in the factory premises.
Put on the safety masks while mixing or transferring alkali and acid.
During production, after reaching at the optimum temperature (above 800C), in case the lid of machine needs to be opened, operator must depressurise the machine and use hand gloves, eye-protecting glass etc. while performing such task for safety.
4.0 Operation Procedure
4.1 Operation Staff
Operation stuffs for Dyeing Process includes :
Manager
Assistant Manager
Production Executive
Production Executive
Operator
Helper
4.2 Machine Set-up
4.2.1 Machine Set-up for Eco-Soft & Mini-Soft Machine
Machine set-up for Poly-Cotton Blended Fabric Dyeing in Eco-Soft & Mini-Soft Machines are as follows :
Machine Group
Fabric Type
G.S.M.
J.P.(Mb)
R.S. (MPM)
ECO-SOFT
&
MINI-SOFT
Single Jersey
Up to 140
0500
200
140 ~ 180
0600
190
180 & Above
0800
180
Polo Pique
Up to 160
0600
200
Black Pique
160 ~ 200
0700
180
Popcorn
200 & Above
0900
180
.
4.2.2 Machine Set-up for Luft-Roto Machine
Machine set-up for Poly-Cotton Blended Fabric Dyeing in Luft-Roto Machine is as follows :
Machine Group
Fabric Type
G.S.M.
J.P.(Mb)
R.S. (MPM)
LUFT-ROTO
Single Jersey
Up to 140
0700
200
140 ~ 180
0800
200
180 & Above
1000
190
Polo Pique
Up to 160
0800
190
Black Pique
160 ~ 200
0900
190
Popcorn
200 & Above
1000
180
4.3 Checklist Before Operation
Following are the items to be checked before production :
Checking the programme in Beacon Controller
Machine set-up
Fabric weight
Fabric quality
Yarn quality
Collar design (Tipping / Solid)
Rib designs (Normal / Lycra)
Chemical availability
Power availability
Steam availability
Water availability
Compressed air
Manpower availability
Fabric stitch is done properly.
4.4 Operation Procedure
4.4.1 One-bath Dyeing Method
Steps of One-bath Dyeing Process
The sequence for one-bath dyeing process is as follows :
Add Electrolytic agent (G. Salt) and circulate for 5 minutes at 500C
Check pH and S. G. of the Dye bath
Add Dye solution by linear dosing and circulate the fabric for 15 minutes at 500C
Circulate the fabric and raise the temperature at 820C
Circulate the fabric for 25 minutes at 820C
Add Soda Ash solution by curve dosing and circulate the fabric for 30 ~ 50 minutes at 820C
Circulate the fabric and decrease the temperature at 600C
Check the shade with approved shade
Rinse and Drain
Add Acetic acid and circulate for 10 minutes at 700C
Drain
Add Soaping Chemical and circulate for 10 minutes at 950C
Drain
Circulate the fabric for 10 minutes at 700C
Drain
Unload
4.5 Product Quality Check
To check the quality of production, following measures are taken :
Check the pH of the bath.
Absorbency of the fabric.
Hardness of the water.
Iron / Impurities contamination of the water.
Heating and Cooling system of the machine.
Check the shade with customer approved shade.
Check the specific gravity of the bath.
4.6 Q.C. Sample Tests
Not applicable.
4.7 Response to Equipment Faults
Following are the response to be taken in case of equipment fault of dyeing machine :
Equipment Fault
Response
Pump Fault
Call Mechanical Maintenance.
Dosing Fault
Self / Call Mechanical / Electrical Maintenance.
Pump Leakage
Call Mechanical Maintenance.
Filling Problem
Call Mechanical / Electrical Maintenance.
Valve Leakage
Call Mechanical Maintenance.
Program Deleting
Call Electrical Maintenance.
Pressure Fluctuation
Self / Call Mechanical / Electrical Maintenance.
Motor Fault
Call Mechanical Maintenance.
4.8 Machine /Area Cleaning
The daily cleaning for machines are described below :
Clean chemical chambers by water flow.
Clean the floor by water flow.
Machine Oiling by oil or greases done by the Mechanical Maintenance Department.
The Maintenance Department performs the preventive maintenance task as per the PM schedule. Refer to Maintenance Specification for details.
5.0 Applicable Forms & Documents
Document Flow
Document flow for the poly-cotton blend fabric dyeing process can be enumerated as below :
Dyeing Department receives the Process Batch Card (F21-101-1) along with the Job Card (F21-101-2) attached to it from the Batch Preparation Section. Process Batch Card is used for fabrics while Job card is used for Collars & Cuffs.
Different specifications (e.g. Lab dip approval #, Fabric weight and quality, Collar quality, shade, etc.) mentioned in the Batch card and Job Card are checked.
Based on the shade and other specification plans for the machines are prepared.
Print-out of the recipe is taken from the DATA-COLOUR computer. The Recipe Card (F51-301-1) is used as an internal document to keep record of dyeing for a particular batch.
Availability of chemicals and dyestuff is checked and program is put in the Becon Controller.
The Shade Batch Card (F51-301-2) is used to keep track of the dyeing production continuity. Production Officer fills out different areas of the form. This is an internal document of the dyeing department.
The Operator fills out the Production Report (R51-301-1) and it is sent to the Planning department. This report contains information like the Quantity produced, Machine wise production, Amount of re-process, Machine utility percentage (%) and shift wise production.
Upon completion of dyeing for a particular batch, if the dyeing is ‘OK’, the Process Batch Card is stamped as “SHADE APPROVED TO FINISH” in Green, on the other hand, if dyeing is ‘NOT OK’, the card is marked as “SHADE APPROVED TO DRY ONLY” in Red. This Process Card is then sent to the Finishing Department.
What is Side Sealing Machine ? Mechanical Maintenance Process
What is Side Sealing Machine ? Mechanical Maintenance Process
Side Sealing Machine is process by which equipment is looked after in such a way that specific product quality required by the customers is sustained. This increases machine life and ensures trouble free services
Side Sealing Machine
There are mainly two types of Maintenance that are carried out by the Utility department. These are:
Corrective Maintenance
Preventive Maintenance
Preventive Maintenance schedules can be further classified as follows:
Daily
Weekly
Monthly
Quarterly
Half-Yearly
Yearly
Frequency
Side Sealing Machine Criteria
Weekly
Check All Moving parts – side sealing machine
Check All Bearing – side sealing machine
Check -side sealing machine for Bearing Lubricating.
Monthly
Check the Emergency switch system – side sealing machine
Check the Motor terminal Loose connection.
Check all mechanical system. – side sealing machine
Check the Heater terminal of side sealing machine for short ckt.
Two Monthly
Check and lubricate all bearing & revolving point with Grease.
Check all Moving parts.
Check all Heater Line.
Check all Gear Box .
Six Monthly
Check the Machine safety system
Check and Refill Gear Oil (Gear Box) – side sealing machine
Check Electrical Equipment.
Yearly
Replace the oil of the Gear box of reel.
Open Motor and check the Main Bearing, Electrical terminal and other component.
Check Electrical Equipment – side sealing machine
Machine Safety
Compressor
Air hoses should be of correct size and suitable for the working pressure.
#Never use frayed, damaged or deteriorated hoses. When blowing through a hose or air line, we ensure that the open end is hold securely.
#Never operate the unit when there is a possibility of taking in flammable or toxic fumes.
#Never operate the unit at pressure below or more than its limit ratings
#Never operate the unit at pressure below or in excess of its limit ratings as indicated on the principal data sheet.
Boiler
Burner programmer with flame sensor provide flame failure safety.
The lavel switch of the level indicating controller is used for raising and audiovisual alarm when water level drops below set point, tripping the burner.
High Steam pressure is detected by a steam pressure switch. It puts OFF the burner giving visual alarm.
In case of low water condition in the boiler ,the flue gas temperature would go up. This would be sensed by flue gas temperature controller, tripping burner giving audio visual alarm.
The pressure switch provided in the gas train detects the high pressure condition & cuts OFF the burner sounding an audio visual alarm.
Boiler room is kept free from flammable gases.
Compressor Unit
Monthly Service Schedule
Motor greasing of Compressor
Moisture trap clean of inter-cooler & cooler
Water separator clean of air Dryer
Compressor motor Clean
Greasing of pump & Motor bearing, if necessary change bearing
Clean air – Filter.
Summery
Preventive maintenance of Side Sealing Machine refers to only a part of a good maintenance programs. It consists of routine actions taken in a planned manner to prevent breakdowns, cut operating cost and improve output quality of the product. Lubrication and Inspection are the two constituents of preventive maintenance.
